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WORKSHOP MANUAL

C&E SERIES

ENGINE CONTROL SYSTEM


(6WF1-TC, 6WG1-TC (Common Rail) models)

SECTION 1A
NOTICE

Before using this Workshop Manual to assist you in performing


vehicle service and maintenance operations, it is recommended that
you carefully read and thoroughly understand the information
contained in Section-0 under the headings “GENERAL REPAIR
INSTRUCTIONS”.

All material contained in this Manual is based on latest product


information available at the time of publication.
All rights are reserved to make changes at any time without prior
notice.

Applicable Model:

C&E Series

This Manual is applicable to 2006 year model vehicles.


THIS MANUAL INCLUDES THE FOLLOWING SECTIONS:

SECTION No. CONTENTS


1A Engine Control
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-1

ENGINE
Engine Control System
(6WF1-TC,6WG1-TC(Common Rail))
TABLE OF CONTENTS
Engine Control System . . . . . . . . . . . . . . . . . . . . . 1A-2 DTC P0242 (Flash code 242) . . . . . . . . . . . . 1A-222
Precautions for servicing . . . . . . . . . . . . . . . . . . 1A-2 DTC P0245 (Flash code 245) . . . . . . . . . . . . 1A-226
Explanation of Functions and Operations . . . . . 1A-4 DTC P0247 (Flash code 247) . . . . . . . . . . . . 1A-230
Parts layout diagram . . . . . . . . . . . . . . . . . . . . 1A-31 DTC P0248 (Flash code 248) . . . . . . . . . . . . 1A-233
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . 1A-36 DTC P0271 (Flash code 271) . . . . . . . . . . . . 1A-236
Connector List . . . . . . . . . . . . . . . . . . . . . . . . . 1A-58 DTC P0272 (Flash code 272) . . . . . . . . . . . . 1A-240
Fault diagnosis process . . . . . . . . . . . . . . . . . . 1A-69 DTC P0273 (Flash code 273) . . . . . . . . . . . . 1A-244
Breakdown diagnosis using the scan tool. . . . . 1A-75 DTC P0274 (Flash code 274) . . . . . . . . . . . . 1A-248
Function Inspection List . . . . . . . . . . . . . . . . . . 1A-88 DTC P0275 (Flash code 275) . . . . . . . . . . . . 1A-252
Oral consultation . . . . . . . . . . . . . . . . . . . . . . . 1A-89 DTC P0276 (Flash code 276) . . . . . . . . . . . . 1A-256
On-Board Diagnosis (OBD) System Check . . . 1A-91 DTC P0277 (Flash code 277) . . . . . . . . . . . . 1A-260
Checking the MIL (check engine lamp) lighting circuit DTC P0278 (Flash code 278) . . . . . . . . . . . . 1A-263
system (MIL does not turn ON) . . . . . . . . . . . . 1A-94 DTC P0411 (Flash code 411) . . . . . . . . . . . . . 1A-266
Checking the MIL (check engine lamp) flashing DTC P0412 (Flash code 412) . . . . . . . . . . . . 1A-270
control system (MIL does not flashing) . . . . . . 1A-97 DTC P0413 (Flash code 413) . . . . . . . . . . . . 1A-274
Checking the Scan Tool Circuit System . . . . . 1A-100 DTC P0416 (Flash code 416) . . . . . . . . . . . . 1A-278
Checking the starting system . . . . . . . . . . . . . 1A-103 DTC P0418 (Flash code 418) . . . . . . . . . . . . 1A-281
Checking the fuel system . . . . . . . . . . . . . . . . 1A-106 DTC P0421 (Flash code 421) . . . . . . . . . . . . 1A-284
Checking the intake air system . . . . . . . . . . . 1A-110 DTC P0424 (Flash code 424) . . . . . . . . . . . . 1A-286
Checking the exhaust system . . . . . . . . . . . . 1A-112 DTC P0441 (Flash code 441) . . . . . . . . . . . . 1A-289
Checking the EGR . . . . . . . . . . . . . . . . . . . . . 1A-116 DTC P0442 (Flash code 442) . . . . . . . . . . . . 1A-293
Checking the engine control module (ECM) power DTC P0446 (Flash code 446) . . . . . . . . . . . . 1A-297
supply and ground circuit . . . . . . . . . . . . . . . . 1A-119 DTC P0447 (Flash code 447) . . . . . . . . . . . . 1A-302
Checking the PTO . . . . . . . . . . . . . . . . . . . . . 1A-122 DTC P0448 (Flash code 448) . . . . . . . . . . . . 1A-307
Table of diagnostics codes . . . . . . . . . . . . . . . 1A-126 DTC P0449 (Flash Code 449) . . . . . . . . . . . . 1A-312
DTC P0014 (Flash code 14) . . . . . . . . . . . . . 1A-137 DTC P0518(Flash Code 518). . . . . . . . . . . . . 1A-317
DTC P0015 (Flash code 15) . . . . . . . . . . . . . 1A-141 DTC P0543(Flash Code 543). . . . . . . . . . . . . 1A-319
DTC P0022 (Flash code 22) . . . . . . . . . . . . . 1A-145 Symptom List . . . . . . . . . . . . . . . . . . . . . . . . . 1A-321
DTC P0023 (Flash code 23) . . . . . . . . . . . . . 1A-149 Engine Stall . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-322
DTC P0024 (Flash code 24) . . . . . . . . . . . . . 1A-153 Engine hunting, rough idle . . . . . . . . . . . . . . . 1A-325
DTC P0025 (Flash code 25) . . . . . . . . . . . . . 1A-157 Lack of power, slugginess or hesitation . . . . . 1A-329
DTC P0032 (Flash code 32) . . . . . . . . . . . . . 1A-162 Excessive white smoke . . . . . . . . . . . . . . . . . 1A-332
DTC P0033 (Flash code 33) . . . . . . . . . . . . . 1A-166 Excessive black smoke . . . . . . . . . . . . . . . . . 1A-334
DTC P0035 (Flash code 35) . . . . . . . . . . . . . 1A-168 Idling revolutions cannot be adjusted. . . . . . . 1A-337
DTC P0042 (Flash code 42) . . . . . . . . . . . . . 1A-170 Idling revolutions cannot be adjusted down . . 1A-339
DTC P0051 (Flash code 51) . . . . . . . . . . . . . 1A-173 Special tool. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-342
DTC P0071 (Flash code 71) . . . . . . . . . . . . . 1A-175 Programming. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-343
DTC P0072 (Flash code 72) . . . . . . . . . . . . . 1A-177 Explanation of Functions and Operations . . . 1A-343
DTC P0115 (Flash code 115). . . . . . . . . . . . . 1A-179 Programming . . . . . . . . . . . . . . . . . . . . . . . . . 1A-344
DTC P0118 (Flash code 118). . . . . . . . . . . . . 1A-183 Special tool. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-354
DTC P0151 (Flash code 151) . . . . . . . . . . . . 1A-189
DTC P0158 (Flash code 158) . . . . . . . . . . . . 1A-195
DTC P0159 (Flash code 159) . . . . . . . . . . . . 1A-199
DTC P0211 (Flash code 211). . . . . . . . . . . . . 1A-203
DTC P0217 (Flash code 217) . . . . . . . . . . . . 1A-206
DTC P0218 (Flash code 218) . . . . . . . . . . . . 1A-209
DTC P0226 (Flash code 226) . . . . . . . . . . . . 1A-212
DTC P0227 (Flash code 227) . . . . . . . . . . . . 1A-217
1A-2 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

Engine Control System


Precautions for servicing Damage Due to Static Electrical Discharge
Use of Circuit Testing Tools The electrical components used in electronic control
systems are designed to operate at very low voltages,
If no specific instruction is made in the diagnostic
so they are vulnerable to damage to static electrical
procedure, test lights should not be used in the
discharge. Even static electricity at 100V or less, which
diagnosis of power train electrical equipment systems.
is usually imperceptible to humans, can damage some
If probe connectors are required for diagnostic
types of electrical components. For reference, a
procedures, use connector test and adaptor kit 5-8840-
voltage of 4,000V is required to produce a human-
0385-0.
perceptible current of static electrical discharge.
There are several ways a person can accumulate static
Vendor Electrical Devices
charge. The most common are through friction and
Vendor electrical devices are electrical devices that are induction.
purchased in the market and mounted in the vehicle • For example, charging due to friction occurs when
after it is shipped from the factory. Care is required a person slides sideways across a car seat.
because no specific consideration was given to such
devices at the vehicle design stage. • Charging through induction occurs when a person
wearing insulating shoes stands near a highly-
CAUTION: charged body and momentarily touches a
Vendor electrical devices must be connected to power grounded body. Charge of the same polarity flows
supply and grounding circuits that are not involved with out, so the person becomes highly charged with
electronic control system circuits. the opposite polarity. Static electricity causes
damage, so great care is required when handling
Even if they are connected normally, vendor electrical or testing electrical components.
devices can cause malfunctions in electrical control
systems. Effects can even be caused by such devices CAUTION:
that are not connected to vehicle electrical systems, Follow the guidelines below to prevent damage by
such as cellular telephones and portable radio static electrical discharge:
equipment. Therefore, when diagnosing power train • Do not touch ECM connector pins or electrical
problems, first check that no vendor electrical devices components that are connected to an ECM circuit
are mounted on the vehicle, and remove any that are. board.
After removing such devices, perform normal • Do not take a replacement component out of its
diagnostic procedures for any problems that persist. packaging before you have completed all
preparations for mounting it.
• Before removing a component from its packaging,
connect that packaging to normal grounding in the
vehicle.
• While sliding across a seat, while sitting from a
standing position, or after handling components
while walking for some distance, touch a normally
grounded object before attaching the components.

Table of abbreviations

Abbreviati Name Meaning, notes


on
ABS Anti-lock Brake System A device to prevent brakes from locking
A/D Analog/Digital Analog/Digital
APP Accelerator Pedal Position The extent to which the accelerator pedal has
been depressed.
ASR Anti Slip Regulator A device to restrict slipping of the driven wheels.
CAN Anti Slip Regulator Communications between control devices
CKP Crankshaft Position Indicates the position of the crankshaft (flywheel).
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-3

Abbreviati Name Meaning, notes


on
DLC Data Link Connector A connector for connecting the scan tool.
DTC Diagnostic Trouble Code Self-diagnostic codes, trouble codes, diagnostic
codes
EBS Electronic Brake System An electronically-controlled brake system.
ECM Engine Control Module A computer for controlling the engine.
ECT Engine Coolant Temperature Temperature of the engine coolant.
ECU Electronic Control Unit Computers for various control functions.
EGR Exhaust Gas Recirculation Recirculation of exhaust gas.
EMI Electronic Magnetic Interference Electromagnetic Interference.
Exh Exhaust Exhaust gas.
FT Fuel Temperature The temperature of the fuel.
GND Ground Connection to ground/earth
GVW Gross Vehicle Weight The gross weight of the vehicle.
IAT Intake Air Temperature Temperature of air taken in (outside air
temperature).
MIL Malfunction Indicator Lamp Warning lamp MIL (check engine lamp)
OBD On Board Diagnostic Diagnostic system on the vehicle (or vehicle-
mounted malfunction diagnostic system)
PCV Pump Control Valve A valve that controls the volume of fuel flowing to
the fuel rail.
P/T Power Tilt Cab tilting mechanism.
PTO Power Take Off System for taking motive power.
PWM Pulse Width Modulation Modulation of wave pulse width
QOS Quick On Start Engine warming system.
RP Rail Pressure Pressure in the rail.
SBF Slow Blow Fuse Slow blow fuse.
SIG Signal Signal
TWV Two Way Valve Valve within an injector.
VGS Variable Geometry Turbo System Variable turbocharge system.
VSS Vehicle Speed Sensor Vehicle speed sensor
1A-4 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Wiring colors
The wiring in all harnesses can be distinguished by the
insulation colors. The harness that is the main circuit
within a given electrical system is identified by single-
colored wires, while sub-circuits of that system are
identified by striped colors. In wiring diagrams, sizes
and colors are indicated by the following method:

LNW38ASH015101

Symbols Colors Symbols Colors


B Black BR Brown
W White LG Light Green
R Red GR Gray
G Green P Peach
Y Yellow SB Sky blue
L Blue V Violet
O Orange

Explanation of Functions and Operations Electronic Control Fuel Injection System


Electronic Control Systems In the electronic control fuel injection system (fuel rail
type), the electronic control module (ECM) obtains data
The electronic control system takes the data detected
such as the engine speed and engine load through
by various types of sensors, and performs calculations
signals from many sensors. The ECM then sends
on it using the control programs of the electronic control
electrical signals to the supply pump, injectors and
module for overall control of fuel injection volume,
elsewhere on the basis of that data, for optimum control
injection timing, starting, high-altitude compensation
of fuel injection timing and volume for each cylinder,
and other factors.
and other parameters.

Injection Volume Control


To achieve the optimum injection volume, the engine
speed and accelerator depression are the main factors
used to control the two-way valve (TWV) in each
injector, controlling the volume.
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-5
Injection Pressure Control Injection Timing Control
Fuel pressure inside the fuel rail is controlled to control In place of the timer function, the optimum fuel injection
the injection pressure. The optimum internal pressure timing is calculated from parameters such as the
for the fuel rail is calculated from parameters such as engine speed and injection volume, and controlled
engine speed and fuel injection volume, and the right using the two way valve (TWV) inside each injector.
volume of fuel is pumped out by controlling the supply
pump (PCV: Pump Control Valve) to control fuel Injection Rate Control
pumping to the fuel rail. To improve combustion in the cylinders, only a small
quantity of fuel is injected at first (pre-injection) and
ignited. Ignition is followed by a second injection (main
injection). Control of the injection timing and quantity is
achieved using the two way valve (TWV) inside each
injector
System Schematic Diagram

Atmospheric temperature sensor

Sensor signals Engine control unit

from switches, etc. (ECU)

Atmospheric pressure sensor


Voltage (built in ECU)
load
circuit

APP sensor
Accelerator switch
PTO Remote
throttle sensor

Injector

Pressure limiter
Fuel leak pipe

Starter motor Fuel rail


Fuel pressure sensor

Flow damper
Supply pump
Air
cleaner

ECT sensor

Fuel filter
Fuel tank
CMP sensor
CKP sensor

Flywheel Feed pump Pre-fuel filter

HCW61ALF000201
1A-6 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
System Control Schematic Diagram

Engine Control Module

Accelerator pedal position sensor input

Boost pressure sensor input


Basic fuel
injection rate
Crankshaft sensor

Camshaft sensor

Compensation Engine coolant temperature sensor input,


Common rail accelerator pedal position sensor input,
pressure sensor start switch input

Compensation
Vehicle speed sensor input,
clutch switch input

PCV opening/closing
timing decision Injector (TWV) power supply time,
timing decision

Common rail pressure sensor

Common rail
(normally high pressure)

TWV(Two Way Valve)

PCV

Supply
pump

Injector

Fuel tank

HCW4ADXF000201
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-7
Exhaust Gas Recirculation (EGR)
The EGR (Exhaust Gas Recirculation) system
recirculates part of the exhaust gas within the intake
manifold, mixing inert gases with intake air. This lowers
the combustion temperature, reducing the generation
of NOx. The EGR volume is controlled by the action
(opening and closing) of the EGR valve, which is
situated between the exhaust manifold and the intake
manifold. The EGR volume is determined according to
the engine speed and engine load rate (fuel injection
volume). A vehicle equipped with an intercooler turbo
has a cooler built into the EGR gas channel, so that hot
EGR gas is cooled by the cooler and mixed with fresh
air. This achieves a greater reduction in combustion
temperature than normal EGR, further reducing NOx
generation (cooled EGR). Furthermore, the EGR
system uses a one-way valve to restrict the backward
flow of EGR gas. As one-way flow is ensured, the EGR
volume can be increased.
System Control Schematic

5
6
7
8
4
9
3
10
17

2
11

1 12

16
15 14 13

HCW4ADMF001501

Legend
1. EGR gas cooling device 9. Engine load
2. EGR valve 10. Accelerator pedal sensor
3. Air line 11. EGR valve
4. EGR magnetic valve 12. EGR gas cooling device
5. Air tank 13. Non return valve
6. Engine control module (ECM) 14. Intake air
7. Crankshaft position (CKP) sensor 15. Non return valve
8. Engine speed 16. Engine
1A-8 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
17. Exhaust gas

Variable Geometry Turbo System (VGS)


Air cylinder stroke (number of magnetic valve steps) is
derived from the engine speed, with corrections for
information received from various inputs to determine
the final air cylinder stroke (number of magnetic valve
steps).
The VGS magnetic valve moves through the
determined number of steps, moving the pneumatic
cylinder with pneumatic pressure to control the nozzle
vane angle inside the turbine housing.

Air Tank

Detection VGS steps C


Engine Speed of the Compensation
VGS steps
B
Various Switch
Signals Input A

Magnetic Valve control Circuit


Engine Control Module
Air
Cylinder

Nozzle Vane

HCW61AMF001101
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-9
Pneumatic Cylinder

9
Port 3 Port 2 Port 1
12

15

18

21 (Full Stroke)

HCW61ASF000901

Pressurizes Air Atmospheric Open


Stroke
Port
0 3 6 9 12 15 18 21

Port1

Port2

Port3

HCW61ASF001001

Idling Control AUTO … Auto mode


During warming operation, the idling control switch can The minimum idling speed is set to the optimum value
be used to adjust the minimum idling speed. The switch for the engine coolant temperature.
can also be used to automatically set the minimum When engine coolant temperature is low, the idling
idling speed to the optimum value for the current speed is high, but it is reduced as the engine coolant
engine coolant temperature. temperature rises.
This function is disabled when PTO control (fuel The idling control switch must be switched to Manual
injection characteristic switching) is used. mode to adjust the idling speed.
MANU … Manual mode
Idling Control Switch The idling control switch can be used to adjust the
The idling control switch can be used to switch the idling speed.
idling control function off and on. The speed set in manual mode remains effective as the
minimum idling speed when the switch is returned to
Auto mode.
1A-10 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Fuel injection characteristic switching
Switching driving characteristics and working
characteristics

Fuel injection characteristic switching


If, and only if, an external accelerator is connected, the
fuel injection characteristics can be switched by the
status of the PTO switch, which is input to the engine
control. However, as before, fuel injection characteristic
switching is only possible when the vehicle is at rest.
The switching conditions are as follows:
Conditions in which it is possible to switch from driving
characteristics to working characteristics (conditions in
which working characteristics can be used).
All the following conditions must be satisfied (these are
AND conditions)
• PTO switch is turned on (PTO switch: ON)
HCW5ADSH000301 • Vehicle is at rest.
• Parking brake is engaged (parking brake switch:
Idling control switch On)
The idling control switch can be used to adjust the • External accelerator input is normal (PTO remote
idling speed. The maximum speed varies according to throttle sensor voltage 0.1-4.8V)
the engine type, vehicle specification and engine
• External accelerator is in idling position (PTO
temperature.
remote throttle sensor <5%)
Up • Drive accelerator is in idling position (accelerator
While the switch is pressed to the Up side, the engine sensor <5%)
speed increases and the idling speed can be
• PTO accelerator switch is not switched on (PTO
increased.
accelerator switch: Off)
Down
While the switch is pressed to the Down side, the NOTE:
engine speed decreases and the idling speed can be These are added setting (modified) switches for
decreased. However, it cannot be reduced below the concrete pump vehicles.
minimum idling speed.
• No DTC has been issued to stop PTO control
(refer to DTCs)
Conditions in which it is possible to switch from working
characteristics to driving characteristics (conditions in
which driving characteristics can be used).
UP All the following conditions must be satisfied (these are
AND conditions)
DOWN • PTO switch is not turned on (PTO switch: OFF)
• Vehicle is at rest.
• Parking brake is engaged (parking brake switch:
High Low On)
UP UP • External accelerator input is normal (PTO remote
throttle sensor voltage 0.1-4.8V)
• External accelerator is in idling position (PTO
remote throttle sensor <5%)
DOWN DOWN
• Drive accelerator is in idling position (accelerator
HCW61ASH000101
sensor <5%)
• No DTC has been issued to stop PTO control
PTO Control (fuel injection characteristic (refer to DTCs)
switching)
PTO control under the engine control system is called
“fuel injection characteristic switching”.
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-11
Accelerator Switching Conditions “switching • Parking brake is engaged (parking brake switch:
between driving accelerator and external On)
accelerator” • External accelerator is in idling position (PTO
Conditions in which the external accelerator can be remote throttle sensor <5%)
used (driving accelerator and external accelerator can Conditions in which the external accelerator is disabled
both be used) (only the driving accelerator can be used)
All the following conditions must be satisfied (these are When any of the conditions below is satisfied
AND conditions) • The parking brake has been released.
• Vehicle is at rest. • The vehicle is in motion (vehicle speed has been
detected).

1 4
2

HCW4ADMF001801

Legend
1. PTO switch 5. PTO accelerator switch “ON” when using
2. Governor characteristic switching conditions operation characteristics
3. Accelerator open 0% 6. Operation characteristics
4. Drive characteristics
1A-12 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Speed Restriction Control
Speed restriction control is a function by which the
engine control module (ECM) controls the fuel injection
volume on the basis of the vehicle speed signal and the
engine speed, so that vehicle speed cannot exceed the
set value (90km/h).
The vehicle speed signal is received by the speed
sensor control unit from the vehicle speed sensor. The
speed sensor control unit corrects the vehicle speed
signal according to the type of vehicle and forwards it to
the ECM, meters and elsewhere. The ECM recognizes
the engine speed from the signal provided by the CKP
signal.
Equipment with speed restriction control (device) is
mandatory under the Road Trucking Vehicle Law for
vehicles with GVW of 8t or more, or with cargo load of
5t or more.

Meter
Other C/U

Engine ECM VSS C/U

Fuel Injection Control

Crank Position (CKP) Ve h i c l e S p e e d S e n s o r


Sensor (VSS)

LFW36ESF000401

Cruise Control Set Coast function (lower the cruise control set
This function can maintain speed at a set level (within speed)
the range 40-80km/h) without depression of the If the Cruise Set switch is pressed during the cruise
accelerator pedal. When the cruise main switch is control, speed reduces for as long as the switch is
turned On (the Cruise Main lamp lights) and the target pressed. Release the Cruise Set switch when speed
speed is reached, the Cruise Set switch can be has fallen to the desired level to change the set speed
operated (push - release) to put the vehicle into auto to the vehicle speed at that time.
cruise mode (the Cruise Set lamp lights). Then, the
target speed is maintained even if the accelerator pedal Tip Down function
is released. This function lowers the set speed during the cruise
control. It is used for fine tuning of the set speed. If the
Temporary Acceleration Function Set switch is briefly pressed and released during the
During the cruise control, the accelerator pedal can be cruise control, the set speed is reduced by 1km/h for
depressed for temporary acceleration. When the each time it is pressed. Fine adjustment of up to 10km/
accelerator pedal is released, the vehicle decelerates h (press 10 times) is possible. However, It is not
and returns to cruise control mode. possible to adjust the set speed below the minimum
cruise control set speed (40km/h).
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-13
NOTE: Resume function (revert to cruise control mode).
If tip down operation is used repeatedly in a short If the cruise control function has been cancelled, the
period, the gap between set speed and actual speed Cruise Resume switch can be operated (press -
increased, so that the auxiliary brake linkage cruise release) to revert to the cruise control state that applied
control function may act to use auxiliary braking before the cancellation (the Cruise Set lamp lights).
(exhaust brake and retarder). However, if the cruise control was cancelled under any
of the following conditions, it is not possible to revert to
Set Acceleration function (raise the cruise control
the cruise control state that applied before the
set speed)
cancellation.
During the cruise control, the Cruise Resume switch The cruise control state must be set again.
can be pressed to raise the speed for as long as it is • The Cruise Main switch was turned Off (Cruise
pressed. Release the Cruise Resume switch when Main switch: Off).
speed has increased to the desired level to change the
set speed to the vehicle speed at that time. • The Cruise Set switch and the Cruise Resume
switch are pressed at the same time (Cruise Set
Tip Up function switch: On AND Cruise Resume switch: On).
This function raises the set speed during the cruise • A malfunction occurs in the engine control system
control. It is used for fine tuning of the set speed. If the (refer to DTCs).
Cruise Resume switch is briefly pressed and released • The engine stops.
during the cruise control, the set speed is raised by
1km/h for each time it is pressed. Fine adjustment of up NOTE:
to 10km/h (press 10 times) is possible. However, It is The Resume function is operable when vehicle speed
not possible to adjust the set speed above the is 40km/h or more.
maximum cruise control set speed (80km/h).

Cruise control cancel


The cruise control function is cancelled under any of
the following conditions:
• The Cruise Main switch is turned Off (Cruise Main
switch: Off)
• Vehicle speed falls down to 30km/h or less.
• The Cruise Set switch and the Cruise Resume
switch are pressed at the same time (Cruise Set
switch: On AND Cruise Resume switch: On).
• A malfunction occurs in the engine control system
(refer to DTCs).
• The engine stops.
• The clutch pedal is depressed (Clutch switch: Off).
• The foot brake is depressed (Brake switch-1: On
OR Brake switch-2: On).
• The Exhaust Brake lever is operated (Exhaust
Brake switch: On).
• The Retarder lever is operated (Retarder switch:
On).
• The Cruise Cancel switch is pressed (Cruise
Cancel switch: Off).
• The Shift lever is moved to neutral (Neutral switch:
On).
1A-14 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Auxiliary Brake Linkage cruise control
During the cruise control, auxiliary braking (exhaust
braking and retarder) are automatically linked, so that
this function restricts acceleration on gentle downward
slopes. The aim is to reduce driving strain on the driver
(by reducing foot brake operations required to counter
speed increases).
When a vehicle driving under the cruise control enters
a downhill slope and the vehicle speed exceeds the
cruise set speed, the exhaust brake acts first to restrict
any increase in speed. If the vehicle speed increases
while the exhaust brake is operating, the retarder acts
in addition to the exhaust brake to restrict any increase
in speed. (The stop lamps light during auxiliary
braking).
When vehicle speed has fallen to the cruise set speed,
auxiliary braking ceases (the retarder is released first,
followed by the exhaust brake).

Downward slope Downward slope Flat way

Exhaust brake and retarder Exhaust brake operates.

operates.

HCW61ASF000301
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-15
Auxiliary braking (exhaust brake and retarder) during
the cruise control is performed through the exhaust
brake and retarder control unit. The Engine Control
Module (ECM) sends an action signal to the exhaust
brake and retarder control unit. In response to the
signal, the exhaust brake and retarder control unit
engages and releases auxiliary braking (exhaust brake
and retarder).

Exhaust
brake operate signal

Engine control Exhaust brake and


Retarder
unit retarder control unit
operate signal

Vehicle speed signal (25pulse)

Retarder Exhaust
Speed sensor control unit
M/V brake M/V

Vehicle speed sensor

HCW61ASF000401
1A-16 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
ECM Communications
The various control units are in communication and
signals necessary for control functions (accelerator
opening, vehicle speed, various switch signals, etc.)
are sent and received.
The communications methods are Pulse Width
Modulation (PWM) and Controller Area Network (CAN).

CAN (Controller Area Network) Communications

ABS/ASR EBS Meter MIMAMORI


ECU (for Truck) ECU (for Tractor) ECU ECU

Resistor Resistor

Air
Smoother-G
Suspension ECM TCM
ECU ECU

HCW61AMF001201

Communications Methods • EBS control unit: Tractor


• PWM (Pulse Width Modulation)
Functions for communications with ABS/ASR, EBS
One type of pulse modulation method, in which the
control units
frequency and amplitude are constant and the
pulse width is varied according to the signal. The Engine Control Module (ECM) uses CAN
The proportion of On time in one cycle is varied to communications with the ABS/ASR and EBS control
create the signal. units.
• CAN (Controller Area Network) • ECM → ABS/ASR and EBS control units (normal
CAN communication is implemented with two transmission) The ECM sends the current
wires (communication lines) to connect control accelerator pedal depression distance, as the ASR
units to each other for communication. accelerator opening signal, to the ABS/ASR and
Each control unit is able to exchange multiple data EBS control units.
items simultaneously at different transfer rates • ABS/ASR and EBS control units → ECM
(high/ medium/ low speed) and with the number of (transmission during ASR control only) The ABS/
signals. Furthermore, signals are shared by each ASR and EBS control units send the restricted
control unit to use for various types of control. accelerator pedal depression distance, as the fuel
reduction volume signal, to the ECM.
Functions for communications with ABS/ASR, EBS
control units and fuel reduction volume control
NOTE:
• ABS/ASR control unit: Truck
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-17
Fuel Reduction volume control
If the ABS/ASR and EBS control units detect slippage
of driven wheels, they send the fuel reduction volume
signal, calculated from the ABS/ASR and EBS
accelerator opening signal, to the ECM. The ECM uses
this fuel volume reduction signal to choke the fuel
injection volume, limiting the output of the engine to
restrict slippage of driven wheels.

Engine Control Module (ECM)

Fuel injection
Detection
Accelerator Pedal APP Control
of the
Position (APP) Sensor injection
quantity

APP Fuel Cut Signal

Signal

ABS/ASR, EBS
ECU

HCW61ASF001101
1A-18 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Engine speed control and communications with the
Smoother-G control unit
When ASR operates, or when there is a gear change
request, in order to synchronize the transmission
revolutions a signal is sent to the engine control module
(ECM) (request to increase or decrease the fuel
injection) to control the engine speed.
Also, the following communications functions are used
with the Smoother-G control unit.

CAN Communications
Accelerator Pedal
APP
Position (APP) Sensor Engine
Switch Signals
Control Smoother-G
Signals Vehicle Speed
Module Control Unit
State of Cruise Control
(ECM)

Fuel Cut Signal

ABS/ASR
EBS
ECU
Accelerator Pedal

Engine Control
Engine

HCW61AMF001301
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-19

Accelerator Pedal
Engine Smoother-G
Position (APP) Sensor
Control Control Unit
Module
21 (ECM)
CAN-H
18
CAN-H
95
Clutch Switch
CAN-L
25
52
CAN-L
Stop Lamp Switch 1 96

53

Stop Lamp Switch 2

80

Cruise Main Switch

60
Cruise Operation Signal
Cruise Set Switch

79
Retarder Operation Signal
Cruise Release Switch 1 45

93
Exhaust Brake
Cruise Resume Switch Operation Signal
92 42

Cruise Release Switch 2

94
27

Exhaust Brake
Speed Sensor
and Retarder
Control Unit
Control Unit

Vehicle Speed Sensor Exhaust Retarder


Brake M/V M/V

HCW61ALF000801
1A-20 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Communications control with the meter ECU
The meter ECU uses the Engine Control Module
(ECM) CAN communications to send engine coolant
temperature data, overheat signal and overheat
warning buzzer action request signal to operate the
engine coolant temperature meter, overheat warning
lamp and overheat warning buzzer.
The ECM receives the parking switch signal from the
meter ECU using CAN communications.

Thermo Meter

Engine Coolant Signal CAN


Temperature Meter
Engine Control
(ECT) Sensor ECT Signal ECU
Module (ECM) Over Heat
Parking Brake
Warning Lamp
Switch Signal

Over Heat
Warning Buzzer

Parking Brake
Switch

HCW61ASF001201

Engine Speed Output to the Tachometer


The Engine Control Module (ECM) outputs engine
speed signal (4 pulses for one rotation of the engine) to
the tachometer as tachometer output. The tachometer
uses the engine speed signal received from the ECM to
display the engine speed.

1 2 3 4 5

HCW46ESF000401

Legend
1. Crankshaft Position (CKP) Sensor 4. Tachometer output
2. Engine Speed 5. Tachometer
3. Engine Control Module (ECM)
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-21

Idle position signal output to the exhaust brake and


retarder control unit
The Engine Control Module (ECM) outputs the
“accelerator pedal depression state (depressed/ not
depressed)” to the brake central control unit as an idle
position signal output.
The exhaust brake and retarder control unit uses the
“accelerator pedal depression state”, together with the
directly detected control operation states (exhaust
brake lever, retarder lever, clutch pedal etc.) to engage
and disengage the exhaust brake and retarder.

Accelerator Pedal
APP Engine Control
Position (APP)
Module (ECM)
Sensor

Idle Position
Signal Output
Exhaust Brake Switch
Exhaust Brake M/V

Retarder Switch
Exhaust Brake and
Retarder Control Unit Retarder M/V
Clutch Switch

HCW61ASF001301

Q Adjustment Data
When the vehicle is shipped, it has a label on the body
to notify of Q adjustment data. Use it to compare
against the content displayed on the scan tool (Tech2).
Label Positions

Q-ADJ T

HCW61ASF001401
1A-22 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Content of the label The ECM is installed under the center cluster inside the
cab. The ECM constantly monitors data sent from
various sensors, and controls the systems of the power
train. It performs diagnostic functions on systems,
detects problems in their operation and uses the MIL
1 2
(Check Engine lamp) to warn the driver, as well as
storing the DTC (diagnostic trouble code). The DTC
identifies the area affected by the problem and assists
the service engineer in making the repair.

ECM Functions
4 The ECM outputs 5V and other voltages to supply
power to the sensors and switches. This power supply
3 passes through the resistance of the ECM, so the
resistance is extremely high and even if a test light is
connected to the circuit, it will not light. In special
cases, the resistance of a normal multi meter may be
too low, so to obtain an accurate reading, it is
HCW46ESH003301 necessary to use a digital multi meter with an input
impedance of more than 10MΩ. Special tool 5-8840-
Legend
2691-0 is suitable. In the ECM, the ground or power
1. Q adjustment data numbers (Q1, Q2, Q3, from
supply circuits are controlled through transistors or
the left)
another device to control the output circuits.
2. Timing correction resistance value (not used)
3. Vehicle model
ECM and Component Parts
4. Factory management number (the number is
different for each vehicle) The ECM is designed to maintain gas emissions at
regulated levels while delivering superior driveability
and fuel efficiency. The ECM monitors the functions of
Engine Control Module (ECM) the engine and the vehicle through sensors such as the
The ECM Crank Position (CKP) sensor and the Vehicle Speed
(VS) sensor.

Explanation of ECM Voltage


The ECM applies standard voltage to various switches
and sensors. The ECM is able to apply voltages in this
way because its own resistance is very high, so that the
voltage actually applied to the circuit is low. In some
cases a test light connected to the circuit will not light.
The input impedance of the multi meter generally used
in servicing workshops is tool low, so they may not give
accurate readings in some cases. Use a digital multi
meter with input impedance of 10MΩ (For example, 5-
8840-2691-0) to obtain accurate readings.
ECM input/ output devices include analog/ digital
converters, signal buffers, counters and special drivers.
The ECM uses electronic switches to control most
components.
HCW4ADSH000301
Electrically Erasable Programmable ROM
(EEPROM)
The EEPROM is a permanent memory chip that is
soldered to the circuit board inside the ECM. It contains
the programs and calibration information the ECM
needs to control the actions of the power train.
The EEPROM cannot be replaced. Replace the ECM if
any malfunction is found in the EEPROM.
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-23
Precautions on ECM Servicing The PCV (Pump Control Valve) is attached to the
The ECM is designed to withstand normal current supply pump and controls the supply of fuel (output
consumption associated with driving. The circuits must volume) to the fuel rail. The Engine Control Module
not be overloaded. When testing for broken wires and (ECM) controls the time of communication to the PCV
short circuits, do not connect the ECM circuitry to a and so controls the fuel output volume.
ground connect or apply voltage to it, unless
specifically instructed to do so. Always use a digital
multi meter 5-8840-2691-0 to perform such circuit tests.

Supply Pump

HCW46ESH003601

The supply pump uses the rotary force of the ending to


highly pressurize fuel and pump it into the fuel rail. The
Pump Control Valve (PCV), Camshaft Position (CMP)
Sensor and feed pump are attached to the supply
pump.

PCV (Pump Control Valve)

MFW31ASH005001
1A-24 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Fuel Rail

HCW46DMF000101

Legend
1. Flow damper 3. Fuel pressure sensor
2. Pressure limiter

The fuel rail receives fuel from the supply pump, Flow Damper
maintains fuel rail (fuel) pressure and distributes fuel to
each cylinder. The fuel pressure sensor, flow damper
and pressure limiter are attached to the fuel rail.

HCW46ESH000101
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-25
The flow damper restricts pressure pulsation inside the Engine Coolant Temperature (ECT) Sensor
fuel rail and prevents injection of excess fuel through
the injectors. When the flow damper acts, fuel supply to
the injectors is stopped.

Pressure Limiter

3
2 1

HCW46ESH001201

Legend
1. Signal
2. Meter output
3. GND
HCW46ESH000201

The pressure limiter acts when pressure inside the fuel The engine coolant temperature (ECT) sensor is
rail becomes abnormally high, releasing the excess attached to the engine block thermostat housing. The
pressure. resistance of its thermistor changes with temperature.
The resistance value falls as the engine coolant
Fuel pressure sensor temperature rises, and vice versa. The Engine Control
Module (ECM) applies 5V to the ECT sensor through
the pull-up resistance and calculates the engine
coolant temperature from the change in that voltage.
The result is used in fuel injection control and other
control functions. The voltage is low when the
resistance is low (i.e. when the temperature is high),
and rises when the resistance is higher (when the
temperature is lower).

HCW46ESH000301

The fuel pressure sensor is attached to the fuel rail and


detects the fuel pressure inside it. The pressure is
converted into a voltage signal and sent to the Engine
Control Module (ECM). The voltage is higher with
higher pressure, and vice versa. The ECM calculates
the actual pressure in the fuel rail (the fuel pressure)
from the voltage signal sent by the sensor, and uses it
for fuel injection control and other purposes.
1A-26 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Cam Shaft Position (CMP) sensor Crankshaft position (CKP) sensor

1
1 2

HCW46ESH001101 HCW46ESH001301

Legend Legend
1. Signal 1. Signal (High)
2. GND 2. Signal (Low)
3. Power supply
The crank position (CKP) sensor is attached to the
The cam shaft position (CMP) sensor is attached to the flywheel housing. A CKP signal is generated when the
supply pump. A CMP signal is generated when the cam hole in the flywheel passes the sensor. The Engine
shaft inside the supply pump passes through the Control Module (ECM) identifies the cylinder from the
sensor. The Engine Control Module (ECM) identifies CKP signal and the CMP signal input from the cam
the cylinder from the crank shaft position (CKP) signal shaft position (CMP) sensor, determines the crank
and the CKP signal input from the CKP sensor, angle and uses it to calculate fuel injection control and
determines the crank angle and uses it to calculate fuel engine speed. These control functions are usually
injection control and engine speed. These control based on the CKP signal, but if the CKP sensor
functions are usually based on the CKP signal, but if malfunctions, they are based on the CMP signal.
the CKP sensor malfunctions, they are based on the
CMP signal.
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-27
Atmospheric Temperature Sensor Accelerator Pedal Position (APP) Sensor

2
3 2 1
1

HCW46ESH001401 HCW46ESH001501

Legend Legend
1. Signal 1. GND
2. GND 2. Signal
3. Temperature sensor 3. Power supply

The atmospheric temperature sensor is attached to the The Accelerator Pedal Position (APP) sensor is
inside of the front lid. The resistance of its thermistor attached to the top of the accelerator pedal and sends
changes with temperature. The resistance value falls a voltage signal to the Engine Control Module (ECM)
as the intake air (external air) temperature rises, and that corresponds to the angle of the accelerator pedal.
vice versa. The Engine Control Module (ECM) applies The ECM calculates the accelerator position from the
5V to the atmospheric temperature sensor through the voltage signal and uses it for fuel injection control and
pull-up resistance and calculates the intake air many other control functions.
temperature from the change in that voltage. The result
is used in fuel injection control and other control Vehicle Speed Sensor (VSS)
functions. The voltage is low when the resistance is low
(i.e. when the temperature is high), and rises when the
resistance is higher (when the temperature is lower).

MFW31ASH001401
1A-28 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
The Vehicle Speed sensor (VSS) is attached to the Atmospheric Pressure Sensor
transmission, and the Hall effect circuit is attached to it.
The magnet attached to the output shaft of the
transmission rotates with the shaft and interacts with
the magnetic field generated to send a signal to the
speed sensor control unit. The Engine Control Module
(ECM) receives the vehicle speed signal from the
speed sensor control unit.

Boost Sensor

HCW4ADSH000301

The atmospheric pressure sensor is mounted inside


3 2 1
the Engine Control Module (ECM) and converts
atmospheric pressure into a voltage signal. The ECM
calculates the atmospheric pressure from the voltage
signal and carries out compensation etc. according to
that pressure.

MFW4ADSH000901 Accelerator Pedal Position (APP) Switch


Legend
1. GND
2. Signal
3. Power supply

The boost sensor is connected to the intake duct of the


engine. It detects the boost (intake pressure) inside the
intake manifold, converts the pressure to a voltage
signal and sends it to the Engine Control Module
(ECM). The voltage is higher with higher pressure, and
vice versa. The ECM calculates the boost (the intake
pressure) from the voltage signal sent by the sensor,
and uses it for fuel injection control and other purposes.

MFW31ASH001201

The Accelerator Pedal Position (APP) switch is


attached to the top of the accelerator pedal and
supplies a switch signal to the Engine Control Module
(ECM) that corresponds to the position of the
accelerator pedal. The ECM calculates the accelerator
pedal position from the voltage signal and uses it for
fuel injection control and many other control functions.
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-29
PTO Remote Throttle Sensor The injectors are mounted on the cylinder head and
inject fuel under the control of the Engine Control
Module (ECM). The ECM raises the injector drive
voltage internally and applies it to the injectors. By
controlling the duration of power supply to the injectors,
it controls the volume, timing and other aspects of fuel
injection.

3 2 1

HCW46ESH001601

Legend
1. GND
2. Signal
3. Power supply

The PTO remote throttle sensor is attached outside the


cab as an external accelerator voltage signal to the
Engine Control Module (ECM) that changes according
to the angle of the accelerator pedal. The ECM
calculates the PTO accelerator opening from the
voltage signal and uses it for fuel injection control and
many other control functions.

Injectors

5A52 701E
35DD 2157
001F 5A00
0000 BD

HVW4ADSH000101

Legend
1. Injector ID code plate
2. Injectors
1A-30 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
MIL (Check Engine Lamp) Display
The MIL (check engine lamp) lights inside the meter. It
lights to warn the driver of a malfunction in the engine
or a related system. When the Engine Control Module
(ECM) detects a malfunction using its self-diagnostic
functions (vehicle-mounted malfunction diagnostic
system), it lights the MIL (check engine lamp). If the
diagnostics switch (the connection with the diagnostics
connector and the diagnostics common connector) is
switched On, the MIL (check engine lamp) flashes, and
the DTC detection status can be checked.
(Reference) The meter for the 6WF1

HCW51AMF000201

Diagnostics Connector, Data Link Connector (DLC)


Diagnostics Switch (diagnostics connector)
The diagnostics switch (diagnostics connector) is
attached to the inside of the inspection cover. When the
diagnostics connector and the diagnostics common
connector are connected, the MIL (check engine lamp)
inside the meter flashes and the DTC is displayed.

DLC (Data Link Connector)


The DLC (data link connector) is attached to the inside
of the inspection cover. It is the connector for
communications and connections with external
diagnostic devices (scan tools) and controllers.
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-31
Parts layout diagram

Instrument Panel
Lower Harness
1
3 4

2
5

HCW61ASH004501

Legend
1. Diagnostics connector (brown)
2. Memory clear connector (white)
3. Diagnostics common connector (green)
4. Data link connector (DLC), 20 terminals
5. Data link connector (DLC), 10 terminals
6. Data link connector (DLC), 3 terminals

Engine Component Layout Diagram

2 3 4 5
1 6

9 8
10

HCW61AMF003101

Legend
1A-32 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
1. Boost Sensor 6. EGR valve
2. EGR valve 7. Crankshaft position (CKP) sensor
3. Engine coolant temperature (ECT) sensor 8. Fuel pressure sensor
4. EGR gas temperature sensor 9. PCV
5. EGR gas temperature sensor 10. CMP sensor

Cab Interior Switch Layout Diagram

2
3

HCW61ALF000901

Legend
1. PTO Switch 4. Idling Control AUTO/MANU Switch
2. ASR Cut Switch 5. Idling Control UP/DOWN Switch
3. Cruise Main Switch
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-33
Cab Interior Control Unit Layout Diagram

2
9

6
7
8

Back of the Radio

<Bracket Section> <Lower Section> <Upper Section>


10 Without Digital Tachograph Without Digital Tachograph

12

11
13 17

18

<Lower Section>
With Digital Tachograph
14

16 15

HCW61AXF001001

Legend
1A-34 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
1. ECM Main Relay 10. Glow Relay
2. Exhaust Brake and Retarder Control Unit 11. QOS Control Unit
3. Tachograph 12. Flasher Unit
4. Speed Sensor Control Unit 13. MIMAMORI Control Unit
5. SRS Control Unit 14. Flasher Unit
6. Digital Tachograph 15. EBS Control Unit
7. ABS/ASR Control Unit 16. Cab Suspension Control Unit
8. Engine Control Module (ECM) 17. EBS Control Unit
9. Retractable Mirror Control Unit 18. Cab Suspension Control Unit

Chassis Component Layout Diagram


Chassis Section

3
1 2

5
6

HCW4ADMF001701

Legend
1. Atmospheric temperature sensor (inside open lit) 4. Transmission section (vehicle speed sensor,
2. Brake valve section neutral switch, reverse switch)
3. Cab rear member section (magnetic valve, PTO 5. Battery
remote throttle sensor) 6. Air tank section
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-35
Cab Rear Member Magnetic Valve

2 3 4 5

7 6

HCW4ADMF001201

Legend
1. Cab back member 5. VGS magnetic valve 3
2. Exhaust brake magnetic valve 6. VGS turbocharger pneumatic cylinder
3. VGS magnetic valve 1 7. Exhaust brake air cylinder
4. VGS magnetic valve 2
1A-36 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Circuit Diagram
ECM System Wiring Diagram
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-37
New Zealand

Starter Switch Engine Control Module (ECM)


48 Check Engine Lamp
82
Battery Relay
A 46
56 83 Cruise Set Lamp A
74 84 Cruise Main Lamp
75
Main Relay 5 Overheat Lamp
6 ( 1)11
Battery 7
Overheat Warning Buzzer
( )12

VGS Fail Safe Relay


APP Sensor 65 A N.C
21
55
( ) 47
CKP Sensor
40 ( )111 M/V;VGS 1
41 ( )112 M/V;VGS 2
39 ( )113
( )114 M/V;VGS 3
133
CMP Sensor 120 ( )115 Injector Power Supply 1
131 106
123 107
Fuel Pressure 121
Sensor 132 103 Injector Signal 1 (Cyl.1)
136
Atmospheric Injector Signal 3 (Cyl.3)
Temperature 104
154
Sensor 135 Injector Signal 5 (Cyl.2)
105
ECT Sensor 155
Injector Power Supply 2
142
143
EGR Gas Temperature 54 Injector Signal 2 (Cyl.5)
Sensor 1 33 137
Injector Signal 4 (Cyl.6)
138
EGR Gas Temperature Injector Signal 6 (Cyl.4)
Sensor 2 30 139
PTO Control Resistance
34 95 CAN H Other
126 96 CAN L ECU
Boost Sensor 128
134
Vehicle
PTO Remote 27 Speed TCM
Throttle Sensor 23 Sensor

Other ECU

1 : 6WF1 Engine
2 : 6WG1 Engine

HCW61AXF001101
1A-38 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

153

PCV 1
152

151 A
PCV 2
Diagnostics Switch 150
68
M/V;Exh.Brake
Parking Brake Switch
97 M/V;Exh.Brake Operation Signal
( 2)91

Accelerator Switch Signal Output


Low Air Pressure Switch ( 2)10
87( 1)
Exh.Brake Drive Signal M/V;Retarder
42
Retarder Drive Signal Exhaust Brake
Stop Lamp Switch 1
53 45 and Retarder
Control Unit
9 Tachometer
Stop Lamp Switch 2
80

Data Link
Neutral Switch 19
61
Connector
N.C Starter Relay

Back Lamp switch


A 77 Starter Switch

44 A
Clutch Switch
52 Starter Cut Relay

Accelerator Switch
58

Cruise Resume Switch


92

Cruise Set Switch


79

Exhaust Brake Switch EGR Fail Safe Relay


49( 1)

B N.C
Cruise Main Switch
60

110
Cruise Release Switch 1 M/V;EGR 1
93 108

M/V;EGR 2
Retarder Switch 109
59

Idling MANU/AUTO Switch


88
Idling Up Switch
81

Idling Down Switch


99 72

73
PTO Switch
89
102

Cruise Release Switch 2 140


94( 2)
(Exhaust Brake Switch) 141

Engine Control Module (ECM)

1 : 6WF1 Engine
2 : 6WG1 Engine

HCW61AXF001201
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-39
G. Exp

Starter Switch Engine Control Module (ECM)


48 Check Engine Lamp
82
Battery Relay
A 46
56 83 Cruise Set Lamp A
74 84 Cruise Main Lamp
75
Main Relay 5 Overheat Lamp
6 ( 1)11
Battery 7
Overheat Warning Buzzer
( )12

VGS Fail Safe Relay


APP Sensor 65 A N.C
21
55
( ) 47
CKP Sensor
40 ( )111 M/V;VGS 1
41 ( )112 M/V;VGS 2
39 ( )113
( )114 M/V;VGS 3
133
CMP Sensor 120 ( )115 Injector Power Supply 1
131 106
123 107
Fuel Pressure 121
Sensor 132 103 Injector Signal 1 (Cyl.1)
136
Atmospheric Injector Signal 3 (Cyl.3)
Temperature 104
154
Sensor 135 Injector Signal 5 (Cyl.2)
105
ECT Sensor 155
Injector Power Supply 2
142
143
EGR Gas Temperature 54 Injector Signal 2 (Cyl.5)
Sensor 1 33 137
Injector Signal 4 (Cyl.6)
138
EGR Gas Temperature Injector Signal 6 (Cyl.4)
Sensor 2 30 139
PTO Control Resistance
34 95 CAN H Other
126 96 CAN L ECU
Boost Sensor 128
134
Vehicle
PTO Remote 27 Speed TCM
Throttle Sensor 23 Sensor

Other ECU

1 : 6WF1 Engine
2 : 6WG1 Engine

HCW61AXF001101
1A-40 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

153

PCV 1
152

151 A
PCV 2
Diagnostics Switch 150
68
M/V;Exh.Brake
Parking Brake Switch
97 M/V;Exh.Brake Operation Signal
( 2)91

Accelerator Switch Signal Output


Low Air Pressure Switch ( 2)10
87( 1)
Exh.Brake Drive Signal M/V;Retarder
42
Retarder Drive Signal Exhaust Brake
Stop Lamp Switch 1
53 45 and Retarder
Control Unit
9 Tachometer
Stop Lamp Switch 2
80

Data Link
Neutral Switch 19
61
Connector
N.C Starter Relay

Back Lamp switch


A 77 Starter Switch

44 A
Clutch Switch
52 Starter Cut Relay

Accelerator Switch
58

Cruise Resume Switch


92

Cruise Set Switch


79

Exhaust Brake Switch EGR Fail Safe Relay


49( 1)

B N.C
Cruise Main Switch
60

110
Cruise Release Switch 1 M/V;EGR 1
93 108

M/V;EGR 2
Retarder Switch 109
59

Idling MANU/AUTO Switch


88
Idling Up Switch
81

Idling Down Switch


99 72

73
PTO Switch
89
102

Cruise Release Switch 2 140


94( 2)
(Exhaust Brake Switch) 141

Engine Control Module (ECM)

1 : 6WF1 Engine
2 : 6WG1 Engine

HCW61AXF001201
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-41
ECM Pin Layout
NOTE:
Use the right control unit for the vehicle, as stated in the
“Comment text” and “Applicable engine identifier name”
stated in the labels.
Use of the wrong control unit for the vehicle will cause
breakdowns.

167 162 136 129 101 97 69 62 34 28


161 154 128 118 96 87 61 54 27 18
153 144 117 108 86 77 53 42 17 8
143 137 107 102 76 70 41 35 7 1

HCS4Z0LF002101

New Zealand
Terminal Terminal
Signal name Signal name
No. No.
1 – 85 –
2 – 86 –
3 – 87 Low air pressure switch signal [6WF1]
4 – 88 Idling MANU/AUTO switch signal
5 Power supply (Main relay) 89 PTO switch signal
6 Power supply (Main relay) 90 –
1A-42 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

Terminal Terminal
Signal name Signal name
No. No.
7 Power supply (Main relay) 91 Exhaust brake magnetic valve (M/V) action
signal input [6WG1]
8 – 92 Cruise resume switch signal
9 Tachometer 93 Cruise release switch 1 signal
10 Accelerator switch signal output [6WG1] 94 Cruise release switch 2 (Exhaust Brake
Switch) signal [6WG1]
11 Overheat lamp [6WF1] 95 CAN-HIGH
12 Overheat buzzer [6WF1] 96 CAN-LOW
13 – 97 Parking brake switch signal
14 – 98 –
15 – 99 Idling Down switch signal
16 – 100 –
17 – 101 –
18 – 102 GND
19 Data link connector (DLC) 103 Injector 1 (No. 1 cylinder)
20 – 104 Injector 3 (No. 3 cylinder)
21 Accelerator pedal position (APP) sensor 105 Injector 5 (No. 2 cylinder)
signal
22 – 106 Injector power supply (injector 1, 3, 5)
23 PTO remote throttle sensor signal 107 Injector power supply (injector 1, 3, 5)
24 – 108 EGR M/V 1
25 – 109 EGR M/V 2
26 – 110 EGR fail safe relay
27 Vehicle speed sensor signal 111 VGS M/V 1 [6WG1]
28 – 112 VGS M/V 2 [6WG1]
29 – 113 VGS M/V 2 [6WG1]
30 EGR gas temperature sensor 2 signal 114 VGS M/V 3 [6WG1]
31 – 115 VGS M/V 3 [6WG1]
32 – 116 –
33 EGR gas temperature sensor 1 signal 117 –
34 PTO control resistance 118 –
35 – 119 –
36 – 120 Camshaft position (CMP) sensor signal
37 – 121 Fuel pressure sensor signal
38 – 122 –
39 Crankshaft position (CKP) sensor shield 123 Fuel pressure sensor power supply
40 CKP sensor (+) 124 –
41 CKP sensor (-) 125 –
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-43

Terminal Terminal
Signal name Signal name
No. No.
42 Exhaust brake drive signal output 126 Boost and PTO remote throttle sensors
power supply
43 – 127 –
44 Starter cut relay 128 Boost sensor signal
45 Retarder drive signal output 129 –
46 Starter switch “ON” signal (Battery relay) 130 –
47 VGS fail safe relay [6WG1] 131 CMP sensor GND
48 Starter switch “START” signal 132 Fuel pressure sensor signal
49 Exhaust brake switch signal [6WF1] 133 CMP sensor power supply
50 Engine stop switch signal 134 Boost, PTO remote throttle sensors GND
51 – 135 Engine coolant temperature (ECT) and
atmospheric temperature sensors GND
52 Clutch switch signal 136 Fuel pressure sensor GND
53 Stop lamp switch 1 signal 137 Injector 2 (No. 5 cylinder)
54 EGR gas temperature sensors and PTO 138 Injector 4 (No. 6 cylinder)
control resistance GND
55 APP sensor GND 139 Injector 6 (No. 4 cylinder)
56 Starter switch “ON” signal (Battery relay) 140 GND
57 – 141 GND
58 Accelerator switch signal 142 Injector power supply (injector 2, 4, 6)
59 Retarder switch signal 143 Injector power supply (injector 2, 4, 6)
60 Cruise main switch signal 144 –
61 Neutral switch signal 145 –
62 – 146 –
63 – 147 –
64 – 148 –
65 APP sensor power supply 149 –
66 – 150 Pomp control valve (PCV) 2
67 – 151 PCV 2
68 Diagnostics switch 152 PCV 1
69 – 153 PCV 1
70 – 154 Atmospheric temperature sensor signal
71 – 155 ECT sensor signal
72 ECM GND 156 –
73 ECM GND 157 –
74 ECM main relay 158 –
75 ECM main relay 159 –
76 – 160 –
1A-44 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

Terminal Terminal
Signal name Signal name
No. No.
77 Back lamp switch signal 161 –
78 – 162 –
79 Cruise Set switch signal 163 –
80 Stop lamp switch 2 signal 164 –
81 Idling Up switch signal 165 –
82 Check engine lamp 166 –
83 Cruise set lamp 167 –
84 Cruise main lamp – –

G. Exp
Terminal Terminal
Signal name Signal name
No. No.
1 – 85 PTO control indicator lamp
2 – 86 –
3 – 87 Low air pressure switch signal
4 – 88 Idling MANU/AUTO switch signal
5 Power supply (Main relay) 89 PTO switch signal
6 Power supply (Main relay) 90 –
7 Power supply (Main relay) 91 –
8 – 92 Cruise resume switch signal
9 Tachometer 93 Cruise release switch 1 signal
10 – 94 Cruise release switch 2 signal
11 Overheat lamp 95 –
12 Overheat buzzer 96 –
13 – 97 Parking brake switch signal
14 – 98 –
15 – 99 Idling Down switch signal
16 – 100 –
17 – 101 –
18 – 102 GND
19 Data link connector (DLC) 103 Injector 1 (No. 1 cylinder)
20 – 104 Injector 3 (No. 3 cylinder)
21 Accelerator pedal position (APP) sensor 105 Injector 5 (No. 2 cylinder)
signal
22 – 106 Injector power supply (injector 1, 3, 5)
23 PTO remote throttle sensor signal 107 Injector power supply (injector 1, 3, 5)
24 – 108 EGR M/V 1
25 – 109 EGR M/V 2
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-45

Terminal Terminal
Signal name Signal name
No. No.
26 – 110 EGR fail safe relay
27 Vehicle speed sensor signal 111 –
28 – 112 –
29 – 113 –
30 EGR gas temperature sensor 2 signal 114 –
31 – 115 –
32 – 116 –
33 EGR gas temperature sensor 1 signal 117 –
34 PTO control resistance 118 –
35 – 119 –
36 – 120 Camshaft position (CMP) sensor signal
37 – 121 Fuel pressure sensor signal
38 – 122 –
39 Crankshaft position (CKP) sensor shield 123 Fuel pressure sensor power supply
40 CKP sensor (+) 124 –
41 CKP sensor (-) 125 –
42 Exhaust brake drive signal output 126 Boost and PTO remote throttle sensors
power supply
43 – 127 –
44 Starter cut relay 128 Boost sensor signal
45 Retarder drive signal output 129 –
46 Starter switch “ON” signal (Battery relay) 130 –
47 – 131 CMP sensor GND
48 Starter switch “START” signal 132 Fuel pressure sensor signal
49 Exhaust brake switch signal 133 CMP sensor power supply
50 Engine stop switch signal 134 Boost, PTO remote throttle sensors GND
51 – 135 Engine coolant temperature (ECT) and
atmospheric temperature sensors GND
52 Clutch switch signal 136 Fuel pressure sensor GND
53 Stop lamp switch 1 signal 137 Injector 2 (No. 5 cylinder)
54 EGR gas temperature sensors and PTO 138 Injector 4 (No. 6 cylinder)
control resistance GND
55 APP sensor GND 139 Injector 6 (No. 4 cylinder)
56 Starter switch “ON” signal (Battery relay) 140 GND
57 – 141 GND
58 Accelerator switch signal 142 Injector power supply (injector 2, 4, 6)
59 Retarder switch signal 143 Injector power supply (injector 2, 4, 6)
60 Cruise main switch signal 144 –
1A-46 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

Terminal Terminal
Signal name Signal name
No. No.
61 Neutral switch signal 145 –
62 – 146 –
63 – 147 –
64 – 148 –
65 APP sensor power supply 149 –
66 – 150 Pomp control valve (PCV) 2
67 – 151 PCV 2
68 Diagnostics switch 152 PCV 1
69 – 153 PCV 1
70 – 154 Atmospheric temperature sensor signal
71 – 155 ECT sensor signal
72 ECM GND 156 –
73 ECM GND 157 –
74 ECM main relay 158 –
75 ECM main relay 159 –
76 – 160 –
77 Back lamp switch signal 161 –
78 – 162 –
79 Cruise Set switch signal 163 –
80 Stop lamp switch 2 signal 164 –
81 Idling Up switch signal 165 –
82 Check engine lamp 166 –
83 Cruise set lamp 167 –
84 Cruise main lamp – –
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-47
ECM Circuit Diagram
New Zealand
1/6

FUSE10 FU55 0.5B/R


J/T:ILLUMINATION

1.25R/G
H7
79

0.5B/R
33 FL68
J/C:4 22
29 FL659

0.85R/G
FUSE17 0.5V/W 20 J/C:5

0.3B/R
FL658 H48
J/C:FUSE17 22 12 H48
0.5V/W

0.85R/G
0.85B/R 18 A IDLING SPEED CONTROL 13
FL1(2) SWITCH(AUTO/MANUAL)

0.3B/R
STARTER 19 CLOSE;MANUAL , OPEN;AUTO
SWITCH 20
21 0.85R/G G53 G53 1 0.3B/R G60
G59 4 J/T:ILLUMINATION
0.5V/W H48 0.5V/W J/T:TAIL
14 5 G53 G53 3
33
IDLING SPEED CONTROL

0.5V/W
FL658
SWITCH (UP/DOWN)

0.5P/W
0.5V/W
J/C:STARTER 31
0.5V/W
SWITCH UP FL134
2 1 4
FL4 FL2 5 FL134
EXCEPT FL134 2
ACCEL CLUTCH DOWN
Smoother-G.AND
SWITCH SWITCH A/T MODEL

DOWN 0.5P/G
H48

0.5P/B
FL4 FL2 7
1 2

0.5P/W
KEY ON 0.5V/W

KEY ON 0.5V/W
0.5B/R

0.5V

EXCEPT A/T MODEL


0.5V/R

UP
2 0.5V/R H282 0.5V/R F70(16)
FL560 Smoother-G
J/C:CLUTCH 2 8 CONTROL
4 UNIT
0.5V/R

48 46 56 58 52 99 81 88
FL558 FL558 FL558 FL558 FL558 FL559 FL559 FL559

ENGINE CONTROL MODULE (ECM)

FL656 FL559 FL559 FL559 FL557 FL558 FL559 FL557 FL558 FL558 FL559
J/C:EXHAUST BRAKE MAGNETIC VALVE 2 91 2 94 97 27 53 80 10 49 59 87
FL522(20) EXHAUST&RETARDER 0.5L/Y 0.5L/Y
0.3H/B

CONTROL UNIT 22 20 FL656 2 1


0.3P/L

J/C:EXHAUST BRAKE SWITCH


FL9(18) COMBINATION SWITCH 0.5L/Y 0.5L/Y
14 12

0.3Y/G
0.5L/W
0.5L/Y
16
FB145(1) PARKING BRAKE SWITCH 0.5L/B H301 0.5L/B H10 0.3L/B FL560
9 49 22 J/C:PARKING 6
FL11(3) SPEED SENSOR 0.5P/L FL659
CONTROL UNIT 11 J/C:5
AUTO CRUISE CONTROL ONLY FL658
J/C:STOP LIGHT SWITCH 1
FL21(1) STOPLIGHT SWITCH 0.3G/B 0.3G/B 6 FL560
28 26 J/C:LOW AIR
PRESSURE
FL658 11
J/C:STOP LIGHT SWITCH 2
0.3Y/G

FL20(1) STOPLIGHT SWITCH 0.3G 0.3G


25 23
FL522(1) EXHAUST&RETARDER 0.3V/W
CONTROL UNIT H6
FL9(18) COMBINATION SWITCH 0.5L/Y 38
FL655
0.5Y/G

FL9(20)COMBINATION SWITCH 0.5L/W J/C:RETARDER


32 30
0.5Y/G
H299 3
J77 FB263
J12(1) LOW AIR PRESSURE SWITCH 0.5Y/G J/T LOW AIR PRESSURE J/T:
(SECONDARY) AIR SUSPENSION
CYJ5 ,EXY5 MODEL
J24(1) LOW AIR PRESSURE SWITCH 0.5Y/G ONLY
(PRIMARY)
J43(1) LOW AIR PRESSURE SWITCH 0.5Y/G
(MAIN)
J44(1) LOW AIR PRESSURE SWITCH 0.5Y/G
(ACCESSORY) 1 6WF1 MODEL ONLY
2 6WG1 MODEL ONLY
J46(1) LOW AIR PRESSURE SWITCH 0.5Y/G
(WHEEL PARK)

HCW58DXF032801
1A-48 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
2/6

AUTO CRUISE CONTROL ONLY


FL605(5) 0.3L/P
EXHAUST BRAKE RELAY
FL54(5) 0.3L/W
RETARDER RELAY
FL658
FU7 J/C:TACHO J/C:TACHO 4P
FU9(5) TACHO METER 0.3W/R 0.3W/R H7 0.3W/R
 6 5 1 15
14

FL400(4) STARTER CUT RELAY 0.3W/B

0.5LG 0.5LG FL658
F11(2) PTO SWITCH H12 14 4 J/C:PTO
2
FL531(3) CAN L 0.5L

FL531(6) CAN H 0.5L/W

FL661(3) ENGINE STOP


CONNECTOR

0.5LG
0.5L/Y

ENGINE STOP ONLY

TACHO OUT (4P)


ENG STOP

EXH.(REQ)
RET.(REQ)
CAN-L
CAN-H

50 95 96 89 44 9 45 42
FL558 FL559 FL559 FL559 FL558 FL557 FL558 FL558

ENGINE CONTROL MODULE (ECM)

E72 E71 E72 FL558 FL557 FL558 FL557


155 135 154 65 21 55 19
GND

0.5GY/L GND
VCC
SIG

SIG

SIG

0.3BR
0.3Y/R

0.3V/R
0.3Y

29 FL511
30 J/C:DATA LINK
0.5GY
H162 H162 H162 CONNECTOR
5 6 7
FU9(7) METER
0.5BR
0.3V/R
0.3Y/G

1
H7
FL537 FL536

SRS CONNECTOR
4 (B)
0.3V/R SRS CONNECTOR
(A)
0.3Y/G

0.3Y/R

1
0.3Y

H20 H20
H10 H10 H10 1 5
0.85BR

49 50 51
0.5Y/G

0.5Y/R

0.5L/W
0.5L/R
0.5V/R

0.5Y/R
0.5Y

0.5L

FL535(15)
2 1 3 SRS CONTROL
UNIT
FB155 FB155 FB155
1 2 3 2 1
I4 I4 FL133 FL133 FL133

COOLANT OUTSIDE ACCELERATION


TEMPERATURE SENSOR TEMPERATURE SENSOR SENSOR

HCW58DXF032901
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-49
3/6

FUSE10 1.25R/G
A 0.5V/W
0.3B/R FU35(8)METER
FL657 AUTO CRUISE CONTROL ONLY
J/C:
FUSE11 0.85Y 22 FUSE11
21 FU55
0.85Y J/T:ILLMINATION

0.5B/R
H7
42 0.5Y H7
0.85Y

0.5Y 79
FU58 0.5Y

0.5B/R
J/T: 10
FUSE11 33 22
FU18

FL68 FL659
INDICATOR LIGHT

23 J/C:4 12 J/C:5
0.5Y

0.5V/W
OVER HEAT

9 16 9

AUTO CRUISE MAIN


16

AUTO CRUISE SET


FU8
FU33
FU8
INDICATOR LIGHT

INDICATOR LIGHT

INDICATOR LIGHT
FU18

0.5R/G

0.3B/R

FL9
3 AUTO CRUISE CONTROL
MAIN SWITCH 16
0.3G

RELEASE SWITCH
6

RESUME SWITCH
6 FL532 5 6 FL532 2

AUTO CRUISE

AUTO CRUISE

AUTO CRUISE
FU62

SET SWITCH
0.3O/B FU5

0.3V/R FU33

FU33
5 J/C:
IE

6 OVER HEAT 15 14 0.5V/W


FL511(4) 3 FL532 1 2 FL532 1
0.3G

DIAGNOSIS JOINT
CONNECTOR 0.3Y
15 11 26
H7 H7 H7 H7

FL559 0.5L/R FL9

FL559 0.5V/R FL9

FL559 0.5V/G FL10


3 2 61 62
15 11 7
FL558 0.3B/W

FL559 0.3O/B

FL559 0.3V/R
0.3G

0.3Y

FL558 0.5V
68 82 11 84 83 60 79 92 93
FL557

FL559

ENGINE CONTROL MODULE (ECM)


0.3B/G FL558

FL559

FL558
FL558
FL558

G-VCC E71
G-SIG E71
0.5GY G-GND E71

E71
E71
E71
E71
61 77 40 41 39 133 120 131 121 132 123 136
0.5R/L

0.5Y NE (+)

SIG-1
SIG-2
0.5BR NE (-)

GND
VCC
7 29
FL658 FL560
0.5GY/W

0.5GY
J/C:NUETRAL 11 33 J/C:BACK
0.85R/L
0.3B/G

9 28
H10 H10
1 2
0.5GY/W H162 0.5GY/W

3
0.85R/L
0.5B/G

0.5Y H162
0.5BR H162

0.5W/L
0.5O/L
0.5W
0.5B

0.5W
0.5O
0.5R

H158 3 FB274
FULLER T/M J/T:BACK
M40(2) 0.5B/G H158 2
NEUTRAL SWITCH MJX16 MANUAL
H175 0.5GY/W

H177 0.5GY
H177 0.5GY

H387 36 1 2 3 4 3 2 1 12 11 10 9 5
0.85R/L

Smoother-G
H177
H177
H177

H177
H177
H177
H177
H175
H175

0.5B/G H215
2
Smoother-G
0.5B

0.5B

0.5B

H158 1
0.5W
0.5O

FULLER T/M
M5(2) 0.85R/L H158 4
BACK LIGHT SWITCH MJX16 MANUAL
0.5BR

E42 0.5W/L
0.5W
0.5B

E42 0.5O/L
0.5R
0.5Y

E42 0.5W

H387 41
Smoother-G 2 1 3 1 2 2 3 1
E45
E45

E46
E46
E46

H215 4
Smoother-G
NE SENSOR G-SENSOR FUEL PRESSURE
(CRANKSHAFT SENSOR
SPEED)
HCW58DXF033001
1A-50 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
4/6

DIODE
(WATER BUZZER)
0.3Y/V 0.3G/Y 0.3G/Y 0.3G/Y FU28(14)
9 3 FL385 FL385 4 15 H7 METER(WATER LEVEL)

FL650
J/C:BUZZER

AUTO CLUTCH & FL657


AIR SUSPENSION BUZZER J/C:FUSE11
0.3Y/V 0.85Y 0.85Y FUSE11
10 2 FL397 FL397 1 20 22

DIODE(BUZZER)
F56 1 0.3W/O 0.3W/O
24 H290
0.3W/O H10 0.5W/O H304 0.5W/O H42
1 16 1 J67(3)
AIR SUSPENSION
0.3Y/V 0.3Y/V F56 BUZZER
11 2 H280 2
8 0.3W/L
F56 3 F70(21)
Smoother-G CONTROL UNIT
0.3Y/V

12
FL557

ENGINE CONTROL MODULE(ECM)

FL557
FL557

FL558

FL557

FL557

E71
E71
E71

33 54 30 34 128 126 134 23


G-GND
G-VCC
G-SIG
GND
SIG

SIG

H162 0.5L/W SIG


0.5G/B

FL655 15
J/C:EGR
21 GRAND
0.5GY/B
0.5GY

20
22
0.5G/W
0.5G/B

0.5G/B
0.5G/O
0.5G/Y

0.5GY

12 13 14
0.5W

0.5B
0.5R

2 1
H162

H162

H162

FL552

FL552

0.5L/W
0.5L/R
0.5L
0.5G/W
0.5G/B

0.5G/Y

PTO MODE
H176 0.5GY

0.5GY H357 0.5GY

CONNECTOR
13 14 15 16 3 4 2 8
H176
H176
H176

H357
H357
H357

1 2 3
H176

H176

H176

0.5B

0.5L/W
0.5L/R
0.5L
0.5W

0.5B
0.5R
0.5G/W
0.5G/B

0.5G/B
0.5G/Y

2 1 2 1 2 3 1 2 3 1
E75

E75

E76

E76

E36
E36
E36

SIG B14
+5V B14
GND B14

EGR EGR BOOST PRESSURE ALL SPEED


TEMPERATURE TEMPERATURE SENSOR ACCELERATION
SENSOR 1 SENSOR 2 SENSOR HCW58DXF033101
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-51
5/6
3W
SLOW BLOW FUSE 1
FL519 FL520
3L/W
SLOW BLOW FUSE 3
J/T: SBF1 J/T: SBF3

3L/W

3L/W
3W

(7.5A)
FUSE49

FUSE16

FUSE48
(15A)

(15A)
1.25W/L
0.5V/W
1.25O

IE MAIN RELAY

FL398

0.5V/W
5
FL398

0.5V/W
1

1.25R/B
1.250
FL398 FL398 EGR RELAY
2 4
FL555 FL555

0.5V/W
1 4
VGS RELAY
FL555
3
FL554 FL554

0.5V/W
FL555 1 4
5
FL554

0.3BR/G
3
FL554
1.25R/B

1.25R/B

1.25R/B

5
0.3R/L

0.3R/L

4
H162

0.3SB
0.3BR/G
75 74 7 6 5 110 47

FL559 FL559 FL557 FL557 FL557 E71 FL558

ENGINE CONTROL MODULE(ECM)

E72 E72 E72 E72 E71 E71 E71 E71 E71 E71 E71

153 152 151 150 108 109 111 112 113 114 115
0.5Y/BR
0.5Y/BR
0.5Y/V

0.5Y/V

1.25WL

1.25WL
0.5W/R
0.5P/W
0.5R/W

0.5R/W

0.5R/B

0.5R/B

5 2
E73

4 J/C; (1) 1 1 3 19 20
0.5Y/G
0.5Y/R
0.5Y/B

0.5Y/BR

6 3
0.5Y/V

9 8 11 6 H162 H162 H162 H162

H176 H177 H176 H177

10 9 7 6 5

H357 H357 H357 H357 H357


0.5R/W

0.5R/W

0.5Y/BR
0.5R/B

0.5R/B

0.5Y/G
0.5Y/R
0.5Y/B

0.5Y/V

1 1 1 1 1
M/V:VGS 3
M/V:EGR 2
M/V:EGR 1

M/V:VGS 1

M/V:VGS 2

B54 B55 B43 B44 B45


0.5R/W

B54 B55 B43 B44 B45


0.5R/B
PRESSURE CONTROL

PRESSURE CONTROL

2 2 2 2 2

2 2
VALVE 1

VALVE 2

E43 E44
0.5W/R

0.5W/R

0.5P/W

0.5P/W

0.5P/W

1.25W/L

1.25W/L
0.5W/R
0.5P/W

E43 E44

1 1

0.5P/W
1.25W/L

1.25W/L

H357
12

0.5W/R
H357
11

1.25W/L
H176
10

1.25W/L
H177
7

HCW58DXF033201
1A-52 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
6/6

ENGINE CONTROL MODULE(ECM)

E71 E71 E71 E71 E71 E72 E72 E72 E72 E72 E71 E72 E72 FL559 FL559

106 103 105 107 104 142 139 137 143 138 102 140 141 72 73

POWER.GND

POWER.GND

POWER.GND

ECU.GND

ECU.GND
1.25B/P

1.25B/P
0.5B

0.5B

5B
* *
0.5GY 0.5GY FL65 29
E59
CASE J/C:1 30
1 3 2
EARTH 33

E74

1.25B

1.25B

1.25B
J/C:1
0.85W

0.85W
0.85G

0.85G
0.85R

0.85R
0.85Y

0.85B

0.85Y

0.85B
0.85L

0.85L

0.85B/O
0.5GY 0.5GY

1.25B

H175 H175 H175 H176 H176 H176


4 5 7 8 6 12
1.25B

H176 H176 H176 H175 H175 H357


4 7 5 8 6 1
1.25B

E78

J/T:
FRAME EARTH
H39

13
1.25B

CYH,CYJ CYZ,EXZ H6
MODEL MODEL
0.85W

83
0.85G

0.85R
0.85Y

0.85B
0.85L
0.85W
0.85L

0.85G
0.85Y

0.85R

FB376 FB267

J/T: J/T:
EARTH EARTH
5B

5B

(CAB GND) (GVNR GND)

0.85B/O

FB39 FB40

* *
CAB EARTH

3 2 7 4 6 3 2 7 4 6
5B

H179 H179 H179 H179 H179 H180 H180 H180 H180 H180 FB82

H179 H179 H179 H179 H179 H180 H180 H180 H180 H180
FRAME
7 6 3 8 2 7 6 3 8 2 EARTH(3)
0.75BR
0.75W

0.75W
0.75G
0.75R

0.75R

0.75Y

0.75B

0.75V
0.75L

E77

0.75R 0.75R 0.75W 0.75W

FRAME EARTH
1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 (ENGINE)
E53 E53 E53 E57 E57 E57 E55 E55 E55 E58 E58 E58 E54 E54 E54 E56 E56 E56
INJECTOR.1 INJECTOR.2 INJECTOR.3 INJECTOR.4 INJECTOR.5 INJECTOR.6
CYLINDER NO.1 CYLINDER NO.5 CYLINDER NO.3 CYLINDER NO.6 CYLINDER NO.2 CYLINDER NO.4

INSIDE CYLINDER HEAD COVER

* : END OF CABLE OPEN

HCW58DXF033301
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-53
G. Exp
1/5

0.5V/W
FUSE17 A 0.5V/W
B
FUSE9

IDLE SWITCH (AUTO/MANUAL)


CLOSE;MANUAL,OPEN;AUTO

0.5B/W

0.5V/W
0.5V/W
FL585 FL585
1 1

0.5V/W

0.5V/W

0.5V/W
IDLING SPEED CONTROL
SWITCH (UP/DOWN)
UP
FL134
2 1 4
FL134
FL4 FL182 5
FL134
2

0.5V/W
DOWN
ACCEL CLUTCH
SWITCH SWITCH

0.5P/W
0.5P/G

0.5P/B
FL4 FL182

1 2

0.5V/R
0.5V
H256 H400 H400 H256 H256 H256 H256 H256
9 9 8 17 16 12 13 11
0.5B/W

0.5V/W

0.5V/W

0.5P/W
0.5P/G
0.5V/R

0.5P/B
0.5V
START SW

KEY ON

KEY ON

DOWN

UP
48 46 56 58 52 99 81 88

FL558 FL558 FL558 FL558 FL558 FL559 FL559 FL559

ENGINE CONTROL MODULE (ECM)

FL559 FL557 FL558 FL559 FL558 FL559 FL558 FL558 FL559

97 27 53 80 61 77 49 59 87
0.3L/B

0.3P/L

0.5L/ 0.5L/ 0.5L/B 0.3L/B


FB145(1) PARKING BRAKE SWITCH H390 H10 H257

0.5L/W
0.3B/G

49 0.5R/L

0.5L/Y
2 10

0.3Y/G
0.5P/L
FL11(3) SPEED SENSOR H257
9
H257

0.5G/B 0.3G/B 0.3G/B 11


FL21(1) STOPLIGHT SWITCH H257
7

0.5G 0.3G 0.3G 0.3Y/G


FL20(1) STOPLIGHT SWITCH H257
8

MJT
0.5B/G 0.5B/G 0.5B/G 0.3B/G
MAL6 M40(2) NEUTRAL SWITCH H158 H10 H400
0.5Y/G

2 9 17
MJX16-MANUAL

0.5R/L
H10 H400
28 18
H10
0.5L/Y 23
FL9(18) COMBINATION SWITCH H257
16
0.5Y/G

H257
5

0.5Y/G
H299
3

J77
J12(1) LOW AIR PRESSURE SWITCH 0.5Y/G J/T:LOW AIR PRESSURE
(SECONDARY)

J24(1)LOW AIR PRESSURE SWITCH 0.5Y/G


(PRIMARY)

J43(1)LOW AIR PRESSURE SWITCH 0.5Y/G


(MAIN)

J44(1) LOW AIR PRESSURE SWITCH 0.5Y/G


(ACCESSORY)

J46(1)LOW AIR PRESSURE SWITCH 0.5Y/G


(WHEEL PARK)

HCW58DXF033401
1A-54 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
2/5

FL128(4) 0.3L/P
EXHAUST BRAKE RELAY

0.3W/R 0.3W/R
FU72(23) TACHO METER H7
1

 0.3W/B
FL400(4) STARTER CUT RELAY

FU14(1) PTO SWITCH 0.5LG 0.5LG
H7 82

0.5LG
H257 H256 H257 H257 H257
1 15 6 4 3
H256
10

TACHO OUT (4P) 0.3W/R


0.5LG

0.3W/B

0.3L/W

0.3L/P
0.5L/Y

ENGINE STOP ONLY


ENG STOP

EXH.(REQ)
RET.(REQ)
50 89 44 9 45 42
FL558 FL559 FL558 FL557 FL558 FL558

ENGINE CONTROL MODULE (ECM)

E72 E71 E72 FL558 FL557 FL558 FL557


155 135 154 65 21 55 19
GND

0.5GY/L GND
0.5L/R VCC
SIG

SIG

0.5L/W SIG
0.3Y/R

0.3V/R
0.3Y

0.3BR
0.5GY
H316 H316 H316
12 13 14
FU8(12) METER
0.5L
0.5Y/V

0.3Y/R

0.3V/R
0.3Y

0.5GY

H256
H7 H400 H400 H257 14
4 3 2 12 H256 H256 H256 H256
21 22 20 19
0.5GY
0.3Y/R
0.5Y/V

0.3Y

0.5BR

H10 H10 H10


64 81 80
0.3V/R

0.3Y/R
0.5Y/G

0.5Y/R

0.5L/W
0.5L/R

0.5GL
0.5Y

2 1 3
FB155 FB155 FB155
1 2 3 2 1
FL466 FL466 FL133 FL133 FL133
1
FL223

COOLANT OUTSIDE ACCELERATION DATA LINK


TEMPERATURE SENSOR TEMPERATURE SENSOR SENSOR CONNECTOR

HCW58DXF033501
3/5

B
0.5Y 0.5Y 0.5Y NE (+)
E45 H175 FL558

1
H316

2
1
0.5BR 0.5BR 0.5BR NE (-) FUSE11
E45 H175 FL558

2
H316

1
2
40 41

SPEED)
AUTO CRUISE MAIN

NE SENSOR
0.5B 0.5GY/W 0.5GY/W 0.5GY/W 0.5GY/W INDICATOR LIGHT

(CRANKSHAFT
H175 H316 FL558

3
3
39
0.3V/R 0.3V/R 0.3B 0.3V/R
FL559 H400 H7 FU18 FU18 H7

4
4
5

56
45

84
0.85Y

0.5R 0.5R G-VCC AUTO CRUISE SET

J/C:
E46 H177 E71

3
4
0.5Y

0.5W 0.5W G-SIG INDICATOR LIGHT FU7

FUSE11
E46 H177 E71

1
3
AUTO CRUISE CONTROL ONLY

0.5B 0.5B 0.5GY G-GND 0.3Y 0.3Y 0.3Y 0.5Y 0.85Y


E46 H177 E71 FL559 H400 H7 FU18 FU18 H7

2
7
8
6

G-SENSOR
57
19
42

133 120 131


83
0.5B 0.5GY
12
22 18

H177

1
0.5W 0.5O 0.5O SIG-1
E42 H177 E71

2
0.5W 0.5W SIG-2 0.5R/G
H177 E71
0.5O/L 0.5O/L VCC
E42 H177 E71

3
0.5V/W
0.5W/L 0.5GY GND

SENSOR
0.5W/L
E42 H177 E71

1
12 11 10 9
0.5R/G

3
6

121 132 123 136


1.25R/G
A

FUEL PRESSURE
0.5B 0.5GY
H177

5
FL532
FL532

1
5

0.5G/W 0.5G/W 0.5G/W SIG


E75 H176 H316 FL557

1
4

2
RELAY

33
FL49(1)

EGR
1
0.5G/B 0.5G/B 0.5G/B 0.5G/B GND
TAIL LIGHT

E75 H176 H316 FL558

SENSOR 1
2

1
2
5
54

3
MAIN SWITCH

FL716

J/C:(2)
0.5G/Y 0.5G/Y 0.5G/Y SIG
E76 H176 H316 FL557

2
3
6
30
AUTO CRUISE CONTROL

2 FL532
6 FL532

0.5G/B

EGR
E76

1
1
2

SENSOR 2
0.5G/O 0.5G/O
FL552 H257 FL557 0.3B

2
0.5V 0.5V

TEMPERATURE TEMPERATURE
FL558 H400

17
34
6

0.5G/B 0.5G/B 60

ENGINE CONTROL MODULE (ECM)


FL552 H257

1
18

PTO MODE
CONNECTOR
AUTO CRUISE
SET SWITCH
0.5W 0.5W G-SIG
E36 H176 E71 0.5L/R

2
15

FL559 H400 FL9


5

0.5R 0.5R 0.5GY/B G-VCC


79
15

E36 H176 E71 AUTO CRUISE

3
0.5B 0.5B 0.5GY G-GND RESUME SWITCH
E36 H176 E71

SENSOR
0.5V/R

13 14 15
128 126 134
11

FL559 H257 FL569


1

0.5B 0.5GY 0.5GY


92
15

H176 AUTO CRUISE

BOOST PRESSURE
16
RELEASE SWITCH
0.5V/G
26
16

FL559 H400 FL569 FL9


2

93
16
16

0.5L/W 0.5L/W 0.5L/W 0.5L/W 0.5L/W SIG


SIG B14 H357 H316 FL557

2
6
7
FL514(1)DIAGNOSIS

5
0.3B/W 0.5B/W
23

0.5L/R 0.5L/R 0.5L/R FL558 H256


+5V B14
5

H357 CONNECTOR

3
4
68

0.5L 0.5L 0.5GY


0.5Y

GND B14 H357

1
2
E74

SENSOR
J/C:(1)

ALL SPEED
0.5GY

ACCELERATION
IE INDICATOR LIGHT
0.5Y

H357

8
0.3O/B 0.3O/B 0.3O/B
FL559 H256 H7 FU5 FU5
3
6
7

52

82
BUZZER
OVERRUN
FL494(2)

OVERHEAT INDICATOR LIGHT

0.3G/Y 0.3G/Y 0.3G/Y


FL557 H400 H7 FU8 FU9
7
1

20
15

11

DIODE(OVERRUN)
0.3G 0.5G
FL557 H400 FL475 FL475
1
2

21

12
FU8(6) METER

FL475
3
Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

5B/L 2FB/L 2B
H10

FB82
40

0.5BR 0.5BR
H7

31

FRAME EARTH(3)
FB253

CENTER
J/T:EARTH

HCW58DXF033601
1A-55
1A-56 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
4/5

3W 3W/L 5W/L
H10 H187 SLOW BLOW FUSE1
45 1
FL519 FL520
3L/W 3Y
FB283 H10 H186 SLOW BLOW FUSE3
J/T: SBF1 J/T: SBF3 37 2
J/T: SBF1
3R
H10 H186 SLOW BLOW FUSE2
46 1

3L/W
3W

3R
FUSE34

FUSE16

FUSE45
(7.5A)
(15A)

(15A)
1.25W/L
0.5V/W
1.25O

0.85R/B FL196(1)
ABS RELAY

IE MAIN RELAY
1.25O
FL398
5
FL398
1
EGR RELAY
1.25O

1.25R/B
FL398 FL398 FL731 FL731
4

0.5V/W
2 3
5

FL731
2
0.3BR/G
FL731
4
1.25R/B

1.25R/B

1.25R/B
0.3R/L

0.3R/L

H257

0.3BR/G
H256 H256 H256 H256 H256
11
18 6 2 7 8
H316
1.25R/B

1.25R/B

1.25R/B

1.25WL

1.25WL
0.5W/R
0.3R/L

0.3R/L

0.3BR/G
75 74 7 6 5 110

FL559 FL559 FL557 FL557 FL557 E71

ENGINE CONTROL MODULE (ECM)

E72 E72 E72 E72 E71 E71

153 152 151 150 108 109


0.5R/W

0.5R/W

0.5R/B

0.5R/B

0.5Y/R
0.5Y/B

9 8 11 6 14 1 15

H177 H177
H176 H176 H400 H256 H400

10 9

H357 H357
0.5R/W

0.5R/W

0.5R/B

0.5R/B

0.5Y/R
0.5Y/B

1 1
M/V;EGR 2
M/V;EGR 1

1.25W/L

1.25W/L

B54 B55
0.5W/R

B54 B55

2 2
0.5R/W

0.5R/B
PRESSURE CONTROL

PRESSURE CONTROL

2 2
VALVE 1

VALVE 2

E43 E44
0.5W/R

0.5W/R

E43 E44

1 1
1.25W/L

1.25W/L

0.5W/R
H357 H316
11 8

1.25W/L 1.25W/L
H176 H316
10 9

1.25W/L 1.25W/L
H177 H316
7 10

HCW58DXF033701
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-57
5/5

ENGINE CONTROL MODULE (ECM)

E71 E71 E71 E71 E71 E72 E72 E72 E72 E72 E71 E72 E72 FL559 FL559
106 103 105 107 104 142 139 137 143 138 102 140 141 72 73

POWER.GND
POWER.GND
POWER.GND

1.25B ECU.GND

1.25B ECU.GND
H257 H257
0.5B 13 14

1.25B

1.25B
0.5B
* *

5B
0.5GY 0.5GY 15
E59
1 3 2 FL65 20
J/C 22
CASE

1.25B/O
E74 EARTH
0.85W

0.85W
0.85G

0.85G
0.85R

0.85R
0.85Y

0.85B

0.85Y

0.85B
J/C:1

1.25B
1.25B
1.25B
0.85L

0.85L

9
FL65
J/C 11
0.5GY 0.5GY

1.25B/O
1.25B
H175 H175 H175 H176 H176 1 H357
1.25B

4 5 7 8 6
1.25B

H176 H176 H176 H175 H175


4 7 5 8 6
H176 H39 E78
12 J/T:FRAME EARTH
13 FB376
1.25B

J/T:EARTH H10
(CAB GND) 42
0.85W

1.25B/L
5B
5B
0.85G

0.85R
0.85Y

0.85B
0.85L
0.85W
0.85L

0.85G
0.85Y

0.85R

FB39 FB40
5B

CAB EARTH
* *
3 2 7 4 6 3 2 7 4 6
H179 H179 H179 H179 H179 H180 H180 H180 H180 H180 E77 FB11 2B/L FB10

H179 H179 H179 H179 H179 H180 H180 H180 H180 H180
7 6 3 8 2 7 6 3 8 2 FRAME EARTH BATTERY FRAME
(ENGINE) EARTH EARTH(1)
0.75BR
0.75W

0.75W
0.75G
0.75R

0.75R
0.75Y

0.75B

0.75V
0.75L

0.75R 0.75R 0.75W 0.75W


1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
E53 E53 E53 E57 E57 E57 E55 E55 E55 E58 E58 E58 E54 E54 E54 E56 E56 E56
INJECTOR 1 INJECTOR 2 INJECTOR 3 INJECTOR 4 INJECTOR 5 INJECTOR 6
CYLINDER NO.1 CYLINDER NO.5 CYLINDER NO.3 CYLINDER NO.6 CYLINDER NO.2 CYLINDER NO.4
INSIDE CYLINDER HEAD COVER

*:END OF CABLE OPEN

HCW58DXF033801
1A-58 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Connector List
No. Connector Face No. Connector Face

B-14 1 2 3 E-42 1 2 3

003-030 003-067

B-41 1 2 E-43 1 2

002-006 002-068

B-43 1 2 E-44 1 2

002-108 002-068

B-44 1 2 E-45 1 2

002-108 002-031

B-45 1 2 E-46 1 2

002-108 002-031

3 2 1

B-54 1 2 E-53

002-108 003-125

3 2 1

B-55 1 2 E-54

002-108 003-125

3 2 1

E-36 1 2 3 E-55

003-067 003-125
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-59
No. Connector Face No. Connector Face
3 2 1

E-56 E-74 1 2 3 4 5 6

003-125 006-070

3 2 1

E-57 E-74 6 5 4 3 2 1

003-125 006-071

3 2 1

E-58 E-75 1 2

003-125 002-006

E-59 E-76 1 2

000-012 002-006

107 106 105 104 103 102

117 116 115 114 113 112 111 110 109 108

E-71 128 127 126 125 124 123 122 121 120 119 118
E-77
136 135 134 133 132 131 130 129

035-003 000-012

143 142 141 140 139 138 137

153 152 151 150 149 148 147 146 145 144

E-72 161 160 159 158 157 156 155 154


E-92
167 166 165 164 163 162

031-004 000-012

E-73 1 2 3 4 5 6 F-11 1 2

006-070 002-067

E-73 6 5 4 3 2 1
F-56 1 2 3

006-071 003-023
1A-60 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
No. Connector Face No. Connector Face

9 8 7 6 5 4 3 2 1

18 17 16 15 14 13 12 11 10

F-70 25 24 23 22 21 20 19 FL-1 1

5
2

6
3

7
4

8
32 31 30 29 28 27 26

032-017 008-007

FB-10 FL-2 1 2

000-012 002-067

FB-11 FL-4 1 2

000-012 002-067

1 2 3 4 5 6 7 8 9 10

FB-39 FL-9 11 1213 141516 17 1819 202122

000-012 022-001

1 2 3 4

FB-40 FL-10 5 6 7 8 9

000-012 009-006

FB-82 FL-11 1 2 3 4

5 6 7 8

000-012 008-016

FB-145 1 2 FL-11 1 2 3 4

5 6 7 8 9 10 1112
002-006 012-038

FB-155 1 2 3 FL-20 2 1

003-105 002-005
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-61
No. Connector Face No. Connector Face

FL-21 2 1
FL-182 1 2

002-005 002-067

1 1

2 3 4 2 3 4

FL-49 5
FL-196 5

005-012 005-012

2 3 4

FL-54 5
FL-223 1 2 3

005-012 003-015

1 2 3 4 5 6 7 8 9 10 11

FL-65 12 13 14 15 16 17 18 19 20 21 22
FL-385 1 2 3 4
23 24 25 26 27 28 29 30 31 32 33

033-001 004-021

1 2 3 4 5 6 7 8 9 10 11

1
FL-68 12 13 14 15 16 17 18 19 20 21 22
FL-397
23 24 25 26 27 28 29 30 31 32 33
2

033-001 002-012

1 1

2 3 4 2 3 4

FL-128 5
FL-398 5

005-012 005-012

2 3 4

FL-133 1 2 3
FL-400 5

003-015 005-012

FL-134 1 2 3 FL-466 1 2

4 5 6

006-004 002-101
1A-62 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
No. Connector Face No. Connector Face

1 2 3 4

FL-475 1 2 3
FL-536 5 6 7 8 9 10

003-023 010-002

4 3 2 1
1
FL-494 FL-537 10 9 8 7 6 5
2

002-012 010-003

1 2 3 4 5 6 7 8 9 10 11
1
FL-511 FL-552
12 13 14 15 16 17 18 19 20 21 22 2

022-005 002-012

1 2
FL-514 FL-554
2
3 4 5

002-012 005-023

2
FL-522 1 2 3 4 5 6 7 8 9 10 FL-555
11 12 13 14 15 16 17 18 19 20 3 4 5

020-008 005-023

7 6 5 4 3 2 1

17 16 15 14 13 12 11 10 9 8

FL-531 1 2 3 4 5 6
FL-557 27 26 25 24 23 22 21 20 19 18

34 33 32 31 30 29 28

006-056 034-004

41 40 39 38 37 36 35

53 52 51 50 49 48 47 46 45 44 43 42
1 2 3
FL-532 4 5 6 FL-558 61 60 59 58 57 56 55 54

69 68 67 66 65 64 63 62
006-002 035-002

76 75 74 73 72 71 70

1 2 3 4 5 6 7 8 9 1011121314 86 85 84 83 82 81 80 79 78 77

FL-535 FL-559 96 95 94 93 92 91 90 89 88 87
151617 1819 2021
101 100 99 98 97
021-001 032-025
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-63
No. Connector Face No. Connector Face

1 2 3 4 5 6 7 8 9 10 11

FL-560 12 13 14 15 16 17 18 19 20 21 22
FL-716 1 2 3 4
23 24 25 26 27 28 29 30 31 32 33

033-001 004-008

2 3 4

FL-569 1 2 3 4 FL-731 5

004-021 005-012

2
FL-605 FU-5 1 2 3 4 5 6 7 8 9 10
3 4 5

005-023 010-027

1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11

FL-655 12 13 14 15 16 17 18 19 20 21 22
FU-7 12 13 14 15 16 17 18 19 20 21 22

23 24 25 26 27 28 29 30 31 32 33 23 24 25 26 27 28 29 30 31 32 33

033-001 033-001

1 2 3 4 5 6 7 8 9 10 11

FL-656 12 13 14 15 16 17 18 19 20 21 22
FU-8 1 2 3 4 5 6 7 8 9 10 11 12

23 24 25 26 27 28 29 30 31 32 33

033-001 012-018

1 2 3 4 5 6 7 8 9 10 11

FL-657 12 13 14 15 16 17 18 19 20 21 22
FU-9 1 2 3 4 5 6 7 8 9 10 11 12 13 14

23 24 25 26 27 28 29 30 31 32 33

033-001 014-007

1 2 3 4 5 6 7 8 9 10 11

FL-658 12 13 14 15 16 17 18 19 20 21 22
FU-14 1 2 3

4 5 6
23 24 25 26 27 28 29 30 31 32 33

033-001 006-024

FL-716 4 3 2 1
FU-18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

004-007 016-031
1A-64 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
No. Connector Face No. Connector Face

1 2 3 4 5 6 7 8 9 1 2 3 4
FU-28 H-20 5 6 7 8
10111213141516171819202122

022-022 008-009

4 3 2 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
FU-33 H-20 8 7 6 5

016-030 008-010

1 2 3 4

1 2 3 5 6 7 8

FU-35 4 5 6 7 8 H-39 9 10 11 12

13 14 15 16

008-030 016-019

4 3 2 1

8 7 6 5

FU-62 1 2 3 4 5 6
H-39 12 11 10 9

16 15 14 13

006-056 016-020

1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4

FU-72 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
H-42 5 6 7 8

030-002 008-005

4 3 2 1
1 2 3
G-53 4 5 6 H-42 8 7 6 5

006-002 008-006

1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6
H-12 11 1213 141516 17 1819 202122 H-48 7 8 9 10 11 12 13 14

022-001 014-003

10 9 8 7 6 5 4 3 2 1 6 5 4 3 2 1

H-12 2221201918 17 16 1514131211 H-48 1413 12 11 10 9 8 7

022-002 014-004
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-65
No. Connector Face No. Connector Face

1 2 3 4

5 6 7 8 1 2 3 4

H-158 9 10 11 12 H-177 5 6
9 10 11 12
7 8

13 14 15 16

016-019 012-013

4 3 2 1

4 3 2 1
8 7 6 5

8 7 6 5
H-158 12 11 10 9
H-177 12 11 10 9
16 15 14 13

016-020 012-014

10 9 8 7 6 5 4 3 2 1

1 2 3 4
H-162 2221201918 17 16 1514131211 H-179
5 6 7 8

022-002 008-046

1 2 3 4 5 6 7 8 9 10
4 3 2 1
H-162 11 1213 141516 17 1819 202122 H-179
8 7 6 5

022-001 008-047

1 2 3 4
1 2 3 4
H-175 5 6
9 10 11 12
7 8
H-180
5 6 7 8

012-013 008-046

4 3 2 1

8 7 6 5 4 3 2 1
H-175 12 11 10 9
H-180
8 7 6 5

012-014 008-047

1 2 3 4

5 6 7 8

H-176 9 10 11 12 H-186 1 2
13 14 15 16 3 4

016-019 004-015

4 3 2 1

8 7 6 5
2 1
H-176 12 11 10 9
H-186 4 3
16 15 14 13

016-020 004-035
1A-66 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
No. Connector Face No. Connector Face

1 1 2 3 4 5 6 7 8 9 10

H-187 2
H-280 11 1213 141516 17 1819 202122

002-010 022-001

10 9 8 7 6 5 4 3 2 1

H-187 1

5
2

6
3

7
4

8
H-280 2221201918 17 16 1514131211

008-017 022-002

1 2 3 4 1 2 3 4 5 6 7 8 9

5 6 7 8

H-215 9 10 11 12 H-282 10 11 12 13 14 15 16 17 18 19 20 21

13 14 15 16
22 23 24 25 26 27 28 29 30 31 32
016-019 032-014

4 3 2 1
9 8 7 6 5 4 3 2 1
8 7 6 5

H-215 12 11 10 9
H-282 21 20 19 18 17 16 15 14 13 12 11 10

16 15 14 13
32 31 30 29 28 27 26 25 24 23 22

016-020 032-015

1 2 3 4 5 6 7 8 9

1 2 3 4 5 6 7 8 9 10

H-256 11 1213 141516 17 1819 202122 H-290 10 11 12 13 14 15 16 17 18 19 20 21

22 23 24 25 26 27 28 29 30 31 32
022-001 032-014

9 8 7 6 5 4 3 2 1
10 9 8 7 6 5 4 3 2 1

H-256 2221201918 17 16 1514131211 H-290 21 20 19 18 17 16 15 14 13 12 11 10

32 31 30 29 28 27 26 25 24 23 22

022-002 032-015

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

H-257 18 17 16 15 14 13 12 11 10 9 H-299 5 6 7 8

018-001 008-005

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

H-257 9 10 11 12 13 14 15 16 17 18
H-299 8 7 6 5

018-002 008-006
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-67
No. Connector Face No. Connector Face

1 2 3 4

5 6 7 8
1 2 3 4

H-301 9 10 11 12 H-390 5 6 7 8
13 14 15 16

016-019 008-005

4 3 2 1

8 7 6 5
4 3 2 1

H-301 12 11 10 9
H-390 8 7 6 5
16 15 14 13

016-020 008-006

1 2 3 4

5 6 7 8

H-304 9 10 11 12 I-4 1 2

13 14 15 16

016-019 002-006

4 3 2 1

8 7 6 5

H-304 12 11 10 9
J-12 1 2
16 15 14 13

016-020 002-006

1 2 3 4 5 6
H-316 7 8 9 10 11 12 13 14
J-24 1 2

014-003 002-006

6 5 4 3 2 1

H-316 1413 12 11 10 9 8 7 J-43 1 2

014-004 002-006

1 2 3 4

H-357 5 6
9 10 11 12
7 8
J-44 1 2

012-013 002-006

4 3 2 1

H-357 J-46
8 7 6 5

12 11 10 9 1 2

012-014 002-006
1A-68 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
No. Connector Face H-7

J-67 1 2

002-006

1 2 3 4 5 6 7 8 9 10 11 12 12 11 10 9 8 7 6 5 4 3 2 1

13 14 15 16 17 18 19 20 21 22 23 24 24 23 22 21 20 19 18 17 16 15 14 13

25 26 27 28 29 30 31 32 33 34 35 36 36 35 34 33 32 31 30 29 28 27 26 25

37 38 39 40
40 39 38 37

41 42 43 44 44 43 42 41

M-5 1 2 45 46 47 48 48 47 46 45

49 50 51 52 53 54 55 56 57 58 59 60 60 59 58 57 56 55 54 53 52 51 50 49

61 62 63 64 65 66 67 68 69 70 71 72 72 71 70 69 68 67 66 65 64 63 62 61
002-006
73 74 75 76 77 78 79 80 81 82 83 84 84 83 82 81 80 79 78 77 76 75 74 73

M-40 1 2 HCW39CSH014301

H-10
002-006

H-6

1 2 3 4 5 6 7 8 9 10 11 12 12 11 10 9 8 7 6 5 4 3 2 1

13 14 15 16 17 18 19 20 21 22 23 24 24 23 22 21 20 19 18 17 16 15 14 13

25 26 27 28 29 30 31 32 33 34 35 36 36 35 34 33 32 31 30 29 28 27 26 25

37 38 39 40
40 39 38 37

1 2 3 4 5 6 7 7 6 5 4 3 2 1
41 42 43 44 44 43 42 41
8 9 10 11 12 13 14 14 13 12 11 10 9 8
15 16 17 18 19 20 20 19 18 17 16 15 45 46 47 48 48 47 46 45

21 22 23 24 24 23 22 21
49 50 51 52 53 54 55 56 57 58 59 60 60 59 58 57 56 55 54 53 52 51 50 49
25 26 27 28 28 27 26 25
61 62 63 64 65 66 67 68 69 70 71 72 72 71 70 69 68 67 66 65 64 63 62 61

73 74 75 76 77 78 79 80 81 82 83 84 84 83 82 81 80 79 78 77 76 75 74 73

29 30 31 32 32 31 30 29
33 34 35 36 36 35 34 33
37 38 39 40 41 42 42 41 40 39 38 37
43 44 45 46 47 48 49 49 48 47 46 45 44 43
50 51 52 53 54 55 56 56 55 54 53 52 51 50

HCW39CSH014301

HCW39CSH014401
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-69
H-387

1 2 3 4 5 6 7 8 9 10 11
11 10 9 8 7 6 5 4 3 2 1

12 13 14 15 16 17 18 19 20 21 22
22 21 20 19 18 17 16 15 14 13 12

23 24 25 26 27 28 29 30 31 32 33
33 32 31 30 29 28 27 26 25 24 23
34 35 36 37 38 39 40 41
41 40 39 38 37 36 35 34
42 43 44 45 46 47
47 46 45 44 43 42
48 49 50 51 52 53 54
54 53 52 51 50 49 48

LNW48ASF000201

Fault diagnosis process The diagnostic procedure is always used to solve E/E
system problems, and forms the starting point for any
System Diagnosis Method
repairs that may be required. The progress of diagnosis
The system diagnosis method is a uniform procedure will be described in the following steps:
for the repair of all electrical/ electronic (E/E) systems.
1. Confirm customer complaint.
E/E system breakdowns differ from general vehicle
breakdowns and often involve the following steps: • To confirm the content of the customer’s
complaint, the vehicle diagnosis engineer must
1. Initial stage of the breakdown;
know the normal operating state of the system.
• Breakdown occurrence is a single incident of
2. Perform preliminary inspection.
short duration, which is often overlooked by the
customer. Customer complaints at that stage • Overall visual inspection
are vague and the problem cannot be • Review service history.
reproduced. However, there many be a record • Detect abnormal noises, odors etc.
of the breakdown in the Engine Control Module
• Use a scan tool (Tech2) to gather DTCs, data
(ECM) memory.
etc.
= Past fault
3. Inspect the service information.
2. Intermediate stage of the breakdown;
4. Refer to “Diagnosis by symptoms” in the manual.
• Breakdown occurrence is a single incident of
short duration, but repeats at intervals, and will • “Diagnosis by Symptoms” includes information
always occur under certain conditions. about systems that is not displayed under the
Customer complaint (nature of the breakdown) DTCs (Diagnostic Trouble Codes). Therefore
is clear and the area of uncertainty is in the “Diagnosis by Symptoms” can be used to
conditions under which the breakdown occurs. confirm proper operation of the system and
Therefore, the vehicle diagnosis engineer can learn the appropriate diagnostic method.
reproduce the breakdown by identifying the 5. Refer to content related to engine mechanics etc.
conditions.
= Intermittent fault If there is a DTC (Diagnostic Trouble Code) in
3. Fault manifestation stage; memory
• The breakdown occurrence is constant and Follow the specified DTC chart precisely to carry out
fixed, with clear and concrete customer the repair.
complaints.
Therefore the diagnosis engineer can If there is no DTC.
reproduce the breakdown. However, a single Select the symptoms from Diagnosis by Symptom.
breakdown incident may have multiple causes. Follow the diagnostic procedure to complete the repair.
= Current fault Inspections can be made with reference to functional
diagnosis.
1A-70 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
If there are no applicable symptoms. 1. Re-investigate the complaint
1. Investigate the complaint in detail. If it is not possible to adequately detect or identify
the problem, the diagnosis must be begun again.
2. Draw up a diagnosis plan.
Recheck the complaint. As described in “If the fault
3. Use wiring diagrams and operating principles. is intermittent” above, the complaint could refer to
Ask for technical assistance with cases resembling an intermittent fault, or the vehicle could actually
repair histories that you can obtain. Make effective use be normal.
of technical knowledge and usable service information.
2. Repair and check.
Carry out the repair after identifying the cause.
If the fault is intermittent
Check whether the vehicle operates normally, and
A fault is said to be intermittent if it does not always check that the symptoms have been corrected. In
appear. Take the following steps to solve an intermittent the situations below, this check will include road
problem. driving tests and other methods to confirm solution
1. Check DTC information and engine data. of the problem.
2. Evaluate signs and conditions described by the • Test in the state described by the customer to
customer. check.
3. Use a check sheet or other method to check the • If a DTC has been diagnosed, check the scan
circuits and electrical system components. tool data while reproducing the state that
applied when the DTC was set, to confirm
If the trouble cannot be detected whether the fault has been repaired.
This state refers to cases where the vehicle is judged to
Verify repair
be operating normally. The state described by the
customer may actually be normal. Compare the If an electrical control system has been repaired, it is
customer’s complaint against a different vehicle that is necessary to check after repairing the vehicle whether
functioning normally. The vehicle state may also the repair was correct. If this check is not performed
involve and intermittent problem. Before returning the thoroughly, the MIL (check engine lamp) could relight
vehicle, check the content of the complaint in the state when the vehicle is being returned to the customer, or
described by the customer. problems in drive performance could recur. With
intermittent faults it is particularly important to
reproduce the conditions of the customer’s complaint
and Verify repair

Item Item Purpose Method


1 DTC check Check the DTC display after Delete the previous DTC. Warm the engine
the repair. thoroughly by idling, then raise the engine speed
to more than 2,000rpm to race the engine, to
establish test conditions.
2 After warming Check whether idling control Check that the idling speed, after warming the
the engine, is normal. engine and with the air conditioning switched off,
check the idling is constant and close to 475-525rpm. If a problem
speed. is observed, refer to “unstable idling” under
Diagnosis by Symptom.
3 Check the scan Make a basic check of the Monitor the scan tool data list and use the
tool data list state of engine control and representative values sheet to check.
communications. Check the representative values for the scan tool
data list.
4 Check re-starting This is to check whether re- After warming the engine, check that the cranking
performance starting control is normal. time for re-starting does not exceed 5s and that
the engine speed after starting is stable.
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-71

Item Item Purpose Method


5 Check devices If a transceiver or other strong Check whether the idling engine speed varies
that emit strong electromagnetic emitter is when the transceiver or other electromagnetic
electromagnetic attached to the vehicle, check emitter is turned on and off. If any problem is
waves that it is not emitting harmful discovered at this stage, notify the customer that
waves. the mounting position and output of the
electromagnetic emitter must be modified.

Assistance in checking strong electromagnetic emitter Defective vehicle maintenance


devices; If such a fault is discovered, notify the On-Board Diagnostics (OBD) system checks are highly
customer of the following check points, as necessary. sensitive, so they can lead to the MIL (check engine
• The antenna should be mounted as far as possible lamp) lighting if vehicle maintenance is not carried out
from the control units, sensors and other elements properly. Insufficient oil changing or oil of the wrong
of the vehicle’s electronic systems. viscosity can cause oil filter or fuel filter blockages or
• The antenna must be more than 20cm away from sediments sticking to the crank case. In such cases,
the control units, sensors and other elements of vehicle malfunctions can occur that were not detected
the vehicle’s electronic systems. before the On-Board Diagnostics (OBD) systems
• The antenna cables and other wiring must not be check.
placed together. The antenna cord and other Improper vehicle maintenance is not classified under
wiring must be kept as far as possible apart. “non-vehicular breakdowns”, but as the On-Board
Diagnostics (OBD) systems checks are so sensitive,
• Devices mounted after the purchase of the vehicle the vehicle maintenance schedule must be observed
must each be mounted exactly as described in the even more strictly.
installation manuals.
• High-output mobile communications equipment Related System Breakdowns
cannot be mounted.
In many On-Board Diagnostics (OBD) systems checks,
CAUTION: the Engine Control Module (ECM) stops operating
Follow the steps below to Verify repair using an On- when a breakdown is detected in a related system or
Board Diagnostics (OBD) systems check. Failure to component.
carry out these steps may result in needless repair
work. Visual inspection of the engine compartment
• Review and record to scan tool data for the DTCs When carrying out a diagnostic procedure, make a
which were diagnosed. careful visual inspection of the engine compartment.
This inspection is often sufficient to solve the problem
• Clear the DTCs.
without starting any needless steps. Follow the
• Drive the vehicle while checking the related scan guidelines below when performing a visual inspection.
tool data.
• Check all compressed air hoses to make sure
there are no punch holes, cuts, detached
Non-OEM parts
connections etc., and check that pipe connections
All On-Board Diagnostics (OBD) systems checks are are correct.
adjusted to run on official components. Therefore if
• Inspect inconspicuous hoses that are positioned
other general-purpose sensors, switches and other
behind other components.
components from other vendors have been attached,
mis-diagnosis will result, and the MIL (check engine • Check that all harnesses in the engine
lamp) will light. compartment are connected properly, with no
Electronic devices from other vendors, such as cellular scorched or worn areas. Also check for harnesses
telephones, audio and anti-theft devices can emit that are unbound, touching sharp edges, or
electronic magnetic interference (EMI) that affects the touching hot components such as the exhaust
control systems. Incorrect sensor information can be manifold or pipes.
generated as a result, causing the MIL (check engine
lamp) to light. Before performing a breakdown
diagnosis, turn the power off for all vendor components,
or remove them.
1A-72 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Basic Knowledge of Necessary Tools • Fuel Pressure Sensor
IMPORTANT: • Vehicle Speed Sensor (VSS)
When carrying out diagnostic procedures, a lack of
basic knowledge of the power train can lead to Output components:
incorrect diagnosis and damage to elements of the For output components, diagnose whether the
power train. Do not attempt to diagnose power train- responses to control unit commands are appropriate. If
related problems without basic knowledge. A basic it is not possible to perform function monitoring, check
understanding of hand tools such as the scan tool is for broken connections in the circuits and values
also required, in order to make effective use of the outside ranges, if such methods are applicable.
service manual. In checked output components, there are the following
circuits (not limited to only these sensors).
On-Board Diagnostics Tests • Injectors
The following aspects of fault diagnosis results must be • PCV
checked.
• Lamps, relay controls
• The diagnostic test for the previous ignition cycle
was completed. Common terminology for self diagnostics
• The diagnostic test for the current ignition cycle If diagnosis is used as a noun, it refers to any desired
was passed. test performed in the vehicle according to the vehicle
• Faults identified by the diagnostic tests no longer diagnosis method. Diagnosis consists of tests
exist. performed on systems or components to ascertain
If a fault was revealed by the diagnostic tests, check whether they are acting according to their
the following points and record the data. specifications. There are many diagnoses, as listed
• The diagnostic test for the previous ignition cycle below.
was completed. • Engine speed
• Faults identified by the diagnostic tests still exist. • Engine coolant temperature (ECT)
• The fault exists in this ignition cycle. • Accelerator switch
• Action status at the time of the breakdown.
Diagnostic executive
Ignition cycle Diagnostic executive refers to adjustment of diagnostic
The ignition cycle is defined as a “starter switch on, run, procedures and specification of priorities, and also to
starter switch off” cycle performed by a method that the recording and presentation of results. The main
satisfies diagnostic standards set for the vehicle. elements of diagnostic executive are as stated below.
• MIL (check engine lamp) On/ Off commands
Comprehensive Diagnostic Operation of • DTC recording and deletion
Component Monitors
• Scan tool data recording
For the engine to run normally, a comprehensive
• Current status information regarding each
diagnosis of component parts is required.
diagnosis
Input Components:
Diagnostic information
Check the input components by inspecting for broken
wires in the circuit and checking that all values are This is the detection of breakdowns in circuits or
within their ranges. This process includes a rationality components using diagnostic procedures. The chart is
inspection. The rationality inspection indicates a fault if drawn up to show that the vehicle functioned normally
there are signals from sensors that appear at the time of assembly and that multiple breakdowns
inappropriate. Such as an APP (accelerator pedal are not occurring at present. There are continuous self-
position) sensor indicating a high throttle position when diagnostic functions for certain control functions. These
the engine load or intake pressure is low. diagnostic functions are supplemented by the
In input components, there are the following sensors diagnostic procedures described in this manual. The
(not limited to only these sensors). DTC system is the language in which the cause of a
functional failure is communicated. When a functional
• Atmospheric temperature sensor failure is detected by a control unit, the DTC is set and
• Crankshaft position (CKP) sensor the MIL (check engine lamp) lights.
• Water Temperature (ECT) Sensor
• Cam shaft position (CMP) sensor
• Accelerator Pedal Position (APP) Sensor
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-73
Multi-function Indicator Lamp (MIL) • Turn the starter switch ON and check that the MIL
The Multi-function Indicator Lamp shows warning (check engine lamp) lights. (Bulb check)
lamps such as the MIL (check engine lamp). Basically, After staying lit for 15 seconds, the lamp flashes 3
the MIL lights when a breakdown occurs in the Engine times on a 1 second cycle, then lights again. The
Control Module (ECM) or other electronic control light goes out when the engine starts. (However,
system, and a DTC (Diagnostic Trouble Code) has the three flashes do not happen on fire car).
been detected. • Turn the starter switch ON with the engine off.
• Connect the diagnostics switch.
Data Link Connector (DLC) • Read the number of times the MIL (check engine
The Data Link Connector (DLC) is the equipment for lamp) flashes.
communication with the control units. The DLC is also • The content of the DTC can be found from the
provided to enable connection with the scan tool. The DTC Table.
general method for using the scan tool is shown below.
• Identification of stored DTCs
• DTC deletion
• Implementation of an output control test Instrument Panel
• Reading serial data Lower Harness
1
3 4
Vehicle Repair Checking
The On-Board Diagnostics (OBD) systems check can 2
be used effectively for checking vehicle repairs. When 5
a repair is complete, the vehicle diagnosis engineer
performs the following steps.
1. Review and record to scan tool data, the
diagnosed DTCs (Diagnostic Trouble Codes)
6
which were diagnosed, or both.
2. Delete the DTC.
3. Run the vehicle according to the scan tool data.
HCW61ASH004501
4. For DTC status information on the specific DTC
that was diagnosed, check until the diagnostic test Legend
related to that DTC is performed by the control 1. Diagnostics connector (brown)
unit. 2. Memory clear connector (white)
The implementation of these steps is extremely 3. Diagnostics common connector (green)
important for checking repairs using an On-Board 4. Data link connector (DLC), 20 terminals
Diagnostics (OBD) systems check. Failure to 5. Data link connector (DLC), 10 terminals
implement these steps may necessitate repairs that 6. Data link connector (DLC), 3 terminals
could have been avoided.
If a scan tool is connected, the DTC can be read by
Diagnostic Trouble Codes (DTCs)
operating the scan tool.
Every time the starter switch is turned on, the Engine
Control Module (ECM) runs a self test of most wiring If the DTC is not stored
and components. If a fault is detected in the system, it The code “1” indicating the start of code display is
is recorded in the ECM memory and backup control is displayed repeatedly.
performed, depending on the DTC. If a fault occurs in a
system that affects driving, the MIL (check engine
lamp) lights on the instrument panel to notify the driver.

Reading Flashing Diagnostic Trouble Codes


Current and past trouble codes (DTCs) recorded in the
ECM can be displayed, and the MIL (check engine
lamp) made to flash by connecting a diagnostics
switch.
1A-74 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
If the DTC is stored
The stored trouble code is shown three times. If
multiple trouble codes are stored, each is displayed
three times, starting from the one with the smallest
number. After all the codes have been shown, the
display starts repeating again from code 23. This
display continues for as long as the diagnostics
connector is connected.

Check engine lamp (in case of code "23")

t4 t3 t2 t3 t2 t1 t2 t1 t2 t1 t4 t1 = About 0.3 sec

ON t2 = About 0.6 sec


t3 = About 1.2 sec
t4 = About 2.4 sec

OFF

Tens digit Units digit

Check engine lamp (in case of code "413")

t4 t1 t2 t1 t2 t1 t2 t1 t2 t3 t2 t1 t2 t1 t2 t1 t4

ON

OFF Tens
Hundreds digit digit Units digit

HCW4ADSF000101

DTCs from the MIL (check engine lamp) flashing 5. Push the accelerator pedal to the WOT position for
display more than 1 second and less than 3 seconds.
While the engine is stopped, both the current DTCs and 6. Release the accelerator pedal for more than 1
past DTCs are displayed. second and less than 3 seconds.
While the engine is running, only currently-occurring 7. After that, turn the starter switch Off again and
DTCs are displayed. back to On.
(Alternatively, disconnect the connector and then
How to delete DTCs using accelerator pedal reconnect).
operation If the deletion process was carried out correctly, the
* Use of this operation deletes all electrical system normal code is displayed.
DTCs, other than those for some electrical systems
(ABS, Smoother-G, SRS, etc.), so proceed with
caution.
• The starter switch is On with the engine stopped.
• Connect the diagnostics connector and the
diagnostics common connector.
Under these conditions, perform the operations below
to delete the trouble codes.
1. After the connector is connected, push the
accelerator pedal to the wide open throttle (WOT)
position for more than 1 second and less than 3
seconds.
2. Release the accelerator pedal for more than 1
second and less than 3 seconds.
3. Push the accelerator pedal to the WOT position for
more than 1 second and less than 3 seconds.
4. Release the accelerator pedal for more than 1
second and less than 3 seconds.
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-75
Breakdown diagnosis using the scan tool.
The Scan Tool (Tech2) and the Tech2 Adapter
This is an effective tool for diagnosing electrical
breakdowns in the electronic control systems and
carrying out system checks. If the Tech2 adapter is
used to connect to the DLC on the vehicle, various
diagnoses and tests can be run on the ECM and
communications on the vehicle.

HCW35ALF001301

Legend
1. PCMCIA card (specialized) 3. DLC cable
2. Tech2 (main unit)
1A-76 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

TE
CH
2
DC
24
VO
LT
AD
2

AP
TE
1

R
7
PS

8
W
1

HCW35AMF001501

Legend
1. Tech2 adapter 3. Adapter cable (for connection to the Tech2 DLC)
2. Adapter cable (for connection to the vehicle
DLC)

Characteristics and precautions concerning the • To delete the diagnostic trouble code (DTC), open
Tech2/ Tech2 adapter the Application menu and select “Clear DTC Info”
• Tech2 is a 12V power supply system. Do not of DTC deletion.
connect it directly to a 24V power supply. The • The Tech2 adapter has a built-in DC-DC converter
Tech2 power supply is supplied via the Tech2 (to transform 24V to 12V). Refer to the instruction
adapter. (The Tech2 adapter has a built-in function manual for details.
to convert from 24V power supply to 12V). • The Tech2 adapter has a selector to switch
Therefore do not power the Tech2 directly from the between signals (electronic control unit (ECU)
battery or cigarette lighter. signals).
• Turn off the power supply before inserting or Select “3” for engine control.
removing the PCMCIA card. • Set the PCMCIA card into the Tech2 and
• Tech2 has 3 (the older version had 2). Attach the DLC cable to the VCI (Vehicle
snapshots of capacity. Communication Interface) on the Tech2 body,
• The PCMCIA card is vulnerable to magnetism and Next, attach the adapter cable to the Tech2
static electricity, so it should be handled with care. adapter. The Tech2 and Tech2 adapter are linked,
and the adapter cable is linked to the vehicle DLC.
• Tech2 can draw a graph of a snapshot.
• When selecting a menu item, used the selection or
function keys to select an item, then press the
Enter key.
• Press the Exit key to go back to the Main Menu at
any time.
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-77
Parts of the Tech2

2
3
13

4
8
14
3

5 6

15

16

7 12

11

9
10
HCW35ALF001401

Legend
1. Soft keypad 10. VCI module fastening bar
2. Selection keys (arrow keys) 11. DLC cable connector
3. Action keys (Yes, No, Enter, Exit) 12. AC adapter connector
4. Function keys (F0 - F9) 13. PCMCIA card slot (with cover)
5. Help key (?) 14. PCMCIA card release button
6. Control key (PWR/ Shift) 15. External communications connector (RS485
7. Wide stand port)
8. Display (LCD screen) 16. External communications connector (RS232
9. Vehicle Communications Interface (VCI) module port)

1. Soft keypad 2. Selection keys (arrow keys)


When Tech2 is operated, the selection instruction These are used for menu selections and display
box appears in the top of the screen. The soft keys switching on the Tech2 screen. The highlighted
correspond to the selection box. If there is no portion of the screen display content is the
selection box on the screen, the instrument cannot selection.
be used.
1A-78 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
3. Action keys (Yes, No, Enter, Exit)
These are used to confirm Tech2 operations,
answer on-screen instructions and questions and
switch/ move between menu screens.
4. Function keys (F0 - F9)
These confirm menu functions within the screen
display. If the screen menu contains elements such
as “F0”, the key corresponds to that display.
5. Help key (?)
When this key is pressed, a screen appears,
explaining the Tech2 function currently in use.
6. Control key (PWR/ Shift)
The PWR key turns the Tech2 power on and off.
The shift key is used to adjust screen contrast. An
LED lights (orange) when the shift key is enabled.
At that time, all keys and functions other than the
selection keys are locked. An LED (green) lights
when the power supply is turned on.
7. Wide stand
This is used as a stand for the instrument. The
stand can be moved through angles of 0-180?.
8. Display (LCD screen)
This is an LCD display with a contrast adjustment
function. It displays ECM information, instruction
screens etc.
9. Vehicle Communications Interface (VCI) module
The module that allows communications between
the vehicle and Tech2.
10. VCI module fastening bar
Operate this bar to mount and fasten the VCI or
remove it.
11. DLC cable connector
This is the connector for using (connecting) Tech2
on a vehicle. Connect the DLC cable.
12. AC adapter connector
This is the connector for connecting the accessory
AC adaptor. This is for using Tech2 outside a
vehicle.
13. PCMCIA card slot (with cover)
Open the cover to insert a PCMCIA card into
Tech2. Insert the PCMCIA card with the cover
open. Never insert or remove the PCMCIA card
while Tech2 is switched on.
14. PCMCIA card release button
Use this button to remove the PCMCIA card from
Tech2. Press the button to take the PCMCIA card
out. Never remove the PCMCIA card while Tech2
is switched On.
15. External communications connector (RS485 port)
This is a telephone line connector, but it is not
currently used on Tech2. Do not connect this
connector to a telephone line etc.
16. External communications connector (RS232 port)
This is the connector to connect Tech2 to another
computer.
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-79
Parts of the Tech2 adapter

TE
4

CH
2
DC
24
VO
LT
AD
2

AP
TE
1

R
7
PS

8
W
1

9
2
3

HCW35AMF001601

Legend
1. Selector 4. Adapter cable (for connection to the vehicle
2. Select switch (signal switching) DLC) connector
3. Adapter cable (for connection to the Tech2 DLC) 5. Vehicle DLC connector
connector

1. Selector 3. Adapter cable (for connection to the Tech2 DLC)


The selector is provided so that Tech2 can connector
recognize the ECM signals and can output signals Tech 2 Attach the cable to connect the DLC cable
to the ECM. and the Tech2 adapter.
The selector position varies according to the 4. Adapter cable (for connection to the vehicle DLC)
system concerned. connector
3: Engine Control Attach the cable to connect the vehicle DLC and
6: Cab suspension the Tech2 adapter.
7: Kick drive (single)
5. Vehicle DLC connector
Other: Free
This is the connector to connect to the vehicle
2. Select switch (signal switching) DLC. Various connectors are available because
This is the switch to switch between signals when the DLC differs from the device mounted on the
Tech2 reads signals from the ECM and sends vehicle.
them to the ECM. 20-pin: Cab suspension
Reading signals from the ECM: Switch1 position 3-pin: Engine, SRS, ABS/ASR, EBS, Smoother-G,
(Reading DTCs, checking data, etc.) air suspension, HAS (with Smoother-G),
Sending signals from Tech2 to the ECM: Switch2 MIMAMORI System.
position
(DTC deletion command, various test instructions, Connection method
etc.)
1. Check that the starter switch is in the OFF
position.
1A-80 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
2. Insert an ISUZU system PCMCIA card into the Operation procedure
Tech2. Select Diagnose from the main menu, then select the
3. Attach the DLC cable to the Tech2 unit. correct model year, model and system for this
4. Attach an adapter cable to the Tech2 adapter. equipment.
5. Link the adaptor cable to the DLC cable.
6. Link the adaptor cable to the DLC.
7. Check the Tech2 adapter selector position.
6: Cab suspension
Other: Free
8. Check that the Tech2 adapter select switch
position is in the “1” direction.
9. Turn the starter switch to the ON position, and
press the Tech2 “PWR” key.
Press (ENTER) To Continue
10. Check the Tech2 display screen.
(ENTER)
F0 : Diagnostics
F1 : Service Programming
System (SPS)
F2 : View Capture Data
F3 : Tool Options
F4 : Down load/Up load Help
Press (ENTER) To Continue
(F0 ENTER)
Vehicle Identification
Select one of the following
HCW46ESH001901 Model Year(s)
CAUTION:
Always make sure that the power supply to the Tech2 is
off before inserting or removing the PCMCIA card.

(Model year ENTER)


HCW46ELH000101
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-81

6WF1-TC/6WG1-TC (Common Rail)


Vehicle Identification
F0: Fault diagnosis code (DTC)
Select one of the following F0: DTC display
Vehicle Type (s) F1: Fault history
F2: DTC deletion
(N*) ELF, NPR, NQR, VFR F1: Data display
(off-Road) Industrial Engine F2: Snapshot
(C*,E*,L*,F*) Heavy, Medium Duty F3: Actuator test
F0: Common rail system
F0: Rail pressure control
(C*,E*,L*,F* ENTER)
F1: Stop injection from each injector
F1: Device control
System Selection Menu F0: Turbocharger control
(C*,E*,L*,F*) Heavy, Medium Duty F1: EGR control
F2: Exhaust brake relay
F0 : Engine F3: Retarder relay
F1 : Transmission F4: Programming
F2 : Chassis
F0: Q adjustment compensation
F0: Q adjustment compensation data
F3 : Body
upload (Tech2)
F1: Q adjustment compensation data
(F0 ENTER)
download (ECM)
F2: Service mode
Vehicle Identification F1: Injector ID code
Select one of the following
F0: Injector ID code
F1: ID code registration
Engine
F2: ID code upload (Tech2)
6WF1-TC (Common Rail)
F3: ID code download (ECM)
F4: History information
6WG1-TC (Common Rail)

6UZ1 (Common Rail) Menu Items


Select menu items to check DTCs and data, and for
(Diagnostic Engine ENTER)
various tests and learning etc.
HCW61ALH000101

List of Menu Items


The table below indicates which functions are
implemented and displayed in the current Tech2
software.
1A-82 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Fault diagnosis code (DTC) Data display
Read, check and delete DTCs The states recognized and controlled by the ECM are
Put the Tech2 adapter select switch in the “1” position displayed in various items.
to read DTCs. Put the Tech2 adapter select switch in the “1” position
Put the Tech2 adapter select switch in the “2” position to read data.
to delete DTCs. The displayed numerical items are stated under
representative values for the Tech2 data list.
Content of the display items is stated under data.
TE
CH
2
AD

Data Display
AP
TE
R
2

System Voltage V
6
1

Engine Speed RPM


PS

8
W
1

Desired Idle Speed RPM


APP(Accelerator Pedal) V
Accelerator Opening %
Accelerator Pedal ON/OFF
APP(Accelerator Pedal) %
Accelerator Position Le V
1

2 Select DTC Quick More


Items Snapshot
HCW61ASH000401

DTCs are the language for the diagnosis engineer to HCW460SH000201


communicate with the vehicle ECM.
DTCs can be broadly divided into past and current This menu can be used to display current data.
DTCs. The display is synchronized with the state of the vehicle
• Current DTCs: Indicate faults (breakdowns) in the and any devices.
current ignition cycle. • If the menu for data display cannot be displayed:
• Past DTCs: Indicate faults (breakdowns) in the last A breakdown has occurred in the wiring between
or earlier ignition cycles. the ECM and the DLC.
The select switch on the Tech2 adapter is in the
• Multiple DTCs: Several DTCs may be displayed at
wrong position.
once. These are called multiple DTCs. This occurs
when multiple faults (breakdowns) happen at once. • If the display shows an abnormal fixed value:
In other cases, when multiple sensors or switches E.g. If the data display values for engine speed
share the same GND or power supply, a broken and various sensors are fixed and differ from the
connection or short in that ground or power actual status. Move the connector or harness by
connection can cause the display of multiple DTCs hand and see if the display stops being fixed. If so,
for all related sensors and switches. If multiple the cause is a poorly fitting terminal, misaligned
DTCs are displayed, refer to the chart for DTCs pins, a broken or shorted harness wire at the
that require inspection of broken connections and position moved by hand, etc., requiring repair.
shorts in common power supply or GND • If the numerical display is marked with “*”:
connections, and delete the vehicle DTC This is a Tech2 software problem.
information. If even one item has an asterisk mark during data
display, the PCMCIA card requires a version
upgrade.

Snapshot
A snapshot is taken so that data can be reviewed and
used in identifying the cause of a breakdown.
• The snapshot can be stored in the data list menu
and displayed graphically.
• Using this mode, the conditions of a customer
complaint can be reproduced and recorded to
identify data faults.
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-83
• If the method of determining the trigger type is Actuator test
used, the data for the moment at which the DTC Perform all applicable tests, operate components,
was displayed can be recorded. inspect functions and confirm that they are either faulty
• Recorded data can be played back on a domestic or normal.
power supply. When performing instructions (commands) for the ECM
from the test screen, place the select switch of the
Programming Tech2 adapter in its second position.
When replacing the ECM, confirm history information
prior to replacing. (Data confirmation), in addition CAUTION:
upload data to Tech2. After replacing the ECM, If conditions concerning the vehicle, operating
download data to the new ECM. conditions, coolant temperature, vehicle speed,
switches, gear position are not satisfied or if a DTC is
detected, there are cases where not all tests are
performed.

Item Description Method of use


M a g n e t i c Exhaust brake valve Confirm operation of the If the magnetic valve does not operate
v a l v e magnetic valve when on/off when turned on, there may be an
system commands are given. abnormality with the exhaust magnetic
valve, harness, or ECM.
VGS valve Confirm operation of the If the magnetic valve does not operate
magnetic valve when on/off when turned on, it means there is an
commands are given. abnormality with the VGS magnetic valve,
harness, or ECM.
EGR valve Confirm operation of the If the magnetic valve does not operate
magnetic valve when on/off when turned on, it means there is an
commands are given. abnormality with the EGR valve, harness,
or ECM.
E n g i n e Rail pressure control Perform a rail pressure increase If the increase in rail pressure does not
control command to check the condition operate when performed, it means there is
of the rail pressure control. an abnormality with the PCV, PCV control
harness or ECM etc.
Stoppage of When a command for stopping If there are no changes to engine rpm or in
injection on a per injection is performed for the the way the engine vibrates when an
injector basis injector for each cylinder, confirm injector stop command is performed, this
the status for each cylinder. indicates that the injector was stopped
prior to the command being performed.
This means that there is an abnormality in
this injector, the harness, or ECM etc.

Method for selecting trigger type and creating a 6. The screen will change and when [continue] is
graph displayed at the bottom of the screen, select
1. Select [data display] in the application menu. [continue].
2. Make the selection when items are displayed on 7. When [plot] is displayed at the bottom of the
the screen. screen, select [plot].
3. When the snapshot option is displayed on the 8. If the item selection screen is displayed, click on
screen, choose the trigger method, and select the desired item and push the enter key, select up
[record snapshot] at the bottom of the screen. to 3 and select the “approval” button at the bottom
of the screen.
4. If (standby) at the bottom of the screen flashes,
select [trigger] at the bottom of the screen. 9. A graph is displayed on the screen.
5. Confirm the trigger type.
1A-84 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Method for playing back a graph of the recorded 2. Make the selection when items are displayed on
data the screen.
1. Select [snapshot data] from the screen after 3. When the snapshot option is displayed on the
turning the Tech2 power on. screen, choose the trigger method, and select
2. Confirm that the snapshot data title is displayed. [record snapshot] at the bottom of the screen.
3. Select the snapshot data title. 4. If (standby) at the bottom of the screen flashes,
select [trigger] at the bottom of the screen.
4. Data is displayed on the screen. If you would like
to see a graph of the data, select on [plot] at the 5. Confirm the trigger type.
bottom of the screen. 6. The screen will change and when [continue] is
5. If the item selection screen is displayed, click on displayed at the bottom of the screen, select
the desired item and push the enter key, select up [continue].
to 3 and select the [approval] button at the bottom 7. When [plot] is displayed at the bottom of the
of the screen. screen, select [plot].
6. A graph is displayed on the screen. 8. If the item selection screen is displayed, click on
the desired item and push the enter key, select up
Graph creation to 3 and select the [approval] button at the bottom
of the screen.
This enables creation of a graph of the snapshot data.
Reviewing this graph enables investigation of the 9. A graph is displayed on the screen.
cause of a failure occurrence.
Method for playing back a graph of the recorded
Method for creating a graph after displaying data data
1. After selecting [data display] in the application 1. Select [snapshot data] from the screen after
menu and vehicle data is displayed, select turning the Tech2 power on.
[snapshot] from the bottom of the screen. 2. Confirm that the snapshot data title is displayed.
2. After a certain amount of time passes, push the 3. Select the snapshot data title.
[Exit] button. 4. Data is displayed on the screen. If you would like
3. The screen will change and when [continue] is to see a graph of the data, select on [plot] at the
displayed at the bottom of the screen, select bottom of the screen.
[continue]. 5. If the item selection screen is displayed, click on
4. When [plot] is displayed at the bottom of the the desired item and push the enter key, select up
screen, select [plot]. to 3 and select the [approval] button at the bottom
5. If the item selection screen is displayed, click on of the screen.
the desired item and push the enter key, select up 6. A graph is displayed on the screen.
to 3 and select the [approval] button at the bottom
of the screen. Tech2 data reference values
6. A graph is displayed on the screen. Data lists are for confirming the status of the vehicle
and each piece of equipment.
Method for selecting trigger type and creating a Compares data from each vehicle to basic values and
graph finds temporary deviations from reference values and
1. Select [data display] in the application menu. cases where deviation is continuous. This is used for
diagnostics. (This Tech2 display menu may be changed
without notification.)

Data display items Units Idle reference values (changes


caused by vehicle conditions)
System voltage V more than 24
Engine RPM RPM With respect to goals ±25
Target idle speed RPM 475-525
Acceleration sensor V 0.25-0.75
Accelerator amount open % 0
Accelerator pedal switch ON/OFF ON
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-85

Data display items Units Idle reference values (changes


caused by vehicle conditions)
Amount accelerator is actually open % 0
Accelerator pedal position learning V 0.25-0.75
idle
Fuel pressure (difference between MPa
target and actual)
Fuel pressure sensor V
Fuel pressure F/B control °CA 0
PCV closed period °CA 174-176
Intake air pressure kPa
Atmospheric temperature sensor V
Engine coolant temperature V
Atmospheric pressure V
Intake air pressure V
Atmospheric temperature °C When the same as external air
temperature
Engine coolant temperature °C 70-85 (when fully warmed up)
EGR gas temperature V
EGR gas temperature 2 V
Atmospheric pressure kPa
Boost (relative pressure) kPa Approx. 2
Vehicle speed km/h 0
Speed limit km/h 0
Cruise set speed km/h -
VGS control mode
EGR control mode
First cylinder correction injection mm3/st -4-4
amount
Second cylinder correction injection mm3/st -4-4
amount
Third cylinder correction injection mm3/st -4-4
amount
Fourth cylinder correction injection mm3/st -4-4
amount
Fifth cylinder correction injection mm3/st -4-4
amount
Sixth cylinder correction injection mm3/st -4-4
amount
Starter switch (ST) ON/OFF OFF
Starter switch ON/OFF ON
Neutral switch ON/OFF On (while vehicle is stopped)
1A-86 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

Data display items Units Idle reference values (changes


caused by vehicle conditions)
Clutch switch ON/OFF On (while vehicle is stopped)
Brake switch 1 ON/OFF OFF
Brake switch 2 ON/OFF OFF
Parking switch ON/OFF On (while vehicle is stopped)
Reverse gear switch ON/OFF OFF
Exhaust brake switch ON/OFF OFF
Air pressure switch ON/OFF OFF
Stop lamp switch ON/OFF
Retard switch ON/OFF OFF
Cruise main switch ON/OFF OFF
Cruise set/down switch ON/OFF OFF
Cruise resume switch ON/OFF OFF
Cruise cancel switch ON/OFF OFF
Exhaust brake actuator ON/OFF
Starter cut operation ON/OFF
CMP sensor installation variability °CA 0-5
correction
Acceleration open request (TCM) %
ASR accelerator opening %
PTO accelerator opening %
PTO accelerator opening V
PTO switch ON/OFF OFF
Idle control switch Manual/auto Auto
Idle up switch On/Off OFF
Idle down switch On/Off OFF
Cruise release switch On/Off OFF
Cruise release switch 2 On/Off OFF
Cruise coast On/Off OFF
Cruise cancel On/Off OFF
Constant speed cruise On/Off OFF
Overrun
Over heat
CKP signal actuator Yes/No
CMP signal actuator Yes/No
Q adjustment resistance data 1 – –
Q adjustment resistance data 2 – –
Q adjustment resistance data 3 – –
ROM code
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-87

Data display items Units Idle reference values (changes


caused by vehicle conditions)
Diagnostics switch On/Off OFF
Final amount injected after mm3/st
correction
Injection amount control mode – –
Injection control mode – –
High pressure pump control mode – –
Final injection amount mm3/st
ISC corrected injection amount mm3/st
1A-88 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Function Inspection List

Oral consultation Point sequence based on customer’s complaint for the


purpose of fully grasping fault symptoms and making
accurate diagnosis.
On-Board Diagnosis (OBD) System Check Inspection for determining failure locations of the
electronic engine control system (inspection procedure)
Checking the MIL (check engine lamp) lighting circuit Inspection for when the MIL (check engine lamp) does
system (MIL does not turn ON) not turn on when the starter switch is turned on.
Checking the MIL (check engine lamp) flashing control Inspection when the MIL (check engine lamp) does not
system (MIL does not flashing) flash (on constantly) when the diagnostic switch is
turned on
Checking the Scan Tool Circuit System Inspection if scan tool is not functioning
Checking the engine starting system Inspection if there is possibility of abnormality in
portions related to starter or engine start-up
Checking the fuel system Inspection if there is possibility of abnormality in
portions related to fuel system
Checking the air intake system Inspection if there is possibility of abnormality in
portions related to air intake system
Checking the exhaust system Inspection if there is possibility of abnormality in
portions related to exhaust system
Checking the EGR system Inspection if there is possibility of abnormality in
portions related to the EGR system
Checking the engine control module (ECM) power Inspection if there is possibility of abnormality in power
supply and ground circuit system circuit and GND system circuit of the ECM
Checking the PTO Inspection if there is possibility of abnormality in PTO
functioning (governor characteristics or accelerator
switching)
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-89
Oral consultation
Oral consultation 1. The fault symptoms may not be reproducible at the
1. Adequately grasp the contents of customer service workshop.
complaints by using the engine control system 2. The customer’s complaint may not necessarily be
questionnaire. a fault.
<Reference> 3. When the fault conditions are not correctly
The oral consultation should not be done at communicated to the person in charge of repairs,
random but should narrow down on the target fault man-hours are wasted.
inferred from the fault phenomena (fact). • The questionnaire is of assistance in the on-board
2. Accurately interpret the fault data. diagnosis, repair, and repair verification at the
Have a solid understanding based on 5W1H. service workshop.
Example: Air temperature is low, at start-up,
regularly, near engine section, metallic sound, etc.

Oral Consultation Points

• What Failure symptoms


• When Date, time, occurrence
frequency
• Where Road conditions
• Under what conditions Driving conditions,
operating conditions,
weather
• How did it turn out How the phenomena
were felt

Engine control system questionnaire


At the time the vehicle is received at the service
workshop from the customer, it is necessary to confirm
the “fault symptoms” and “fault occurrence data” based
on the engine control system questionnaire with the
customer.

HCW01ASH011801

Legend
1. Fault symptoms
2. Fault frequency / fault conditions

Because:
1A-90 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

ENGINE CONTROL SYSTEM CHECK SHEET Inspectors Name


Customer’s Name Model & Model Year
Driver’s Name Chassis No.
Date Vehicle Brought In Engine No.
License No. Odometer Reading km/miles

Engine Does Engine does not crank No initial combustion No complete combustion
Not Run
Hard Start Engine cranks slowly Other ( )
Abnormal idling speed High idling speed ( RPM) Low idling speed ( RPM)
Problem Symptoms

Incorrect Idle Rough idling


Other ( )
Hesitation, sag, stumble Surge, chuggles Cut out, misses
Poor Lack of power, sluggishness, sponginess
Driveability
Other ( )
Soon after starting After accelerator pedal depressed
Engine Stall During A/C operation After accelerator pedal released Shifting from N to D
Other ( )
Black smoke White smoke Poor fuel economy
Others Fuel knock, combustion noise
Other ( )

Dates problem occurred


Problem frequency Constant Intermittently ( times per day/month) Once only
Other ( )
Weather Fine Cloudy Rainy Snow
Various/Other ( )
Outside Hot (approx. ) Warm Cool Cold (approx. )
Condition When Problem Occurs

Temperature Any temperature


Highway Suburbs City area Uphill
Place
Downhill Rough road Other ( )
Load Condition Over (approx. tons) No load
Other (approx. tons)
Engine Cold Warming up After warming up Any temperature
Temperature Other ( )
Starting Just after starting ( Min.) Idling
Engine Operation Racing Driving Constant speed Acceleration
Deceleration A/C switch On/Off
Other ( )
Fuel Amount Full Above 1/2 Below 1/2 Near empty
Fuel Bland

Condition of Check Engine Lamp Remains On Intermittently turns On Does not turn On

Present Code Nothing P Code & Symptom Code


No. ( )
Diagnostic Trouble
Code (DTC) or Flash
Code P Code & Symptom Code
History Code Nothing No. ( )

Other Additional
Condition

HCW46EXF002401
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-91
On-Board Diagnosis (OBD) System Check
Description Test Description
The on-board diagnosis (OBD) system check is the The following numbers show the step numbers of the
starting point for all vehicle driving condition diagnoses. diagnostic chart:
Before using this procedure, carefully do a visual
inspection to ensure there is no dirt or loose fittings in
2. The MIL (check engine lamp) is continually on
engine control module (ECM), connectors, and power
while the starter switch is on but engine is not
supply and grounding.
running and afterwards turns off. If it does not
In addition, this is a method for confirming by each
turn on, use a diagnostic chart to inspect
function the problems arising from imperfect
functions in order to check the MIL circuit and
functioning of engine control system. repair it.
3. Make sure the ECM has the capability to control
Diagnostic Aids
the MIL and that the MIL drive circuit is
Intermittent fault (intermittent) may occur due to poor connected to ground. If there is an abnormality,
connection or harness damage. Check for the following use a diagnostic chart to inspect functions in
conditions, and repair or replace if fault is detected. order to check the MIL flash circuit and repair it.
• Poor connection at ECM: At the harness 4. Inspect the data communication circuit, and
connector, inspect to ensure there is no projecting confirm the ability of ECM to transmit serial data.
terminal end portion, inappropriate fit, lock 6. If the specified DTC is detected, the engine may
damage, inappropriate shape or damage to not start. In addition, inspect and repair since the
terminal, or poor connection of terminal and wire. engine control may not be functioning normally.
• Damage to harness: Inspect to ensure there is no 11. Reference an inspection method for each DTC
abrasion of wire insulation, broken wire inside the and perform an inspection
insulation, and the like. 14. If the scan tool data differs from the
representative value, this will be useful in
checking the areas where an abnormality has
occurred.

Step Action Value(s) Yes No


Perform oral consultation (confirmation of
1 vehicle conditions, etc.) by using check sheet. — Go to “Oral
Was oral consultation carried out? Go to Step 2 Consultation”
Make sure the MIL (check engine lamp) turns
on.
1. Turn the starter switch ON.
(At this time, engine does not start up)
2 After turning on for 15 seconds, flashes —
three times with a 1 second period and
then remains on until the engine is
started. Go to “Checking
the MIL lighting
Did the MIL (check engine lamp) turn on? Go to Step 3 circuit system”
Make sure the MIL (check engine lamp)
flashes correctly.
1. Turn the starter switch ON.
(At this time, engine does not start up)
3 2. Connect the diagnostic switch (diagnostic —
connector and diagnostic common
connector).
Go to “Checking
Did the MIL (check engine lamp) flash the MIL flashing
correctly? Go to Step 4 circuit system”
1A-92 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

Step Action Value(s) Yes No


Connect the scan tool.
1. Turn the starter switch OFF.
2. Connect scan tool to data link connector
(DLC:3 pole).
3. Turn the starter switch ON.
4 —
4. Turn ON the scan tool.
5. Communicate with the engine control
module (ECM) using a scan tool.
Go to “Checking
Was power supplied to scan tool, and was the scan tool
connection with the ECM confirmed? Go to Step 5 circuit system”
DTC is read and recorded using scan tool.
1. Turn the starter switch ON. (At this time,
engine does not start up)
5 2. Turn ON the scan tool. —
3. Read the DTC using scan tool.

Is the action complete? Go to Step 6 —


Check the content of the DTC and check if
6 DTCs [P0033, P0035] have been detected. — Go to applicable
Were DTCs [P0033, P0035] detected? DTC Go to Step 7
Check to see if the engine starts. Go to “Checking
7 — the engine starting
Did the engine start up? Go to Step 8 system”
DTC is read and recorded using scan tool.
1. Turn the starter switch ON, and start the
engine.
8 2. Turn ON the scan tool. —
3. Read the DTC using scan tool.

Is the action complete? Go to Step 9 —


Reconfirm the content of the DTC.
9 Are current DTCs and previous DTCs — Go to applicable
recorded? DTC Go to Step 10
In DTC confirmation of step 9, confirm that Repair the
previous DTCs are still recorded. problem refer to
the applicable
10 Are the previous DTCs still available? — symptom
diagnostic table
and the scan tool
data Go to Step 11
Inspect the fuel system.
View DTCs [P0014, P0015] (inspection of
engine timing sensors), DTCs [P0271-P0276]
(inspection related to injectors), DTC [P0115,
P0118, P0151, P0245, P0226, P0227, P0245,
11 P0247, P0248] (related to fuel pressure, —
inspection of supply pump), perform an
inspection and if there is an abnormality,
perform a repair or replacement.
Is the action complete? Go to Step 12 —
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-93

Step Action Value(s) Yes No


Perform inspection of the engine control
status (ECM).
Carry out each type of actuator test using a
scan tool, and judge whether the test
performed normally and whether the test
results are normal.
1. Rail pressure control
When changing the set pressure of the
fuel pressure inside the fuel rail, confirm
that the actual pressure follows the set
pressure and when pressure is increased
whether or not there are any leaks from
12 the fuel piping system. —
2. Stoppage of injection on a per injector
basis
Stop the injector for one cylinder at a time
to make sure fuel is being injected
correctly. When normal, the sound of the
engine will change when an injector is
stopped; however, if there is an
abnormality, the sound of the engine will
not change.

Were you able to complete the test correctly,


and were the results normal? Go to Step 14 Go to Step 13
1. Repair/replace the portions judged to be
abnormal by the inspection performed in
Step 12, and related portions. In addition
if the tests could not be performed
making it so there is not any results one
way or the other, replace the engine
control module.
13 —
IMPORTANT:
After replacing the ECM, perform the following
items of programming.
• Q adjustment data
• Injector ID code

Is the action complete? Go to Step 14 —


Inspect/repair fault portions according to the
phenomena considered to be faults by
14 referring to oral consultation (user data) and —
engine data. Go to applicable
symptom
Is the action complete? Go to Step 15 diagnostic table
Erase DTCs from the ECM and restore the
15 vehicle to its initial state. —
Is the action complete? Verify repair —
1A-94 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Checking the MIL (check engine lamp) lighting circuit system (MIL does not turn ON)

Fuse 11
(7.5A)

0.5Y
KEY ON
A30 Meter

ECM

A14 C8
GND

0.3 O/B
0.5B
5B/L
8B

82 Engine
Control
Module
(ECM)

HCW61AMF001401

Circuit Description Also check for abnormality such as of other ECM


When the starter switch is turned on, the MIL (check internal fault, meter, valve and the like, and repair or
engine lamp) turns on and turns off based on the replace if fault is detected.
following conditions.
Test Description
• After turning on for 15 seconds, flashes three times
with a 1 second period and then remains on until The following numbers show the step numbers of the
the engine is started and then turns off once the diagnostic chart:
engine starts. (However, the three flashes do not
happen on fire car). 1. If other lamp in the meter is lit, it can be judged
When the engine control module (ECM) confirms the that abnormality may exist in the power circuit
on signal from the starter, it performs MIL turn on/turn from battery to MIL (check engine lamp).
off control. 4. As the ECM controls the MIL, make sure there is
no abnormality in the ECM power supply and
Diagnostic Aids ground circuits.
Intermittent fault (intermittent) may occur due to poor
connection or harness damage. Check for the following
conditions, and repair or replace if fault is detected.
• Poor connection at ECM: At the harness
connector, inspect to ensure there is no projecting
terminal end portion, inappropriate fit, lock
damage, inappropriate shape or damage to
terminal, or poor connection of terminal and wire.
• Damage to harness: Inspect to ensure there is no
abrasion of wire insulation, broken wire inside the
insulation, and the like.
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-95

Step Action Value(s) Yes No


Make sure the other lights (parking brake light,
charge light, etc.) in the display turn on.
1. Turn the starter switch on.
1 2. Make sure the lights in the display turn —
on.

Did the other lights turn on? Go to Step 5 Go to Step 2


Check the power supply system of meter.
1. Turn the starter switch OFF. Between
2. Disconnect the meter. connector
power
2 3. Turn the starter switch ON, and measure
terminal and
the voltage between the display harness
GND: Battery
connector and GND.
voltage
Is the voltage value normal? Go to Step 4 Go to Step 3
Inspect the power supply circuit and ground
circuit of the display.
3 When fault is detected, replace if necessary. —

Is the action complete? Go to Step 5 —


Check the power supply and GND circuit for
the engine control module (ECM).
Go to “Engine control module (ECM) power
4 supply and ground circuit”. —
When fault is detected, replace if necessary.

Is the action complete? Go to Step 5 —


Make sure the MIL (check engine lamp) turns
on again.
1. Connect all the harnesses.
2. Turn the starter switch ON.
5 —
(At this time, engine does not start up)
After staying lit for 15s, the lamp flashes 3
times on a 1s cycle, then lights again. Verify repair and
return to the OBD
Did the MIL (check engine lamp) turn on? system check Go to Step 6
Check the MIL (check engine lamp) drive
circuit.
1. Turn the starter switch OFF.
2. Disconnect the harness from the ECM.
6 3. Turn on the starter switch and confirm —
that the MIL (check engine lamp) turns on
when a jumper is used between the ECM
harness connector and ground.
Did the MIL (check engine lamp) turn on? Go to Step 8 Go to Step 7
Repair or replace the MIL (check engine lamp)
7 drive circuit. —
Is the action complete? Go to Step 9 —
1A-96 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

Step Action Value(s) Yes No


Make sure the MIL (check engine lamp) turns
on again.
1. Connect all the harnesses.
2. Turn the starter switch ON.
8 —
(At this time, engine does not start up)
After staying lit for 15s, the lamp flashes 3
times on a 1s cycle, then lights again. Verify repair and
return to the OBD
Did the MIL (check engine lamp) turn on? system check Go to Step 9
1. Replace the ECM.

IMPORTANT:
After replacing the ECM, perform the following
9 items of programming. —
• Q adjustment data
• Injector ID code Verify repair and
return to the OBD
Is the action complete? system check —
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-97
Checking the MIL (check engine lamp) flashing control system (MIL does not flashing)

Fuse 11
(7.5A)

0.5Y
KEY ON
A30 Meter

ECM

A14 C8

GND

0.3 O/B
0.5B
5B/L
8B

82 Engine
Control
Module
(ECM)

HCW61AMF001401

Circuit Description Test Description


When the starter switch is turned on, the MIL (check The following numbers show the step numbers of the
engine lamp) turns on and turns off based on the diagnostic chart:
following conditions.
• After turning on for 15 seconds, flashes three times 3. If the circuit is shorted to ground, the MIL (check
with a 1 second period and then remains on until engine lamp) will not flash. Check the circuit for
the engine is started. Turns on after engine is abnormalities
started. (Fire trucks do not flash three times) 5. If the display is shorted to ground internally, the
MIL (check engine lamp) will not flash. Check
Diagnostic Aids the circuit for abnormalities
Intermittent fault (intermittent) may occur due to poor 8. As the ECM controls the MIL (check engine
connection or harness damage. Check for the following lamp), make sure there is no abnormality in the
conditions, and repair or replace if fault is detected. ECM power supply and ground circuits.
• Poor connection at ECM: At the harness
connector, inspect to ensure there is no projecting
terminal end portion, inappropriate fit, lock
damage, inappropriate shape or damage to
terminal, or poor connection of terminal and wire.
• Damage to harness: Inspect to ensure there is no
abrasion of wire insulation, broken wire inside the
insulation, and the like.
Also check for abnormality such as of other ECM
internal fault, meter, diagnostic switch and the like, and
repair or replace if fault is detected.
1A-98 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

Step Action Value(s) Yes No


Check the diagnostic switch circuit.
1. Turn the starter switch OFF.
2. Disconnect the harness from the Engine
Control Module (ECM).
3. Check that there are no short circuits or
1 broken wires in the harness between the —
ECM and the diagnostic switch.
4. If fault is detected, repair or replace as
necessary.
Was an abnormality detected? Go to Step 2 —
Check the diagnostic switch circuit.
1. Turn the starter switch OFF.
2. Disconnect the harness from the ECM.
3. Check that there are no short circuits or
2 broken wires in the harness between the —
diagnostic switch and ground.
4. If fault is detected, repair or replace as
necessary.

Was an abnormality detected? Go to Step 3 —


Check the MIL (check engine lamp) drive
circuit.
1. Turn the starter switch OFF.
2. Disconnect the harness from the display.
3. Disconnect the harness from the ECM.
3 4. Check that there are no short circuits in —
the harness between the display and the
ECM.
5. If fault is detected, repair or replace as
necessary.

Was an abnormality detected? Go to Step 4 —


Make sure the MIL (check engine lamp)
flashes correctly again.
1. Connect all the harnesses.
2. Turn the starter switch ON.
(At this time, engine does not start up)
4 —
3. Connect the diagnostic switch (diagnostic
connector and diagnostic common
connector).
Verify repair and
Did the MIL (check engine lamp) flash return to the OBD
correctly? system check Go to Step 5
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-99

Step Action Value(s) Yes No


Check the display.
1. Turn the starter switch OFF.
2. Disconnect the harness from the ECM.
3. Turn the starter switch ON.
5 —
4. Make sure the MIL (check engine lamp)
turns on.
Did the MIL (check engine lamp) turn off
correctly? Go to Step 8 Go to Step 6
Replace the meter.
6 —
Is the action complete? Go to Step 7 —
Make sure the MIL (check engine lamp)
flashes correctly again.
1. Connect all the harnesses.
2. Turn the starter switch ON.
7 (At this time, engine does not start up) —
3. Connect the diagnostic switch
(connector).
Verify repair and
Did the MIL (check engine lamp) flash return to the OBD
correctly? system check Go to Step 8
Inspect the power supply circuit and ground
circuit of the ECM.
8 When fault is detected, replace if necessary. —

Is the action complete? Go to Step 9 —


Make sure the MIL (check engine lamp)
flashes correctly again.
1. Connect all the harnesses.
2. Turn the starter switch ON.
9 (At this time, engine does not start up) —
3. Connect the diagnostic switch
(connector).
Verify repair and
Did the MIL (check engine lamp) flash return to the OBD
correctly? system check Go to Step 10
1. Replace the ECM.

IMPORTANT:
After replacing the ECM, perform the following
10 items of programming. —
• Q adjustment data
• Injector ID code Verify repair and
return to the OBD
Is the action complete? system check —
1A-100 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Checking the Scan Tool Circuit System

Fuse 22
(7.5A)

0.5V 3

Data Link 2 0.5B/P 1.25B/O


Connector
(DLC)

0.5B/P
1

2B/L
Diagnostics Common
Connector (Green)

Diagnostics Connector
(Brown)
0.3Br

0.5B/W

19 68 Engine
Control
Module
(ECM)

HCW61AMF001501

Circuit Description • Damage to harness: Inspect to ensure there is no


The Tech2 can communicate with the engine control abrasion of wire insulation, broken wire inside the
module (ECM) through a connection using a data link insulation, and the like.
connector (DLC) and the power supply for the scan tool Also check for abnormality such as of other ECM
is supplied through the DLC. internal fault, scan tool and the like, and repair or
replace if fault is detected.
Diagnostic Aids
Test Description
Intermittent fault (intermittent) may occur due to poor
connection or harness damage. Check for the following The following numbers show the step numbers of the
conditions, and repair or replace if fault is detected. diagnostic chart:
• Poor connection at ECM: At the harness
connector, inspect to ensure there is no projecting 7. As the ECM controls the MIL (check engine
terminal end portion, inappropriate fit, lock lamp), make sure there is no abnormality in the
damage, inappropriate shape or damage to ECM power supply and ground circuits.
terminal, or poor connection of terminal and wire.

Step Action Value(s) Yes No


Check the power circuit of scan tool.
1. Turn the starter switch OFF.
2. Connect scan tool to data link connector
1 (DLC). —
3. Turn the starter switch ON.
4. Turn ON the scan tool.

Was the scan tool turned ON? Go to Step 3 Go to Step 2


Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-101

Step Action Value(s) Yes No


Check to ensure that there is no broken wire
or short circuit in the power supply and GND
circuit of the DLC.
2 If fault is detected, repair or replace as —
necessary.
Is the action complete? Go to Step 3 —
Check the communication circuit of scan tool.
1. Turn the starter switch OFF.
2. Disconnect the harness from the Engine
Control Module (ECM).
3. Check to ensure that there is no broken
3 —
wire or short circuit in the communication
circuit of the DLC.
4. If fault is detected, repair or replace as
necessary.

Is the action complete? Go to Step 4 —


Connect the scan tool again.
1. Turn the starter switch OFF.
2. Connect the scan tool to the DLC.
3. Turn the starter switch ON.
4 4. Turn ON the scan tool. —
5. Communicate with the ECM using a scan
tool.
Verify repair and
Was power supplied to scan tool, and was return to the OBD
connection with the ECM confirmed? system check Go to Step 5
Inspect the scan tool.
1. Reference the users manual and perform
a auto diagnostics of the main unit.
• Cable for connecting DLC
5 • PCMCIA card —
• Scan tool main unit
2. If fault is detected, repair or replace as
necessary.
Is the action complete? Go to Step 6 —
Connect the scan tool again.
1. Turn the starter switch OFF.
2. Connect the scan tool to the DLC.
3. Turn the starter switch ON.
6 4. Turn ON the scan tool. —
5. Communicate with the ECM using a scan
tool.
Verify repair and
Was power supplied to scan tool, and was return to the OBD
connection with the ECM confirmed? system check Go to Step 7
Inspect the power supply circuit and ground
circuit of the ECM.
7 When fault is detected, replace if necessary. —

Is the action complete? Go to Step 8 —


1A-102 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

Step Action Value(s) Yes No


Connect the scan tool again.
1. Turn the starter switch OFF.
2. Connect the scan tool to the DLC.
3. Turn the starter switch ON.
8 4. Turn ON the scan tool. —
5. Communicate with the ECM using a scan
tool.
Verify repair and
Was power supplied to scan tool, and was return to the OBD
connection with the ECM confirmed? system check Go to Step 9
1. Replace the ECM.

IMPORTANT:
After replacing the ECM, perform the following
9 items of programming. —
• Q adjustment data
• Injector ID code Verify repair and
return to the OBD
Is the action complete? system check —
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-103
Checking the starting system

SBF.4 Fuse 16 Fuse 28


(80A) (7.5A) (15A) Smoother-G

B1 S G M1 M2 B2 P2 P1
OFF
ACC Smoother-G
ON A/T Smoother-G Control unit
HEAT
START

0.85B/R
0.5V/W

Starter
Cut Relay
Neutral
Emergency
Relay
Starter
Relay

0.3W/B

8W

Starter
Relay

Battery
B
+
C
3B/L

44 Engine
61
- Control
Module
(ECM)

HCW61AMF001601

Circuit Description Test Description


The starter circuit applies voltage to the starter relay The following numbers show the step numbers of the
when the starter switch is in the “start” position diagnostic chart:
activating the relay and power is supplied to the starter
main unit. In addition, the starter relay operating
2. Inspect the starter body, starter switch, starter
voltage is sent to the engine control module (ECM) as a
relay, neutral relay, and circuit etc. and perform
starter operating signal and is used for controlling start
any necessary repairs and/or replacements. In
of the engine.
addition, inspect the flywheel (ring gear) and if
For trucks with Smoother-G, starting of engine may be
there are any abnormalities, perform needed
restricted using the neutral inhibitor function.
repairs and/or replacements.
3. Inspect for the amount of fuel, air removal, fuel
Diagnostic Aids
piping etc. and if there are any abnormalities
• Start system abnormalities (starter, starter relay, perform needed repairs and/or replacements.
starter circuit, battery etc.) 4. Inspect the air intake pipe, and air cleaner and if
• Engine control system down (ECM, power supply, there are any abnormalities perform any needed
ground abnormality etc.) repairs and/or replacements.
• Supply pump abnormality (main unit, PCV, feed 5. Inspect the exhaust brake and exhaust brake
pump) magnetic valve etc. and if there are any
• Injector abnormality abnormalities perform any needed repairs and/
or replacements.
• Fuel rail abnormality
• Fuel system abnormality
• Intake air system abnormality
• Exhaust system abnormality
• Engine body abnormality
1A-104 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

Step Action Value(s) Yes No


Check battery voltage.
Recharge or replace if there is battery voltage
1 (specific gravity) abnormality. —

Is the action complete? Go to Step 2 —


Make sure the starter operates properly.
1. Make sure the starter operates when the
starter switch is turned to the “start”
position and if it does not operate,
perform needed repairs.
• For vehicles with Smoother-G check
the DTCs for each system and if an
2 issue is found, perform inspections —
and repair (reference corresponding
repair manual).
• Reference engine mechanical repair
manual section 1E and perform
needed inspections and repairs.
Is the action complete? Go to Step 3 —
Check the fuel system.
3 — Go to “Checking
Is the action complete? Go to Step 4 the fuel system”
Check the air intake system. Go to “Checking
4 — the air intake
Is the action complete? Go to Step 5 system”
Check the exhaust system. Go to “Checking
5 — the exhaust
Is the action complete? Go to Step 6 system”
Check the fuel injection timing.
1. Inspect the mechanical timing at two
locations of the supply pump and the
crank pulley.
• Supply pump (coupling):
6 Matching of inscribed line with the —
pointer
• Crank pulley: BTDC 0°
2. Make adjustments if there is an
abnormality with the mechanical timing.
Is the action complete? Go to Step 7 —
Check whether DTC is detected.
(DTCs that stop engine based on backup
control)
1. Connect the scan tool.
2. Check whether or not the following DTCs
7 —
are detected.
DTC: P0014, P0015, P0033, P0035,
P0051, P0072, P0118, P0158, P0159,
P0227
Go to applicable
Is DTC detected? DTC Go to Step 8
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-105

Step Action Value(s) Yes No


1. Check the mechanical areas of the
engine and if there are any problems,
make any necessary repairs.
• Valve system
8 • Compression pressure —
• Timing gear
• Piston and crankshaft

Is the action complete? Go to Step 9 —


Restore the vehicle and Verify repair
9 —
Is the action complete? Verify repair —
1A-106 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Checking the fuel system

3
4
12

2
11

10

7 5

8 6

HCW3C0MF001401

Legend
1. Fuel filter 7. PCV
2. Flow damper 8. Supply pump
3. Injector 9. Field pump
4. Fuel pipe 10. Pressure limiter
5. Overflow valve 11. Fuel pressure sensor
6. Fuel tank 12. Fuel rail

Circuit Description • Supply pump internal failure (internal seal ability


The fuel system is separated into the high pressure deterioration etc.)
system and the low pressure system. The high • Feed pump failure
pressure system describes the area between the • Fuel system pipe malfunction (fuel leak, blockage,
supply pump, the fuel rail and the injectors. The low crushed pipe etc.)
pressure side describes the area between the tank and • Fuel filter abnormality (blockage, overflow valve
the supply pump as well as the fuel return. There are failure etc.)
several filters (main, coarse filter etc.) installed in the
fuel system. In addition in order to prevent discharge of • Fuel tank malfunction (blockage, amount of fuel,
fuel, there is a flow damper and a pressure limiter additional tank etc.)
installed in the fuel rail and an over flow valve installed • Fuel freezing
in the supply pump to prevent discharge of fuel. • Amount and quality of fuel

Diagnostic Aids Test Description


• Air getting into the fuel piping The following numbers show the step numbers of the
• Pressure limiter, flow damper (operation, internal diagnostic chart:
seal ability deterioration etc.)
• Injector internal malfunction
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-107

4. Remove air from the fuel system (high pressure


3. Remove air from the fuel system (low pressure side). As air removal from the high pressure side
side). Separation of air removal operation into is performed through operation of the injectors, it
low pressure and high pressure areas makes it can not be performed if there is an abnormality
easier to determine areas with abnormalities. with engine control.

Step Action Value(s) Yes No


Inspect the amount of fuel.
1 — Filling with fuel,
Is there sufficient fuel? Go to Step 2 and go to Step 2
Inspect the quality of the fuel.
1. Discharge some fuel from the fuel tank.
2. Fill with fuel to the designated amount.
2 —
3. Remove air from the fuel piping.
4. Start the engine.

Did the engine start? Go to Step 7 Go to Step 3


Remove air from the fuel piping (work
performed only with the priming pump).
(Air removal areas: between the fuel tank -
feed pump - fuel filter - supply pump). In
addition, if fuel is not supplied to the fuel filter,
inspect the supply pump over flow valve and if
3 there is an abnormality, replace the pump. —
If there is not an abnormality with the over
flow valve, connect the fuel hoses on top the
fuel tank (in and out) backward and remove
air and if fuel is seen, reference step 7 and
inspect the fuel tank.

Is the action complete? Go to Step 4 —


Make sure the fuel filter is normal.
(Main fuel filter)
4 If the filter is dirty or plugged, clean or replace —
the filter.

Is the action complete? Go to Step 5 —


Check the fuel piping and also inspect for fuel
leaks.
Inspect the fuel piping for crushing, breaks,
cracking, looseness, and for abnormalities of
5 the filter inside the pump section such as —
accumulation of filth and if there are any
abnormalities perform any needed repairs
and/or replacements.

Is the action complete? Go to Step 6 —


1A-108 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

Step Action Value(s) Yes No


1. Check the fuel tank.
• Are there any foreign materials
inside the tank?
(Is the fuel suction opening
blocked?)
• Is the fuel suction pipe bent?
• Are there cracks in the fuel suction
pipe?
6 • Is the fuel tank deformed? —
• Is the fuel tank mounted correctly?
• Are the fuel tank cap and air removal
hole plugged?
• Is there water in the fuel tank?
2. If there are any abnormalities with the
fuel tank perform any needed repairs
and/or replacements.

Is the action complete? Go to Step 7 —


Restore the vehicle to its initial state, remove
7 air from the fuel lines again and Verify repair —
Is the action complete? Verify repair —

Air removal method Fuel filter


1. Turn the supply pump priming pump cap until it
flips up.
2. Loosen the air removal plug on the fuel filter.
3. Operate the priming pump to discharge air bubbles
from the air removal plug. 1
4. In addition, operate the priming pump and when air
bubbles are no longer discharged from the air
removal plug, tighten the air removal plug.
5. Tighten the supply pump air removal plug.
6. Operate the priming pump to discharge air bubbles
from the air removal plug.
7. In addition, operate the priming pump and when air
bubbles are no longer discharged from the air
removal plug, tighten the air removal plug.
8. After tightening all of the plugs, push the priming
pump over 150 times. HCW5ADSH001001
9. Return the priming pump cap to its original position Legend
and securely tighten the cap. 1. Air removal plug
10. Wipe up spilled fuel, start the engine and make
sure there are not any fuel leaks. Here, if the
engine does not start, repeat starting from step 8.
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-109
Supply Pump

2 1

HCW5ADSH001101

Legend
1. Priming pump
2. Air removal plug
3. Supply Pump
1A-110 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Checking the intake air system

Fuse 16
(7.5A)

0.5V/W
0.5V/W
0.5V/W

3 1
3 1

VGS
EGR
Fail Safe
Fail Safe
Relay
Relay

0.5/P/W
5

0.35B
5 4
0.3Br/G

0.5W/R

0.5P/W
0.5P/W
0.5P/W
0.5W/R

0.5W/R

2 2 2

2 2 VGS VGS
VGS
M/V2 M/V3
M/V1
EGR EGR
M/V1 M/V2
1

0.5Y/Br
1 1

0.5Y/V
0.5Y/G

1 1
0.5Y/R
0.5Y/B

0.5Y/Br
0.5Y/V

0.5Y/Br
0.5Y/V
Engine
110 108 109 47 111 112 113 114 115
Control
Module
(ECM)

HCW61AMF001701

Circuit Description Test Description


The air intake system starts with air intake through the The following numbers show the step numbers of the
air cleaner and air is supplied through the turbo diagnostic chart:
charger, the intake cooler and then to the engine. As air
pressure is increased using a turbo charger, air leaks in
1. Check to see if the air cleaner is dirty or
the ducts will adversely affect engine performance.
plugged. If there is an abnormality, perform
An indicator is mounted on the air cleaner that detects
necessary cleaning and/or replacement. Also,
air intake conditions (such as dirtiness of the filter). If
the condition of the air cleaner can be inspected
the air cleaner is detected as being dirty or plugged, the
using the indicator.
indicator signal area will turn red providing notification.
7. An abnormality with the intercooler duct will
The VGS magnetic valve is used to supply air to the
cause problems with the boost pressure and
VGS air cylinder. Controlling the air supply to the air
adversely affect engine performance; therefore,
cylinder enables the air cylinder for the VGS to be
carefully inspect clip position and direction and
appropriately controlled.
how the duct is mounted etc.
Diagnostic Aids
• Air filter plugged
• Abnormality with air intake duct (crushed,
damaged)
• Abnormality with the intake cooler duct (crushed,
damaged, mounting failure)
• Abnormality with intake cooler body
• VGS turbo abnormality (operation failure, air
cylinder does not return)
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-111

Step Action Value(s) Yes No


Check the condition of the air cleaner.
(Inspect the indicator and whether or not the
1 filter is dirty) —

Is the air cleaner status normal? Go to Step 3 Go to Step 2


Clean or replace the air cleaner.
2 —
Is the action complete? Go to Step 3 —
Inspect inside the air cleaner case to make
3 sure there is not any water or filth. —
Is the inside of the case clean? Go to Step 5 Go to Step 4
Clean inside the air cleaner case or inspect
the water removal valve.
If there is an abnormality such as being
4 plugged, perform any necessary repair and/or —
replacements.
Is the action complete? Go to Step 5 —
Inspect the intake air duct for crushing,
5 looseness, or damage. —
Is the air intake duct normal? Go to Step 7 Go to Step 6
Repair or replace the crushed or damaged
6 areas of the intake air duct. —
Is the action complete? Go to Step 7 —
Inspect the intake cooler duct for being
crushed, looseness, damage, and mounting
7 failure. —

Is the intercooler duct normal? Go to Step 9 Go to Step 8


Repair or replace the crushed for damaged
8 areas of the intercooler duct. —
Is the action complete? Go to Step 9 —
Inspect the VGS turbo.
1. Connect the scan tool (Tech2), inspect
the VGS valve operating condition using
the VGS M/V test.
9 —
2. If an issue is found, inspect the valve for
deposits, air cylinder return, and for air
leakage and perform repairs as needed.
Was an issue found? Go to Step 10 —
Restore the vehicle and Verify repair
10 —
Is the action complete? Verify repair —
1A-112 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Checking the exhaust system

Fuse 13
(7.5A)
0.5SB

Exhaust
Brake
switch
0.5L/Y

0.5L/Y
0.5L/Y

0.5L/Y

0.85L/Y
A12 A20
1
Exhaust Brake and Retarder Control unit Exhaust
Brake

0.5L/Y

0.5L/Y
A17 A1 M/V

2
0.3V/W
0.3L/P

2B
10 91 Engine
42 49
Control
Module
(ECM)

HCW61AMF001801

Circuit Description Assumed factors


Power is supplied to the exhaust brake operation circuit • Exhaust brake error (air cylinder not returning with
by fuse No. 13. When the exhaust brake switch exhaust brake left closed, etc.)
(combination switch) is ON, signals are sent to the • Exhaust brake magnetic valve error
intensive control unit. Or, signal (exhaust brake switch
• Brake intensive control unit error
signal) is also sent to engine control module (ECM) at
the same time. The brake intensive control unit that • Exhaust brake switch system error
receives the signal operates the exhaust brake
magnetic valve, and that operation signal is also sent to
the ECM at the same time.

Step Action Value(s) Yes No


Check exhaust brake operating status.
1. Turn the starter switch ON.
2. Start engine and leave in an idling state.
3. Unhook connector (PA1-terminal, green)
1 inside inspection cover. —

4. Turn exhaust brake switch lever to ON.

Did the engine start and exhaust brake


operate? Go to Step 10 Go to Step 2
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-113

Step Action Value(s) Yes No


Inspect exhaust brake switch.
1. Connect scan tool (Tech2).
2. Set the gear position to neutral.
3. Turn the starter switch ON.
4. Inspect switch input with scan tool.
2 5. Operate exhaust brake switch. —
6. Confirm on scan tool screen data display
whether exhaust switch (ON, OFF)
changes according to operation of the
switch.

Does display change according to operation


of switch? Go to Step 4 Go to Step 3
Check conduction at exhaust brake switch
circuit, and repair or replace places with
errors.
1. Combination switch body
2. Fuse No. 13 to connection switch
3. Connection switch to base harness
connector
4. Base harness connector to engine control
module (ECR)
5. Combination switch to floor (left) harness
3 —
connector
6. Instrument (lower) harness connector to
seat harness connector
7. Floor (left) harness connector to brake
intensive control unit connector (A)
8. After repairing or replacing, use the
connector (PA 1-terminal, green) inside
the inspection cover again to check
exhaust brake operation.

Does the exhaust brake operate? Go to Step 10 Go to Step 4


1. Measure resistance of exhaust brake
magnetic valve with a digital multi meter
(DMM).
4 • Between multimedia terminals: 34 - —
40 Ω
• Between terminal and body: ∞Ω

Are the resistance values normal? Go to Step 6 Go to Step 5


Replace the exhaust brake magnetic valve.
After repairing or replacing, use the connector
5 (PA 1-terminal, green) inside the inspection —
cover again to check exhaust brake operation.

Does the exhaust brake operate? Go to Step 10 Go to Step 6


1A-114 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

Step Action Value(s) Yes No


Check conduction at exhaust brake magnetic
valve circuit, and repair or replace places with
errors.
1. Brake intensive control unit connector (A)
to floor (left) harness connector
2. Seat harness connector to instrument
(lower) harness connector
3. Floor (left) harness connector to frame
(Ft) harness connector
4. Floor (left) harness connector to ECM
6 —
5. Instrument (lower) harness connector to
member harness connector
6. Frame (Ft) harness connector to exhaust
brake magnetic valve
7. Member harness connector to earth point
8. After repairing or replacing, use the
connector (PA 1-terminal, green) inside
the inspection cover again to check
exhaust brake operation.

Does the exhaust brake operate? Go to Step 10 Go to Step 7


Inspect the functioning of the exhaust brake
magnetic valve.
1. Connect scan tool.
2. Set the gear position to neutral.
3. Turn the starter switch ON.
4. Inspect switch input with scan tool.
7 5. Confirm on scan tool data display —
whether exhaust brake switch (ON, OFF)
changes by disconnecting/connecting
connector (PA 1-terminal, green) inside
inspection cover.

Did the display change by disconnecting/


connecting connector (PA 1-terminal, green)? Go to Step 8 Go to Step 9
Replace the exhaust brake valve.
8 —
Is the measure complete? Go to Step 10 —
Replace the brake intensive control unit, or
check the brake intensive control unit power
9 supply and GND circuit, and repair or replace —
if there are abnormalities.

Is the measure complete? Go to Step 10 —


Restore the vehicle and check repair.
10 — Inspection
Is the measure complete? complete —
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-115
Magnetic valve appearance, connector name and Magnetic valve connector name
resistance
Connector Signal name
Magnetic valve appearance number
1 Magnetic valve (coil)
2 Magnetic valve (coil)

2 1

HCW31ASH008101

<Magnetic valve resistance>


Check area Resistance Comments
Z-type 1↔2 34-40Ω Between magnetic valve coils
connector
1↔body ∞Ω Between magnetic valve coil and body
(gray) 2-
terminal 2↔body ∞Ω Between magnetic valve coil and body

NOTE:
Resistance values vary depending on the magnetic
valve temperature.
1A-116 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Checking the EGR

Fuse 16
(7.5A)

0.5V/W
0.5V/W
0.5V/W

3 1
3 1

VGS
EGR
Fail Safe
Fail Safe
Relay
Relay

0.5/P/W
5

0.35B
5 4
0.3Br/G

0.5W/R

0.5P/W
0.5P/W
0.5P/W
0.5W/R

0.5W/R

2 2 2

2 2 VGS VGS
VGS
M/V2 M/V3
M/V1
EGR EGR
M/V1 M/V2
1

0.5Y/Br
1 1

0.5Y/V
0.5Y/G

1 1
0.5Y/R
0.5Y/B

0.5Y/Br
0.5Y/V

0.5Y/Br
0.5Y/V
Engine
110 108 109 47 111 112 113 114 115
Control
Module
(ECM)

HCW61AMF001701

Description of circuit • ECM malfunction


EGR magnetic valves 1 and 2 are used as valves to
supply air to EGR valve air cylinder. EGR valves are Assumed factors
controlled appropriately by controlling air supply. EGR • EGR valve air cylinder abnormalities
magnetic valve power is supplied through EGR • EGR pipe abnormality (loose, crushed, damaged,
magnetic valve fail safe relay, and connected to the gas leaking, etc.)
engine control module (ECM) through the EGR
• EGR valve, EGR magnetic valve (main body, air
magnetic valve. ECM controls individual EGR magnetic
pipe abnormality, etc.)
valves. If abnormalities are detected, it controls the
EGR magnetic valve fail safe relay to stop power • ECM abnormalities
supply to individual EGR magnetic valves and stop
controls.

Diagnostic aids
Check the connector for poor connection, and check to
make sure that there are no abnormalities such as a
frayed or broken harness, frayed wiring in the harness,
or a short to another circuit. Furthermore, perform
functional diagnostics to check things like operation
and control of each component. Resolve any
abnormality.
• EGR valve air cylinder abnormalities
• EGR pipe abnormality (loose, crushed, damaged,
gas leaking, etc.)
• EGR valve, EGR magnetic valve (main body, air
pipe abnormality, etc.)
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-117

Step Action Value(s) Yes No


Use scan tool (Tech2) to inspect engine
coolant temperature. If there are any
abnormalities (temperature values fixed or
1 extremely low), refer to the DCT P0023 —
diagnostic chart.

Is the measure complete? Go to Step 2 —


Inspect for incorrect assembly of air pipe and
harness to EGR magnetic valve. If there are
2 any abnormalities, reassemble to specified —
condition.
Is the measure complete? Go to Step 3 —
Magnetic valve (EGR-related system) DTC:
Check whether P0424, P0441, P0442, P0446,
3 P0447, P0448, and P0449 are detected. —
Go to applicable
Was the DTC detected? DTC Go to Step 4
Use scan tool to inspect EGR magnetic valve
operation.
1. Connect scan tool.
2. Turn the starter switch ON. At this time,
engine does not start up
3. Remove air pipe from EGR valve air
cylinder.
4. Use scan tool to check magnetic valve
4 —
operation.
5. At the same time, use the scan tool to
operate the magnetic valve, and inspect
for air being sent to EGR valve and air
cylinder. (Refer to “Scan Tool” in the scan
tool for fault diagnosis actuator test and
magnetic valve operation check.)

Did the magnetic valve function normally? Go to Step 6 Go to Step 5


Repair or replace magnetic valve with
5 abnormality. —
Is the measure complete? Go to Step 6 —
Check the functioning of EGR valve.
1. Disconnect EGR valve from the engine.
2. Attach air piping to EGR valve.
3. Use scan tool to operate magnetic valve
as in Step 4.
(With the EGR valve removed from the
engine, attach air piping and inspect
6 —
valve function.)

CAUTION:
EGR system disassembly and assembly in
ways other than the repair manual procedures
for each engine may result in gas leaks, etc.

Did the EGR valve function? Go to Step 8 Go to Step 7


1A-118 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

Step Action Value(s) Yes No


Repair or replace EGR valve.
7 —
Is the measure complete? Go to Step 8 —
Restore the vehicle and check repair.
8 — Inspection
Is the measure complete? complete —

Magnetic valve arrangement


Cab rear member

3
4
5

1 6

HCW61ASH004701

Legend
1. EGR magnetic valve 2
2. EGR magnetic valve 1
3. VGS magnetic valve 3
4. VGS magnetic valve 2
5. VGS magnetic valve 1
6. Midway connectors
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-119
Checking the engine control module (ECM) power supply and ground circuit

Fuse 49 Fuse 17
(15A) (7.5A)
1.25 O

0.5V/W
1.25 O
1.25 O

2 5
Main
Relay POWER GND 5B

Accelerator
4 1
switch
0.3R/L

.25R/B

ECM GND
1.25B/O
KEY ON
1.25R/B

KEY ON
1.25R/B

1.25B/P

1.25B/P
1.25R/B
0.3R/L

0.3R/L

1.25B
1.25B

1.25B

75 74 5 6 7 58 46 56 102 140 141 72 73 Engine


Control
Module
(ECM)

HCW61AMF001901

Circuit Description • Damage to harness: Inspect to ensure there is no


Engine control module (ECM) power supply is applied abrasion of wire insulation, broken wire inside the
to ECM through the battery, slow blow fuse (SBF), insulation, and the like.
starter switch, and fuse. Power is applied to ECM Also check for abnormality such as of other fuses,
when starter switch is in the ON or Start position, the battery cables, and earth points, and repair or replace if
ECM turns the main relay on, main power is supplied to fault is detected.
ECM.
Test Description
Diagnostic help The following numbers show the step numbers of the
Intermittent fault (intermittent) may occur due to poor diagnostic chart:
connection or harness damage. Check for the following
conditions, and repair or replace if fault is detected. 2. Inspect fuse, slow blow fuse (SBF), and
• Poor connection at ECM: At the harness harness. Replace if there are any abnormalities.
connector, inspect to ensure there is no projecting 3. Power is also supplied from main relay when
terminal end portion, inappropriate fit, lock main switch is other than ON. Refer to “DTC
damage, inappropriate shape or damage to P0416 Main Relay System Abnormalities” to
terminal, or poor connection of terminal and wire. check main relay system.
7. Ground circuit has case GND, ECM GND, and
Power GND. So, check all ground circuits.

Step Action Value(s) Yes No


Check battery voltage.
Recharge or replace if there are any battery
1 voltage (specific gravity) abnormalities. —

Is the measure complete? Go to Step 2 —


1A-120 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

Step Action Value(s) Yes No


Check the fuses and harness.
Replace if any abnormalities are found in
2 fuses and harness. —

Is the measure complete? Go to Step 3 —


Check engine control module (ECM) power
supply harness for disconnection or shorts.
1. Turn the starter switch Off.
2. Disconnect the harness from the ECM.
3. Attach a digital multi meter (DMM)
between the ECM connector terminals
and ground.
4. Measure the voltage of the switch circuit.
• At starter switch ON position:
Between pin 46 and GND: Battery
3 voltage —
• At starter switch ON position:
Between pin 56 and GND: Battery
voltage
• At other than starter switch ON or
START position:
Between pin 46 and GND: 0V
• At other than starter switch ON or
START position:
Between pin 56 and GND: 0V

Is the applied voltage normal? Go to Step 7 Go to Step 4


Check starter switch.
1. Turn the starter switch Off.
2. Disconnect the harness from the starter
switch.
4 —
3. Attach digital multimedia (DMM) to starter
switch, operate the switch, and inspect
switch function.

Is the starter switch normal? Go to Step 5 Go to Step 6


Check starter switch circuit.
1. Check that there are no short circuits or
broken wires in the harness between the
ECM and starter switch.
2. Check that there are no short circuits or
5 broken wires in the harness between the —
power supply and starter switch.
3. If a fault is detected, repair or replace if
necessary.

Is the measure complete? Go to Step 7 —


Replace starter switch.
6 —
Is the measure complete? Go to Step 7 —
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-121

Step Action Value(s) Yes No


Check ground circuit.
1. Turn the starter switch Off.
2. Disconnect the harness from the ECM.
3. Check that there are no short circuits or
7 broken wires in the harness between the —
ECM and ground.
4. If a fault is detected, repair or replace if
necessary.

Is the measure complete? Go to Step 8 —


Restore the vehicle and check repair.
8 —
Is the measure complete? Verify repair —
1A-122 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Checking the PTO

Fuse 13
(7.5A) Smoother-G/A/T

0.85SB 0.5SB

0.85SB

0.85SB
Smoother-G

PTO PTO
PTO Switch Switch
PTO
Switch (Dump 0.5LG
Switch
(Dump Lever) Lever)

Fire Car
0.5LG

A/T (Neutral) PTO


Relay M/V
0.5LG
PTO
Lamp
0.5SB
A/T

0.5LG
A/T PTO
Relay Relay
(PTO)
1

PTO PTO
M/V Lamp
Parking
0.5LG

Brake
2
Switch

Parking
Brake
switch
97 87 Engine V22 V13 32
82 69
Control Transmition

Module
Control Module Smoother-G
(TCM)
(ECM) Control Unit

HCW61AMF002001

Circuit Description Test Description


PTO control switches engine properties and The following numbers show the step numbers of the
accelerator (external accelerator or accelerator pedal) diagnostic chart:
depending on superstructure use conditions. The
engine control module (ECR) switches accelerator and
1. If the PTO is not operated through normal
engine properties according to signal input from
procedure, the PTO may not work properly.
accelerator, PTO switch, engine speed, parking switch,
5. When the PTO is operated through normal
etc.
procedures, fuel injection characteristic
switching (driving characteristics and working
Diagnostic Aids
characteristics) is checked.
Intermittent fault (intermittent) may occur due to poor 6. Check switch as, if there is no PTO switch input,
connection or harness damage. Check for the following fuel injection characteristics are not working
conditions, and repair or replace if fault is detected. characteristics.
• Poor connection at ECM:
At the harness connector, inspect to ensure there
is no projecting terminal end portion, inappropriate
fit, lock damage, inappropriate shape or damage to
terminal, or poor connection of terminal and wire.
• Harness damage:
Inspect to ensure there is no abrasion of wire
insulation, broken wire inside the insulation, and
the like.
Also check for abnormality such as in PTO operation
procedure, PTO relay and PTO circuit, and repair or
replace if fault is detected.
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-123

Step Action Value(s) Yes No


Inspect whether PTO operation is normal.
1. ON operation:
Operate the PTO switch when all the
following conditions are met:
• Parking lever is pulled.
• Gear position is in neutral.
• It is in idling state.
1 • Depress the clutch pedal. (Manual —
transmission vehicle)
2. OFF operation: Operate the PTO switch
when all the following conditions are met
• Leave in idling state.
• Set the gear position to neutral.
• Release (lower) the parking lever.

Are the operations normal? Go to Step 3 Go to Step 2


Recheck PTO operation.
2 —
Did the PTO operations work normally? Go to Step 3 Go to Step 1
Inspect the positions of accelerator pedal and
external accelerator when the PTO is not in
use.
The accelerator pedal is returned. (Idling
3 position) —
The external accelerator lever is returned.
(Idling position)

Are the positions of the accelerator pedal and


external accelerator returned? Go to Step 5 Go to Step 4
Return the positions of the accelerator pedal
and external accelerator to normal positions
4 (idling positions). —

Is the measure complete? Go to Step 5 —


1. Conduct PTO operation, and check if fuel
injection characteristics switch (driving
and working characteristics) is performed
normally.
• When working characteristics:
PTO remote throttle sensor can be
used.
5 • When driving characteristics: —
The idling control switch changes the
idling speed. (When normal driving)
If the idling speed does not change at this
time, inspect/repair the idling control
switch, circuit, and the like.

Is the measure complete? Go to Step 6 —


1A-124 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

Step Action Value(s) Yes No


Inspect the PTO switch circuit.
1. Connect the scan tool.
2. Set the gear position to neutral.
3. Turn the starter switch ON.
4. Inspect switch input with scan tool.
5. Operate the PTO switch.
6 6. Confirm whether the PTO switch (ON, —
OFF) in the data display on the scan tool
screen changes according to operation of
switch.
If the switch input display (ON/OFF) does
not change at this time, inspect/repair the
PTO switch, circuit and the like.

Is the measure complete? Go to Step 7 —


Check external accelerator (PTO remote
throttle sensor) adjustment.
1. Turn the starter switch ON.
2. Operate the PTO acceleration position
sensor, change output voltage, and check
PTO acceleration position sensor output
voltage.
7 • Idle position: 0.3 to 0.5 V —
• Full throttle: 4.2 to 4.6 V
3. If abnormalities occur in output voltage at
this time, refer to “Function Inspection:
External Accelerator Check,” and inspect/
repair.

Is the measure complete? Go to Step 8 —


Inspect the parking switch circuit.
1. Connect the scan tool.
2. Set the gear position to neutral.
3. Turn the starter switch ON.
4. Inspect switch input with scan tool.
5. Operate the parking switch.
8 6. Confirm whether the parking switch (ON, —
OFF) in the data display on the scan tool
screen changes according to operation of
the switch.
If the switch input display (ON/OFF) does
not change at this time, inspect/repair the
parking switch, circuit and the like.

Is the measure complete? Go to Step 9 —


Conduct PTO operation, and check if
accelerator switch state switch is (drive
accelerator and external accelerator) is
9 performed normally. —
Does engine speed change normally if using
drive accelerator or external accelerator when
using PTO? Go to Step 11 Go to Step 10
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-125

Step Action Value(s) Yes No


1. Replace the ECM.

IMPORTANT:
After replacing the ECM, perform the following
10 items of programming. —
• Q adjustment data
• Injector ID code

Is the measure complete? Go to Step 11 —


Restore the vehicle and check repair.
11 —
Is the measure complete? Verify repair —
1A-126 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Table of diagnostics codes

DTC Item Failure details Judgment


time
P0014 CMP sensor system malfunction One or fewer pulses per two engine rotations Continue
Store. for one
second
P0015 CKP sensor system malfunction One or fewer pulses per one engine rotation Continue
Store. for one
second
P0022 Atmospheric temperature sensor Atmospheric temperature sensor output value Continue
Store. system malfunction exceeds 4.9 V or is less than 0.085 V. for 0.5
seconds
P0023 Engine coolant temperature sensor Engine coolant temperature sensor output Continue
Store. system malfunction value exceeds 4.9 V or is less than 0.085 V. for one
second
P0024 Accelerator pedal position sensor Accelerator pedal position sensor output value Continue
Store. system malfunction exceeds 4.85 V or is less than 0.1 V. for one
second
P0025 Vehicle speed sensor system Vehicle speed pulse input malfunction Continue
Store. malfunction for one
second
(Small
pulse
interval)
Continue
for 5
seconds
(Large
pulse
interval)
P0032 (1) Boost sensor system malfunction or (1) Boost temperature sensor output value (1):
Store. (2) High boost malfunction exceeds 4.9 V or is less than 0.085 V. Continue
(2) Boost voltage is in the high boost for one
malfunction range (according to map) second
(2):
Continue
for 10
seconds
P0033 Malfunction of IC for monitoring CPU Malfunction of IC for monitoring CPU is
Store. detected. –
(RUN pulse reversal interval malfunction)
P0035 Low charge malfunction or • Low charge malfunction state detected in
Store. over charge malfunction circuit. Continue
for one
• Low over malfunction state detected in second
circuit.
P0042 High boost malfunction Boost voltage is in the high boost malfunction Continue
Store. range (according to map) for 0.5
seconds
P0051 CPU malfunction No RUN pulse reversal after power turned on

Store.
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-127

DTC Item Failure details Judgment


time
P0071 Atmospheric pressure sensor Atmospheric temperature sensor output value Continue
Store. malfunction exceeds 4.9 V or is less than 0.085 V. for one
second
P0072 CKP & CMP both sensor malfunction No pulse input for both CKP and CMP when Continue
Do not starter switch is turned on. for 5
store. seconds
P0015 Fuel pressure sensor output fixed PC sensor output value does not change Continue
Store. when fuel pressure is larger than 10 MPa. for 8
seconds
P0115 Common Rail Pressure Sensor Output PC sensor output value doesn't change when Continue
Record Fixed the common rail pressure has increased over for 8
10MPa seconds
P0118 Fuel pressure malfunction Actual fuel pressure exceeds 165 MPa.
Continue
Store. (Control system 1st level, 2nd level) (1st level)
for 0.1
Actual fuel pressure exceeds 170 MPa.
seconds
(2nd level)
P0151 Fuel pressure malfunction (pump PCV closing timing is 180°CA or difference 256 times
Store. overpressure transmission) between target fuel pressure and actual Continue
pressure is larger than 10 MPa. (*1)
P0158 Injector power supply system • Injector (TWV) 1, 3, 5 harness ground short
Store. malfunction (Common 1 [indicator 1,3,5 or Common 1 harness ground short.
system]) –
• Injector (TWV) 1, 3, 5 harness B short or
Common 1 harness B short.
P0159 Injector power supply system • Injector (TWV) 2, 4, 6 harness ground short
Store. malfunction (Common 2 [indicator 2, 4, or Common 2 harness ground short.
6 system]) –
• Injector (TWV) 2, 4, 6 harness B short or
Common 2 harness B short.
P0211 Fuel temperature sensor malfunction Fuel temperature sensor output value Continue
Store. exceeds 4.9 V or is less than 0.085 V. for one
(6WG1) second
P0217 PCV1 system short (battery, power When PCV1=ON: PCV1 drive voltage value Continue
Store. supply system circuit) malfunction malfunction for one
second
P0218 PCV2 system short (battery, power When PCV2=ON: PCV2 drive voltage value Continue
Store. supply system circuit) malfunction malfunction for one
second
P0226 Fuel pressure malfunction (pump no PCV closing timing is below PCV closing 256 times
Store. pressure transmission) timing control value +1°CA or fuel pressure Continue
feedback control value is below -60°CA. (*1)
P0227 Fuel pressure malfunction (fuel When DTC P0226 is in a state where
Store. outflow) conditions are met and the difference between
the actual fuel pressure is and target fuel 256 times
pressure is smaller than +5 MPa, the PCV Continue
closing timing is below +1°CA or the fuel (*1)
pressure feedback control value is below -
50°CA.
P0241 Accelerator switch OFF malfunction. Accelerator sensor output is less than 0.65 V Continue
Store. and accelerator switch=OFF for one
second
1A-128 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

DTC Item Failure details Judgment


time
P0242 Accelerator switch ON malfunction Accelerator sensor output is in access of 3.06 Continue
Store. V and accelerator switch=ON for 0.5
seconds
P0245 Fuel pressure sensor malfunction PC sensor output value is more than 4.7 V or Continue
Store. less than 0.7 V. for 0.1
seconds
P0247 PCV1 system broken wire or short When PCV1=OFF: PCV1 drive voltage value Continue
Store. circuit (ground circuit) malfunction malfunction for one
second
P0248 PCV2 system broken wire or short When PCV2=OFF: PCV2 drive voltage value Continue
Store. circuit (ground circuit) malfunction malfunction for one
second
P0271 1st cylinder injector drive system Injector (TWV) 1 coil or harness disconnection

Store. malfunction
P0272 2nd cylinder injector drive system Injector (TWV) 5 coil or harness disconnection

Store. malfunction
P0273 3rd cylinder injector drive system Injector (TWV) 3 coil or harness disconnection

Store. malfunction
P0274 4th cylinder injector drive system Injector (TWV) 6 coil or harness disconnection

Store. malfunction
P0275 5th cylinder injector drive system Injector (TWV) 2 coil or harness disconnection

Store. malfunction
P0276 6th cylinder injector drive system Injector (TWV) 4 coil or harness disconnection

Store. malfunction
P0277 Injector circuit disconnection (Common Disconnection of injectors (TWV) 1, 3, and 5

Store. 1 injector 1, 3, 5 system) or disconnection of Common 1 harness
P0278 Injector circuit disconnection (Common Disconnection of injectors (TWV) 2, 4 and 6 or

Store. 2 injector 2, 4, 6 system) disconnection of Common 2 harness
P0411 VGS magnetic valve 1 drive system When VGS M/V1=ON: Drive voltage Continue
Store. malfunction malfunction for 1.2
seconds
P0412 VGS magnetic valve 2 drive system When VGS M/V2=ON: Drive voltage Continue
Store. malfunction malfunction for 1.2
seconds
P0413 VGS magnetic valve 3 drive system When VGS M/V3=ON: Drive voltage Continue
Store. malfunction malfunction for 1.2
seconds
P0416 Main relay system malfunction Main relay=OFF output Continue 7
Store. (When starter switch is OFF and ECM power seconds
source cannot be shut down from
starter
switch=OF
F
P0418 VGS magnetic valve relay malfunction When VGS fail safe relay=ON: Relay drive Continue
Store. voltage malfunction for one
second
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-129

DTC Item Failure details Judgment


time
P0421 Both PCV 1 and 2 systems malfunction When PVC=OFF: PCV drive voltage value
Continue
Store. malfunction or
for one
When PCV=ON: PCV drive voltage value
second
malfunction
P0424 EGR magnetic valve relay malfunction When EGR fail safe relay=ON: Relay drive Continue
Store. voltage malfunction for one
second
P0441 EGR magnetic valve 1 drive error When EGR M/V1=ON: Drive voltage Continue
Store. malfunction for 1.2
seconds
P0442 EGR magnetic valve 2 drive error When EGR M/V2=ON: Drive voltage Continue
Store. malfunction for 1.2
seconds
P0446 Abnormalities in fixation when closing EGR temperature 1 is higher than 210°C Continue
Store. EGR valve1 when EGR is not functioning. for three
minutes
P0447 Abnormalities in fixation when opening EGR temperature 1 is lower than 40°C when Continue
Store. EGR valve1 EGR is functioning. for three
minutes
P0448 Abnormalities in fixation when closing EGR temperature 2 is higher than 210°C Continue
Store. EGR valve 2 when EGR is not functioning. for three
minutes
P0449 Abnormalities in fixation when opening EGR temperature 2 is lower than 40°C when Continue
Store. EGR valve 2 EGR is functioning. for three
minutes
P0518 ROM error Checksum mismatch in target domain for

Store. inspection
P0543 Overrun error 6WF1: Engine speed is 2450 rpm or more.

Store. 6WG1: Engine speed is 2700 rpm or more.

*1: Reference
Engine speed 500 rpm: approx. 10 sec.
Engine speed 1000 rpm: approx. 5 sec.
Engine speed 1500 rpm: approx. 3.5 sec.
Engine speed 2000 rpm: approx. 2.5 sec.

Backup contents
DTC
DATA Control Cruise VGS EGR
P0014 Only perform control with Reset Regular Regular

Store. CMP sensor completely control control
P0015 Only perform control with Reset Regular Regular

Store. CKP sensor completely control control
P0022 Control atmospheric Control with backup value Regular Regular

Store. temperature -25°C control control
P0023 When starting: engine coolant Control with backup value
Store. temperature= -25°C Regular Regular

Other: engine coolant control control
temperature= 50È
1A-130 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

Backup contents
DTC
DATA Control Cruise VGS EGR
P0024 Accelerator opening ratio regulation when judging malfunction
Store. (0% fixed). When depressing the accelerator, quickly increase
accelerator opening ratio to 10%, then gradually increase to
Reset Regular Control
50% (max. 50%). Decrease accelerator opening ratio to 0%
completely control stopped
when not depressing the accelerator. Afterwards, control
accelerator opening ratio by accelerator switch through a
certain amount of acceleration and deceleration. (max. 50%)
P0025 Stop speed limiter, and Reset Regular Regular

Store. control engine speed completely control control
P0032 (1) Boost pressure = 53 kPa (1) Control with backup value Reset Regular Control
Store. (2) Make backup full Q map (2) - completely control stopped
P0033 Fuel consumption regulation Control with backup value Reset Regular Regular
Store. (Max. 110 mm 3/st) completely control control
P0035 Fuel pressure regulation
Store. (Max. 60 MPa) Reset Regular Regular

Fuel consumption regulation completely control control
(Max. 110 mm 3/st)
P0042 Make backup full Q map Control Control
Reset
Store. – stopped stopped
completely
Relay drive Relay drive
P0051 Engine stop {injector (TWV) / Regular Regular
– -
Store. PVC power supply stop} control control
P0071 Control atmospheric pressure Control with backup value Reset Regular Control
Store. = 100 kPa completely control stopped
P0072 Engine stop {injector (TWV) /
Reset Regular Regular
Do not – PVC power supply stop}
completely control control
store.
P0115 Fuel pressure regulation Expected control
Store. (Max. 60 MPa) Reset Regular Control
Fuel consumption regulation completely control stopped
(Max. 110 mm 3/st)
P0118 (1st level) (2nd level)
Store. Fuel pressure regulation Engine stop {injector (TWV) /
Reset Regular Control
(Max. 60 MPa) PVC power supply stop}
completely control stopped
Fuel consumption regulation
(Max. 110 mm 3/st)
P0151 Fuel pressure regulation
Store. (Max. 60 MPa) Reset Regular Control

Fuel consumption regulation completely control stopped
(Max. 110 mm 3/st)
P0158 Fuel pressure regulation
Store. (Max. 60 MPa)
Reset Regular Control
Fuel consumption regulation –
completely control stopped
6WF1: (Max. 165mm 3/st)
6WG1: (Max. 200mm 3/st)
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-131

Backup contents
DTC
DATA Control Cruise VGS EGR
P0159 Fuel pressure regulation
Store. (Max. 60 MPa)
Reset Regular Control
Fuel consumption regulation –
completely control stopped
6WF1: (Max. 165mm 3/st)
6WG1: (Max. 200mm 3/st)
P0211 When starting: Control fuel Control with backup value
Store. temperature= -25°C Regular Regular

(6WG1) Other: Control fuel control control
temperature=40°C
P0217 Fuel pressure regulation Reset Regular Control

Store. (Max. 60 MPa) completely control stopped
P0218 Fuel pressure regulation Reset Regular Control

Store. (Max. 60 MPa) completely control stopped
P0226 Fuel pressure regulation
Store. (Max. 60 MPa) Reset Regular Control

Fuel consumption regulation completely control stopped
(Max. 110 mm 3/st)
P0227 Fuel pressure regulation Stop engine one minute after
Store. (Max. 60 MPa) fault conditions are met Reset Regular Control
Fuel consumption regulation {injector (TWV) / PVC power completely control stopped
(Max. 110 mm 3/st) supply stop}
P0241 Control accelerator opening
Reset Regular Regular
Store. ratio regulation –
completely control control
(max. 80%)
P0242 Control accelerator opening
Reset Regular Regular
Store. ratio regulation –
completely control control
(20% fixed)
P0245 Fuel pressure regulation Expected control
Store. (Max. 60 MPa) (PCV open control) Reset Regular Control
Fuel consumption regulation completely control stopped
(Max. 110 mm 3/st)
P0247 Fuel pressure regulation Reset Regular Control

Store. (Max. 60 MPa) completely control stopped
P0248 Fuel pressure regulation Reset Regular Control

Store. (Max. 60 MPa) completely control stopped
P0271 Fuel consumption regulation
Reset Regular Control
Store. 6WF1: (Max. 165mm 3/st) –
completely control stopped
6WG1: (Max. 200mm 3/st)
P0272 Fuel consumption regulation
Reset Regular Control
Store. 6WF1: (Max. 165 mm 3/st) –
completely control stopped
6WG1: (Max. 200 mm 3/st)
P0273 Fuel consumption regulation
Reset Regular Control
Store. 6WF1: (Max. 165 mm 3/st) –
completely control stopped
6WG1: (Max. 200 mm 3/st)
P0274 Fuel consumption regulation
Reset Regular Control
Store. 6WF1: (Max. 165 mm 3/st) –
completely control stopped
6WG1: (Max. 200 mm 3/st)
1A-132 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

Backup contents
DTC
DATA Control Cruise VGS EGR
P0275 Fuel consumption regulation
Reset Regular Control
Store. 6WF1: (Max. 165 mm 3/st) –
completely control stopped
6WG1: (Max. 200 mm 3/st)
P0276 Fuel consumption regulation
Reset Regular Control
Store. 6WF1: (Max. 165 mm 3/st) –
completely control stopped
6WG1: (Max. 200 mm 3/st)
P0277 Fuel pressure regulation
Store. (Max. 60 MPa)
Reset Regular Control
Fuel consumption regulation –
completely control stopped
6WF1: (Max. 165 mm 3/st)
6WG1: (Max. 200 mm 3/st)
P0278 Fuel pressure regulation
Store. (Max. 60 MPa)
Reset Regular Control
Fuel consumption regulation –
completely control stopped
6WF1: (Max. 165 mm 3/st)
6WG1: (Max. 200 mm 3/st)
P0411 VGS M/V 1, 2, 3 Control Control Control
Reset
Store. – stopped stopped stopped
completely
Relay drive Relay drive
P0412 VGS M/V 1, 2, 3 Control Control Control
Reset
Store. – stopped stopped stopped
completely
Relay drive Relay drive
P0413 VGS M/V 1, 2, 3 control Control Control
Reset
Store. – stopped stopped stopped
completely
Relay drive Relay drive
P0416 Regular Regular
– – –
Store. control control
P0418 VGS, EGR M/V control Control
Store. stopped stopped
Reset Control
– Relay drive
completely stopped
(At ground
short)
P0421 Reset Regular Control
– –
Store. completely control stopped
P0424 EGR M/V 1, 2 control stopped Control
Store. stopped
Reset Regular
– Relay drive
completely control
(At ground
short)
P0441 EGR M/V 1, 2 control stopped Control
Reset Regular
Store. – stopped
completely control
Relay drive
P0442 EGR M/V 1, 2 control stopped Control
Reset Regular
Store. – stopped
completely control
Relay drive
P0446 Reset Control Control
– –
Store. completely stopped stopped
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-133

Backup contents
DTC
DATA Control Cruise VGS EGR
P0447 Reset Regular Regular
– –
Store. completely control control
P0448 Reset Control Control
– –
Store. completely stopped stopped
P0449 Reset Regular Regular
– –
Store. completely control control
P0518 Reset Regular Regular
– –
Store. completely control control
P0543 Engine stop {injector (TWV) /
Reset Regular Regular
Store. – PVC power supply stop}
completely control control
Exhaust brake drive

Check engine lamp


display
Control restore
DTC DIAG SW DIAG SW Comments 6WG1 6WF1 6WF1
conditions
Open Short (For New (For
(User) (Dealer) Zealand) G.Exp)
P0014 When CMP pulse
Store. frequency is less than Lights up 1•4 { { {
200 ms
P0015 When CKP pulse
Store. frequency is less than Lights up 1•5 { { {
200 ms
P0022 A t m o s p h e r i c
Store. temperature sensor
Lights up 2•2 { { {
output is 0.85 V or more,
or 4.9 V or less.
P0023 Engine coolant
Store. temperature sensor
Lights up 2•3 { { {
output is 0.85 V or more,
or 4.9 V or less.
P0024 Held until ECM power
Lights up 2•4 { { {
Store. source is turned OFF.
P0025 Held until ECM power
Lights up 2•5 { { {
Store. source is turned OFF.
P0032 (1) Boost sensor output
Store. is 0.85 V or more, or 4.9
V or less. Lights up 3•2 { { {
(2) Held until ECM power
source is turned OFF.
P0033 Held until ECM power
Lights up 3•3 { { {
Store. source is turned OFF.
P0035 Engine does not stall
Lights up 3•5 { { {
Store. again after stalling
P0042 Held until ECM power
Lights up 4•2 { – –
Store. source is turned OFF.
1A-134 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

Check engine lamp


display
Control restore
DTC DIAG SW DIAG SW Comments 6WG1 6WF1 6WF1
conditions
Open Short (For New (For
(User) (Dealer) Zealand) G.Exp)
P0051 CPU normal Do not light
5•1 { { {
Store. up
P0071 Atmospheric pressure
Store. sensor output is 0.85 V Lights up 7•1 { { {
or more, or 4.9 V or less.
P0072 When there is CKP pulse
Do not or CMP pulse input Lights up 7•2 { { {
store.
P0015 When PC sensor output
Lights up 1•1•5 { { {
Store. value changes
P0118 Actual fuel pressure is
Store. less than 130 MPa.
If control is stopped,
Lights up 1•1•8 { { {
engine stall or actual fuel
pressure is 10 MPa or
less.
P0151 Engine does not stall
Lights up 1•5•1 { { {
Store. again after stalling
P0158 Engine does not stall
Lights up 1•5•8 { { {
Store. again after stalling.
P0159 Engine does not stall
Lights up 1•5•9 { { {
Store. again after stalling.
P0211 Fuel temperature sensor
Store. output value is 0.85 V or
Lights up 2•1•1 { – –
(6WG1 more, or 4.9 V or less.
)
P0217 PCV 1 drive voltage
Lights up 2•1•7 { { {
Store. normal
P0218 PCV 2 drive voltage
Lights up 2•1•8 { { {
Store. normal
P0226 Engine does not stall
Lights up 2•2•6 { { {
Store. again after stalling.
P0227 Engine does not stall
Lights up 2•2•7 { { {
Store. again after stalling.
P0241 Held until ECM power
Lights up 2•4•1 { { {
Store. supply is turned OFF.
P0242 Held until ECM power
Lights up 2•4•2 { { {
Store. source is turned OFF.
P0245 PC sensor output value
Store. is 4.7 V or more, or 0.7 V Lights up 2•4•5 { { {
or less.
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-135

Check engine lamp


display
Control restore
DTC DIAG SW DIAG SW Comments 6WG1 6WF1 6WF1
conditions
Open Short (For New (For
(User) (Dealer) Zealand) G.Exp)
P0247 Held until ECM power Check engine
Lights up 2•4•7 { { {
Store. source is turned OFF. lamp lights
even when
P0248 Held until ECM power
Lights up 2•4•8 storing as { { {
Store. source is turned OFF.
past failure.
P0271 Engine does not stall
Store. again when current value Lights up 2•7•1 { { {
is normal or after stalling.
P0272 Engine does not stall
Store. again when current value Lights up 2•7•2 { { {
is normal or after stalling.
P0273 Engine does not stall
Store. again when current value Lights up 2•7•3 { { {
is normal or after stalling.
P0274 Engine does not stall
Store. again when current value Lights up 2•7•4 { { {
is normal or after stalling.
P0275 Engine does not stall
Store. again when current value Lights up 2•7•5 { { {
is normal or after stalling.
P0276 Engine does not stall
Store. again when current value Lights up 2•7•6 { { {
is normal or after stalling.
P0277 Engine does not stall
Lights up 2•7•7 { { {
Store. again after stalling.
P0278 Engine does not stall
Lights up 2•7•8 { { {
Store. again after stalling.
P0411 Held until ECM power
Lights up 4•1•1 { – –
Store. source is turned OFF.
P0412 Held until ECM power
Lights up 4•1•2 { – –
Store. source is turned OFF.
P0413 Held until ECM power
Lights up 4•1•3 { – –
Store. source is turned OFF.
P0416 Held until ECM power Do not light
4•1•6 { { {
Store. source is turned OFF. up
P0418 When fail safe relay=ON:
Store. Relay drive voltage Lights up 4•1•8 { – –
normal
P0421 –
Lights up 4•2•1 { { {
Store.
P0424 When fail safe relay=ON:
Store. Relay drive voltage Lights up 4•2•4 { – {
normal
1A-136 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

Check engine lamp


display
Control restore
DTC DIAG SW DIAG SW Comments 6WG1 6WF1 6WF1
conditions
Open Short (For New (For
(User) (Dealer) Zealand) G.Exp)
P0441 Held until ECM power
Lights up 4•4•1 { { {
Store. source is turned OFF.
P0442 Held until ECM power
Lights up 4•4•2 { { {
Store. source is turned OFF.
P0446 EGR temperature 1 is
Lights up 4•4•6 { – –
Store. 200°C or less.
P0447 EGR temperature 1 is
Lights up 4•4•7 { – –
Store. 45°C or less.
P0448 EGR temperature 2 is
Lights up 4•4•8 { – –
Store. 200°C or less.
P0449 EGR temperature 2 is
Lights up 4•4•9 { – –
Store. 45°C or less.
P0518 When power ON is reset
Lights up 5•1•8 { { {
Store.
P0543 6WF1: Engine speed is
Store. 2250 rpm or less. Does not
5•4•3 { { {
6WG1: Engine speed is light up
2600 rpm or less.
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-137
DTC P0014 (Flash code 14)
Camshaft position (CMP) sensor system
malfunction

Engine
Control
Module
(ECM)
40 41 39 133 120 131

GND
VCC

SIG
(+)

(-)
0.5B/R
0.5Y

0.5W
0.5R

0.5B
2 1 3 1 2

Crankshaft Position Camshaft Position


(CKP) Sensor (CMP) Sensor
HCW61AMF002101

Description of circuit Set conditions of DTC


The SMP sensor detects the cam shaft revolutions When engine speed is 400rpm (idling) or more, there is
inside the supply pump and discriminates between the pulse input from the CKP sensor (at 450 times input),
cylinders. When the pulsar installed in the camshaft but no pulse input from the CMP sensor.
crosses the CMP sensor tip section, voltage is In this condition, “Camshaft position (CMP) sensor
generated that becomes a pulse signal. The engine system malfunction” is diagnosed, and [DTC P0014] is
control module (ECM) reads this pulse signal, then displayed.
discriminates between the cylinders based on the The judgment time differs depending on engine speed.
signal. If the engine speed is low, the judgment time is long,
whereas if the engine speed is high, the judgment time
Main trouble phenomena is accordingly short.
• Momentary revolution slip
Actions when DTC is set
• Start up deterioration
If the CKP sensor is normal, control based on the
• Fluctuation of revolutions (hunting)
signals from the CKP sensor.
• Rough idling
• PTO stop Clear conditions of MIL/DTC
• When both CKP sensor and CMP sensor are lost, When trouble occurs in the system and that DTC is
the engine stops memorized by ECM, since the fault region is not
eliminated as it is by DTC, it should be deleted in the
following ways. Furthermore, inspection and repair may
require that you check DTCs, so be sure to note and
clear the DTCs before performing inspection.
1A-138 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
DTC deletion method • CMP sensor malfunction
• Deleting DTC by operating the accelerator pedal (Sensor internal or detection section malfunction)
(Refer to “How to delete DTCs by operating the • Supply pump internal rotor malfunction
accelerator pedal” in “Fault diagnosis process”) • ECM internal malfunction
• Use the scan tool (Tech2) to clear DTC. • Check the connector for poor connection, and
check to make sure that there are no abnormalities
Diagnostic Aids such as a frayed or broken harness, frayed wiring
• Connector section bad connection in the harness, or a short to another circuit.
Furthermore, perform functional diagnostics to
• CMP sensor power supply, signal, GND circuit
check things like operation and control of each
broken wire or short circuit
component. Resolve any abnormality.
• CKP sensor signal condition

Step Action Value(s) Yes No


Perform an on-board diagnostic (OBD)
1 system check. — Go to “OBD
Is the procedure complete? Go to Step 2 system check”
Check the installation condition of the
camshaft position (CMP) sensor.
1. Turn the starter switch OFF.
2. Perform a visual inspection for play or
2 slackness in the sensor installation —
condition.
3. When fault is detected, if necessary it is
corrected.

Is the procedure complete? Go to Step 3 —


Check the installation condition of the CMP
sensor, ECM and midway connectors.
1. Check whether there is any play or
slackness in the condition of connector
3 installed. —
2. When any fault is detected, if necessary
do repair or replacement.

Is the procedure complete? Go to Step 4 —


Recheck the DTC.
1. Connect all harnesses.
2. Clear the DTC.
3. Turn the starter switch OFF, wait for more
4 —
than 15 seconds, then turn the switch ON
and start the engine.
4. Check the DTC.

Was DTC P0014 detected? Go to Step 5 Go to Step 11


Remove the CMP sensor, and inspect the
5 sensor tip for scratches or damage. —
Is the CMP sensor normal? Go to Step 6 Go to Step 9
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-139

Step Action Value(s) Yes No


Check the CMP sensor circuit harness.
1. Turn the starter switch OFF.
2. Remove the ECM and CMP sensor
harness.
3. Connect jumper wires to each terminal of
the CMP sensor harness connector side.
4. Measure the resistance value between
ECM harness connector terminals with
and without jumper wires.
• With jumper wires
6 - Between pins 120 and 131/133: —
less than 0.5Ω
- Between pins 131 and 133: less
than 0.5Ω
• Without jumper wires
- Between pins 120 and 131/133:
∞Ω
- Between pins 131 and 133: ∞Ω
5. When any fault is detected, if necessary
do repair or replacement.

Was an abnormality detected? Go to Step 11 Go to Step 7


Check the CMP sensor circuit for GND shorts.
1. Turn the starter switch OFF.
2. Remove the harness from the ECM and
CMP sensors.
Between pins
3. Measure the resistance value between
7 120/133 and
the ECM harness connector terminals
GND: ∞Ω
and GND.
4. When any fault is detected, if necessary
do repair or replacement.
Was an abnormality detected? Go to Step 11 Go to Step 8
Check the CMP sensor circuit for a short to
the power supply.
1. Turn the starter switch OFF.
2. Remove the harness from the ECM and
CMP sensors. Between
each
8 3. Turn the starter switch ON, and measure
terminals and
the voltage between the CMP sensor
GND: 0V
harness connector terminal and GND.
4. When any fault is detected, if necessary
do repair or replacement.
Was an abnormality detected? Go to Step 11 Go to Step 10
Replace the CMP sensor.
9 —
Is the procedure complete? Go to Step 11 —
1A-140 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

Step Action Value(s) Yes No


1. Replace the ECM.

IMPORTANT:
After replacing the ECM, perform the following
10 items of programming. —
• Q adjustment data
• Injector ID code

Is the procedure complete? Go to Step 11 —


Recheck the DTC.
1. Connect all harnesses.
2. Clear the DTC.
3. Turn the starter switch OFF, wait for more
11 —
than 15 seconds, then turn the switch ON
and start the engine.
4. Check the DTC.

Was DTC P0014 detected? Go to Step 2 Go to Step 12


Use the scan tool to check if other DTCs are
12 detected. — Go to applicable
Are other DTCs detected? DTC Verify repair

CMP sensor

HCW46ESH001101

Legend
1. Signal
2. GND
3. Power supply
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-141
DTC P0015 (Flash code 15)
Crankshaft position (CKP) sensor system
malfunction

Engine
Control
Module
(ECM)
40 41 39 133 120 131

GND
VCC

SIG
(+)

(-)
0.5B/R
0.5Y

0.5W
0.5R

0.5B
2 1 3 1 2

Crankshaft Position Camshaft Position


(CKP) Sensor (CMP) Sensor
HCW61AMF002101

Description of circuit Set conditions of DTC


The crankshaft position (CKP) sensor detects the When engine speed is not less than 400rpm (idling),
engine speed. When the sensing ball installed in the there is pulse input from the CMP sensor (at 40 times
flywheel housing crosses the CKP sensor tip section, input), but no pulse input from the CKP sensor.
voltage is generated that becomes a pulse signal. This In this condition, “Crankshaft position (CKP) sensor
pulse signal is read by the engine control module system malfunction” is diagnosed, and [DTC P0015] is
(ECM), and the engine speed, injection timing and displayed. The judgment time differs depending on
injection cylinder are requested based on that signal. engine speed. If the engine speed is low, the judgment
time is long, whereas if the engine speed is high, the
Main trouble phenomena judgment time is accordingly short.
• Momentary revolution slip
Actions when DTC is set
• Start up deterioration
• MIL (Check engine lamp) lights.
• Fluctuation of revolutions (hunting)
• If the CMP sensor is normal, control is performed
• Rough idling
based on the signals from the CMP sensor.
• Poor tachometer malfunction
• PTO stop Clear conditions of MIL/DTC
• When both the CKP sensor and camshaft position When trouble occurs in the system and that DTC is
(CMP) sensor are lost, the engine stops memorized by ECM, since the fault region is not
eliminated as it is by DTC, it is eliminated in the
following ways. Furthermore, inspection and repair may
require that you check DTCs, so be sure to note and
clear the DTCs before performing inspection.
1A-142 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
DTC deletion method • Malfunction in the sensor main unit installation
• Deleting DTC by operating the accelerator pedal condition (gap, looseness)
(Refer to “How to delete DTCs by operating the • Flywheel sensing section malfunction
accelerator pedal” in “Fault diagnosis process”) (Blockage, dirt, damage)
• Use the scan tool (Tech2) to clear DTC. • ECM internal malfunction
• Check the connector for poor connection, and
Diagnostic Aids check to make sure that there are no abnormalities
• Connector section bad connection such as a frayed or broken harness, frayed wiring
in the harness, or a short to another circuit.
• CKP sensor (+) circuit broken wire or short circuit
Perform functional diagnostics to check things like
• CKP sensor (-) circuit broken wire or short circuit operation and control of each component. Resolve
• CKP sensor malfunction any abnormality.
(Sensor internal or detection section malfunction)

Step Action Value(s) Yes No


Perform an on-board diagnostic (OBD)
1 system check. — Go to “OBD
Is the procedure complete? Go to Step 2 system check”
Check the installation condition of the
crankshaft position (CKP) sensor.
1. Perform a visual inspection for play or
slackness in the sensor installation
2 condition. —
2. When fault is detected, if necessary it is
corrected.

Was an abnormality detected? Go to Step 10 Go to Step 3


Inspect the CKP sensor circuit.
1. Turn the starter switch OFF.
2. Disconnect the harness from the ECM.
3. Measure the resistance values between
ECM harness connector terminals.
3 —
• Between pins 40 and 41: 110-140Ω
• Between pin 40 and pin 39 /GND:
∞Ω
• Between pin 41 and 39/GND: ∞Ω
Are the resistance values normal? Go to Step 6 Go to Step 4
Inspect the CKP sensor.
1. Disconnect the harness from the CKP
sensor.
2. Measure the resistance values of sensor
connector terminals.
4 3. When fault is detected, replace if —
necessary.
• Between terminals: 110-140Ω
• Between each terminal- GND: ∞Ω (at
normal temperatures)

Was an abnormality detected? Go to Step 10 Go to Step 5


Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-143

Step Action Value(s) Yes No


Inspect the CKP sensor harness.
1. Check that there are no short circuits or
broken wires between the ECM-CKP
5 sensors. —
2. When any fault is detected, if necessary
do repair or replacement.

Was an abnormality detected? Go to Step 10 Go to Step 6


Use a scan tool and check the engine data
display.
1. Attach the harness.
2. Connect scan tool.
6 475-525rpm
3. Start the engine.
4. Display the engine data and check
[Engine speed].

Are the engine speed normal? Go to Step 7 Go to Step 8


Check for engine speed fluctuations.
7 —
Is the engine speed stable? Go to Step 9 Go to Step 8
1. Perform a visual inspection of the CKP
sensor and fly wheel, and inspect for
damage or dirt.
8 2. When any fault is detected, if necessary —
do repair or replacement.

Was an abnormality detected? Go to Step 10 Go to Step 9


1. Replace the ECM.

IMPORTANT:
After replacing the ECM, perform the following
9 items of programming. —
• Q adjustment data
• Injector ID code

Is the procedure complete? Go to Step 10 —


Recheck the DTC.
1. Connect all harnesses.
2. Clear the DTC.
3. Turn the starter switch OFF, wait for more
10 than 15 seconds, then turn the switch ON —
and start the engine.
4. Check the DTC.

Was DTC P0015 detected? Go to Step 2 Go to Step 11


Use the scan tool to check if other DTC are
11 detected. — Go to applicable
Are other DTCs detected? DTC Verify repair
1A-144 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
CKP sensor

HCW51ASH000201

2 1

HCW01ASH011901

Legend
1. Sensor signal (-)
2. Sensor signal (+)

Item Specifications Condition


Resistance 110-140 Ω 20°C
CKP sensor
between
terminals
Insulation ∞Ω DC500V Mega-
resistance (not less than ohm meter
10MΩ) Between terminal
and other
conductors
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-145
DTC P0022 (Flash code 22)
Atmospheric temperature sensor system
malfunction

Engine
Control
6WG1
Module

155 135 154 162 (ECM)

GND
SIG

SIG

SIG
0.5Y/R
0.3Y

0.5Y/G
0.3Y/R

0.3V/R

0.5Y/R
0.3Y

0.5Y/R
0.5Y

1 3 1 2 1 2

Atmospheric Fuel Temperature


Temperature Sensor
Sensor
Engine Coolant
Temperature (ECT)
Sensor
HCW61AMF002201

Description of circuit Actions when DTC is set


The atmospheric temperature sensor detects the • MIL (Check engine lamp) lights.
atmospheric temperature (temperature outside the • When the atmospheric temperature sensor is
vehicle). The engine control module (ECM) applies malfunctioning, the ECM controls using the backup
voltage to the atmospheric temperature sensor value (-25°C at startup).
installed inside the front lid, reads the changes in
applied voltage as signals, and optimizes the fuel Clear conditions of MIL/DTC
injection control based on those signals. Also, the
When trouble occurs in the system and that DTC is
sensor’s GND circuit is shared by each temperature
memorized by ECM, since the fault region is not
related sensor.
eliminated as it is by DTC, it should be deleted in the
following ways. Furthermore, inspection and repair may
Main trouble phenomena
require that you check DTCs, so be sure to note and
• White smoke (while cooling) clear the DTCs before performing inspection.
• Start up deterioration
• Black smoke (at engine start) DTC deletion method
• Deleting DTC by operating the accelerator pedal
Set conditions of DTC (Refer to “How to delete DTCs by operating the
If the voltage value applied to the atmospheric accelerator pedal” in “Fault diagnosis process”)
temperature sensor exceeds 4.9V, or remains lower • Use the scan tool (Tech2) to clear DTC.
than 0.085V for 0.5 seconds or more, “Atmospheric
temperature sensor system malfunction” is diagnosed, Diagnostic Aids
and [DTC P0022] is displayed. • Connector section bad connection
1A-146 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
• Atmospheric temperature sensor (SIG) circuit • Check the connector for poor connection, and
broken wire or short circuit check to make sure that there are no abnormalities
• Atmospheric temperature sensor (GND) circuit such as a frayed or broken harness, frayed wiring
broken wire or short circuit in the harness, or a short to another circuit.
Furthermore, perform functional diagnostics to
• Atmospheric temperature sensor malfunction
check things like operation and control of each
(Sensor internal or detection section malfunction)
component. Resolve any abnormality.
• ECM internal malfunction

Step Action Value(s) Yes No


Perform an on-board diagnostic (OBD)
1 system check. — Go to “OBD
Is the procedure complete? Go to Step 2 system check”
Check the installation condition of the
atmospheric temperature sensor connector.
1. Perform a visual inspection for play or
slackness in the connector installation
2 condition. —
2. When fault is detected, if necessary it is
corrected.

Was an abnormality detected? Go to Step 7 Go to Step 3


Inspect the atmospheric temperature sensor
harness.
1. Turn the starter switch OFF.
2. Disconnect the harness from the ECM.
3. Check that there are no short circuits or
3 broken wires in the harness between the —
atmospheric temperature sensor - ECM.
4. When any fault is detected, if necessary
do repair or replacement.

Was an abnormality detected? Go to Step 7 Go to Step 4


Inspect the atmospheric temperature sensor
circuit.
1. Turn the starter switch OFF.
Between
2. Disconnect the harness from the connector
atmospheric temperature sensor. power supply
4
3. Turn the starter switch ON, and measure terminal and
the voltage between the sensor harness GND: 4.75-
connector power supply terminal and 5.25V
GND.

Are the voltage values normal ? Go to Step 5 Go to Step 6


Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-147

Step Action Value(s) Yes No


Inspect the atmospheric temperature sensor.
1. Disconnect the harness from the
atmospheric temperature sensor.
2. Measure the resistance values of sensor
connector terminals.
5 3. When fault is detected, replace if —
necessary.
• Between terminals: 3kΩ (20°C)
• Between each terminal- GND: ∞Ω (at
normal temperatures)

Was an abnormality detected? Go to Step 7 Go to Step 6


1. Replace the ECM.

IMPORTANT:
After replacing the ECM, perform the following
6 items of programming. —
• Q adjustment data
• Injector ID code

Is the procedure complete? Go to Step 7 —


Recheck the DTC.
1. Connect all harnesses.
2. Clear the DTC.
3. Turn the starter switch OFF, wait for more
7 than 15 seconds, then turn the switch ON —
and start the engine.
4. Check the DTC.

Was DTC P0022 detected? Go to Step 2 Go to Step 8


Use the scan tool to check if other DTC are
8 detected. — Go to applicable
Are other DTCs detected? DTC Verify repair
1A-148 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Atmospheric temperature sensor

HCW46ESH001401

Legend
1. Signal
2. GND
3. Temperature sensor

Sensor resistance value properties (reference)


100
10
k
Resistance value

1
0.1

-40 -30 -20 -10 0 10 20 30 40

Temperature °C

HCW61ASH002101

Resistance values between each terminal


Resistance Comments
value
B e t w e e n Approx. 3.0kΩ 25°C
terminals
Between each ∞Ω
terminal and –
body
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-149
DTC P0023 (Flash code 23)
Engine coolant temperature sensor system
malfunction

Engine
Control
6WG1
Module

155 135 154 162 (ECM)

GND
SIG

SIG

SIG
0.5Y/R
0.3Y

0.5Y/G
0.3Y/R

0.3V/R

0.5Y/R
0.3Y

0.5Y/R
0.5Y

1 3 1 2 1 2

Atmospheric Fuel Temperature


Temperature Sensor
Sensor
Engine Coolant
Temperature (ECT)
Sensor
HCW61AMF002201

Description of circuit Actions when DTC is set


The engine coolant temperature (ECT) sensor detects • MIL (Check engine lamp) lights.
the engine coolant temperature. The engine control • When the ECT sensor is malfunctioning, the ECM
module (ECM) applies voltage to the ECT sensor controls using the backup value (at startup: -25°C,
installed in the cylinder body, reads the changes in other times: 50°C).
applied voltage as signals, and optimizes the fuel
injection control based on those signals. Also, the Clear conditions of MIL/DTC
sensor’s GND circuit is shared by each temperature
When trouble occurs in the system and that DTC is
related sensor.
memorized by ECM, since the fault region is not
eliminated as it is by DTC, it is eliminated in the
Main trouble phenomena
following ways. Furthermore, inspection and repair may
• White smoke require that you check DTCs, so be sure to note and
• Start up deterioration (while cooling) clear the DTCs before performing inspection.
• Rough idling
DTC deletion method
• Engine speed does not increase when in idling
revolutions auto mode. • Deleting DTC by operating the accelerator pedal
(Refer to “How to delete DTCs by operating the
Set conditions of DTC accelerator pedal” in “Fault diagnosis process”)
If the voltage value applied to the ECT sensor exceeds • Use the scan tool (Tech2) to clear DTC.
4.9V, or remains lower than 0.085V for 1 second or
more, “engine coolant temperature sensor system Diagnostic Aids
malfunction” is diagnosed, and [DTC P0023] is • Connector section bad connection
displayed.
1A-150 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
• ECT sensor (SIG) circuit broken wire or short • Check the connector for poor connection, and
circuit check to make sure that there are no abnormalities
• ECT sensor (GND) circuit broken wire or short such as a frayed or broken harness, frayed wiring
circuit in the harness, or a short to another circuit.
Furthermore, perform functional diagnostics to
• ECT sensor malfunction
check things like operation and control of each
(Sensor internal or detection section malfunction)
component. Resolve any abnormality.
• ECM internal malfunction

Step Action Value(s) Yes No


Perform an on-board diagnostic (OBD)
1 system check. — Go to “OBD
Is the procedure complete? Go to Step 2 system check”
Check the installation condition of the engine
coolant temperature (ECT) sensor connector.
1. Perform a visual inspection for play or
slackness in the connector installation
2 condition. —
2. When fault is detected, if necessary it is
corrected.

Was an abnormality detected? Go to Step 7 Go to Step 3


Inspect the ECT sensor harness.
1. Turn the starter switch OFF.
2. Disconnect the harness from the ECM.
3. Check that there are no short circuits or
3 broken wires in the harness between the —
ECT sensor - ECM.
4. If fault is detected, repair or replace as
necessary.

Was an abnormality detected? Go to Step 7 Go to Step 4


Inspect the ECT sensor circuit.
1. Turn the starter switch OFF.
2. Disconnect the harness from the ECT Between
sensor. connector
power supply
4 3. Turn the starter switch ON, and measure
terminal and
the voltage between the sensor harness
GND: 4.75-
connector power supply terminal and
5.25V
GND.

Are the voltage values normal ? Go to Step 5 Go to Step 7


Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-151

Step Action Value(s) Yes No


Inspect the ECT sensor.
1. Disconnect the harness from the ECT
sensor.
2. Measure the resistance values of sensor
connector terminals while adding
temperature changes.
5 3. When fault is detected, replace if —
necessary.
• Between terminals: Refer to the
graph
• Between each terminal - GND: ∞Ω
(Excluding terminals for meters)

Was an abnormality detected? Go to Step 7 Go to Step 6


1. Replace the ECM.

IMPORTANT:
After replacing the ECM, perform the following
6 items of programming. —
• Q adjustment data
• Injector ID code

Is the procedure complete? Go to Step 7 —


Recheck the DTC.
1. Connect all harnesses.
2. Clear the DTC.
3. Turn the starter switch OFF, wait for more
7 than 15 seconds, then turn the switch ON —
and start the engine.
4. Check the DTC.

Was DTC P0023 detected? Go to Step 2 Go to Step 8


Use the scan tool to check if other DTC are
8 detected. — Go to applicable
Have been other DTCs detected? DTC Verify repair
1A-152 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Water Temperature (ECT) Sensor

4
5

3
2
1

MFW31ASH004201

Legend
1. Sensor signal (for SIG, engine control)
2. Sensor signal (for SIG, meter)
3. Sensor (GND)
4. Temperature sensor for engine control
5. Temperature sensor for meter

ECT sensor properties


100
k

10
Resistance value

1
0.1

-50 0 50 100

Temperature °C
HCW61ASH002201
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-153
DTC P0024 (Flash code 24)
Accelerator pedal position sensor system
malfunction

Engine
Control
Module

65 21 55 (ECM)

GND
VCC

SIG
0.3L/W
0.3L/R

0.3L

3 2 1

Accelerator Pedal
Position (APP) Sensor
HCW61AMF002301

Description of circuit Actions when DTC is set


The accelerator pedal position (APP) sensor detects • MIL (Check engine lamp) lights.
the opening ratio of the accelerator pedal. Voltage is • The ECM is linked with the accelerator position
applied to the APP sensor installed in the accelerator (APP) switch, and changes the accelerator pedal
pedal link, and the voltage value that returns to the opening ratio to the backup value to control it.
engine control module (ECM) becomes a signal. The
ECM reads changes in the voltage from the APP Clear conditions of MIL/DTC
sensor, then optimizes the fuel injection control and
When trouble occurs in the system and that DTC is
accelerator opening ratio based on those signals.
memorized by ECM, since the fault region is not
eliminated as it is by DTC, it is eliminated in the
Main trouble phenomena
following ways. Furthermore, inspection and repair may
• Lack of output require that you check DTCs, so be sure to note and
• Accelerator pedal reaction (response) malfunction clear the DTCs before performing inspection.
• Fluctuation of revolutions (hunting)
DTC deletion method
• PTO stop
• Deleting DTC by operating the accelerator pedal
Set conditions of DTC (Refer to “How to delete DTCs by operating the
accelerator pedal” in “Fault diagnosis process”)
If the APP sensor signal voltage value exceeds 4.85V,
or remains lower than 0.1V for 1 second or more, • Use the scan tool (Tech2) to clear DTC.
“Accelerator pedal position sensor system malfunction”
is diagnosed, and [DTC P0024] is displayed. Diagnostic Aids
• Connector section bad connection
1A-154 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
• APP sensor (power source) circuit broken wire or • Accelerator pedal failure
short circuit (Poor adjustment, looseness, link malfunction,
• APP sensor (SIG) circuit broken wire or short spring malfunction)
circuit • Accelerator switch failure (poor adjustment,
• APP sensor (GND) circuit broken wire or short looseness)
circuit • Check the connector for poor connection, and
• APP sensor malfunction check to make sure that there are no abnormalities
(Sensor internal or detection section malfunction) such as a frayed or broken harness, frayed wiring
in the harness, or a short to another circuit.
• ECM internal malfunction
Furthermore, perform functional diagnostics to
• APP sensor installation failure (poor adjustment, check things like operation and control of each
looseness) component. Resolve any abnormality.

Step Action Value(s) Yes No


Perform an on-board diagnostic (OBD)
1 system check. — Go to “OBD
Is the procedure complete? Go to Step 2 system check”
Accelerator pedal position (APP) sensor
connector attachment
Check the condition.
1. Perform a visual inspection for play or
2 slackness in the connector installation —
condition.
2. When fault is detected, if necessary it is
corrected.

Was an abnormality detected? Go to Step 9 Go to Step 3


Inspect the APP sensor harness.
1. Turn the starter switch OFF.
2. Disconnect the harness from the ECM.
3. Check that there are no short circuits or
3 broken wires in the harness between the —
APP sensor - ECM.
4. If fault is detected, repair or replace as
necessary.

Was an abnormality detected? Go to Step 9 Go to Step 4


Inspect the APP sensor circuit.
1. Turn the starter switch OFF.
2. Disconnect the harness from the APP Between
sensor. connector
power supply
4 3. Turn the starter switch ON, and measure
terminal and
the voltage between the sensor harness
GND: 4.75-
connector power supply terminal and
5.25V
GND.

Are the voltage values normal ? Go to Step 5 Go to Step 8


Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-155

Step Action Value(s) Yes No


Use a scan tool and check the engine data
display.
1. Turn the starter switch OFF.
2. Attach the harness.
3. Connect scan tool.
5 4. Turn the starter switch ON. 0.25-0.75V
5. Display the engine data, and while
operating the accelerator pedal, check for
smooth data motion and check the idling
accelerator voltage value.
Go to diagnostic
Are the voltage values normal ? aids Go to Step 6
1. Replace the APP sensor.
2. Use a scan tool to check the APP sensor
6 output voltage in the idling position. 0.25-0.75V

Are the voltage values normal? Go to Step 9 Go to Step 7


Adjust the APP sensor installation.
7 —
Is the procedure complete? Go to Step 9 —
1. Replace the ECM.

IMPORTANT:
After replacing the ECM, perform the following
8 items of programming. —
• Q adjustment data
• Injector ID code

Is the procedure complete? Go to Step 9 —


Recheck the DTC.
1. Connect all harnesses.
2. Clear the DTC.
3. Turn the starter switch OFF, wait for more
9 than 15 seconds, then turn the switch ON —
and start the engine.
4. Check the DTC.

Was DTC P0024 detected? Go to Step 2 Go to Step 10


Use the scan tool to check if other DTC are
10 detected. — Go to applicable
Are other DTCs detected? DTC Verify repair
1A-156 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
Accelerator Pedal Position (APP) Sensor

3 2 1

MFW31ASH002601

Legend
1. Sensor (GND)
2. Sensor (SIG)
3. Sensor (power supply)

Accelerator position sensor properties (reference)

4
Output voltage (V)

0.5

IDLE FULL

Accelerator pedal position

HCW4ADSH000201
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-157
DTC P0025 (Flash code 25)
Vehicle speed sensor system malfunction

Fuse 17
(7.5A)

4(8)

KEY ON

Speed Sensor
Control Unit
SPEED SPEED SPEED
VB SIG GND DATA 25P 8P
3(7) 10(2) 12(5) 9

0.3P
0.3P/L
0.3G
0.3B/P
0.3W
0.3R

Tachograph

Smoother-
} Control Unit

Other ECU
1.25B/O
0.3B/P

2B/L

1(3) 3(2) 2(1)

27 Engine
Control
Module
(ECM)

Vehicle Speed Sensor


Note:
Number with "( )" is for A/T
HCW61AMF002401

Description of circuit Main trouble phenomena


The vehicle speed sensor detects vehicle speed. The • Lack of output
speed sensor is installed in the transmission or the • PTO stop
transfer output section. The speed sensor is driven
through the drive gear and the sensor shaft section Set conditions of DTC
rotates. When the shaft rotates, voltage is generated by
If there is a vehicle speed pulse input malfunction,
the magnet attached to the sensor (magnetic force),
“Speed sensor system malfunction” is diagnosed, and
which is output as a pulse signal. The sensor output
[DTC P0025] is displayed.
signal changes the time between pulse signals
(frequency) according to the vehicle speed (sensor
Actions when DTC is set
shaft revolutions). (When the number of sensor shaft
revolutions is low, the frequency is low, and when the • MIL (Check engine lamp) lights.
number of revolutions is high, high frequency pulses • Stop speed limiter.
are output.) The ECM converts the vehicle speed • ECM carries out speed control.
sensor signals into vehicle speed, which it uses for
vehicle speed inhibitory control etc. Clear conditions of MIL/DTC
As the transmission, deferential gear ratio, and tire
radius is different for each vehicle, and the pulse signal When trouble occurs in the system and that DTC is
(frequency) from the speed sensor changes according memorized by ECM, since the fault region is not
to the speed, the speed sensor control unit is installed eliminated as it is by DTC, it is eliminated in the
to correct the pulse signals so that meters a various following ways. Furthermore, inspection and repair may
controls can use the speed information correctly. (at require that you check DTCs, so be sure to note and
Vehicle speed 60km/h, corrects the vehicle speed clear the DTCs before performing inspection.
sensor shaft revolutions to the equivalent of 637rpm.)
The pulse signal voltage changes between High lever
(approx. 14V) to Low level (approx. 2V).
1A-158 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
DTC deletion method • ECM internal malfunction
• Deleting DTC by operating the accelerator pedal • Vehicle speed sensor installation failure
(Refer to “How to delete DTCs by operating the (looseness, shaft malfunction)
accelerator pedal” in “Fault diagnosis process”) • Malfunction of drive gear for vehicle speed sensor
• Use the scan tool (Tech2) to clear DTC. shaft revolutions
(Transmission etc.)
Diagnostic Aids • Neutral switch failure
• Connector section bad connection • Clutch switch failure
• Vehicle speed sensor (power source) circuit • Parking switch failure
broken wire or short circuit • Speed sensor control unit malfunction
• Vehicle speed sensor (SIG) circuit broken wire or • Check the connector for poor connection, and
short circuit check to make sure that there are no abnormalities
• Vehicle speed sensor (GND) circuit broken wire or such as a frayed or broken harness, frayed wiring
short circuit in the harness, or a short to another circuit.
• Vehicle speed sensor malfunction Furthermore, perform functional diagnostics to
(Sensor internal or detection section malfunction) check things like operation and control of each
component. Resolve any abnormality.

Step Action Value(s) Yes No


Perform an on-board diagnostic (OBD)
1 system check. — Go to “OBD
Is the procedure complete? Go to Step 2 system check”
Check the installation condition of the vehicle
speed sensor connector.
1. Perform a visual inspection for play or
slackness in the connector installation
2 condition. —
2. When fault is detected, if necessary it is
corrected.

Was an abnormality detected? Go to Step 12 Go to Step 3


Inspect the vehicle speed sensor circuit.
1. Turn the starter switch OFF.
2. Remove the harness from the ECM,
speed sensor control unit, and vehicle
speed sensor.
3. Check the circuits between the ECM-
3 speed sensor control unit, and between —
the speed sensor control unit - vehicle
speed sensor for broken wires and short
circuits.
4. If fault is detected, repair or replace as
necessary.

Was an abnormality detected? Go to Step 12 Go to Step 4


Inspect the vehicle speed signal for
malfunctions.
1. Start the engine and drive the vehicle.
4 —
2. Check that the vehicle speed display in
the scan tool is correct.

Whether the numerical value is normal? Go to Step 12 Go to Step 5


Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-159

Step Action Value(s) Yes No


Inspect the vehicle speed sensor.
1. Turn the starter switch OFF.
2. Remove the vehicle speed sensor.
3. Check the vehicle speed sensor shaft,
gears etc. for malfunctions. Voltage
At this time, inspect the transmission gear changes
5 section if necessary and repair any between 1.0-
malfunctions. 3.0V and
4. Attach the harness to the vehicle speed 12.0-15.0V
sensor, and turn the starter switch ON.
5. Slowly rotate the vehicle speed sensor
shaft and check the changes in voltage.

Is the vehicle speed sensor normal? Go to Step 7 Go to Step 6


Replace the vehicle speed sensor.
6 —
Is the procedure complete? Go to Step 12 —
Inspect the speed sensor control unit for
malfunctions.
1. Turn the starter switch OFF.
2. Connect to the vehicle speed sensor and
7 harness. —
3. Start the engine and drive the vehicle.
4. Check that the vehicle speed display in
the scan tool is correct.

Whether the numerical value is normal? Go to Step 9 Go to Step 8


Replace the speed sensor control unit.
8 —
Is the procedure complete? Go to Step 12 —
1. Using a scan tool, operate the following
switches and inspect whether the inputs
are correct.
• Neutral switch
9 —
• Clutch switch
• Parking switch

Are the inputs for each switch normal? Go to Step 11 Go to Step 10


Repair or replace the switch system in which
10 the fault was detected. —
Is the procedure complete? Go to Step 12 —
1. Replace the ECM.

IMPORTANT:
After replacing the ECM, perform the following
11 items of programming. —
• Q adjustment data
• Injector ID code

Is the procedure complete? Go to Step 12 —


1A-160 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))

Step Action Value(s) Yes No


Recheck the DTC.
1. Connect all harnesses.
2. Clear the DTC.
3. Turn the starter switch OFF, wait for more
12 —
than 15 seconds, then turn the switch ON
and start the engine.
4. Check the DTC.

Was DTC P0025 detected? Go to Step 2 Go to Step 13


Use the scan tool to check if other DTC are
13 detected. — Go to applicable
Are other DTCs detected? DTC Verify repair

Vehicle speed sensor 4. Slowly rotate the vehicle speed sensor shaft
section and measure the output voltage.
When the vehicle speed sensor shaft is revolving
Output voltage: Voltage changes between 0.5.0-
1.5V and 12.0-15.0V

MFW31ASH002201
1
Legend
1. Sensor (power supply)
2. Sensor (SIG) MFW31ASH003001
3. Sensor (GND)
Legend
1. Shaft
Vehicle sensor signal checking procedure
5. Turn the starter switch OFF, and remove the
The output voltage from the vehicle speed sensor
harness from the vehicle speed sensor.
changes according to the shaft revolution angle.
Slowly rotate the shaft section by hand and measure 6. Attach the vehicle speed sensor.
the output voltage. Tightening torque = 25-34N.m {2.5-3.5kgf.m}
1. Remove the vehicle speed sensor.
2. Connect the harness to the vehicle speed sensor.
3. Turn the starter switch ON.
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-161
Speed sensor control unit
Connecto Connecto Signal name
r number r number
(12 pin) (8 pin)
1 1 8 pulse signal output (SIG)
2 4 25 pulse signal output (SIG)
3 7 Power supply to vehicle
speed sensor
4 8 Speed sensor control unit
power supply
10 2 Pulse signal input (SIG)
12 5 Ground
1 2 3 4
1 2 3 4 5 6 7 8
5 6 7 8 9 10 1112

MFW31ASH005301

Vehicle sensor
Parts checked Output voltage Remarks
shaft condition
12 pins 4 ↔ 12
– Battery voltage (28V)
8 pins 5↔8
12 pins 3 ↔ 12
– Battery voltage (28V)
8 pins 5↔7

Not rotating 1.0 - 3.0V or 10 pin:


(vehicle stop) 12.0 - 15.0V Measurement of
12 pins 10 ↔ 12
25 pulse input
8 pins 2↔5 Rotating Pulse signal which changes signal from
(vehicle between vehicle speed
Speed sensor
traveling) 1.0 - 3.0V and 12.0 - 15.0V sensor
control unit
connector (12 Not rotating
pins or 8 pins) 1.0 - 3.0V 2 pin:
12 pins 2 ↔ 12 (vehicle stop)
Measurement of
8 pins 4↔5 Rotating Pulse signal which changes 25-pulse output
(vehicle between signal
traveling) 1.0 - 3.0V and 12.0 - 15.0V

Not rotating
0 - 1.5V
12 pins 1 ↔ 12 (vehicle stop) Measurement of
8-pulse output
8 pins 1↔5 Rotating Pulse signal which changes
signal
(vehicle between 0 - 1.5V and meter power
traveling) source (8.0V) - 0.5V
1A-162 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
DTC P0032 (Flash code 32)
Boost sensor system malfunction/ height
boost malfunction

Engine
Control
Module
(ECM)
128 126 134 128

GND
VCC
SIG

0.5G/B
0.5W

0.5Gy
0.5R

0.5B

0.5L/W

0.5L/R

0.5L

2 3 1 2 3 1

Boost Sensor PTO Remote Throttle Sensor


HCW61AMF002501

Description of circuit • Boost sensor system malfunction


The boost sensor detects pressure inside the intake If the boost sensor output value exceeds 4.9V, or
manifold. The boost sensor is installed in the intake remains lower than 0.085V for 1 second or more,
duct section. When the pressure inside the intake “boost sensor system malfunction” is diagnosed,
manifold changes due to the condition of the engine and [DTC P0032] is displayed.
(turbocharger), the output voltage of the boost sensor • High boost malfunction
changes (output voltage is low when the intake IF the actual boost pressure remains high for not
manifold interior pressure is low, and the output voltage less than 10 seconds when compared to the boost
increases when the pressure increases). pressure being used as standard by the ECM,
The engine control module (ECM) reads this change in [High boost malfunction] is diagnosed, and [DTC
output voltage, converts it to boost pressure and uses it P0032] is displayed.
for control.
The boost sensor shares use of the sensor power Actions when DTC is set
supply (5V), and GND circuit with the PTO remote • MIL (Check engine lamp) lights.
throttle sensor.
• When the boost sensor is malfunctioning, the ECM
uses the backup value for control.
Main trouble phenomena
• Lack of output Clear conditions of MIL/DTC
• Black smoke When trouble occurs in the system and that DTC is
memorized by ECM, since the fault region is not
Set conditions of DTC eliminated as it is by DTC, it is eliminated in the
[DTC P0032] is set by either of the conditions shown following ways. Furthermore, inspection and repair may
below. require that you check DTCs, so be sure to note and
clear the DTCs before performing inspection.
Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-163
DTC deletion method • Failure of the boost sensor body (malfunction
• Deleting DTC by operating the accelerator pedal inside the sensor or of the sensing element)
(Refer to “How to delete DTCs by operating the • ECM internal malfunction
accelerator pedal” in “Fault diagnosis process”) • Boost sensor detection hole blocked
• Use the scan tool (Tech2) to clear DTC. • Induction system malfunction (intercooler, intake
pipe, air cleaner etc.)
Diagnostic Aids • Check the connector for poor connection, and
• Connector section bad connection check to make sure that there are no abnormalities
• Boost sensor (power source) circuit broken wire or such as a frayed or broken harness, frayed wiring
short circuit in the harness, or a short to another circuit.
Furthermore, perform functional diagnostics to
• Boost sensor (SIG) circuit broken wire or short
check things like operation and control of each
circuit
component. Resolve any abnormality.
• Boost sensor (GND) circuit broken wire or short
circuit

Step Action