Page 1 WORKSHOP MANUAL 727 (N SERIES) ENGINE CONTROL SYSTEM (4HL1 ENGINE) SECTION 1A International Service & Parts Tokyo, Japan...
Page 2 N O T I C E Before using this Workshop Manual to assist you in performing vehicle service and maintenance operations, it is recommended that you carefully read and thoroughly understand the information contained in Section - 0A under the headings “GENERAL REPAIR INSTRUCTIONS”...
Page 3 Engine Control System 1A-1 ENGINE Engine Control System CONTENTS Engine Control System ....1A-2 DTC118 - Common Rail Pressure Fault Precautions on Service ....1A-2 (Control System) .
Page 4 1A-2 Engine Control System Engine Control System Precautions on Service polarity flow out and resultantly the person is charged at high opposite polarity. Since static Circuit test tools electric charges cause damages, it is important Unless otherwise specified in diagnostic procedures, when you handle or test electronic components.
Page 5 Engine Control System 1A-3 Symbol Color Symbol Color Black Brown White Light green Gray Green Pink Yellow Light blue Blue Violet Orange Function and Operation Voltages from ECM The ECM supplies reference voltages to various Electronic Control System switches and sensors. Resistances of the ECM are The electronic control system processes the data, very high and this allows the ECM to supply voltages to which has been collected with various types of sensors,...
Page 6 1A-4 Engine Control System Engine Control System Accelerator AP sensor Relay Idle position switch ECO Relay, Atomospheric Exhaust Brake Starter pressure sensor Switch Ignition switch A/C switch Lamp Starter switch Exhaust Brake Lamp Glow Lamp Battery Relay/Lamp (Engine Control Module) Brake Starter cut relay (Vehicle Interface Module)
Page 7 Engine Control System 1A-5 Fuel Injection Control DTC Detection Status Battery Voltage Compensation Key Switch Position Engine Speed Injector Injector Vehicle Speed Energize Time/ Control Timing Determine Engine Coolant Temp. Compensation Intake Air Temp. Fuel Temp. Desired Injection Status Judge Quantity Determine Common Rail Pressure...
Page 8 1A-6 Engine Control System Intake Throttle Control LNW21AMF005701 Legend 1. Intake throttle valve 3. Intake throttle DC motor 2. ITP (intake throttle position) sensor The intake throttle control system changes (throttles) switch is turned off (within 0.5 to 3.0 seconds). the air according to the vehicle status and reduces There is an opposing relationship between intake suction noises generated from the working exhaust...
Page 9 Engine Control System 1A-7 EGR Control LNW21AMF005801 Legend 1. EGR valve 3. EGR DC motor 2. EGR valve position sensor The EGR control system recirculates a portion of Note 1: Duty (%) = T (*) / 5 (msec) × 100 exhaust gas to the intake to drop the combustion * T = Duty input time (see motor drive voltage temperature and thus reduce NOx.
Page 10 1A-8 Engine Control System QWS Control • For a manual transmission vehicle, the clutch pedal pressed. automatic The QWS (quick warm-up system) curtails the engine transmission vehicle, the exhaust brake command warm-up time. The glow control covers the engine is not sent from the automatic transmission. warm-up during the period from pre-startup to •...
Page 11 Engine Control System 1A-9 Powertrain System Components Component Layout - Vehicle Side LNW21AMF005501 Legend 1. Engine 6. Accelerator pedal 2. Neutral switch 7. DLC (data link connector) 3. ECM (engine control module) 8. CHECK ENGINE lamp (MIL) 4. VIM (vehicle interface module) 9.
Page 12 1A-10 Engine Control System Component Layout - Engine Side LNW21AMF005301 Legend 1. ECT (engine coolant temperature) sensor 5. FT (fuel temperature) sensor 2. EGR valve 6. SCV (suction control valve) 3. Intake throttle valve 7. Common rail pressure sensor 4. CKP (crank position) sensor 8.
Page 13 Engine Control System 1A-11 EGR Valve and EGR Valve Position Sensor The intake throttle valve is installed to the intake throttle and operated by a DC motor. The DC motor operates the intake throttle valve by changing the drive voltage. The valve is closed when the drive voltage is increased while opened when the voltage is decreased.
Page 14 1A-12 Engine Control System CKP Sensor LNW21ASH007501 LNW21ASH007601 The SCV (suction control valve) is installed to the The CKP (crank position) sensor is installed to the supply pump and controls the suction fuel quantity. The flywheel housing and, when flywheel teeth pass the SCV is fully opened in normal state and larger drive sensor, a CKP signal is generated.
Page 15 Engine Control System 1A-13 IAT Sensor voltage signal for use in fuel injection control and other diversified control tasks. Idle Position Switch LNW21ASH008401 The IAT (intake air temperature) sensor is installed to LNW21ASH008801 the intake air duct and the thermistor in the sensor alters the resistance in response to the temperature The idle position switch is installed to the accelerator change.
Page 16 1A-14 Engine Control System VS Sensor Exhaust Brake Solenoid Valve LNW21ASH008701 LNW21ASH009001 The exhaust brake solenoid valve is installed to the The VS (vehicle speed) sensor is installed to the rear of the right front wheel frame (some vehicle types transmission.
Page 17 Engine Control System 1A-15 The ECM is installed in the inner part of the engine left CHECK ENGINE Lamp (MIL) side cover. The ECM uses signals sent from diversified sensors to control those systems directly related to the engine, for example, fuel injection control, intake throttle control, EGR control, and QWS control.
Page 18 1A-16 Engine Control System Fuse Layout [Fuse Box Label, In Glove Box] [Fuse Box, Front Left of Radiator] LNW21ALF000401-X Legend 1. Spare fuse Indication on label Capacity Devices connected CONTROLLER Control unit HAZARD,HORN (12V) Hazard warning flashing lamp, horn HAZARD,HORN (24V) —...
Page 19 Engine Control System 1A-17 Indication on label Capacity Devices connected POWER WINDOW (24V) Power window TAIL.ILLUMI (12V) Tail lamp TAIL.ILUMI (24V) FOG.CORNER Fog lamp, cornering lamp ELEC.PTO (24V) PTO switch (electric PTO) WIPER,WASHER Wiper, window washer TURN Turn signal lamp GENERATOR (12V) Generator ELEC.PTO (24V)
Page 20 1A-18 Engine Control System Relay Layout Relay Box No.1 Relay Box No.2 Bracket Spare Power Circuit Upper Fuse & Front Right Relay Box Cooler Relay LNW21ALF006101-X Legend 12 V: On relay 24 V: Charge relay Horn relay 12 V: ABS, VSV, FICD, EXH brake, valve (12 V) 24 V: Headlamp relay Tail relay 12 V: Headlamp relay...
Page 21 Engine Control System 1A-19 Legend Cornering lamp relay 10 Air conditioner thermo relay 12 V: Charge relay 24 V: Key on relay 12 Heater & air conditioner relay 24 V: PTO cut relay for electric PTO in fire engine (MT) 24 V: PTO solenoid relay for electric PTO (AT) 12 V: Exhaust brake cut relay (MT) 24 V: Idle on relay for fire engine (AT)
Page 22 1A-20 Engine Control System Circuit Diagram ECM Circuit Diagram Starter Switch (ON) 0.75B/O 0.5L 0.5L/W CHECK ENGINE Sensor 0.5L/R Lamp 0.5Y/B 0.5B/Y Idle Position Switch 0.5W/L A/C Condenser 0.75W/R 0.5R/B Starter A/C Magnetic 0.5G/W Switch (ST) Clutch Sensor 0.5B/W 0.5R/G Starter Starter Cut Relay...
Page 23 Engine Control System 1A-21 VIM Circuit Diagram Starter SW (ON) 0.85B/O Exhaust Brake Lamp 0.5B/R 0.3BR/W 0.3B/G 0.3LG/B 0.5LG/B 0.5L/R A/T ECU Exhaust 0.5LG Brake Solenoid PTO Lamp Tachometer PTO ECU 0.5BR PTO SW 0.5V/W 0.5B/R ABS/ASR 0.3B/L 0.5G/Y Starter SW (ST) 0.5B/W 0.5G Sound Alarm...
Page 24 1A-22 Engine Control System ECM/VIM Circuit Diagram (1/5) SBF-1 80A/100A MAIN 5 W/B 5 W/B 3 W/B SBF-2 50A 3 W/L 3 W/L 3B/Y B-67 B-67 F-16 15A 3B/W B-67 ENG. CONT SBF-3 60A Starter Switch GLOW PTO Cut Relay B-216 (4) SBF-5 3 W/G...
Page 25 Engine Control System 1A-23 ECM/VIM Circuit Diagram (2/5) 3B/Y F-19 3W/B 0.5W/R Meter Charge Relay 3B/W B-172 X-12 X-12 B-47 Inhibitor Switch Joint (JATCO) (AISIN) Connector Heater & A/C Relay B-172 J-69 J-69 Joint X-12 X-12 0.85 Connector 0.5B 0.5B 1.25B B-274 J-50...
Page 26 1A-24 Engine Control System ECM/VIM Circuit Diagram (3/5) 3B/W F-22 STARTER 0.5B/W LG/B B-352 B-351 B-351 B-351 B-351 B-351 B-352 B-351 B-351 B-351 B-351 B-351 B-352 B-352 B-352 B-352 B-352 BR/W LG/W J-177 J-177 J-177 J-177 EHCU LNW21AXF002901-X...
Page 27 Engine Control System 1A-25 ECM/VIM Circuit Diagram (4/5) 0.5B/W Injector No.2 No.3 No.4 No.1 E-115 E-115 E-115 E-115 E-115 E-115 E-115 E-115 0.75 0.75 1.25 1.25 0.75 0.75 1.25 1.25 0.75 E-111 E-1114 E-111 E-111 E-111 E-111 E-111 E-111 E-111 E-111 E-111 E-111...
Page 28 1A-26 Engine Control System ECM/VIM Circuit Diagram (5/5) Accelerator Sensor Meter B-51 (CHECK ENGINE Lamp) B-280 B-280 B-280 IAT Sensor J-190 J-190 0.85 J-191 J-191 J-191 J-191 J-191 J-191 J-191 J-191 J-191 J-191 J-191 J-191 J-191 J-191 J-191 0.75 1.25 1.25 1.25 B-75...
Page 29 Engine Control System 1A-27 Component Layout 41,42,43,44,45,46 33,34,35,36,37,38 26,27,28,29,30 LNW21ALF006301 Legend 1 B-172 Joint connector 2 X-12 Heater and air conditioner relay (825/151) 3 X-33 Diode (810/002) 4 B-349, 350, 351, (826/646) 5 J-31 Exhaust brake magnetic valve (156/086) 6 J-50 Neutral switch (230/171) 7 J-166...
Page 30 1A-28 Engine Control System 15 E-114 Intake throttle motor (025/373) 16 E-98 Crank position sensor (826/648) 17 E-112 Cam position sensor (040/001) 18 E-96 Timing control valve (040/001) 18 E-111 (060/613) 19 H-105 Intermediate connector 20 J-190 IAT sensor (060/820) 21 E-116 Suction control valve (040/001)
Page 31 Engine Control System 1A-29 Connector List Connector face Connector face B-79 B-31 006-024 016-033 B-89 B-51 2 3 4 5 6 7 8 9 1011121314 1516 171819 20 002-011 020-024 B-172 B-52 005-025 022-005 B-274 B-67 000-012 004-035 B-67 B-280 004-015 003-098 B-69...
Page 32 1A-30 Engine Control System Connector face Connector face B-346 E-90 000-037 003-095 38 37 B-349 E-93 76 75 022-025 002-208 B-350 E-94 012-054 005-034 B-351 E-98 016-067 002-178 13 12 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 11 10 9 B-352...
Page 33 Engine Control System 1A-31 Connector face Connector face E-115 J-31 008-046 002-008 E-116 J-50 002-178 002-210 9 8 7 6 9 10 11 12 J-177 13 14 15 16 17 18 19 20 21 22 20 19 18 17 16 26 27 28 29 30 31 32 33 34 020-002 034-001...
Page 34 1A-32 Engine Control System Connector face (24V) 000-028 " " & & ! " # $ % & & % $ # " ! " " ' & ' ! & ! ! !& !' " " !' !&...
Page 35 Engine Control System 1A-33 H - 6 H - 7 " " & & ! " # $ % & & % $ # " ! 1 2 3 4 4 3 2 1 " "...
Page 36 1A-34 Engine Control System 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 106107108109110111112113 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 98 99 100101102103104105 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 90 91 92 93 94 95 96 97...
Page 37 Engine Control System 1A-35 Pin No. Connected to Pin No. Connected to CKP sensor (+) Common rail pressure sensor signal Shield ground (CMP, CKP, common rail Common rail pressure sensor signal pressure) CMP sensor ground EGR valve position sensor signal —...
Page 38 1A-36 Engine Control System Pin No. Connected to Pin No. Connected to CHECK ENGINE lamp ECM power ground — ECM power ground — ECM power ground VIM Pinouts LNW21AMF005101...
Page 39 Engine Control System 1A-37 37 38 16 17 20 21 25 26 32 33 34 50 51 68 69 70 71 LNW21ASF001901 26-Way Connector Pin No. Connected to Pin No. Connected to — VIM power ground Exhaust brake solenoid valve —...
Page 40 1A-38 Engine Control System 12-Way Connector Pin No. Connected to Pin No. Connected to — Signal ground — — DLC (Tech 2 communications) — — — ECM (CAN communications) — ECM (CAN communications) Shield ground (CAN communications) 22-Way Connector Pin No. Connected to Pin No.
Page 41 Engine Control System 1A-39 • “Sympton Diagnosis Chart” contain information on 3. Use a check sheet or other method to identify the a system that may not be suppored by one or more circuit or electrical system component. DTCs. Sympton Diagnosis Chart verify proper operation of the system.
Page 42 1A-40 Engine Control System Item Objective Method Verifying the To check electric wave Turn on and off the electric wave emission electromagnetic emission equipment such as equipment, such as transceiver, to check whether compatibility of transceiver, if added, does not idle speed will change.
Page 43 Engine Control System 1A-41 When a diagnostic test reports a fail result, the • Engine speed Diagnostic Executive records the following data: • Vehicle speed • The diagnostic test has been completed since the • ECT (engine coolant temperature) last ignition cycle. •...
Page 44 1A-42 Engine Control System • Reading serial data 1. Turn on the starter switch and check the CHECK ENGINE lamp (MIL) is turned on. (Bulb check) LNW21ASH001801 LNW21ASH000201 Verifying Vehicle Repair 2. Keep the starter switch turned on and the engine turned off.
Page 45 Engine Control System 1A-43 Diagnostic Trouble Codes Stored Code 12 that is displayed three times and then stored code is displayed three times. When multiple DTCs are stored, each code is displayed three times, starting from the lowest number. After all DTCs are displayed, above sequence is repeated from code 12 as long as DLC is being shorted.
Page 46 1A-44 Engine Control System ECM Voltage and Continuity Test/Measurement To test and measure the ECM for voltage and continuity, use a circuit breaker box and 4HL1 adapter harness. LNW21ASH010501 Functional Check List Hearing The objective is to comprehend the symptom completely based on the customer complaint and provide accurate diagnostic.
Page 47 Engine Control System 1A-45 Engine Control System Diagnostic Chart When receiving the vehicle from the customer in the service factory, you must verify both the symptom and failure data using the Engine Control System Diagnostic Chart. LNW21ASH001301 Legend 1. Symptom 2.
Page 48 1A-46 Engine Control System Engine Control System Diagnostic Chart Inspector: Vehicle model and model Customer year Vehicle ID Driver Engine model Vehicle acceptance Engine ID date Engine type Registration No. Odometer reading No cranking No initial combustion Incomplete initial combustion No engine start Long cranking (6 seconds or more) Poor startability...
Page 49 Engine Control System 1A-47 On-Board Diagnostic (OBD) System Check 100A 3W/L Battery (ST) (ON) 0.5B Glow Relay Main CHECK Relay ENGINE Lamp Glow Relay 118 117 116 115 114 (Engine Control Module) 121 120 119 95 87 LNW21ALF006001-X Circuit Description The on-board diagnostic (OBD) system check is a rubbed-through wire insulation or wire broken starting point for any driveability complaint diagnosis.
Page 50 1A-48 Engine Control System 13: A Tech 2 parameter that is not within the typical range may help to isolate the area that is causing the problem. Step Action Value(s) Check the main relay. Remove the main relay. Check the main relay for open wiring or —...
Page 51 Engine Control System 1A-49 Step Action Value(s) Replace the ECM. IMPORTANT: If necessary (for the vehicle equipped with — idle stop function), input the number of startups to the replacing ECM. Is the action complete? Go to Step 4 — Observe the CHECK ENGINE lamp for operation.
Page 52 1A-50 Engine Control System Inactive CHECK ENGINE Lamp Check 100A 3W/L Battery (ST) (ON) 0.5B Glow Relay Main CHECK Relay ENGINE Lamp Glow Relay 118 117 116 115 114 (Engine Control Module) 121 120 119 95 87 LNW21ALF006001-X Circuit Description •...
Page 53 Engine Control System 1A-51 Step Action Value(s) Perform the "On-Board Diagnostic (OBD) Refer to OBD System Check". — System Check Was the OBD System Check performed? Go to Step 2 and go to Step 2 Check other lamps in the meter (such as parking brake lamp and charge lamp) are turned on.
Page 54 1A-52 Engine Control System Step Action Value(s) Check the CHECK ENGINE lamp bulb. Remove the CHECK ENGINE lamp bulb. — Check the bulb is broken. Is the bulb in normal condition? Go to Step 14 Go to Step 13 Replace the bulb. Verify repair and —...
Page 55 Engine Control System 1A-53 Step Action Value(s) Replace the ECM. Important: If necessary (for the vehicle equipped with — idle stop function), input the number of startups to replacing the ECM. Verify repair and Is the action complete? go to Step 2 —...
Page 56 1A-54 Engine Control System Unblinking CHECK ENGINE Lamp Check 100A 3W/L Battery (ST) (ON) 0.5B Glow Relay Main CHECK Relay ENGINE Lamp Glow Relay 118 117 116 115 114 (Engine Control Module) 121 120 119 95 87 LNW21ALF006001-X Circuit Description •...
Page 57 Engine Control System 1A-55 Step Action Value(s) Perform the "On-Board Diagnostic (OBD) Refer to OBD System Check". — System Check Was the OBD System Check performed? Go to Step 2 and go to Step 2 Check the circuit between ECM and CHECK ENGINE lamp for short to ground.
Page 58 1A-56 Engine Control System Step Action Value(s) Re-observe the CHECK ENGINE lamp for operation. Certainly connect connectors. Short DLC pins 4 and 6. — Starter switch "ON", and observe the CHECK ENGINE lamp. The repair is Does the CHECK ENGINE lamp blink? complete Go to Step 1 ECM Power Supply and Grounding System Circuit Check...
Page 59 Engine Control System 1A-57 Diagnostic Aids • Damaged harness: Inspect the wiring harness for rubbed-through wire insulation or wire broken An intermittent may be caused by a poor connection, a inside the insulator. rubbed-through wire insulation, or a wire broken inside the insulator.
Page 60 1A-58 Engine Control System Step Action Value(s) Repair or replace the harness between SBF (ECM: 50A) and SBF (engine controller: 30A). — Verify repair and Is the action complete? go to Step 10 — Check the main relay coil circuit for open Pins 4- wiring.
Page 61 Engine Control System 1A-59 Diagnosis with Tech 2 Scan Tool Tech 2 Scan Tool Tech 2 is an effective tool for diagnosis of electrical failures on the engine control system. This scan tool is a small and lightweight handheld tester and, once connected to the DLC on a vehicle, communicates with the on-board ECM to perform various diagnostics and tests.
Page 62 • To clear DTC(s), you should open the application menu and select "F1: Clear DTC Info" or "Clear DTC". Connection 1. Insert the ISUZU System PCMCIA card into Tech 2. Install the SAE 16/19-pin adapter to the DLC cable. 3. Connect the DLC cable to Tech 2.
Page 63 Vehicle Identification Select one of the following Eingine Vehicle Identification Denso 4H* Select one of the following Model Year(s) 4JHI-TC Bosch 4HL1/4HJ1(COMMON RAIL) 2003 4HL1/4HJ1(Vehicle Interface Module) 2002 4HE1-TC (Diesel) 2001 2000 1999 (4HL1/4HJ1(COMMON RAIL) or 1998 4HL1/4HJ1(Vehicle Interface Module) ENTER)
Page 64 1A-62 Engine Control System Data Display F2: Snaphot • Typical values are described in the Tech 2 data F3: Actuator Test list. F0: Common Rail Pressure Control Test F1: Injector Balance Test Data Display F2: Intake Throttle Test System Voltage F3: EGR Control Test Vehicle Speed km/h...
Page 65 Engine Control System 1A-63 • In the snapshot after determination of trigger type, Replaying recorded data graph you can record the data obtained when the DTC is 1. Turn on Tech 2 and select "Snapshot data" displayed. Reviewing this data can reveal the displayed thereafter.
Page 66 1A-64 Engine Control System Actuator test F3: Actuator F0: Common This test aims at checking the common rail pressure is correctly controlled by the Test Rail Pressure ECM and common rail pressure sensor. Control Test Test procedure: 1. Select "Common Rail Pressure Control Test" from "Actuator Test". 2.
Page 67 Engine Control System 1A-65 F3: Actuator F1: Injector This test aims at checking the injector drive signals are correctly sent to injectors Test Balance Test to operate the devices accordingly. Test procedure: 1. Select "Injector Balance Test" from "Actuator Test". 2.
Page 68 1A-66 Engine Control System F3: Actuator F3: EGR This test aims at checking the working condition of the EGR valve and EGR valve Test Control Test position sensor. Test procedure: 1. Select "EGR Control Test" from "Actuator Test". 2. Press "Decrease" or "Increase" soft key to check the data list. 3.
Page 69 Engine Control System 1A-67 Tech 2 Engine Date ECM Date • Engine status: starter switch ON (room temperature: 20°C, all peripheral devices (air conditioner, freezer, etc.): OFF) Values at starter Tech 2 Data Display Units displayed Fail-safe values switch ON System Voltage 24 (DTC84 is detected) 16 ~ 38...
Page 70 1A-68 Engine Control System Values at starter Tech 2 Data Display Units displayed Fail-safe values switch ON Approx. 100 100 (DTC61 or DTC84 is (The value will change Barometric Pressure detected) depending on the barometric pressure) 60 or less (DTC115, DTC118, DTC227, Desired Rail Pressure —...
Page 71 Engine Control System 1A-69 Values at starter Tech 2 Data Display Units displayed Fail-safe values switch ON ASR Accelerator Opening 100 (DTC84 is detected) Starter Switch ON/OFF ON (DTC84 is detected) Ignition Switch ON/OFF ON (DTC84 is detected) Clutch Switch ON/OFF OFF(DTC84 is detected) Neutral Switch...
Page 72 1A-70 Engine Control System Tech 2 Data Display Units displayed Fail-safe values Values at idling Normal running phase: 80 ~ 85 (The value will change Coolant Temperature °C Startup phase: –20 depending on (DTC23 is detected) temperatures around 80 (DTC84 is detected) the engine) 2.3 ~ 2.4 (The value will change...
Page 73 Engine Control System 1A-71 Tech 2 Data Display Units displayed Fail-safe values Values at idling Intake Throttle Duty Ratio — Approx. 10 ~ 11 50 or less (DTC115, DTC118, DTC227, Desired Injection Quantity Approx. 11.4 ~ 12.7 DTC245, or DTC247 is detected) Desired Fuel Injection Timing °CA...
Page 74 1A-72 Engine Control System Tech 2 Data Display Units displayed Fail-safe values Values at idling QWS Switch ON/OFF OFF(DTC84 is detected) ECO Relay ON/OFF OFF(DTC84 is detected) Freezer Switch ON/OFF OFF(DTC84 is detected) The value is Transmission Coding MT/AT MT (DTC84 is detected) determined by the transmission type.
Page 75 Engine Control System 1A-73 Values at around Tech 2 Data Display Units displayed Fail-safe values 1500 rpm Approx. 3.6 (The value will change Barometric Pressure Sensor — depending on the barometric pressure) Approx. 100 100 (DTC61 or DTC84 is (The value will change Barometric Pressure detected) depending on the...
Page 76 1A-74 Engine Control System Values at around Tech 2 Data Display Units displayed Fail-safe values 1500 rpm Idle Up Volume 0 (DTC84 is detected) Approx. 0.4 PTO Accelerator Sensor 0 (DTC84 is detected) 0.3 ~ 0.6 0 (DTC28 or DTC84 is PTO Accelerator Opening detected) ASR Accelerator Opening...
Page 77 Engine Control System 1A-75 Tech 2 Data Display Units displayed Fail-safe values Typical data values 0 (DTC28 or DTC84 is PTO Accelerator Opening detected) Ignition Switch ON/OFF OFF(DTC84 is detected) Idle Up Volume 0 (DTC84 is detected) Approx. 0.4 Idle Manual Switch ON/OFF OFF(DTC84 is detected) Clutch Switch...
Page 78 1A-76 Engine Control System Tech 2 Engine Data Description ECM Data Tech 2 Data Units Item Description How to use parameters Display displayed 1/63 System Voltage This parameter refers to the When the display substantially power supply voltage applied to deviates from the actual battery the ECM from the battery.
Page 79 Engine Control System 1A-77 Tech 2 Data Units Item Description How to use parameters Display displayed 7/63 ECT Sensor This parameter refers to the The engine coolant temperature (Engine Coolant signal voltage input to the ECM is a proper criterion for various Temperature) from the ECT (engine coolant control configurations (e.g.,...
Page 80 1A-78 Engine Control System Tech 2 Data Units Item Description How to use parameters Display displayed 16/63 Actual Rail This parameter refers to the This parameter should be used Pressure value calculated by the ECM by comparing to the desired using the signals from the common rail pressure.
Page 81 Engine Control System 1A-79 Tech 2 Data Units Item Description How to use parameters Display displayed 23/63 EGR Current This parameter refers to the When the display deviates from Position value calculated by the ECM the specified level, the DC motor, using the signals from the EGR EGR valve, sensor, circuit, or position sensor.
Page 82 1A-80 Engine Control System Tech 2 Data Units Item Description How to use parameters Display displayed 33/63 Cylinder 4 This parameter refers to the When the display deviates from Compensation calibrated fuel injection quantity the specified level, the injector, calculated using the signals from fuel injection system, sensors, CKP and CMP sensors.
Page 83 Engine Control System 1A-81 Tech 2 Data Units Item Description How to use parameters Display displayed 42/63 PTO Accelerator This parameter refers to the When the display deviates from Opening value calculated by the VIM using the specified level as the PTO the signals from the PTO accelerator opening is changed, accelerator sensor.
Page 84 1A-82 Engine Control System Tech 2 Data Units Item Description How to use parameters Display displayed 50/63 Exhaust Brake ON/OFF This parameter refers to the When the display is fixed, the Valve status of the signals output from exhaust brake valve, circuit, VIM, the VIM to the exhaust brake or ECM may be faulty.
Page 85 Engine Control System 1A-83 Tech 2 Data Units Item Description How to use parameters Display displayed 58/63 Starter Relay ON/OFF This parameter refers to the When the display is fixed, the status of the signals output from relay, circuit, or ECM may be the ECM to the starter cut relay.
Page 86 1A-84 Engine Control System VIM Data Tech 2 Data Units Item Description How to use parameters Display displayed 1/31 System Voltage This parameter refers to the When the display substantially power supply voltage applied to deviates from the actual battery the VIM from the battery.
Page 87 Engine Control System 1A-85 Tech 2 Data Units Item Description How to use parameters Display displayed 9/31 Idle Manual ON/OFF This parameter refers to the When the display is fixed, the idle Switch status whether the idle control is control change-over switch, manual or automatic.
Page 88 1A-86 Engine Control System Tech 2 Data Units Item Description How to use parameters Display displayed 18/31 PTO Idle Position ON/OFF This parameter refers to the When the display is fixed, the Switch working condition of the PTO PTO idle position switch, circuit, accelerator.
Page 89 Engine Control System 1A-87 Tech 2 Data Units Item Description How to use parameters Display displayed 27/31 ASR-PWM ON/OFF This parameter refers to the When the display is fixed, Output status whether accelerator communications with ABS/ASR position signals are input to the control unit, ABS/ASR system, VIM from the ASR controller.
Page 90 1A-88 Engine Control System Diagnostic Chart CAUTION: The values in "Judgment criteria" may vary depending on measurement conditions. Chart 1 (1/3) CHECK Fault ENGINE Judgment start conditions Judgment criteria Fail-safe lamp status No CMP signal is input while the When the CKP sensor is sound, the The battery voltage is at least 16 V CMP Sensor System Fault CKP signal is input to the ECM 450...
Page 91 Engine Control System 1A-89 Chart 1 (2/3) CHECK Fault ENGINE Judgment start conditions Judgment criteria Fail-safe lamp status ECM Internal Fault The sub CPU judges the CPU fail. — (CPU Error) (by sub CPU) With the battery voltage 20 V or —...
Page 92 1A-90 Engine Control System Chart 1 (3/3) CHECK Fault ENGINE Judgment start conditions Judgment criteria Fail-safe lamp status Pump control and pump feedback The SCV drive current is at least are in normal mode, the SCV drive 1500 mA. (+B short is detected on SCV Drive System Short —...
Page 93 Engine Control System 1A-91 Chart 2 (1/2) Fault Major faulty event Parts to be inspected Applicable Tech 2 parameter Wire harnesses and connectors (G sensor CMP Sensor System Fault Poor startability Engine Speed system), G sensor, ECM Poor startability Wire harnesses and connectors (NE sensor CKP Sensor System Fault Engine Speed Poor driveability...
Page 94 1A-92 Engine Control System Chart 2 (2/2) Fault Major faulty event Parts to be inspected Applicable Tech 2 parameter Fuel Temperature Sensor Wire harnesses and connectors (FT sensor Poor driveability Fuel Temperature, FT Sensor System Fault system), FT sensor, ECM Poor startability Generation of white/black smoke Wire harnesses and connectors (SCV+ to ECM),...
Page 95 Engine Control System 1A-93 DTC14 - CMP Sensor System Fault (Engine Control Module) 8 27 26 63 66 6764 EGR Valve Common Sensor Sensor Sensor Position Rail Sensor Pressure Sensor LNW21AMF006901-X Circuit Description Conditions for Clearing MIL/DTC The CMP (cam position) sensor is installed to each When the system fails and the DTC is stored to the cylinder head and, when the hole on the camshaft gear ECM, even repairing the faulty portion will not clear the...
Page 96 1A-94 Engine Control System Diagnostic Aids Test Description Poor connection or damaged harness may cause Number(s) below refer to the step number(s) on the intermittents. Check for the following conditions and, if Diagnostic Chart. the fault is detected, repair or replace the faulty portion. 3.
Page 97 Engine Control System 1A-95 Step Action Value(s) Check the harness between ECM and CMP Pins 27-8 sensor for open wiring or short. (jumpered: pins 2-3): 0 Ω Disconnect the CMP sensor connector. (not jumpered): Jumper the CMP sensor connector pins ∞...
Page 98 1A-96 Engine Control System Sensor Description LNW21ASF003301 Legend 1. CMP sensor 3. Sensor ground 2. Shield ground 4. Sensor signal...
Page 99 Engine Control System 1A-97 DTC15 - CKP Sensor System Fault (Engine Control Module) 8 27 26 63 66 6764 EGR Valve Common Sensor Sensor Sensor Position Rail Sensor Pressure Sensor LNW21AMF006901-X Circuit Description Conditions for Clearing MIL/DTC The CKP (crank position) sensor is installed to the When the system fails and the DTC is stored to the flywheel housing and, when flywheel teeth pass the ECM, even repairing the faulty portion will not clear the...
Page 100 1A-98 Engine Control System Diagnostic Aids Test Description Poor connection or damaged harness may cause Number(s) below refer to the step number(s) on the intermittents. Check for the following conditions and, if Diagnostic Chart. the fault is detected, repair or replace the faulty portion. 3.
Page 101 Engine Control System 1A-99 Step Action Value(s) Check the harness between ECM and CKP Pins 25-6 sensor for open wiring or short. (jumpered: pins 1-2): 0 Ω Disconnect the CKP sensor connector. (not jumpered): Jumper the CKP sensor connector pins ∞...
Page 102 1A-100 Engine Control System Sensor Description LNW21ASF003201 Legend 1. CKP sensor 3. Sensor signal (+) 2. Projections on flywheel 4. Sensor signal (–)
Page 103 Engine Control System 1A-101 DTC18 - Starter Degradation (For Only Vehicles Equipped with Idle Stop Function) Circuit Description 3. Turn off the idle position switch for not less than 1 second but not more than 3 seconds. (Press the The number of starter operations is stored to the VIM. accelerator pedal.) The VIM receives the signal from the starter switch 4.
Page 104 1A-102 Engine Control System Step Action Value(s) Reset the accumulated number of startups. Engine "OFF", starter switch "ON". Using Tech 2, reset the accumulated number of startups. — Start the engine. Engine "OFF", starter switch "OFF". Is the action complete? Go to Step 7 —...
Page 105 Engine Control System 1A-103 DTC22 - IAT Sensor System Fault (Engine Control Module) 91 83 Sensor LNW21AMF007701-X Circuit Description Conditions for Clearing MIL/DTC The IAT (intake air temperature) sensor consists of When the system fails and the DTC is stored to the thermistor and alters the resistance in response to ECM, even repairing the faulty portion will not clear the temperature change.
Page 106 1A-104 Engine Control System Diagnostic Aids Test Description Poor connection or damaged harness may cause Number(s) below refer to the step number(s) on the intermittents. Check for the following conditions and, if Diagnostic Chart. the fault is detected, repair or replace the faulty portion. 3.
Page 107 Engine Control System 1A-105 Step Action Value(s) Check the harness between ECM and IAT sensor for open wiring. Pins 91-83 Starter switch "OFF". (jumpered: pins 1-2): 0 Ω Disconnect the ECM. Pins 91-83- Disconnect the IAT sensor connector. ground Jumper the IAT sensor connector pins (jumpered: and measure the resistance at the ECM pins 1/2-...
Page 108 1A-106 Engine Control System Step Action Value(s) Check DTC22 will not be set again. Using Tech 2, clear the DTC. — Refer to Perform test run and review the DTC. Diagnostic Aids Repair is Is DTC22 detected? and go to Step 2 complete Characteristics of IAT Sensor (Reference) -40 -30 -20 -10...
Page 109 Engine Control System 1A-107 DTC23 - ECT Sensor System Fault (Engine Control Module) 49 46 Sensor Sensor LNW21AMF007101-X Circuit Description • The ECM controls the powertrain using the set engine coolant temperature (normal running The ECT (engine coolant temperature) sensor consists phase: 110°C, startup phase: –20°C).
Page 110 1A-108 Engine Control System 7. Turn off the starter switch. Wait for 5 seconds and inside the insulator. If the harness appears to be turn on the starter switch again. OK, observe the display on Tech 2 while moving When Tech 2 has been connected to the vehicle, the connectors and wiring harnesses related to the DTC can be cleared through the memory clear sensor.
Page 111 Engine Control System 1A-109 Step Action Value(s) Check the ground circuit common to ECT and Pins 49-46 FT sensors for open wiring or short. (not jumpered): ∞ Ω Starter switch "OFF". Pins 46- Disconnect the ECM. ground Disconnect the ETC sensor connector. (jumpered: Jumper the ETC sensor connector pins pins 2-...
Page 112 1A-110 Engine Control System Step Action Value(s) Repair or replace the faulty harness. Verify repair and — Is the action complete? go to Step 20 — Check the ECT sensor. Disconnect the ECT sensor. Provide temperature change on the thermosensitive element of the ECT See graph sensor and measure the resistance between the sensor connector pins.
Page 113 Engine Control System 1A-111 Sensor Description LNW21ASF003101 Legend 1. ECT sensor 4. Sensor ground 2. Thermistor for ECM 5. Sensor signal (on ECM) 3. Thermistor for meter 6. Sensor signal (on meter)
Page 114 1A-112 Engine Control System DTC24 - Accelerator Sensor System Fault (Engine Control Module) 90 84 94 108 Idle Switch Sensor LNW21AMF007501-X Circuit Description • ON/OFF fault judgment is disabled on idle position switch. The AP (accelerator pedal position) sensor sends the voltage signal that alters in response to the change in Conditions for Clearing MIL/DTC accelerator pedal angle to the ECM.
Page 115 Engine Control System 1A-113 When Tech 2 has been connected to the vehicle, the connectors and wiring harnesses related to the DTC can be cleared through the memory clear sensor. A change in the display will indicate the operation with Tech 2. location of the fault.
Page 116 1A-114 Engine Control System Step Action Value(s) Check the AP sensor signal circuit for +B short. Starter switch "OFF". Pins 84-109/ Disconnect the ECM. 114/115/116: ∞ Ω At the ECM connector pins, measure the resistance. Was the resistance within range? Go to Step 10 Go to Step 8 Repair or replace the faulty harness.
Page 117 Engine Control System 1A-115 Step Action Value(s) Check DTC24 will not be set again. Using Tech 2, clear the DTC. — Refer to Perform test run and review the DTC. Diagnostic Aids Repair is Is DTC24 detected? and go to Step 2 complete Switch Description LNW21ASF003001...
Page 118 1A-116 Engine Control System DTC25 - Vehicle Speed Sensor System Fault (Vehicle Interface Module) Y/BR PTO Sensor Idling VS Sensor Control LNW21AMF007801-X Circuit Description Conditions for Clearing MIL/DTC The VS (vehicle speed) sensor is equipped with a Hall When the system fails and the DTC is stored to the effect circuit.
Page 119 Engine Control System 1A-117 Diagnostic Aids OK, observe the display on Tech 2 while moving connectors and wiring harnesses related to the Poor connection or damaged harness may cause sensor. A change in the display will indicate the intermittents. Check for the following conditions and, if location of the fault.
Page 120 1A-118 Engine Control System Step Action Value(s) Check the VS sensor ground circuit for open wiring. Starter switch "OFF". Pins 2- Measure the resistance between VS ground: 0 Ω sensor connector ground pin and ground (e.g., frame or body) Was the resistance within range? Go to Step 8 Go to Step 9 Check the VS sensor signal circuit for open...
Page 121 Engine Control System 1A-119 Sensor Description LNW21ASF002801 Legend 1. VS sensor 3. Sensor ground 2. Sensor signal 4. Sensor power...
Page 122 1A-120 Engine Control System DTC28 - PTO Accelerator Sensor System Fault (Vehicle Interface Module) Y/BR PTO Sensor Idling VS Sensor Control LNW21AMF007801-X Circuit Description DTC from the memory. To clear the DTC, conduct the following steps. The PTO accelerator sensor sends the voltage signal 1.
Page 123 Engine Control System 1A-121 Diagnostic Aids OK, observe the display on Tech 2 while moving connectors and wiring harnesses related to the Poor connection or damaged harness may cause sensor. A change in the display will indicate the intermittents. Check for the following conditions and, if location of the fault.
Page 124 1A-122 Engine Control System Step Action Value(s) Check the PTO accelerator sensor circuit for short. Pins 71-31: Disconnect the VIM. ∞ Ω Disconnect the PTO accelerator sensor Pins 31-34: connector. ∞ Ω Pins 71-34: At the VIM connector pins, measure the ∞...
Page 125 Engine Control System 1A-123 DTC31 - Idle Up Volume System Fault (Vehicle Interface Module) Y/BR PTO Sensor Idling VS Sensor Control LNW21AMF007801-X Circuit Description DTC from the memory. To clear the DTC, conduct the following steps. The idle up volume switch controls the idle speed 1.
Page 126 1A-124 Engine Control System Diagnostic Aids Test Description Poor connection or damaged harness may cause Number(s) below refer to the step number(s) on the intermittents. Check for the following conditions and, if Diagnostic Chart. the fault is detected, repair or replace the faulty portion. 3.
Page 127 Engine Control System 1A-125 Step Action Value(s) Check the idle up volume switch circuit Pins 71-34 harness for open wiring or short. (jumpered: pins 1-2): 0 Ω Starter switch "OFF". (not jumpered): Disconnect the VIM. ∞ Ω Disconnect the idle up volume switch Pins 31-34 connector.
Page 128 1A-126 Engine Control System Idle Up Volume Switch Description Circuit Diagram LNW21ASF000701-X Legend 1. Power supply 3. Signal 2. Ground...
Page 129 Engine Control System 1A-127 DTC33 - VIM Internal Fault (EEPROM Write Error) Circuit Description 4. Turn on the idle position switch for not less than 1 second but not more than 3 seconds. (Release the The EEPROM is a memory device mounted inside the accelerator pedal.) VIM and counts the accumulated number of starter 5.
Page 130 1A-128 Engine Control System Step Action Value(s) Check the VIM ground circuit for open wiring. Starter switch "OFF". Disconnect the VIM. Pins 39/52/ 60/66/73- Measure the resistance between VIM ground: 0 Ω connector pin and ground (e.g., frame or body) Was the resistance within range? Go to Step 6 Go to Step 5...
Page 131 Engine Control System 1A-129 DTC34 - ECM Internal Fault (Charge Circuit Fault) (Engine Control Module Cylinder 4 Cylinder 1 Cylinder 2 Cylinder 3 LNW21AMF007001-X Circuit Description following steps. 1. Turn off the idle position switch for not less than 1 The charge circuit in the ECM steps up the voltage for second but not more than 3 seconds.
Page 132 1A-130 Engine Control System Diagnostic Aids OK, observe the display on Tech 2 while moving connectors and wiring harnesses related to the Poor connection or damaged harness may cause sensor. A change in the display will indicate the intermittents. Check for the following conditions and, if location of the fault.
Page 133 Engine Control System 1A-131 Step Action Value(s) Check DTC34 will not be set again. Using Tech 2, clear the DTC. — Refer to Perform test run and review the DTC. Diagnostic Aids Repair is Is DTC34 detected? and go to Step 1 complete...
Page 134 1A-132 Engine Control System DTC35 - VIM Internal Fault (A/D Conversion Fault) Circuit Description 3. Turn off the idle position switch for not less than 1 second but not more than 3 seconds. (Press the The VIM converts analog signals (voltage signals) input accelerator pedal.) from various sensors into digital signals to perform 4.
Page 135 Engine Control System 1A-133 Step Action Value(s) Check the VIM ground circuit for open wiring. Starter switch "OFF". Disconnect the VIM. Pins 39/52/ 60/66/73- Measure the resistance between VIM ground: 0 Ω connector pin and ground (e.g., frame or body) Was the resistance within range? Go to Step 6 Go to Step 5...
Page 136 1A-134 Engine Control System DTC43 - ITP Sensor System Fault (Engine Control Module) 8 27 26 63 66 6764 EGR Valve Common Sensor Sensor Sensor Position Rail Sensor Pressure Sensor LNW21AMF006901-X Circuit Description Conditions for Clearing MIL/DTC The ITP (intake throttle position) sensor sends the When the system fails and the DTC is stored to the voltage signal that alters in response to the change in ECM, even repairing the faulty portion will not clear the...
Page 137 Engine Control System 1A-135 Diagnostic Aids Test Description Poor connection or damaged harness may cause Number(s) below refer to the step number(s) on the intermittents. Check for the following conditions and, if Diagnostic Chart. the fault is detected, repair or replace the faulty portion. 3.
Page 138 1A-136 Engine Control System Step Action Value(s) Check the circuit ground common or common Pins 64-63 power circuit to ITP, EGR position and (not jumpered): ∞ Ω common rail pressure sensors for open wiring or short. Pins 64- ground Starter switch "OFF". (jumpered): Disconnect the ECM.
Page 139 Engine Control System 1A-137 Step Action Value(s) Check the between ECM to ITP sensor Pins 69-64 harness for open wiring or short. (jumpered: 1-2): 0 Ω Starter switch "OFF". (not jumpered): Disconnect the ECM. ∞ Ω Disconnect the Intake throttle connector. Pins 69-63 Jumper the Intake throttle connector and (jumpered:...
Page 140 1A-138 Engine Control System Intake Throttle Valve Description LNW21ASF002101 Legend 1. Throttle valve 6. Sensor signal 2. ITP sensor 7. Motor (–) 3. Reduction gears 8. Sensor power 4. DC motor 9. Motor (+) 5. Sensor ground...
Page 141 Engine Control System 1A-139 DTC44 - EGR Valve Position Sensor System Fault (Engine Control Module) 8 27 26 63 66 6764 EGR Valve Common Sensor Sensor Sensor Position Rail Sensor Pressure Sensor LNW21AMF006901-X Circuit Description Conditions for Clearing MIL/DTC The EGR valve position sensor sends the voltage When the system fails and the DTC is stored to the signal that alters in response to the change in EGR ECM, even repairing the faulty portion will not clear the...
Page 142 1A-140 Engine Control System Diagnostic Aids Test Description Poor connection or damaged harness may cause Number(s) below refer to the step number(s) on the intermittents. Check for the following conditions and, if Diagnostic Chart. the fault is detected, repair or replace the faulty portion. 3.
Page 143 Engine Control System 1A-141 Step Action Value(s) Check the circuit ground common or common Pins 64-63 power circuit to ITP sensor, EGR position (not jumpered): ∞ Ω sensor and common rail pressure sensors for open wiring or short. Pin 64- ground Starter switch "OFF".
Page 144 1A-142 Engine Control System Step Action Value(s) Check the EGR valve position sensor circuit Pins 63-64 harness for open wiring or short. (jumpered: pins 1-2): 0 Ω Starter switch "OFF". (not jumpered): Disconnect the ECM. ∞ Ω Disconnect the EGR valve connector. Pins 64-68 Jumper the EGR vale connector pin and (jumpered:...
Page 145 Engine Control System 1A-143 Step Action Value(s) Check DTC44 will not be set again. Using Tech 2, clear the DTC. — Refer to Perform test run and review the DTC. Diagnostic Aids Repair is Is DTC44 detected? and go to Step 2 complete EGR Valve Description LNW21ASF002201...
Page 146 1A-144 Engine Control System DTC45 - EGR Valve System Fault (Engine Control Module) Intake Throttle DC Motor DC Motor LNW21AMF007301-X Circuit Description Conditions for Clearing MIL/DTC The EGR valve is operated by the DC motor. The DC When the system fails and the DTC is stored to the motor changes the drive duty to operate the valve, and ECM, even repairing the faulty portion will not clear the increasing the duty opens the valve while decreasing...
Page 147 Engine Control System 1A-145 Diagnostic Aids connectors and wiring harnesses related to the sensor. A change in the display will indicate the Poor connection or damaged harness may cause location of the fault. intermittents. Check for the following conditions and, if the fault is detected, repair or replace the faulty portion.
Page 148 1A-146 Engine Control System Step Action Value(s) Replace the EGR valve (EGR DC motor). Verify repair and — Is the action complete? go to Step 10 — Review the DTC. Certainly connect the EGR valve position sensor and ECM connectors. —...
Page 149 Engine Control System 1A-147 DTC46 - Exhaust Brake System Fault 100A Battery Key SW Key SW (START) (ON) # 22 # 19 Main Relay 0.5 L/Y 0.5 L/Y Exhaust Exhaust Glow Brake Brake Relay Lamp Lamp 1.25 1.25 1.25 0.85 BR/W LG/B 0.5R...
Page 150 1A-148 Engine Control System 1. Turn off the idle position switch for not less than 1 Diagnostic Aids second but not more than 3 seconds. (Press the Poor connection or damaged harness may cause accelerator pedal.) intermittents. Check for the following conditions and, if 2.
Page 151 Engine Control System 1A-149 Step Action Value(s) Check the exhaust brake solenoid valve circuit. Pins 2- ground Starter switch "OFF". (jumpered: Disconnect the VIM. pins 2- Jumper the solenoid valve connector and ground): 0 Ω measure the resistance at the VIM (not jumpered): connector.
Page 152 1A-150 Engine Control System DTC51 - ECM Internal Fault (CPU Error / CPU History Error) Circuit Description 3. Turn off the idle position switch for not less than 1 second but not more than 3 seconds. (Press the The CPU is a processor mounted in the ECM and accelerator pedal.) receives and processes signals from sensors and 4.
Page 153 Engine Control System 1A-151 Step Action Value(s) Check the ECM ground circuit for open wiring. Starter switch "OFF". Disconnect the ECM. Pins 87/95/ 119/120/121- Measure the resistance between ECM ground: 0 Ω connector pin and ground (e.g., frame or body) Was the resistance within range? Go to Step 6 Go to Step 5...
Page 154 1A-152 Engine Control System DTC52 - ECM Internal Fault (Sub CPU Error) Circuit Description 3. Turn off the idle position switch for not less than 1 second but not more than 3 seconds. (Press the The sub CPU monitors the CPU in the ECM and accelerator pedal.) detects fault(s) of the CPU.
Page 155 Engine Control System 1A-153 Step Action Value(s) Check the ECM ground circuit for open wiring. Starter switch "OFF". Disconnect the ECM. Pins 87/95/ 119/120/121- Measure the resistance between ECM ground: 0 Ω connector pin and ground (e.g., frame or body) Was the resistance within range? Go to Step 6 Go to Step 5...
Page 156 1A-154 Engine Control System DTC61 - Intake Throttle Valve System Fault (Engine Control Module) Intake Throttle DC Motor DC Motor LNW21AMF007301-X Circuit Description Conditions for Clearing MIL/DTC The intake throttle valve is operated by the DC motor. When the system fails and the DTC is stored to the The DC motor operates the intake throttle valve by ECM, even repairing the faulty portion will not clear the changing the drive voltage (duty).
Page 157 Engine Control System 1A-155 Diagnostic Aids connectors and wiring harnesses related to the sensor. A change in the display will indicate the Poor connection or damaged harness may cause location of the fault. intermittents. Check for the following conditions and, if the fault is detected, repair or replace the faulty portion.
Page 158 1A-156 Engine Control System Step Action Value(s) Replace the intake throttle (intake throttle DC motor). — Verify repair and Is the action complete? go to Step 10 — Review the DTC. Certainly connect the intake throttle and ECM connectors. — Using Tech 2, clear the DTC.
Page 159 Engine Control System 1A-157 DTC71 - Barometric Pressure Sensor Fault Circuit Description 4. Turn on the idle position switch for not less than 1 second but not more than 3 seconds. (Release the The atmospheric (barometric) pressure sensor is accelerator pedal.) installed inside the ECM and converts the atmospheric 5.
Page 160 1A-158 Engine Control System Step Action Value(s) Review the DTC. Using Tech 2, check and store the DTC. Clear the DTC. Start the engine. Run the engine at idle — for 1 minute. Review the DTC. Refer to Is DTC71 detected? Go to Step 4 Diagnostic Aids Replace the VIM.
Page 161 Engine Control System 1A-159 DTC81 - Clutch Switch System Fault 100A Battery Key SW Main Relay (START) (ON) # 19 # 22 Torque Exhaust M/T : N Warm Clutch Freezer Brake A/T : P or N 0.85 L/B Vehicle Vehicle 0.85 0.5 LG/L BR/R...
Page 162 1A-160 Engine Control System 4. Turn on the idle position switch for not less than 1 the fault is detected, repair or replace the faulty portion. second but not more than 3 seconds. (Release the • Poor connection VIM: Inspect harness accelerator pedal.) connectors for backed-out pins, improper mating,...
Page 163 Engine Control System 1A-161 Step Action Value(s) Check the clutch switch circuit for open wiring. Starter switch "OFF", and disconnect the VIM. Disconnect the clutch switch connector and jumper it. Pins 49- Starter switch "ON". ground: 24 V Measure voltage between connector pin and ground (e.g., frame or body)
Page 164 1A-162 Engine Control System Step Action Value(s) Review the DTC. Certainly connect the clutch switch and VIM connectors. — Using Tech 2, clear the DTC. Perform test run and review the DTC. Refer to Is DTC81 detected? Go to Step 14 Diagnostic Aids Replace the VIM.
Page 165 Engine Control System 1A-163 DTC82 - Neutral Switch System Fault 100A Battery Key SW Main Relay (START) (ON) # 19 # 22 Torque Exhaust M/T : N Warm Clutch Freezer Brake A/T : P or N 0.85 L/B Vehicle Vehicle 0.85 0.5 LG/L BR/R...
Page 166 1A-164 Engine Control System 2. Turn on the idle position switch for not less than 1 Diagnostic Aids second but not more than 3 seconds. (Release the Poor connection or damaged harness may cause accelerator pedal.) intermittents. Check for the following conditions and, if 3.
Page 167 Engine Control System 1A-165 Step Action Value(s) Check the neutral (P/N) switch circuit for short. Starter switch "OFF", and disconnect the VIM. Disconnect the neutral switch connector. Pins 44- Starter switch "ON". ground: 0 V Measure voltage between connector pin and ground (e.g., frame or body) Was the voltage within range? Go to Step 6...
Page 168 1A-166 Engine Control System DTC84 - CAN Communication Fault (CAN Bus Error) (Engine Control Module) LNW21AMF007601-X Circuit Description 2. Turn on the idle position switch for not less than 1 second but not more than 3 seconds. (Release the Mutual communications (CAN communications) are accelerator pedal.) established between ECM and VIM so that the data 3.
Page 169 Engine Control System 1A-167 Diagnostic Aids connectors and wiring harnesses related to the sensor. A change in the display will indicate the Poor connection or damaged harness may cause location of the fault. intermittents. Check for the following conditions and, if the fault is detected, repair or replace the faulty portion.
Page 170 1A-168 Engine Control System Step Action Value(s) Replace the ECM. IMPORTANT: If necessary (for the vehicle equipped with — idle stop function), input the number of startups to the replacing ECM. Verify repair and Is the action complete? go to Step 7 —...
Page 171 Engine Control System 1A-169 DTC86 - CAN Communication Fault (CAN Timeout Error) (Engine Control Module) LNW21AMF007601-X Circuit Description 2. Turn on the idle position switch for not less than 1 second but not more than 3 seconds. (Release the Mutual communications (CAN communications) are accelerator pedal.) established between ECM and VIM so that the data 3.
Page 172 1A-170 Engine Control System Diagnostic Aids connectors and wiring harnesses related to the sensor. A change in the display will indicate the Poor connection or damaged harness may cause location of the fault. intermittents. Check for the following conditions and, if the fault is detected, repair or replace the faulty portion.
Page 173 Engine Control System 1A-171 Step Action Value(s) Replace the ECM. IMPORTANT: If necessary (for the vehicle equipped with — idle stop function), input the number of startups to the replacing ECM. Verify repair and Is the action complete? go to Step 7 —...
Page 174 1A-172 Engine Control System DTC115 - Common Rail Pressure Sensor Fixed Output Fault LNW21AMF005401 Legend 1. Fuel tank 6. Common rail 2. Fuel filter 7. Common rail pressure sensor 3. Supply pump 8. Injector 4. SCV (suction control valve) 9. ECM (engine control module) 5.
Page 175 Engine Control System 1A-173 (Engine Control Module) 8 27 26 63 66 6764 EGR Valve Common Sensor Sensor Sensor Position Rail Sensor Pressure Sensor LNW21AMF006901-X Circuit Description Action Taken When the DTC Sets The common rail pressure sensor detects the fuel •...
Page 176 1A-174 Engine Control System 7. Turn off the starter switch. Wait for 5 seconds and Test Description turn on the starter switch again. 5. When the common rail pressure sensor harness and When Tech 2 has been connected to the vehicle, the other sensor harness are shorted, DTC245 may not be DTC can be cleared through the memory clear set.
Page 177 Engine Control System 1A-175 Step Action Value(s) Check the common rail pressure sensor Pins 63-66/ 67: ∞ Ω circuit harness for open wiring or short. Pins 66/67- Starter switch "OFF". 64: ∞ Ω Disconnect the ECM. Pins 63-64: Disconnect the common rail pressure ∞...
Page 178 1A-176 Engine Control System Step Action Value(s) Replace the supply pump. — Is the action complete? Go to Step 15 — Check DTC115 will not be set again. Restore the vehicle. Bleed the air from the fuel system. — Using Tech 2, clear the DTC. Perform test run and review the DTC.
Page 179 Engine Control System 1A-177 DTC118 - Common Rail Pressure Fault (Control System) LNW21AMF005401 Legend 1. Fuel tank 6. Common rail 2. Fuel filter 7. Common rail pressure sensor 3. Supply pump 8. Injector 4. SCV (suction control valve) 9. ECM (engine control module) 5.
Page 180 1A-178 Engine Control System (Engine Control Module) 8 27 26 63 66 6764 EGR Valve Common Sensor Sensor Sensor Position Rail Sensor Pressure Sensor LNW21AMF006901-X Circuit Description Conditions for Clearing MIL/DTC The common rail pressure is detected by the common When the system fails and the DTC is stored to the rail pressure sensor and sent to the ECM.
Page 181 Engine Control System 1A-179 Diagnostic Aids Test Description When the air mixes into the fuel system, the fuel 3. When the flow damper has been working, it will be pressure (common rail pressure) may read incorrect returned to the ordinary condition only after left inactive value.
Page 182 1A-180 Engine Control System Step Action Value(s) Check the common rail pressure. Engine off: Desired Install Tech 2. pressure - Starter switch "ON". 0 MPa Observe "Desired Rail Pressure" and Actual "Actual Rail Pressure" displays. pressure - Start the engine. Run the engine at idle 0 MPa for warm-up.
Page 183 Engine Control System 1A-181 Step Action Value(s) Replace the common rail (common rail pressure sensor). — Verify repair and Is the action complete? go to Step 18 — Review the DTC. Restore the vehicle. Bleed the air from the fuel system. —...
Page 184 1A-182 Engine Control System DTC158 - Injector Power Supply System Short (Common 1) (Engine Control Module Cylinder 4 Cylinder 1 Cylinder 2 Cylinder 3 LNW21AMF007001-X Circuit Description Conditions for Clearing MIL/DTC The common 1 injector drive circuit is a high-voltage When the system fails and the DTC is stored to the system and drives injectors installed to cylinders 1 and ECM, even repairing the faulty portion will not clear the...
Page 185 Engine Control System 1A-183 Diagnostic Aids connectors and wiring harnesses related to the sensor. A change in the display will indicate the Poor connection or damaged harness may cause location of the fault. intermittents. Check for the following conditions and, if the fault is detected, repair or replace the faulty portion.
Page 186 1A-184 Engine Control System Step Action Value(s) Check the intermediate connector for fault. Pins 1-2/3/4 (jumpered: Disconnect ECM side and injector side pins 1-2/3/4): connectors from intermediate 0 Ω connector. (not jumpered): Remove the intermediate connector from ∞ Ω the engine block. Pins 2-3/4 Jumper the intermediate connector that (jumpered:...
Page 187 Engine Control System 1A-185 Step Action Value(s) Replace the ECM. IMPORTANT: If necessary (for the vehicle equipped with — idle stop function), input the number of startups to the replacing ECM. Verify repair and Is the action complete? go to Step 16 —...
Page 188 1A-186 Engine Control System DTC159 - Injector Power Supply System Short (Common 2) (Engine Control Module Cylinder 4 Cylinder 1 Cylinder 2 Cylinder 3 LNW21AMF007001-X Circuit Description Conditions for Clearing MIL/DTC The common 2 injector drive circuit is a high-voltage When the system fails and the DTC is stored to the system and drives injectors installed to cylinders 2 and ECM, even repairing the faulty portion will not clear the...
Page 189 Engine Control System 1A-187 Diagnostic Aids connectors and wiring harnesses related to the sensor. A change in the display will indicate the Poor connection or damaged harness may cause location of the fault. intermittents. Check for the following conditions and, if the fault is detected, repair or replace the faulty portion.
Page 190 1A-188 Engine Control System Step Action Value(s) Check the intermediate connector for fault. Pins 1-2/3/4 (jumpered: Disconnect ECM side and injector side pins 1-2/3/4): connectors from intermediate 0 Ω connector. (not jumpered): Remove the intermediate connector from ∞ Ω the engine block. Pins 2-3/4 Jumper the intermediate connector that (jumpered:...
Page 191 Engine Control System 1A-189 Step Action Value(s) Replace the ECM. IMPORTANT: If necessary (for the vehicle equipped with — idle stop function), input the number of startups to the replacing ECM. Verify repair and Is the action complete? go to Step 16 —...
Page 192 1A-190 Engine Control System DTC211 - Fuel Temperature Sensor System Fault (Engine Control Module) 49 46 Sensor Sensor LNW21AMF007101-X Circuit Description Conditions for Clearing MIL/DTC The FT (fuel temperature) sensor consists of thermistor When the system fails and the DTC is stored to the and alters the resistance in response to temperature ECM, even repairing the faulty portion will not clear the change.
Page 193 Engine Control System 1A-191 Diagnostic Aids Test Description Poor connection or damaged harness may cause Number(s) below refer to the step number(s) on the intermittents. Check for the following conditions and, if Diagnostic Chart. the fault is detected, repair or replace the faulty portion. 3.
Page 194 1A-192 Engine Control System Step Action Value(s) Repair or replace the faulty harness. Verify repair and — Is the action complete? go to Step 9 — Review the DTC. Certainly connect the FT sensor and ECM connectors. — Using Tech 2, clear the DTC. Perform test run and review the DTC.
Page 195 Engine Control System 1A-193 Step Action Value(s) Check the FT sensor. Disconnect the FT sensor. Provide temperature change on the thermosensitive element of the FT sensor See graph and measure the resistance between the sensor connector pins. Was the resistance within range? Go to Step 19 Go to Step 18 Replace the supply pump (FT sensor).
Page 196 1A-194 Engine Control System Characteristics of FT Sensor (reference) 20 40 60 80 100120 Temperature ( C) LNW21ASH010401-X Sensor Description LNW21ASF002601 Legend 1. FT sensor signal 5. SCV 2. FT sensor ground 6. SCV (HI) 3. FT sensor 7. SCV (LO) 4.
Page 197 Engine Control System 1A-195 DTC217 - SCV Drive System Short (Engine Control Module) 75 74 81 80 LNW21AMF007201-X Circuit Description Action Taken When the DTC Sets The SCV (suction control valve) is installed to the • After the DTC is set, the ECM will illuminate the supply pump and controls the suction fuel quantity.
Page 198 1A-196 Engine Control System 5. Turn off the idle position switch for not less than 1 intermittents. Check for the following conditions and, if second but not more than 3 seconds. (Press the the fault is detected, repair or replace the faulty portion. accelerator pedal.) •...
Page 199 Engine Control System 1A-197 Step Action Value(s) Review the DTC. Certainly connect the SCV and ECM connectors. — Using Tech 2, clear the DTC. Perform test run and review the DTC. Refer to Is DTC217 detected? Go to Step 10 Diagnostic Aids Replace the ECM.
Page 200 1A-198 Engine Control System DTC227 - No Pump Pressure Feed (Fuel Leak) LNW21AMF005401 Legend 1. Fuel tank 6. Common rail 2. Fuel filter 7. Common rail pressure sensor 3. Supply pump 8. Injector 4. SCV (suction control valve) 9. ECM (engine control module) 5.
Page 201 Engine Control System 1A-199 (Engine Control Module) 8 27 26 63 66 6764 EGR Valve Common Sensor Sensor Sensor Position Rail Sensor Pressure Sensor LNW21AMF006901-X Circuit Description 1. Turn off the idle position switch for not less than 1 second but not more than 3 seconds. (Press the The pump pressure is controlled with the common rail accelerator pedal.) pressure.
Page 202 1A-200 Engine Control System Test Description 3. When the flow damper has been working, it will be returned to the ordinary condition only after left inactive overnight. Step Action Value(s) Perform the "On-Board Diagnostic (OBD) Refer to OBD System Check". —...
Page 203 Engine Control System 1A-201 Step Action Value(s) Check the common rail pressure. Engine off: Desired Install Tech 2. pressure - Starter switch "ON". 0 MPa Observe "Desired Rail Pressure" and Actual "Actual Rail Pressure" displays. pressure - Start the engine. Run the engine at idle 0 MPa for warm-up.
Page 204 1A-202 Engine Control System Step Action Value(s) Replace the common rail (common rail pressure sensor). — Verify repair and Is the action complete? go to Step 18 — Review the DTC. Restore the vehicle. Bleed the air from the fuel system. —...
Page 205 Engine Control System 1A-203 DTC241 - Idle Position Switch Circuit Open Wiring (Engine Control Module) 90 84 94 108 Idle Switch Sensor LNW21AMF007501-X Circuit Description • In case of AP sensor fault, the ECM controls the powertrain using the set accelerator position (20 The idle position switch is installed to the accelerator pedal, and is turned off when the pedal is pressed and turned on when the pedal is released.
Page 206 1A-204 Engine Control System When Tech 2 has been connected to the vehicle, the • Damaged harness: Inspect the wiring harness for DTC can be cleared through the memory clear rubbed-through wire insulation or wire broken operation with Tech 2. inside the insulator.
Page 207 Engine Control System 1A-205 Step Action Value(s) Check the idle position switch circuit (switch to switch connector) for open wiring. Switch-on (switch is Disconnect idle position switch released): connector. 50 Ω, max. Measure the resistance between the idle Switch-off position switch connector pins while (switch is operating the switch with a finger.
Page 208 1A-206 Engine Control System DTC242 - Idle Position Switch Circuit Short (Engine Control Module) 90 84 94 108 Idle Switch Sensor LNW21AMF007501-X Circuit Description • In case of AP sensor fault, the ECM controls the powertrain using the set accelerator position (20 The idle position switch is installed to the accelerator pedal, and is turned off when the pedal is pressed and turned on when the pedal is released.
Page 209 Engine Control System 1A-207 When Tech 2 has been connected to the vehicle, the • Damaged harness: Inspect the wiring harness for DTC can be cleared through the memory clear rubbed-through wire insulation or wire broken operation with Tech 2. inside the insulator.
Page 210 1A-208 Engine Control System Step Action Value(s) Check the idle position switch circuit (switch to switch connector) for short. Switch-on (switch is Disconnect idle position switch released): connector. 50 Ω, max. Measure the resistance between the idle Switch-off position switch connector pins while (switch is operating the switch with a finger.
Page 211 Engine Control System 1A-209 DTC245 - Common Rail Pressure Sensor System Fault (Engine Control Module) 8 27 26 63 66 6764 EGR Valve Common Sensor Sensor Sensor Position Rail Sensor Pressure Sensor LNW21AMF006901-X Circuit Description • The common rail pressure and fuel injection quantity are limited.
Page 212 1A-210 Engine Control System 6. After the above operations are properly completed, OK, observe the display on Tech 2 while moving the CHECK ENGINE lamp (MIL) illuminates for 3 connectors and wiring harnesses related to the seconds to report the memory is cleared. sensor.
Page 213 Engine Control System 1A-211 Step Action Value(s) Check the circuit ground common or common Pins 64-63 power circuit harness to ITP sensor, EGR (not jumpered): ∞ Ω position sensor and common rail pressure sensors for open wiring or short. Pins 64- ground Starter switch "OFF".
Page 214 1A-212 Engine Control System Step Action Value(s) Check the common rail pressure sensor Pins 64-66/67 circuit harness for open wiring or short. (jumpered: pins 1-2): 0 Ω Starter switch "OFF". (not jumpered): Disconnect the ECM. ∞ Ω Disconnect the common rail pressure Pins 66/67-63 sensor connector.
Page 215 Engine Control System 1A-213 Step Action Value(s) Review the DTC. Certainly connect common rail pressure sensor and ECM connectors. — Using Tech 2, clear the DTC. Perform test run and review the DTC. Refer to Is DTC245 detected? Go to Step 19 Diagnostic Aids Replace the ECM.
Page 216 1A-214 Engine Control System Sensor Description LNW21ASF002901 Legend 1. Pressure limiter 4. Sensor signal 2. Common rail pressure sensor 5. Sensor power 3. Sensor ground...
Page 217 Engine Control System 1A-215 DTC247 - SCV Drive System Fault (Engine Control Module) 75 74 81 80 LNW21AMF007201-X Circuit Description SCV– and ECM, short to ground between SCV– and ECM, or open wiring between SCV and ECM is not The SCV (suction control valve) is installed to the detected.) supply pump and controls the suction fuel quantity.
Page 218 1A-216 Engine Control System 4. Turn on the idle position switch for not less than 1 • Poor connection ECM: Inspect harness second but not more than 3 seconds. (Release the connectors for backed-out pins, improper mating, accelerator pedal.) broken locks, improperly formed or damaged pins, and poor pin-to-wire connection.
Page 219 Engine Control System 1A-217 Step Action Value(s) Check the SCV. At the SCV connector pins, measure the 8 Ω resistance. Was the resistance within range? Go to Step 10 Go to Step 8 Replace the supply pump (SCV). Verify repair and —...
Page 220 1A-218 Engine Control System SCV Description LNW21ASF002601 Legend 1. FT sensor signal 5. SCV 2. FT sensor ground 6. SCV (HI) 3. FT sensor 7. SCV (LO) 4. Camshaft...
Page 221 Engine Control System 1A-219 DTC271 - Cylinder 1 (Injector Drive System) Fault (Engine Control Module Cylinder 4 Cylinder 1 Cylinder 2 Cylinder 3 LNW21AMF007001-X Circuit Description • Fuel injection at cylinder 1 (injector #1) is terminated. The injector drive circuit is a low-voltage system and drives injectors.
Page 222 1A-220 Engine Control System When Tech 2 has been connected to the vehicle, the inside the insulator. If the harness appears to be DTC can be cleared through the memory clear OK, observe the display on Tech 2 while moving operation with Tech 2.
Page 223 Engine Control System 1A-221 Step Action Value(s) Check the intermediate connector for fault. Pins 5-6/7/8 (jumpered: Disconnect ECM side and injector side pins 5-6/7/8): connectors from intermediate 0 Ω connector. (not jumpered): Remove the intermediate connector from ∞ Ω the engine block. Pins 6-7/8 Jumper the intermediate connector that (jumpered:...
Page 224 1A-222 Engine Control System Step Action Value(s) Replace the ECM. IMPORTANT: If necessary (for the vehicle equipped with — idle stop function), input the number of startups to the replacing ECM. Verify repair and Is the action complete? go to Step 16 —...
Page 225 Engine Control System 1A-223 DTC272 - Cylinder 2 (Injector Drive System) Fault (Engine Control Module Cylinder 4 Cylinder 1 Cylinder 2 Cylinder 3 LNW21AMF007001-X Circuit Description • Fuel injection at cylinder 2 (injector #4) is terminated. The injector drive circuit is a low-voltage system and drives injectors.
Page 226 1A-224 Engine Control System When Tech 2 has been connected to the vehicle, the inside the insulator. If the harness appears to be DTC can be cleared through the memory clear OK, observe the display on Tech 2 while moving operation with Tech 2.
Page 227 Engine Control System 1A-225 Step Action Value(s) Check the intermediate connector for fault. Pins 5-6/7/8 (jumpered: Disconnect ECM side and injector side pins 5-6/7/8): connectors from intermediate 0 Ω connector. (not jumpered): Remove the intermediate connector from ∞ Ω the engine block. Pins 6-7/8 Jumper the intermediate connector that (jumpered:...
Page 228 1A-226 Engine Control System Step Action Value(s) Replace the ECM. IMPORTANT: If necessary (for the vehicle equipped with — idle stop function), input the number of startups to the replacing ECM. Verify repair and Is the action complete? go to Step 16 —...
Page 229 Engine Control System 1A-227 DTC273 - Cylinder 3 (Injector Drive System) Fault (Engine Control Module Cylinder 4 Cylinder 1 Cylinder 2 Cylinder 3 LNW21AMF007001-X Circuit Description • Fuel injection at cylinder 3 (injector #2) is terminated. The injector drive circuit is a low-voltage system and drives injectors.
Page 230 1A-228 Engine Control System When Tech 2 has been connected to the vehicle, the inside the insulator. If the harness appears to be DTC can be cleared through the memory clear OK, observe the display on Tech 2 while moving operation with Tech 2.
Page 231 Engine Control System 1A-229 Step Action Value(s) Check the intermediate connector for fault. Pins 5-6/7/8 (jumpered: Disconnect ECM side and injector side pins 5-6/7/8): connectors from intermediate 0 Ω connector. (not jumpered): Remove the intermediate connector from ∞ Ω the engine block. Pins 6-7/8 Jumper the intermediate connector that (jumpered:...
Page 232 1A-230 Engine Control System Step Action Value(s) Replace the ECM. IMPORTANT: If necessary (for the vehicle equipped with — idle stop function), input the number of startups to the replacing ECM. Verify repair and Is the action complete? go to Step 16 —...
Page 233 Engine Control System 1A-231 DTC274 - Cylinder 4 (Injector Drive System) Fault (Engine Control Module Cylinder 4 Cylinder 1 Cylinder 2 Cylinder 3 LNW21AMF007001-X Circuit Description • Fuel injection at cylinder 4 (injector #3) is terminated. The injector drive circuit is a low-voltage system and drives injectors.
Page 234 1A-232 Engine Control System When Tech 2 has been connected to the vehicle, the inside the insulator. If the harness appears to be DTC can be cleared through the memory clear OK, observe the display on Tech 2 while moving operation with Tech 2.
Page 235 Engine Control System 1A-233 Step Action Value(s) Check the intermediate connector for fault. Pins 5-6/7/8 (jumpered: Disconnect ECM side and injector side pins 5-6/7/8): connectors from intermediate 0 Ω connector. (not jumpered): Remove the intermediate connector from ∞ Ω the engine block. Pins 6-7/8 Jumper the intermediate connector that (jumpered:...
Page 236 1A-234 Engine Control System Step Action Value(s) Replace the ECM. IMPORTANT: If necessary (for the vehicle equipped with — idle stop function), input the number of startups to the replacing ECM. Verify repair and Is the action complete? go to Step 16 —...
Page 237 Engine Control System 1A-235 DTC277 - Injector Power Supply System Open Wiring Fault (Common 1) (Engine Control Module Cylinder 4 Cylinder 1 Cylinder 2 Cylinder 3 LNW21AMF007001-X Circuit Description Conditions for Clearing MIL/DTC The common 1 injector drive circuit is a high-voltage When the system fails and the DTC is stored to the system and drives injectors installed to cylinders 1 and ECM, even repairing the faulty portion will not clear the...
Page 238 1A-236 Engine Control System Diagnostic Aids • Damaged harness: Inspect the wiring harness for rubbed-through wire insulation or wire broken Poor connection or damaged harness may cause inside the insulator. If the harness appears to be intermittents. Check for the following conditions and, if OK, observe the display on Tech 2 while moving the fault is detected, repair or replace the faulty portion.
Page 239 Engine Control System 1A-237 Step Action Value(s) Replace the intermediate connector. — Is the action complete? Go to Step 14 — Check the common 1 injector drive circuit (intermediate connector to injector) for open wiring. Cylinder 1- Disconnect the injector side connector pins 1: from the intermediate connector.
Page 240 1A-238 Engine Control System Injector Description LNW21ASH010701 Legend 1. Injector 2. Power supply harness 3. Drive harness...
Page 241 Engine Control System 1A-239 DTC278 - Injector Power Supply System Open Wiring Fault (Common 2) (Engine Control Module Cylinder 4 Cylinder 1 Cylinder 2 Cylinder 3 LNW21AMF007001-X Circuit Description Conditions for Clearing MIL/DTC The common 2 injector drive circuit is a high-voltage When the system fails and the DTC is stored to the system and drives injectors installed to cylinders 2 and ECM, even repairing the faulty portion will not clear the...
Page 242 1A-240 Engine Control System Diagnostic Aids • Damaged harness: Inspect the wiring harness for rubbed-through wire insulation or wire broken Poor connection or damaged harness may cause inside the insulator. If the harness appears to be intermittents. Check for the following conditions and, if OK, observe the display on Tech 2 while moving the fault is detected, repair or replace the faulty portion.
Page 243 Engine Control System 1A-241 Step Action Value(s) Replace the intermediate connector. — Is the action complete? Go to Step 14 — Check the common 2 injector side connectors drive circuit (intermediate connector injector) for open wiring or short. Cylinder 2- Disconnect the injector side connector pins 2: from the intermediate connector.
Page 244 1A-242 Engine Control System Injector Description LNW21ASH010701 Legend 1. Injector 2. Power supply harness 3. Drive harness...
Page 245 Engine Control System 1A-243 DTC416 - Main Relay System Fault 100A 3W/L Battery (ST) (ON) 0.5B Glow Relay Main Relay Glow Relay 118 117 116 115 114 (Engine Control Module) 95 87 121 120 119 LNW21ALF005001-X Circuit Description Conditions for Clearing MIL/DTC The main relay engages and disengages supplying the When the system fails and the DTC is stored to the power supply voltage (24 V) to both the ECM and VIM,...
Page 246 1A-244 Engine Control System 6. After the above operations are properly completed, the fault is detected, repair or replace the faulty portion. the CHECK ENGINE lamp (MIL) illuminates for 3 • Poor connection ECM: Inspect harness seconds to report the memory is cleared. connectors for backed-out pins, improper mating, 7.
Page 247 Engine Control System 1A-245 Main Relay Description LNW21ASF002701 Legend 1. Contact 1 (battery side) 4. Contact 3 2. Contact 2 (ECM side) 5. Coil 2 (ECM side) 3. Coil 1 (battery side)
Page 248 1A-246 Engine Control System DTC417 - Starter Switch System Fault 100A 3W/L Battery (ST) (ON) 0.5B Glow Relay Main Relay Glow Relay 118 117 116 115 114 (Engine Control Module) 95 87 121 120 119 LNW21ALF005001-X Circuit Description Conditions for Clearing MIL/DTC The starter switch, after moved to the position "ST", is When the system fails and the DTC is stored to the turned on and activates the starter.
Page 249 Engine Control System 1A-247 6. After the above operations are properly completed, the fault is detected, repair or replace the faulty portion. the CHECK ENGINE lamp (MIL) illuminates for 3 • Poor connection ECM: Inspect harness seconds to report the memory is cleared. connectors for backed-out pins, improper mating, 7.
Page 250 1A-248 Engine Control System Step Action Value(s) Review the DTC. Certainly connect relay connector. — Using Tech 2, clear the DTC. Perform test run and review the DTC. Refer to Is DTC417 detected? Go to Step 8 Diagnostic Aids Replace the ECM. IMPORTANT: If necessary (for the vehicle equipped with —...
Page 251 Engine Control System 1A-249 DTC543 - High Engine Speed Error Circuit Description 4. Turn on the idle position switch for not less than 1 second but not more than 3 seconds. (Release the The ECM calculates engine speeds using the signals accelerator pedal.) from CKP and CMP sensors.
Page 252 1A-250 Engine Control System Step Action Value(s) Replace the ECM. IMPORTANT: If necessary (for the vehicle equipped with — idle stop function), input the number of startups to the replacing ECM. Verify repair and Is the action complete? go to Step 6 —...
Page 253 Engine Control System 1A-251 Symptom Diagnosis Chart 1 (1/2) Easy engine Poor startability Faulty idling stall Symptom Check item System voltage /Battery Atmospheric pressure sensor Pump assembly D-10 FT sensor Common rail pressure sensor Common rail / flow damper / D-14 pressure limiter Injector...
Page 254 1A-252 Engine Control System Symptom Diagnosis Chart 1 (2/2) Easy engine Poor startability Faulty idling stall Symptom Check item EGR system Exhaust brake Catalyst Starter switch Starter cut relay Starter relay Starter D-13 AP sensor Idle position sensor VS sensor Idle up volume Freezer switch QWS switch...
Page 255 Engine Control System 1A-253 Symptom Diagnosis Chart 2 Inspection method A: sensor system Common rail pressure sensor 1. With the starter switch turned on and engine warmed up, observe "Desired Rail Pressure" and "Actual Rail Pressure" displays on Tech 2. Reference value: Starter switch ON: 0 MPa Engine warmed up: approx.
Page 256 1A-254 Engine Control System Refrigerator switch (N/C) 1. Move the starter switch to the "OFF" position and observe QWS switch (N/O) the display for each switch. A/C switch (N/O) 2. When any of the switches is not turned off, check the switch PTO switch (N/O) circuit and the single switch for short.
Page 257 Engine Control System 1A-255 1. Install Tech 2 and display the data list. 2. If the data does not appear or the displayed data is incorrect, perform the "On-Board Diagnostic (OBD) System Check". D: Engine mechanical system Valve clearance 1. Using tools, measure and adjust the valve clearance. (Refer to "Functional Check"...
Page 258 1A-256 Engine Control System 13 Starter 1. Check the starter for motor rotation and pinion projection. (Refer to "Starter" in "Electrical System".) 14 Common rail / flow damper / pressure limiter 1. Check the flow damper or pressure limiter is not working. 2.
Page 259 Engine Control System 1A-257 Wiring Harness Repair: Shielded Cable Removal Procedure 3. Wrap the splice with mylar and with the drain (uninsulated) wire. 1. Remove the outer jacket. 2. Unwrap the aluminum/mylar tape. Do not remove the mylar. LNW21ASH004401 4. Tape over the whole bundle to secure. LNW21ASH004201 3.
Page 260 1A-258 Engine Control System Twisted Leads Removal Procedure 2. Cover the splice with tape in order to insulate it from the other wires. 1. Locate the damaged wire. 2. Remove the insulation as required. LNW21ASH004801 LNW21ASH004701 3. Twist the wires as they were before starting this procedure.
Page 261 Engine Control System 1A-259 4. Tape the wires with electrical tape. Hold in place. LNW21ASH005101...
Page 262 1A-260 Engine Control System Weather-Pack Connector Removal Procedure 3. Cut the wire immediately behind the cable seal. A Weather-Pack connector can be identified by a rubber seal at the rear of the connector. This engine room connector protects against moisture and dirt, which could form oxidation and deposits on the pins.
Page 263 Engine Control System 1A-261 5. Push the pin and the connector to engage the 6. Close the secondary locking hinge. locking tangs. LNW21ASH005401 Special Tools Tool No. Illustration Tool name 5-8840-0388-0 Weather-Pack Terminal Remover...
Page 264 1A-262 Engine Control System Com-Pack III General Information The Com-Pack III pin looks similar to some Weather- Pack pins. This pin is not sealed and is used where resistance to the environment is not required. Use the standard method when repairing a pin. Do not use the Weather-Pack Terminal tool...
Page 265 Engine Control System 1A-263 Metri-Pack Removal Procedure Installation Procedure Metri-Pack pins are also referred to as "pull-to-seat" Some connectors use pins called Metri-Pack Series pins. 150. These may be used at the engine coolant temperature (ECT) sensor. 1. In order to install a pin onto a wire, the wire must be inserted through the seal (2) and through the 1.
Page 266 You are requested to order this manual using the manual number that is shown above. All rights reserved. This manual may not be reproduced in whole or in part, without the permission in writing of ISUZU MOTORS LIMITED. Issued by ISUZU MOTORS LIMITED INTERNATIONAL SERVICE DEPARTMENT Tokyo, Japan First edition Nov., 2002...
Page 267 No.LG4HL-WE-0229DOM...

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