Engine Emission: Workshop Manual

WORKSHOP MANUAL
F&G-SERIES
ENGINE EMISSION
6SD1-TC
SECTION 6E
International Service & Parts

Tokyo, Japan
Contents
Chapter 1 Overview of IE system Checking the parking switch . . . . . . . . . . . . 3-46

1. Overview and specifications of IE system. . . . . 1-2 Idling speed cannot be adjusted . . . . . . . . . . 3-51
Overview of IE system . . . . . . . . . . . . . . . . 1-2 Idling speed cannot be decreased . . . . . . . . . 3-53
Specifications of IE system . . . . . . . . . . . . 1-2
Electronically controlled fuel injection system Chapter 4 Checking procedure for each
(common-rail type) . . . . . . . . . . . . . . . . . 1-3 diagnostic trouble code
VGS (Variable Geometry Turbo System) . 1-5 Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Output of idle position signal to brake intensive 14 G sensor system trouble . . . . . . . . . . . . . . 4-3
control unit. . . . . . . . . . . . . . . . . . . . . . . . 1-7 15 NE sensor system trouble . . . . . . . . . . . . . 4-8
Output of engine rotations to tachometer . . 1-7 22 Atmospheric temperature sensor system
External view of engine control unit . . . . . 1-8 trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Engine control unit input/output list. . . . . . 1-9 23 Water temperature sensor system trouble. . 4-19
2. IE system schematic connection diagram . . 1-11 24 Accelerator sensor system trouble . . . . . 4-25
3. Control unit/sensor/switch installing position. 1-13 25 Vehicle speed sensor system trouble . . . . 4-31
4. Functions of input/output and vehicle behavior 32 Boost sensor system trouble . . . . . . . . . . 4-38
upon failure (influence) . . . . . . . . . . . . . . 1-18 33 CPU monitoring IC trouble. . . . . . . . . . . 4-44
5. Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 35 A/D conversion error/charger
Object and procedure for accelerator learning circuit trouble . . . . . . . . . . . . . . . . . . . . . 4-46
(learning of accelerator pedal idling position 42 High boost trouble. . . . . . . . . . . . . . . . . . 4-48
and full-throttle position) . . . . . . . . . . . 1-20 65 Low boost trouble . . . . . . . . . . . . . . . . . . 4-54
Q adjustment data. . . . . . . . . . . . . . . . . . . 1-21 71 Atmospheric pressure sensor trouble . . . 4-60
115 Fuel pressure sensor output fixed . . . . . 4-62
Chapter 2 Failure Diagnosis 118 Common-rail pressure trouble. . . . . . . . 4-67
1. Self-diagnosis of IE system . . . . . . . . . . . . 2-2 151 Common rail pressure trouble
Method of checking the diagnostic trouble (pump excessive pressure feed) . . . . . . . 4-74
code by SERVICE ENGINE SOON lamp 158 TWV power system trouble (Common 1
and multi- warning (engine control "Injector 1, 3, 5 Systems") . . . . . . . . . . . 4-81
indication) . . . . . . . . . . . . . . . . . . . . . . . . 2-2 159 TWV power system trouble (Common 2
Erasing the diagnostic trouble code by memory "Injector 2, 4, 6 Systems") . . . . . . . . . . . 4-86
clear switch (connector) . . . . . . . . . . . . . 2-5 211 Fuel temperature sensor trouble . . . . . . 4-91
Tech 2 Operation manual . . . . . . . . . . . . . . 2-6 217 PCV1 system short circuit (battery and
2. Vehicle diagnostic procedure . . . . . . . . . . 2-16 power supply circuit) trouble. . . . . . . . . 4-97
3. Diagnostic trouble codes list. . . . . . . . . . . 2-19 218 PCV2 system short circuit (battery and
power supply circuit) trouble. . . . . . . . 4-101
Chapter 3 Functional diagnosis 226 Supply pump no pressure feed or
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 pressure limiter operated . . . . . . . . . . . 4-105
Checking of SERVICE ENGINE SOON lamp 227 Pump no pressure feed
lighting circuit system (SERVICE ENGINE (Fuel outflow) . . . . . . . . . . . . . . . . . . . 4-110
SOON lamp does not turn ON). . . . . . . . . . 3-3 241 Accelerator switch off trouble . . . . . . . 4-115
Checking the SERVICE ENGINE SOON lamp 242 Accelerator switch on trouble . . . . . . . 4-120
flickering control system (SERVICE ENGINE 245 Fuel pressure sensor Trouble. . . . . . . . 4-125
SOON lamp does not flicker) . . . . . . . . . . . 3-11 247 PCV1 system harness, short
Checking the Tech II . . . . . . . . . . . . . . . . . . 3-16 (GND circuit) trouble . . . . . . . . . . . . . 4-130
Checking the engine starting system . . . . . . 3-21 248 PCV2 system harness, short
Checking the power supply circuit . . . . . . . . 3-24 (GND circuit) trouble . . . . . . . . . . . . . 4-136
Checking the staring system. . . . . . . . . . . . . 3-32 271 No.1 cylinder injector drive
Checking the fuel system . . . . . . . . . . . . . . . 3-37 system trouble . . . . . . . . . . . . . . . . . . . 4-142
Checking the intake system . . . . . . . . . . . . . 3-39 272 No.2 cylinder injector drive
Checking the exhaust system . . . . . . . . . . . . 3-41 system trouble . . . . . . . . . . . . . . . . . . . 4-147
Contents
273 No.3 cylinder injector drive PCV (pump control valve),

system trouble . . . . . . . . . . . . . . . . . . . 4-152 PCV relay circuit . . . . . . . . . . . . . . . . . 6-16
274 No.4 cylinder injector drive Injector (TWV) circuit (6SD1 engine) . . . 6-17
system trouble. . . . . . . . . . . . . . . . . . . 4-157 Magnetic valve, magnetic valve fail safe
275 No.5 cylinder injector drive relay circuit (C∗∗ 23 model vehicle) . . 6-18
system trouble . . . . . . . . . . . . . . . . . . . 4-162 Vehicle speed sensor circuit
276 No.6 cylinder injector drive (Except ECOGIT vehicle) . . . . . . . . . . 6-19
system trouble . . . . . . . . . . . . . . . . . . . 4-167 Starting circuit (battery relay, key switch,
411 Magnetic valve "A" drive slow blow fuse and fuse circuit) . . . . . . 6-20
system trouble . . . . . . . . . . . . . . . . . . . 4-172 Meter circuit (SERVICE ENGINE SOON
412 Magnetic valve "B" drive lamp, tachometer output) . . . . . . . . . . . 6-21
system trouble . . . . . . . . . . . . . . . . . . . 4-180 Self-diagnosis circuit (diagnosis switch,
415 Magnetic valve "C" drive memory clear switch and Tech II
system trouble . . . . . . . . . . . . . . . . . . . 4-188 connector circuit) . . . . . . . . . . . . . . . . . 6-22
416 Main relay system trouble . . . . . . . . . . 4-196 Neutral circuit (Except automatic
417 Starter switch trouble. . . . . . . . . . . . . . 4-201 transmission vehicles). . . . . . . . . . . . . . 6-23
418 Fail-safe (Magnetic valve cut) Clutch switch circuit. . . . . . . . . . . . . . . . . 6-24
relay "A" system trouble . . . . . . . . . . . 4-206 Brake switch circuit . . . . . . . . . . . . . . . . . 6-25
421 PCV relay system ttrouble . . . . . . . . . . 4-211 Reverse circuit . . . . . . . . . . . . . . . . . . . . . 6-26
518 EOL data error. . . . . . . . . . . . . . . . . . . 4-216 Idling control switch and idling control
543 Excessive high revolution error. . . . . . 4-218 selector switch circuit . . . . . . . . . . . . . . 6-27
Exhaust brake circuit . . . . . . . . . . . . . . . . 6-28
Chapter 5 Checking Method for Symptom
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Chapter 7 How to use IE System Inspection
Engine stall . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 Tools
Engine hunting, rough idle . . . . . . . . . . . . . . . 5-6 1. Tech II. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Lack output power of engine, insufficient Tech II. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
blow up, pulsating combustion . . . . . . . . . . 5-9
White smoke (large) . . . . . . . . . . . . . . . . . . . 5-13 Chapter 8 Others
Black smoke (large) . . . . . . . . . . . . . . . . . . . 5-16 Inspection item chart for IE system
condition . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Chapter 6 Wiring check Abbreviation list . . . . . . . . . . . . . . . . . . . . . . . 8-3
1. Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Programming / upload / download fuel
Identification of wires . . . . . . . . . . . . . . . . 6-2 delivery rate data . . . . . . . . . . . . . . . . . . . . 8-5
Wiring specifications . . . . . . . . . . . . . . . . . 6-2
Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Handling of connectors and harness. . . . . . 6-4
2. Vehicle wiring harness . . . . . . . . . . . . . . . 6-10
3. Wiring check. . . . . . . . . . . . . . . . . . . . . . . 6-11
Engine control unit power source,
GND circuit. . . . . . . . . . . . . . . . . . . . . . 6-11
NE, G and fuel pressure sensor circuit . . . 6-12
Boost, all speed accelerator sensor circuit. . 6-13
Accelerator sensor and accelerator
switch circuit. . . . . . . . . . . . . . . . . . . . . 6-14
Water temperature, fuel temperature and
atmospheric temperature sensor circuit . . 6-15
How to read this Manual
This IE System Troubleshooting Manual describes the inspection procedure for the IE System (an electronically
controlled fuel injection system (common-rail)).
This manual will help you in correct and speedy service operation for the IE System.
1
Chapter 1 Overview of IE system
• Specifications of IE system
• Control mechanism of IE system
• Input/output of IE system
• Sensor & actuator installing position of each engine
2
Chapter 2 Failure diagnosis
• View of diagnostic trouble codes
• IE lamp does not light ON, or the diagnosis monitor displays no data
• Contents of diagnostic trouble codes
3
Chapter 3 Functional diagnosis
• Checking method for proper operation of IE System or its functions
Chapter 4 Checking procedure for each diagnostic trouble code

• Checking method when a diagnostic trouble is displayed
4
Chapter 5 Checking method for symptom (when no trouble code lights ON)
• When no diagnostic trouble code is displayed, how to know the position to be checked based on
the failure condition
Chapter 6 Wiring check

• Wiring connection condition 5
• Connector inspection method
• Wire arrangement
Chapter 7 How to use IE system inspection tools

• How to use the wiring harness for checking the wiring harness checker, Tech II, and voltage
6
Chapter 8 Others
• Check sheet of IE system and simplified troubleshooting
8
1
Chapter 1
Overview of IE system
1. Overview and specifications of IE system
Overview of IE system
The IE system is an electronic control system which controls the engine combustion condition optimally
according to the traveling requirements of the vehicle. The IE system comprises the following components:
1. Electronically controlled fuel injection system (common-rail type)
2. EGR (exhaust gas recirculation)
3. VGS turbo control (6SD1-TC engine)
4. CCS control (6WG1-TC engine)
5. Idle control
6. PTO control
The IE system has other functions as follows in addition to the engine control function.
A. Auto cruise control
B. Auxiliary brake-linked auto cruise control
C. NR (noise reducer) control
D. Communication function with ASR control unit and fuel reducing control
E. Communication function with ECOGIT control unit and fuel injection control (gear speed matching at
the time of gear shifting)
F. Communication function with semi-auto clutch control unit
G. Communication function with A/T (automatic transmission) control unit
H. Communication function with simplified fuel cost/vehicle weight indicator control unit
I. Output of accelerator opening (idle position) and other signals to brake integrated control unit
J. Engine speed output to tachometer
K. Self-diagnosis function
Specifications of IE system
List of IE system specifications
(common-rail type)
Electronically controlled fuel

injection system
Communication function
Auto cruise control
NR control
Self-diagnosis function
Engine model Output E C V
with each electric system
G C G
Intake shutter
Auxiliary brake-linked function
R S S
semi-auto clutch
vehicle weight
Simplified fuel cost /
A E A
S C /
R O T
G
I
T
kW {PS}
345 6SD1-TC (SorN) 250 {340} O O O
349 6SD1-TC 280 PS O O O
230 6SD1-TC O O O
O - Standard equipment Œ Optional
1-2
Overview and specifications of IE system
Electronically controlled fuel injection system (common-rail type)

The engine control unit (ECU) acquires information (signals from many sensors) such as engine speed,
engine load and others. Based on such information, ECU sends electric signals to the supply pump, injector,
1
etc. to control the fuel injection rate and injection timing properly for each cylinder.
= Injection rate control
The two-way valve (TWV) in the injector is controlled based on the signals mainly from the engine speed
and accelerator opening to control the fuel injection rate properly.
= Injection pressure control
By controlling the fuel pressure in the common-rail, the injection pressure is controlled. Proper pressure
in the common-rail is calculated based on the engine speed, fuel injection rate, and other conditions. By
controlling the supply pump (PCV: Pump Control Valve), fuel in a proper quantity is discharged and fed
to the common-rail under controlled pressure
= Injection timing control
The injection timing control substitutes for the timer. Proper fuel injection timing is calculated based on
the engine speed and fuel injection rate to control the TWV (two-way valve) in the injector.
= Injection rate control
In order to improve the combustion in the cylinder, a small quantity of fuel is injected (pilot injection) first
and ignited, and then the second injection (main injection) follows. The injection timing and the injection
quantity are controlled by controlling the TWV (two-way valve) in the 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
⋅ Accelerator sensor
⋅ Accelerator switch Fuel
⋅ All speed temperature
Accelerator sensor control
Injector
Pressure limiter
Fuel leak pipe
Starter motor Common-rail fuel
pressure sensor
Flow damper
Supply pump
Air
cleaner
Water temperature
sensor Fuel filter
Fuel tank
G sensor
NE sensor
Flywheel Feed pump Pre-fuel filter
1-3
System control schematic diagram
Engine control unit (ECU)
Accelerator sensor input

Boost sensor input
Basic fuel injection rate
NE (engine speed)
sensor
G (cylinder distinction)
sensor
Compensation Water temperature sensor input,

accelerator sensor input,
start switch input
Fuel pressure sensor Fuel temperature sensor input
ASR demand signal (fuel cut signal)

Compensation Vehicle speed sensor input,
clutch switch signal, etc.
PCV
opening/closing Injector (TWV) power supply time,
timing decision timing decision
Fuel pressure sensor

Common-rail
(normally high pressure)
TWV
(Two Way Valve)
PCV
Supply
Injector
pump
Fuel tank
1-4
VGS (Variable Geometry Turbo System)

Air cylinder stroke distance (No. of steps of magnetic valve) is obtained from the engine speed, which is
compensated according to information from various inputs to obtain the final stroke distance (No. of stages
1
of magnetic valve) for the air cylinder.
The VGS magnetic valve is operated by the number of steps decided and the air cylinder is moved under air
pressure to control the nozzle vane angle in the turbine housing.
Air tank
No. of
change-over
Decision of steps of VGS C
Engine speed No. of change-over Compensation
steps of VGS
B
Inputs
⋅ Input from A
switches, etc.
Magnetic valve drive circuit

Engine control unit Air
cylinder
Nozzle vane
1-5
= Idling control switch

The idling speed can be adjusted by operating the idling control switch. The upper limit of speed varies
depending on the engine model, vehicle specifications and engine warming up condition.
UP
While the UP side of the switch is pushed, the engine speed
increases and the idling speed is increased accordingly.
UP
DOWN
While the DOWN side of the switch is pushed, the engine speed
DOWN
decreases and the idling speed can be decreased, only down to the
lower limit.
High Low
UP UP
DOWN DOWN
1-6
Output of idle position signal to brake intensive control unit

The engine control unit issues the "accelerator pedal stepping condition (stepped/not stepped)" to the brake
integrated control unit as idle position signal output.
1
The brake intensive control unit operates or releases the exhaust brake and retarder according to the
"accelerator pedal stepping condition" sent from the engine control unit and the operating condition of the
exhaust brake lever, retarder lever, clutch pedal, etc. which is directly detected.
Accelerator
Accelerator opening
Engine control unit
sensor
Idle position
signal output
Exhaust brake switch Exhaust brake
magnetic valve
Brake intensive
control unit
Clutch switch
Output of engine rotations to tachometer

The engine control unit sends the "engine speed pulse (4 pulses per speed of engine)" to the tachometer and
the tachometer output.
The tachometer indicates the engine speed. according to the "engine speed pulse" sent from the engine
control unit.
NE sensor Tachometer
Engine speed output
Engine control unit
G sensor Tachometer
1-7
External view of engine control unit
Label
90 81 50 41 10 1
100 91 60 51 20 11
110 101 70 61 30 21
120 111 80 71 40 31
90 81 50 41 10 1
100 91 60 51 20 11
110 101 70 61 30 21
120 111 80 71 40 31
Note: Operate the control unit suited to the vehicle according to the "Comment" and "Applicable engine
identification name" described on the label.
If a control unit not fitted for the vehicle is used, failure may result.
1-8
Engine control unit input/output list

Pin
No.
Name of signal
Engine model
6S 6W 6T
Pin
No.
O: Circuit used -: Unused circuit Œ : Circuit used properly depending on vehicles
Name of signal
Engine model
6S 6W 6T
1
1 Magnetic valve A (6S, 6W, 6T) 41 Accelerator sensor 1 signal (SIG) O O O
VGS turbo magnetic valve 1 (M/V A) O - - 42 Accelerator sensor 2 signal (SIG) O O O
CCS magnetic valve 1 (M/V A ) - O - 43 - - - -
Intake shutter magnetic valve 1 (M/V A ) - - O 44 Accelerator sensor 1 power source O O O
2 Cruise exhaust drive output signal. To brake integrated ECU Œ Œ - 45 Accelerator sensor 1 GND O O O
3 Magnetic valve B (6S, 6T ) 46 Accelerator sensor 2 GND O O O
VGC turbo magnetic valve 2 (M/V B ) O - - 47 - - - -
Intake shutter magnetic valve 2 (M/V B ) - - O 48 NE sensor (+) signal (SIG) O O O
4 - - - - 49 G sensor (+) signal (SIG) O O O
5 - - - - 50 - - - -
6 Memory clear switch signal (SIG ) O O O 51 - - - -
7 Clutch switch signal (SIG ) O O O 52 Fuel temperature sensor signal (SIG) O O O
8 Exhaust brake operation input signal (SIG ) O O O 53 Atmosphere temperature sensor signal (SIG) O O O
9 - - - - 54 Accelerator sensor 2 Power source O O O
10 Idling control UP switch signal (SIG ) O O O 55 Fuel pressure sensor GND O O O
11 - - - - 56 Boost, all speed accelerator sensor O O O
AMP double lock plate type
12 - - - - 57 NE sensor (-) signal (SIG) O O O

13 Key switch (ON) signal (SIG ) O O O 58 G sensor (-) signal (SIG) O O O
14 - - - - 59 CaseGND O O O
15 Air low pressure switch signal (SIG ) O O O 60 - - - -
16 PTO switch signal (SIG ) Œ Œ Œ 61 Boost sensor signal (SIG) O O -

17 Stop lamp switch signal (SIG ) O - - 62 Fuel pressure sensor signal (SIG) O O O
18 - - - - 63 All speed accelerator sensor signal (SIG) Œ Œ Œ
19 Parking switch signal (SIG ) O O O 64 - - - -
20 Accelerator switch signal (SIG ) O O O 65 - - - -
21 Pump control valve (PCV )1 O O O 66 Temperature sensor common GND O O O
22 Pump control valve (PCV )1 O O O 67 - - - -
23 Key switch (ON) signal (SIG ) O O O 68 - - - -
24 Starter switch signal (SIG ) O O O 69 - - - -
25 Diagnosis switch O O O 70 - - - -
26 Brake switch 2 signal (SIG ) O O O 71 Fuel pressure sensor signal (SIG) O O O
27 Idling control change-over switch signal (SIG ) O O O 72 Boost, all speed accelerator sensor Power source O O O
28 - - - - 73 Fuel pressure sensor Power source O O O
29 Idling control DOWN switch signal (SIG ) O O O 74 - - - -
30 Water temperature sensor signal (SIG ) O O O 75 Vehicle speed sensor signal (SIG) O O O
31 Pump control valve (PCV )2 O O O 76 NE sensor shield O O O
32 Pump control valve (PCV )2 O O O 77 G sensor shield O O O
33 Neutral signal (SIG ) O O O 78 - - - -
34 Test mode switch signal (SIG ) O - - 79 - - - -
35 - - - - 80 - - - -
36 Reverse switch signal (SIG ) O O -
37 - - - -
38 - - - -
39 Magnetic valve C (6S, 6T )
VGS turbo magnetic valve 3 (M/V C ) O - -
Intake shutter magnetic valve 3 (M/V C ) - - O
40 - - - -
1-9
Pin Engine model

Name of signal
No. 6S 6W 6T
81 Power source GND O O O
82 Power source GND O O O
83 - - - -
84 - - - -
85 Injector 6 (6S, 6W: 4th cylinder, 6T: 2nd cylinder) O O O
86 Injector 5 (6S, 6W: 2nd cylinder, 6T: 3rd cylinder) O O O
87 Injector 4 (6S, 6W: 6th cylinder, 6T: 4th cylinder) O O O
88 Injector 3 (6S, 6W: 3rd cylinder, 6T: 5th cylinder) O O O
90 Injector 1 (6S, 6W: 1st cylinder, 6T: 1st cylinder) O O O
91 Control unit power source (battery) O O O
92 - - - -
93 Magnetic valve fly-back (6S, 6W, 6T) - - -
VGS magnetic valve fly-back O - -
CCS magnetic valve fly-back - O -
Intake shutter magnetic valve fly-back - - O
94 Injector 6 (6S, 6W: 4th cylinder, 6T: 2nd cylinder) O O O
95 Injector 5 (6S, 6W: 2nd cylinder, 6T: 3rd cylinder) O O O
97 Injector 3 (6S, 6W: 3rd cylinder, 6T: 5th cylinder) O O O
99 Injector 1 (6S, 6W: 1st cylinder, 6T: 1st cylinder) O O O

100 Injector power source common 1 O O O
101 Control unit power source (battery) O O O
102 ECU GND O O O
103 - - - -
104 - - - -
105 Service engine soon lamp O O O
106 - - - -
107 - - - -
108 Cruise retarder drive output signal (to brake integrated ECU) O O O
109 Main relay O O O
111 ECU GND O O O
112 Output signal to tachometer (SIG) O O O
113 Tech II RXD O O O
114 Tech II TXD O O O
115 Fail safe relay (FS REL A) 6S, 6T)
VGS fail sale relay (FS REL A) O - -
Intake shutter fail safe relay (FS REL A) - - O
116 - - - -
117 - - - -
118 Main relay O O O
1-10
1-11
R/L ; P.C.V
1.25 1.25
Wire diameter
1.25 Use wire of φ1.25 for the pims 21, 22, 31, 32, 81, 82, 91, 100,
101, 102, 110, 111, 119, and 120.
R/L ; MAIN 1.25 +BP 91 PUMP CONTROL VALVE (PCV)1 Wire of φ0.85 is permissible for the pims 85-90 and 94-99 for
1.25 1.25 which the shielded wire is used.
101 22
MAIN R/L 21
109
Plating of pin
OFF 118 PUMP CONTROL VALVE (PCV)2
All of the ECU pins should be gold-plated.
ACC KEY 13 31
ON 32
23
KEY SW START 24 100
START 41 SIG 110
CASE GND
44 VCC
119
ACCEL 45 GND
120
SENSOR 42 SIG
54 VCC 90 TWV1
46 GND 99 1ST CYLINDER
SW ; ACCEL(N.C.)
20 86 TWV5
SW ; EXB. BRAKE 95 2ND CYLINDER
8
M/V ; EXB. BRAKE 88 TWV3

97 3RD CYLINDER
INJECTOR
R/L ; EXB. BRAKE 87 TWV4
P/L ; EXB. BRAKE 96 6TH CYLINDER
2
DAIG LAMP 89 TWV5

105
SW ; PARKING 98 5TH CYLINDER
19
85 TWV6
15 94 4TH CYLINDER
SW ; AIR PRESS
SW ; IDLE MANUAL SIG 48
27
UP NE SENSOR CAP GND (FRAME GND)
SW ; IDLE CONT. 10 GND 57
DOWN 29 SHIELD 76
SW ; CLUTCH(N.C) SIG 49
7
G SENSOR
GND 58
SHIELD 77
2. IE system schematic connection diagram
SIG 62
SIG 71 FUEL PRESSURE
VCC 73 SENSOR
GND 55
SW ; RETARDER
37
SIG 61
M/V ; RETARDER VCC 72 BOOST SENSOR
GND 56
P/L ; RETARDER 108

R/L ; RETARDER
SW ; ENG STOP
38
GND 66
WATER TEMP. SENSOR
SIG 30
SW ; DIAGNOSIS
25
SW ; MEMORY CLEAR SIG 52 FUEL TEMP. SENSOR
6
SIG 53 ATMOSPHERIC TEMP. SENSOR

SW ; BACK UP LAMP
36
R/L NEUTRAL
SW ; SUB START R/L
STARTER
SW ; NEUTRAL
33
R/L ; VGS FAIL SAFE (N.C.)
STOP LAMP
RELAY
115
M/V ; A(VGS1)
1
26
BRAKE SIG.2 M/V ; B(VGS2)
SW ; STOP LAMP 3
M/V ; C(VGS3)
39
FLY BAG
93
CHECKER SW (TRANSMITTED)
114
CHECKER CHECKER SW (RECEIVED) 113
TACHOMETER OUTPUT
METER 112
ATMOSPHERIC
PRESSURE
SENSOR
VEHICLE PULSE COMPRESSOR R/L
VEHICLE SPEED SIG
SPEED MATCHING 75
SENSOR DEVICE 4
81 82 102 101 59 *Pin (4) is used when the engine idling speed is
increased for the air conditioning system.
CASE GND
THERMO SW AIR CONDITION MODE SW
1-12
1
3. Control unit/sensor/switch installing position
<Right below the steering wheel>

Pulse matching device
<At the rear of passenger seat>

⋅ Brake integrated control unit
⋅ DMU (data memory unit)
⋅ Engine control unit
Note: Only control units related with the engine

control unit are described in this diagram.
1-13
Control unit/sensor/switch installing position
PTO switch
Relay box
⋅ Exhaust brake switch
Fuse box
⋅ Retarder switch
H 5 15
10
20 60 80
10 40 100
C 15
25 20 120
5
H
30
0 140
E
⋅ Accelerator sensor
⋅ Accelerator switch
Clutch Idle control switch

switch ⋅ Idle UP switch
⋅ Idle DOWN switch
⋅ TECH II connector
⋅ Diagnosis switch
(Black and white ones of LC 20-pole
connectors connected)
⋅ Memory clear switch
(White one of CM 2-pin connectors)
SERVICE ENGINE SOON lamp

[Vehicle equipped with no multi warning]
SERVICE
ENGINE
SOON
CRUISE HSA SRS AIR AUTO

MAIN CLUTCH
CRUISE
SET P RET
H
H
C
C
X100kPa
k m /h
E TRIP A
ODO B
A/T ABS
LOCK ASR REFRESH
A/T ABS POWER

LOCK OIL ASR STEER
1-14
Atmosphere
temperature sensor
(in open slit)
Transmission
⋅ Vehicle speed sensor
⋅ Neutral switch
⋅ Reverse switch
Brake valve
⋅ Brake switch 1 Cab rear members
⋅ Brake switch 2 ⋅ Magnetic valve
(Intake shutter, Exhaust brake, CCS, VGS)
Battery
Air tank
⋅ Air low pressure switch
1-15
Cab rear member (6S series)
1 2 3
Legend
1 M/V (C)
2 M/V (B)
3 M/V (A)
1-16
Engine (6S series)

1
Boost sensor
Fuel temperature sensor Fuel pressure sensor
NE sensor
Supply pump
⋅ PCV
⋅ G sensor
Air cylinder
Injector
for VGS turbo
Water temperature
sensor
1-17
4. Functions of input/output and vehicle behavior upon failure (influence)
Diagnostic trouble
Input/output name Pin No. Function Vehicle behavior upon failure
code (engine)
Control unit power source Engine stall, improper starting, SERVICE ENGINE SOON lamp
91, 101 Power supply to engine control unit -
(battery) light up
Main relay 109, 118 Power supply relay to engine control unit driven Engine stall, improper starting 416
<Self-diagnosis taking place>

Deteriorated exhaust gas, large exhaust brake operating sound,
1, 3, 39, 411, 412,
Magnetic valve, A, B, C, D, E EGR valve, VGS turbo, intake shutter driven SERVICE ENGINE SOON lamp ON when idling continues.
106, 116 413, 444, 415
< Self-diagnosis not taking place>
Black smoke, output shortage, deteriorated exhaust braking force
Magnet valve Upon the magnetic valve system failure
Power supply to the magnetic valve cannot be cut off when the
Fail safe relay 115, 117 (411, 412, 413, 444, 415 ), 418,424
magnetic valve fails.
(power cut relay) power supply to the magnetic valve is cut off.
Magnetic valve 411, 412,

92, 93 Reduction of magnetic valve electrical noise Vehicle trouble cannot be felt.
Fly-back 413, 444, 415
41, 42, 44, Detection of accelerator pedal opening (traveling accelerator) Output shortage, improper engine power up (slow reaction to
Accelerator sensor 24
45, 46, 54 * Mutual diagnosis with "accelerator switch ON" accelerator pedal), SERVICE ENGINE SOON lamp light up
Detection of accelerator pedal stepping condition Output shortage, improper engine power up, (slow reaction to
Accelerator switch 20 241,242
* Mutual diagnosis with "accelerator sensor input" accelerator pedal, SERVICE ENGINE SOON lamp light up
Detection of external accelerator opening (working PTO cannot be controlled (accelerator cannot be changed over).
All speed accelerator sensor 56, 63, 72 -
accelerator) External accelerator does not work.
Output shortage, improper engine power up, idling condition
Boost sensor 56, 61, 72 Detection of boost pressure 32,42
continued, SERVICE ENGINE SOON lamp light up
Detection of water temperature (engine cooling water White smoke generated and unsmooth starting when extremely
Water temperature sensor 30, 66 23
temperature) cold, idling continued, SERVICE ENGINE SOON lamp light up
White smoke generated when extremely cold,
Atmospheric temperature sensor 53, 66 Detection of open air temperature 22
SERVICE ENGINE SOON lamp light up
Output shortage when hot,
Fuel temperature sensor 52, 66 Detection of fuel temperature 211
Atmospheric pressure sensor In ECU Detection of atmospheric pressure Deterioration of exhaust gas 71
Idling continued and SERVICE ENGINE SOON lamp light up
Detection of engine speed, injection cylinder, injection * Engine speed can be detected with the G sensor but vehicle
NE sensor 48, 57, 76 15
timing trouble cannot be felt.
Idling continued and SERVICE ENGINE SOON lamp light up
* Engine speed can be detected with the NE sensor but vehicle
G sensor 49, 58, 77 Detection of injection cylinder, backup of NE sensor 14
trouble cannot be felt.
Output shortage 245,115,151,
Fuel pressure sensor 55, 62, 71, 73 Detection of fuel pressure in common-rail
SERVICE ENGINE SOON lamp light up 118
Power supply to injector (TWV)
100, 110,
Injector (TWV) power source For common 1, injector 1,3 5 Engine stop 158,159
119, 120
For common 2, injector 2,4,6
Engine control unit controls the injector (TWV) based on
85 - 90, Output shortage, improper engine power up, deteriorated exhaust 271,272,273,
Injector (TWV) the power supply time/timing, hereby controlling the fuel
94 - 99 gas, SERVICE ENGINE SOON lamp light up 274,275,276
injector volume and injection timing.
20, 21, Fuel pressure in the common-rail is controlled by Output shortage, improper engine power up, deteriorated exhaust 217,218,
PCV(Pump control valve)
31, 32 opening/closing timing of PCV. gas, SERVICE ENGINE SOON light up 247,248
PCV (pump control valve) relay 20, 21, Engine stop.
Detection of drive power supply to PCV relay 421
31, 32 SERVICE ENGINE SOON lamp light up.
Auto cruise does not work, speed limiter does not work, SERVICE
Vehicle speed sensor 75 Detection of vehicle speed 25
ENGINE SOON lamp light up only for vehicles equipped with NR.
Cruise exhaust drive output signal Exhaust brake driven when the auxiliary brake-linked Exhaust brake does not work at auxiliary brake-linked cruise
2 -
cruise is operated. condition.
Cruise retarder drive output signal 108 Retarder driven when the auxiliary brake-linked cruise operated Retarder does not work at the auxiliary brake-linked cruise condition -
Transmission of "idle position" to brake integrated control Exhaust brake does not work, exhaust brake not released with the
Accelerator opening (idle output) 80 -
unit accelerator pedal
Transmission of "engine speed" to tachometer and tacho Tachometer does not work, engine speed not recorded on the tacho
Tachometer output 112 -
graph graph
Detection of exhaust brake (magnetic valve) operating
Exhaust brake operation input 8 Black smoke generated -
condition
Exhaust brake switch Detection of operating condition of combination switch for Auto cruise not released when the exhaust brake is operated,
12 -
(cruise cancel switch 2) "exhaust brake lever" auto cruise does not work.
Start switch Black smoke generated, hunting, unsmooth starting when extremely
24 Detection of engine start condition 417
(start switch at "S" position) cold, SERVICE ENGINE SOON lamp light up
Start switch Engine stop,
13, 23 Detection of start switch condition 416
(start switch at "ON" position) SERVICE ENGINE SOON lamp light up
Cruise main switch 14 Detection of cruise main switch operating condition Auto cruise does not work -
Cruise set switch 18 Detection of cruise set switch operating condition Auto cruise does not work. -
1-18
DMU (data memory unit) and switch box function of input/output and vehicle behavior (influence)
Terminal Diagnostic trouble
1
Input/output name Function Vehicle behavior upon failure
No. code (engine)
Auto cruise does not work. Resume function and set accelerator
Cruise resume switch 28 Detection of cruise resume switch operating condition -
function do not work.
Auto cruise does not work. Resume function and set accelerator
Cruise cancel switch 11, 12 Detection of cruise resume switch operating condition -
function do not work.
Detection of combination switch for "retarder lever" Auto cruise not released when retarder works. Auto cruise does not
Retarder operation input 37 -
operating condition work.
Brake switch 1 17 Detection of foot brake stepping condition Auto cruise does not work. -
Auto cruise does not work.
Accelerator opening does not return to 0% with the foot brake
Brake switch 2 26 Detection of foot brake stepping condition operation upon the failure of the accelerator sensor. -
* Cannot be felt when the accelerator sensor is normal and the auto
cruise is not used.
<Manual transmission vehicle>
Detection of clutch pedal stepping condition
Clutch switch 7 <Semi-auto clutch vehicle, ECOGIT, MIX vehicle> Auto cruise does not work. -
Detection of clutch connecting condition
(disconnected/connected)
Detection of idle control selector switch operating condition
AUTO mode and MANUAL mode of the idle control cannot be
Idle control selector switch 27 (changing over between AUTO mode and MANUAL
changed .
mode)
Idle control UP switch 10 Idle control switch UP side operating condition Idling speed cannot be adjusted (increased). -
Idle control DOWN switch 29 Idle control switch "DOWN" operating condition Idling speed cannot be adjusted (decreased). -
PTO control (accelerator change-over or governor property change-
Parking brake switch 19 Detection of parking brake operating condition -
over) is impossible.
Low air pressure switch 15 Detection of air pressure condition Deteriorated exhaust gas -
Reverse switch 36 Detection of shift lever operating condition (reverse position) Slightly too high vehicle reverse speed -
Neutral switch 33 Detection of shift lever operating condition (neutral position) Auto cruise does not work. -
PTO switch 16 Detection of PTO switch operating condition PTO control (governor property change-over) is impossible. -
PTO idle switch
PTO control (governor property change-over) is impossible. Idling
* Limited to concrete pump vehicle 34 Detection of PTO idle switch operating condition -
condition is not attained by operating the switch.
(Optional modification)
Detection of diagnosis switch (20-pin connector (black)) Self-diagnosis code cannot be recognized with the SERVICE -
Diagnosis switch 25
operating condition ENGINE SOON lamp.
Detection of memory clear switch (2-pin connector (white)) Diagnostic trouble code cannot be erased.
Memory clear switch 6 -
operating condition * Can be erased with Tech II.
Diagnostic trouble system trouble cannot be recognized. Diagnostic
Engine control system trouble indicated by the lamp light up.
Service engine soon lamp 105 trouble code cannot be recognized. -
Self-diagnosis code indicated by the lamp blinking.
* Can be recognized with Tech II.
Auto cruise operating condition cannot be recognized.
Cruise set lamp 107 Indicates auto cruise operating condition. -
* Can be recognized with Tech II.
Simplified fuel cost/vehicle weight Following data transmitted to simplified fuel cost/vehicle
indicator related weight indicator:
Simplified fuel cost indicator does not work. Simplified vehicle
⋅ Engine rotation signal output 5, 34, 69 ⋅ Engine speed -
weight indicator does not work.
⋅ Engine load signal output ⋅ Engine load signal output
⋅ Boost cut signa ⋅ Zero boost demand
<ABS/ASR vehicle>
Following data transmitted to ABS/ASR control unit:
ABS/ASR related ASR engine control is impossible (malfunction of ASR).
⋅ Accelerator opening
⋅ ASR accelerator opening signal 67, 68 Detection of diagnostic trouble code with ABS/ASR control unit -
Demand from ABS/ASR control unit recognized
⋅ ASR reduced fuel level signal <Semi-auto clutch vehicle>
⋅ Reduced fuel level signal
Slower speed change at the time of acceleration
ECOGIT related
Following data transmitted to ECOGIT control unit:
⋅ MUX-LINE
⋅ Target fuel injection rate Speed cannot be changed. Vehicle cannot start. 511
(Target fuel injection rate and
74, 103 ⋅ Accelerator opening Diagnostic trouble code detected with ECOGIT control unit. PWM only.
accelerator opening)
Demand from ECOGIT control unit recognized * A spanner mark indicated.
⋅ PWM-LINE (demanded fuel
⋅ Demanded fuel injection rate
injection rate)
Automatic transmission related
Gear shifting shock caused (particularly when shifting from N to D)
⋅ CAN-H 60, 70 "Accelerator opening" transmitted to A/T control unit -
Diagnostic trouble code detected with A/T control unit.
⋅ CAN-L
Engine control condition cannot be recognized. Diagnostic trouble
Diagnosis related Engine control condition and self-diagnosis data 518
code cannot be recognized.
⋅ Diagnosis signal (transmission) 35, 113, 114 transmitted to Tech II (Accelerator
* Can be recognized with SERVICE ENGINE SOON lamp.
⋅ Diagnosis signal (reception) "Accelerator learning" data from Tech II recognized learning only)
"Accelerator learning" impossible.
59, 81, 82, GND for the control unit, magnetic valve drive power,
GND (earth) Vehicle trouble cannot be felt. -
102, 111 injector power, case and others
1-19
5. Others
Object and procedure for accelerator learning (learning of accelerator pedal idling
position and full-throttle position)
Accelerator learning (learning of idling position and full-throttle position) process has been adopted from
00GIGA in order to control the inconstant fuel injection rate according to the accelerator pedal operating
distance, for the purpose of improving the fuel cost performance.
By learning the "idling position" and "full-throttle position" for each vehicle, excess play of the accelerator
pedal can be reduced and the effective stroke distance to the pedal opening (actual accelerator opening) can
be increased. As a result, wasteful fuel consumption when the vehicle is traveling at a constant speed can be
reduced.
= Accelerator learning procedure

Tech II is used for the accelerator learning. The "idling position" and "full-throttle position" of the vehicle
are read into Tech II once and then written (recorded) into the control unit.
Follow the instructions displayed on the screen of Tech II. (Refer to Item 2, "Learning of Accelerator",
Chapter 7,"How to use the IE System Inspection Tools" for details.)
Carry out the accelerator learning process:
• after replacing the engine control unit,
• after replacing the accelerator sensor or bracket assembly, and
• after adjusting the floor bolt.
Be sure to perform the accelerator learning process while
the floor bolt is properly adjusted, If not, output shortage
or other trouble may be caused. (Refer to the description
of the accelerator link mechanism below.)
= Accelerator link mechanism

The accelerator link (ENG CONT BRKT) is provided with a
stopper used to control (assure) the operating angle of the
accelerator sensor lever for the accelerator link itself. As a
result, the operating angle of the accelerator pedal is controlled
with the accelerator link. Therefore, the floor bolt does not
function as a stopper; it is set up as a pedal protection function. Stopper
mechanism
Adjust the floor bolt as illustrated below.
When the accelerator

pedal is fully
stepped on
1.0 - 2.0mm (gap)
Stopper bolt
Lock nut
1-20
Others
Q adjustment data
A seal is attached to the vehicle body to indicate the Q adjusting data at the time of the shipment of the
vehicle. It is used to compare the description with that of the Tech II.
1
Seal position
Seal is attached
to this panel surface.
Checker connector
on the vehicle side
Description on seal
Q adjustment data No. Timing compensation

(Q1, Q2, Q3 from the left) resistance value (unused)
Q adjustment value T compe.
Control No. in plant

(varying depending on vehicle)
-
Vehicle model
1-21
Chapter 2
Failure diagnosis 2
1. Self-diagnosis of IE system
Diagnostic trouble codes can be checked or erased in the following procedure.

<Check of diagnostic trouble code>
• Check by SERVICE ENGINE SOON lamp or multi-warning (engine control indication)
• Check by Tech II (with the Tech II connected)
• Check by diagnosis monitor (with the diagnosis monitor connected)
<Erasure of diagnostic trouble code>
• Erasure by memory clear switch (with the connector connected)
• Erasure by Tech II (using the communication mode)
• Erasure by diagnosis monitor
Method of checking the diagnostic trouble code by SERVICE ENGINE SOON lamp and
multi- warning (engine control indication)
As shown in the figure below, the indication method is different between vehicles with multi-warning system
and those without multi-warning system.
On vehicles without the multi-warning system, diagnostic trouble codes can be checked by the service engine
soon lamp blinking as before. On vehicles with the multi-warning system, diagnostic trouble codes are
checked by the multi-warning"Engine Control" lamp blinking. In this case, the indication should be changed
over by operating the multi-warning switch. Immediately after the indication is changed over, the self-
diagnose code is kept indicated and so the indication at that moment is not correct. After changing over the
indication on a vehicle with the multi-warning function, wait for "Lamp OFF term for 2.4 seconds" which is
a pause for the diagnostic trouble code indication.
SERVICE ENGINE SOON lamp

[Vehicle equipped with no multi warning]
SERVICE
ENGINE
SOON
CRUISE HSA SRS AIR AUTO

MAIN CLUTCH
CRUISE
SET P RET
H
H
C
C
X100kPa
k m /h
E TRIP A
ODO B
A/T ABS
LOCK ASR REFRESH
A/T ABS POWER

LOCK OIL ASR STEER
2-2
Self-diagnosis of IE system
Connector installing position
Installing position
3
2
When the inspection cover is removed
1 2
6 Wound with PVC-Y tape
8 9 10
12
11
13
Diagnositic trouble code indication procedure
• Disconnect the diagnosis connector 1 and 2 (LC 20-pin, black) which are usually connected.
• Connect the diagnosis connector (knob with white tape) disconnected above and another diagnosis
connector (knob with white tape).
• Turn the multi-warning switch (change-over knob) in the meter panel counterclockwise. "Engine
Control" lights up.
* This step is not required for vehicles without the multi-warning system.
• The indication starts blinking. Wait for the "Lamp OFF term for 2.4 seconds", which is a pause of the
self-diagnosis code indication, and then read the self-diagnosis code from the blinking condition.
* When more than two self-diagnosis codes are available, indicate one code 3 times respectively and
repeat the above procedure.
2-3
Diagnostic trouble code blinking pattern
Service engine soon lamp (in case of code "23")
t4 t3 t2 t3 t2 t1 t2 t1 t2 t1 t4 t1 = About 0.3 sec.

t2 = About 0.6 sec.
ON
t3 = About 1.2 sec.
t4 = About 2.4 sec.
OFF
Tens digit Units digit
Service engine soon 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
Hundreds digit Tens digit Units digit
Contents of diagnostic trouble codes

• Engine stop ➡ Both the diagnostic trouble code for the current condition and past one in the
memory are indicated at the same time.
• Engine running ➡ Only the current diagnostic trouble code is indicated.
2-4
Erasing the diagnostic trouble code by memory clear switch (connector)

The diagnostic trouble codes can be erased by operating the memory clear switch (connector) installed in the
inspection cover on the vehicle.
* Since the all diagnostic trouble codes of the electric systems are erased at one time except for some electric
systems (ABB/ASR, ECOGIT, SRS, A/T, etc.) by operating this switch, it should be handled with care.
Connector installing place

Installing place 2
Instrument lower harness

3
When inspection cover is removed

1 2
No. Color No. of pins

6 Wound with PVC-Y tape 1 Black 20 pin connector
4 2 Black 20 pin connector

7 Natural
4 20 pin connector
(white)
5
8 9 10
12
11
13
Self-diagnosis code erasing procedure

• Make sure that the diagnosis connectors 1 and 2 (LC
20-pin, black) are connected.
3
* If these connectors are disconnected, the diagnostic
Connect and disconnect
the connectors 4 to erase
trouble code cannot be erased.
1 2
the diganostic trouble code • Make sure that the memory clear connector (CN 2-pin,
white) is disconnected.
• Turn ON the starter switch.
* The engine, if running, needs not be stopped since the
4 diagnostic trouble code can be erased while the engine
is running.
• More than one second after the starter switch is turned
ON, connect the memory clear connector (CN 2-pin,
white), and disconnect it after leaving it at that condition
for more than 1 second.
* The diagnostic trouble code is erased a short time after
the connect is disconnected.
2-5
Tech II Operation manual
Diagnosis Strategy-Based Diagnostics

Strategy-Based Diagnostics
The strategy-based diagnostic is uniform approach to repair all Electrical/Electronic (E/E) systems. The
diagnostic flow can always be used to resolve an E/E system problem and is a starting point when
repairs are necessary. The following steps will instruct the technician how to proceed with a diagnosis:
1. Verify the customer complaint.
To verify the customer complaint, the technician should know the normal operation of the system. =
not present (History)
2. Perform preliminary checks.

• Conduct a thorough visual inspection.
• Review the service history.
• Detect unusual sounds or odors.
• Gather diagnostic trouble code information to achieve an effective repair. = Intermittent
3. Check bulletins and other service information. System checks contain information on a system that may
not be supported by one or more DTCs. System checks verify proper operation of the system. This will
lead the technician in an organized approach to diagnostics. = Present
Reading Diagnostic Trouble Codes Using the Tech II Scan Tool

The procedure for reading diagnostic trouble code(s) is to use a diagnostic Scan Tool. When reading
DTC(s), follow instructions supplied by the tool manufacturer.
Clearing Diagnostic Trouble Codes.

IMPORTANT: Do not clear DTCs unless directed to do so by the service information provided for each
diagnostic procedure. When DTC(s) is cleared, the Failure Record data that may help diagnose and
intermittent fault will also be erased from the memory.
To clear Diagnostic Trouble Codes (DTCs), use the diagnostic Scan Tool "clear information" or
"Programming" function. When the DTC(s) is cleared the following instructions are supplied by the tool
manufacturer.
Tech II Features
1. Tech II is a 12 volts system. Do not apply 24 volts.
NOTE: Install the Tech II Adapter and supply voltage is 12 volts for Tech II.
2. After connecting and/or installing the Vehicle Communication Interface (VCI) module, PCMCIA card
and DLC connector to the Tech II, connect the tool to the vehicle DLC.
3. Make sure the Tech II is powered OFF when removing or installing the PCMCIA card.
4. The PCMCIA card has a capacity of 10 Megabytes.
5. The Tech II has two snapshots.
6. The PCMCIA card is sensitive to magnetism and static electricity, so care should be taken in the
handling of the card.
7. The Tech II can plot a graph when replaying snapshot.
2-6
8. Always return to the Main Menu by pressing the EXIT key several times before shutting down.
9. To clear Diagnostic Trouble codes (DTCs), open Application Menu and press "F1: Clear DTC info".
NOTE: The DLC cable is only to be used for diagnosis of Tech II

Refer to users guide of the Tech II.
To prevent system damage, the ignition key must be "OFF" when disconnecting or reconnecting
battery power.
2
2-7
Overview
Tech is useful for engine diagnoses and system checks. Although trouble diagnosis can be performed
without Tech II, using Tech II will increase efficiency.
Tech II is portable, compact and light tester. Connected with the self-test connector of the vehicle, TechII
performs various diagnoses and tests by communicating with ECM.
Tech II
Legend
(1) PCMCIA card
(2) DLC cable (For diagnosis of Tech II.)
(3) SAE 16/19 pin adapter
(4) Adapter cable
(5) Tech II
Notes:
• Tech II requires power supply of 12V.
• Be sure to use the adapter cable.
• ISB applicable vehicle model is equipped with a 24 V power supply.
• Be sure to turn the power OFF when removing and attaching PCMCIA card.
• Be sure to use a conversion adapter to comply with a 20-pin connector of DLC (vehicle equipment).
• Mount the adapter to DLC and connect Tech II to the adapter.
• Be sure to use the Tech II adapter.
2-8
Tech II adapter
Legend
(1) Tech adapter
Note: Be sure to set the TXD switch to the right side as illustrated and select the system selector
switch to the #3 position.
(2) Adapter cable

*1. DLC cable
*2. Adapter cable
*3. Connector for I/E
2-9
20 Pins Connector Pin assignment
Pin No. 3 = Power supply

Pin No. 4 = Tech signal (TXD)
Pin No. 12 = Tech signal (RXD)
Pin No. 13 = Ground earth
Operation of Tech II
1. Check the initial display appears.
Main Menu 2. Press [ENTER].

The Main menu appears.
F0: Diagnostics
F1: Service Programming System (SPS)
F2: View Capture Data
F3: Tool Options
F4: Download / Upload Help
3. Select [F0] and press [ENTER].

Vehicle Identification
Select one of following The Vehicle Identification display to select Model
Model Year(s)
appears.
( I ) 2001
(Y) 2000
(X) 1999
(W) 1998
1/3
(Y) 2000
2-10
4. Select Applicable Model Year.
Select one of following For instance "2000" and press [ENTER].
Vehicle Type(s)
(UB) Trooper, Bighorn
(UE) Rodeo / Amigo, Wizerd/MU
(UG) V-Cross
(UC) Frontier, LAO-Rodeo
(TF) LUV (C＊, E＊, L＊, F＊)
(TB) Panther
(N*) ELF, NPR, NQR
(C＊, E＊, L＊, F＊) Heavy, Medium Duty
(Y) (C*, E*, L*, F*) Heavy, Medium Duty
8/8
2
5. Select [Heavy, Medium Duty] and press [ENTER].
System Selection Menu
(Y) 2000 (C＊, E＊, L＊, F＊) Heavy, Medium Duty
The System Selection Menu appears.
F0: Engine
F1: Transmission
F2: Chassis
F3: Body

Select one of following
The Vehicle Identification display to select engine
Engine appears.
(IE) 6HK1-X (Common Rail) Taiwan
(IE) 6HH1/6HK1-TC(China)
(IE) 6HH1 (EXP)
(IE) 6SD1-TC (Common Rail)
(IE) 6HE1-TC
(IE) 6WA1-TC
(IE) 6WG1-TC
(IE) 8PE1 (SKW)
Other 2/9
(IE) 6SD1-TC (Common Rail)
7. Select engine model 6SDI-TC (Common Rail) and

System Identification
(C＊, E＊, L＊, F＊) Heavy, Medium Duty press [ENTER].
Engine/ (IE) 6SD1-TC (Common Rail) The System Identification display to turn on ignition
appears.
If the engine identification is "OK", set the Ignition key
Turn On Ignition! from "OK" to "Start" and press the soft key "Confirm"
according to the instruction on the screen. If the
operation is incorrect, press the [EXIT] key and you
Confirm
will be back to the main menu. Then restart selection.
System Identification
8. Turn on the ignition and press [Confirm]. The
(C＊, E＊, L＊, F＊) Heavy, Medium Duty System identification display to enter ROM ID.
Engine/ (IE) 6SD1-TC (Common Rail)
number appears.
ROM Identification 6SD1: 22116040
Enter the ROM Identification number then confirm it.
6SD1-TC (Common rail)
Confirm
2-11
Engine
9. After engine display appears, select [F0] and press
[ENTER].
F0: Diagnostics Trouble Codes
F1: Data Display
F2:Snapshot

Diagnostic Trouble Codes
The Diagnostic Trouble Codes display appears.
F0: Road DTC info Ordered By Priority
F1: Clear DTC Information

Clear DTC Information
The Clear DTC Information display appears.
Engine: (IE) 6SD1-TC (Common Rail) Press [Yes] and the DTC number is cleared.
Do you want to clear DTCs? (Yes / No)
NO YES
12. The Clear DTC Information display appears.

Press [Continue] and then return to the Diagnostic
Trouble Codes display.
Clear DTC Information Successful
Continue
13. After the DTC number is cleared, check and

confirm the DTC number.
Engine: (IE) 6SD1-TC (Common Rail)
Please Check DTCs.
Confirm
2-12
14. Select the Snapshot Options display.

Snapshot Options
Trigger Type : Manual Trigger

F0: Manual Trigger
F1: Any Code
F2: Single Code
Trigger Point : Center
F4: Beginning
F5: Center
F6: End
Record
Snapshot
Review
Data 2
2-13
Flow Chart for Snapshot relay (Plotting Graph)
Press the enter-key in the initial display.
Select "VIEW CAPTURE DATA"
If snapshot options are displayed, decide a

trigger type, and select "REVIEW DATA".
When the data triggered by vehicle is

displayed, select the data.
(Plural display of data depending on the
number of times of triggering.)
Data is displayed on the screen.

To see the graph, select "PLOT" in the
lower part of the monitor screen.
Changed to the item selection screen,

push the enter key up to three times.
And select "ACCEPT" under screen.
The graph is displayed on the screen.
2-14
Plotting Graph Flow Chart (Plotting graph after obtaining vehicle informaion)
Procedure Base on Data Display Procedure Base on Trigger Type Decision

After confirming FLOW "MAIN MENU After confirming FLOW "MAIN MENU
DIAGNOSIS" -ID, select "DATA DISPLAY" DIAGNOSIS" -ID, select "SNAP SHOT"
from APPLICATION MENU. from APPLICATION MENU.
2
After the display of vehicle data, select
"QUICK SNAPSHOT" in the lower part Select when the items have been displayed.
of the monitor screen
After the display of snapshot option,

decide a trigger type, and select "RECORD
SNAPSHOT".
After the lapse of some time, push "EXIT" If (STANDBY) blinks, and the upper right
button of the screen, select "TRIGGER".
Confirm the trigger type.
If "CONTINUE" is displayed in the lower part

of the monitor screen after the screen is
changed, select the data.
If "PLOT" is displayed in the lower part of the

monitor screen, select "PLOT".
When changed to the item selecting screen,

push the enter key in accordance with the
items up to three items and select "ACCEPT"
in the lower part of the monitor screen.
The graph is displayed on the screen.
2-15
2. Vehicle diagnostic procedure
Troubleshooting (Checking steps and corrective actions)

Perform the checking and corrective actions following the steps shown below.
Steps Checking and Corrective Actions Result YES NO
1 Confirm the user information (checking the vehicle condition) - Step 2 Confirm the
using the check sheet (Section 8). user
Did you check the vehicle condition? information
2 Check the ENGINE CONTROL lamp or SERVICE ENGINE Lamp Step 3 Chapter 3
SOON lamp for lighting. turns on (OK) Check the
1. Turn the starter switch on. SERVICE
(At this time, do not start the engine.) ENGINE
Does the ENGINE CONTROL lamp or SERVICE ENGINE SOON SOON lamp
lamp turn on? lighting circuit
(SERVICE
ENGINE SOON
lamp does not
turn on)
(NG)
3 Check the ENGINE CONTROL lamp or SERVICE ENGINE Lamp Step 4 Chapter 3
SOON lamp for flickering. flickers (OK) Check the
1. Turn the starter switch on. SERVICE
(At this time, do not start the engine.) ENGINE
2. Connect the diagnostic switch (connector). SOON lamp
Does the ENGINE CONTROL lamp or SERVICE ENGINE SOON flickering
lamp flicker? control system
(SERVICE
ENGINE
SOON lamp
does not
flicker)
(NG)
4 Connect the Tech II. Tech II Step 5 Chapter 3
1. Turn the starter switch off. turns on, (OK) Check the
2. Connect the Tech II to the connector. and the Tech II
3. Turn the starter switch on. Engine (NG)
4. Turn the Tech II on. Control Unit
5. Using the Tech II, communicate with the Engine Control is
Unit. recognized
Does the Tech II turn on, and is the Engine Control Unit
recognized?
5 Using the Tech II, read and record diagnostic trouble codes. - Step 6 -
(Recording current and past codes: Memo 1)
(Read diagnostic trouble codes with the engine in stop status)
Did the corrective actions complete?
2-16
Vehicle diagnostic procedure

6 Confirm the diagnostic trouble codes in Memo 1 to check if Diagnostic Chapter 4 Step 7
diagnostic trouble codes 33 and 35 are detected. trouble Checking by
Note: If the diagnostic trouble codes 33 and 35 are detected, codes 33 diagnostic
replace the Engine Control Unit as necessary. and 35 are trouble code
Are the diagnostic trouble codes 33 and 35 detected? detected
7 Check if the engine starts.

Does the engine start?
Engine
starts
Step 8
(OK)
Chapter 3
Checking the
2
engine starting
system
(NG)
8 Using the Tech II read and record diagnostic trouble code. - Step 9 -
(Recording current code: Memo 2)
(Read the diagnostic trouble code with the engine running)
Did corrective actions complete?
9 Compare the Memo 1 with Memo 2 to check the diagnostic trouble - Chapter 4 Step 10
codes. Checking by
Current code . . .? diagnostic
Past code . . . . . .? trouble code
*If normal, the diagnostic trouble code "1" is displayed.
Is current code displayed?
10 Is past code of diagnostic trouble codes displayed in step 9? - Repair following Step 11
the checking by
diagnostic
trouble code, or
engine data
displayed on
Tech II
11 Check the common rail system. - Step 12 -
Referring to the items for diagnostic trouble codes "14 and 15"
(checking engine timing sensors), "271-276" (checking injector
related), and "115, 118, 151, 245, 226, 227" (checking common rail
fuel pressure related, and supply pump), and repair or replace if
faulty.
2-17
Vehicle diagnostic procedure

12 Did corrective actions complete? No fault is Step 14 Step 13
Check the Engine Control Unit (engine control condition). Using found. (OK) (NG)
the Tech II, perform various tests to check if the tests terminated
successfully or the test results are normal.
(Conduct various tests by referring to Section 7 Tech II)
⋅ Fuel Pressure Control
Changing the fuel pressure in common rail, check if actual
pressure follows the set pressure, or the fuel leaks from the fuel
piping when the pressure is raised.
⋅ Injection Timing
Changing the fuel injection timing, check if the injection timing
control operates according to the variations of engine speeds or
exhaust gas conditions. (White smoke in case of negative
advance)
⋅ RPM Control
Changing the set idling speeds, check if actual idling speed
follows the set speed and the idling control operates normally.
⋅ Pilot Injector Stop
Stop the pilot injector, and check from the change in engine
sound at idling if the pilot injection control operates normally.
⋅ Injection Stop
Stop the injection, and check if the engine stops.
⋅ Exhaust Brake Control
With the engine in stop status, check the exhaust brake and
retarder for function.
⋅ Solenoid Valve
Check the magnetic valves for function.
Note that the quantity and applications of magnetic valves are
different depending on the engine.
Did the tests terminate successfully, or are the test results normal?
13 Repair or replace the parts judged faulty in step 12. Or, replace the - Step 14 -
Engine Control Unit if no fault was detected and the tests could not
be conducted.
14 Referring to the user information and the data in Data Memory Unit - Step 15 Chapter 5,
and the engine data, check and repair possible faulty parts. Checking by
Did corrective actions complete? symptom
15 Clear the memory in the Data Memory Unit. - Step 16 -
16 Clear the memory in the Engine Control Unit. - Check the -
Did corrective actions complete? repair
2-18
3. Diagnostic trouble codes list
Backup control
diagnostic Judge
trouble Item Failure Contents Time DATA Control
code
15 NE pulse not input while G pulse is input - - Control with G sensor only
(Memorized) NE sensor trouble at the engine speed more than 40rpm
14 NE pulse not input while G pulse is input - - Control with NE sensor only
(Memorized) G sensor trouble at the engine speed more than 450rpm
15&14 No pulse input between NE & G with the 2.5 sec.

NE & G both sensor error - Stop of power supply to TWV and PCV
(Not Memorized) starter SW ON. continued
2
Common-rail pressure regulation (max. 60MPa)
245 Fuel pressure sensor system PC sensor output value larger than 4.7V 0.1 sec. Fuel injection rate Prospective control
(Memorized) trouble or smaller than 0.7V continued (6WGI: max. 120 mm3/st)
(6SD1, 6TE1: max. 50 mm3/st)
Common-rail pressure regulation (max. 60MPa)

When the common rail pressure is larger Approx.
115 Fuel pressure sensor output Fuel injection rate
than 10 MPa, PC sensor output value does 9sec. Prospective control
(Memorized) fixed (6WGI: max. 120 mm3/st)
not change. continued (6SD1, 6TE1: max. 50 mm3/st)
PCV closing timing is after 217.5°CR or Common-rail pressure regulation (max. 60MPa)
Approx.
151 Common-rail pressure Trouble the difference between the target Fuel injection rate
9 sec. Prospective control
(Memorized) (pump excessive pressure feed) common-rail pressure and actual common (6WGI: max. 120 mm3/st)
continued
rail pressure is larger than 10MPa. (6SD1, 6TE1: max. 50 mm3/st)
PCV closing timing is below PCV closing Common-rail pressure regulation (max. 25MPa)
226 Supply pump no pressure feed timing control value + 1°CA or the 1 sec. Fuel injection rate -
(Memorized) or pressure limiter operated common-rail pressure F/B control value is continued (6WGI: max. 120 mm3/st)
below -60°CA. (6SD1, 6TE1: max. 60 mm3/st)
When the actual common-rail pressure is below

Common-rail pressure regulation (max. 25MPa) When the time elapsed exceeded the value
the target common-rail pressure +5MPa, the Approx. obtained from the difference between the
227 Pump no pressure feed Fuel injection rate
PCV closing timing is below the PCV closing 9 sec. target common-rail pressure and actual
(Memorized) (fuel out flow) (6WGI: max. 120 mm3/st)
timing limit value +1°CA or common-rain continued common-rail pressure, the control stops
(6SD1, 6TE1: max. 60 mm3/st)
pressure F/B control value is below 50°CA (power supply to TWV and PCV is stopped).
Common-rail pressure regulation (max. 60MPa) When the actual common-rail pressure
118 Actual common-rail pressure exceeded 0.2 sec. Fuel injection rate exceeded about 130MPa for about 0.2 seconds,
(Memorized) Common-rail pressure trouble about 125MPa. continued (6WGI: max. 120 mm3/st) the control stops (power supply to TWC and
(6SD1, 6TE1: max. 50 mm3/st) PCV stops).
Controlled water temperature at start

23 Water temperature sensor Water temperature sensor output value is 1 sec. = 6WG:-20, 6SD, 6TE: -20°C Control based on the backup value.
(Memorized) system trouble over 4.8V or below 0.1V. continued Other controlled water temperature
= 6SD, 6WG: 55, 6TE: 55°C
Held until ECU is turned OFF. When trouble 2 or 4 is judged, accelerator opening is controlled (fixed to
0%).
24 Accelerator sensor system Accelerator sensor output value is over 1 sec. When the accelerator SW is turned OFF, the accelerator is opened to 10% in 1.5 seconds and then
(Memorized) trouble 4.8V or below 0.1V. continued increased to 46% in 1.5 seconds (up to 46% at the maximum). When the accelerator switch is turned
ON, the accelerator opening is reduced to 10% in 1 second. After that, the accelerator opening is
controlled from 10% to 46% (1.5 sec.) and then 46% to 10% ( 1 sec.) with the accelerator switch.
241 Accelerator switch was turned OFF when the 1 sec. Controlled accelerator opening (max. 80% ) -
(Memorized) Accelerator SW OFF trouble accelerator sensor output value is below 0.65V. continued
242 Accelerator switch was turned ON when the 0.5 sec. Control based on the accelerator backup map
Controlled accelerator opening (max. 25% )
(Memorized) Accelerator SW ON trouble accelerator sensor output value exceeded 3.06V. continued (work map)
1st cylinder injector drive Fuel injection rate

271 Disconnection of TWV1 coil or harness - (6WGI: max. 180 mm3/st) -
(Memorized) system trouble (disconnected (6SD1, 6TE1: max. 60 mm3/st)
wire on the TWV side)
2nd cylinder injector drive Fuel injection rate

3rd cylinder injector drive Fuel injection rate

4th cylinder injector drive Fuel injection rate


275 Disconnection of TWV5 coil or harness (6WGI: max. 180 mm3/st) -

158 TWV power source system trouble TWV1, 3, 5 harness power source short circuit - -
(Memorized) (Common 1 "injector 1, 3, 5 system) or common 1 harness power source short circuit Power supply to TWV and PCV is stopped.
159 TWV power source system trouble TWV2, 4, 6, harness power source short circuit - -
(Memorized) (Common 2 "injector 2, 4, 6 system) or common 1 harness power source short circuit Power supply to TWV and PCV is stopped.
217 PCV 1 system short circuit (battery, When the PCV1 is turned ON, Key SW= PCV1 is turned OFF.
(Memorized) power source system circuit) trouble PCV1 drive voltage ON Common-rail pressure regulation (max. 60MPa)
218 PCV 2 system short circuit (battery, When the PCV2 is turned ON, Key SW=
(Memorized) power source system circuit) Common-rail pressure regulation (max. 60MPa) PCV1 is turned OFF.
trouble PCV2 drive voltage ON
247 Disconnection or short circuit of When the PCV1 is turned OFF, Key SW= -
(Memorized) PCV1 system (GND circuit) Common-rail pressure regulation (max. 60MPa)
248 Disconnection or short circuit of When the PCV2 is turned OFF, Key SW= -
(Memorized) PCV2 system (GND circuit) Common-rail pressure regulation (max. 60MPa)
421 When the PCV is turned OFF, After the key Main relay is turned OFF 5 seconds after the -
(Memorized) PCV power source trouble trouble PCV drive voltage SW = OFF key SW=OFF
2-19
Diagnostic trouble codes list
Note: Failure indication symbols of the service engine soon lamp (in user mode) are listed in the table below.
O: Conditional lighting up (going out at a speed more than 650rpm and lighting up again when the engine speed below 650rpm continued for 20 seconds) ◎ : Lights up continuously. -: Does not light up.
EGR PTO SERVICE ENGINESOON lamp Applicable engine

Intake
(common VGS CCS (common Auto cruise failure indication
shutter Control recovery conditions Remarks
to all (6SD1) (6WG1) to all (6SD1) 6SD1 6WG1 6TE1
(6TE1) DIAG SW DIAG SW
engines) engines) open (user) short circuit (dealer)
Regular Regular Regular Regular Regular Reset NE pulse was input. O 1·5 O O O
control control control control control completely.
Regular Regular Regular Regular Regular Reset G pulse was input. O 1·4 O O O
Regular Regular Regular Regular Regular Reset 1·4

NE pulse or G pulse was input. ◎ O O O
control control control control control completely. 1·5
Control Regular Regular Regular Control Reset Fuel pressure sensor output value is ◎ 2·4·5 O O O
stopped. control control control stopped. completely. below 4.7V and above 0.7V.
Control Regular Regular Regular Control Reset Fuel pressure sensor output value was ◎ 1·1·5 O O O
stopped. control control control stopped. completely. changed.
Control Regular Regular Regular Control Reset Engine stalls and actual common-rail ◎ 1·5·1 O O O
stopped. control control control stopped. completely. pressure is below 10MPa.
Control Regular Regular Regular Regular Reset Once the engine stalls, the engine ◎ 2·2·6 O O O
stopped. control control control control completely. does not stop.
Control Regular Regular Regular Regular Reset Once the engine stalls, the engine ◎ 2·2·7
stopped. control control control control completely. does not stop. O O O
When the actual common-rail

Control Regular Regular Regular Control Reset pressure is below 110MPa and
control stops, the engine stalls and ◎ 1·1·8
stopped. control control control stopped. completely. O O O
actual common-rail pressure is below
10MPa.
Regular Regular Regular Regular Regular Regular Water temperature sensor output is
O 2·3 O O O
control control control control control control over 0.1V and below 4.8V.
Control Regular Regular Regular Control Reset Held until ECU power source is
◎ 2·4
stopped. control control control stopped completely. turned OFF.
Regular Regular Regular Regular Regular Reset Held until ECU power source is
◎ 2·4·1 O O O
control control control control control completely. turned OFF.
Control Regular Regular Regular Control Reset Held until ECU power source is
◎ 2·4·2 O O O
stopped. control control control stopped. completely. turned OFF.
Control Regular Regular Regular Control Reset Current side is normal or engine does 6SD1, 6WG1: TWV1
◎ 2·7·1 O O O
stopped. control control control stopped. completely. not stall once it stalled. 6TE1: TWV1
◎ 2·7·2 O O O
Control Regular Regular Regular Control Reset Current side is normal or engine does ◎ 6SD1, 6WG1: TWV3
2·7·3 O O O
2·7·4 O O O
2·7·5 O O O
◎ 2·7·6 O O O
Control Regular Regular Regular Control Reset 1·5·8

Engine does not stall once it stalled. ◎ O O O
stopped. control control control stopped. completely. (COM1 system)

Engine does not stall once it stalled. ◎ O O O
stopped. control control control stopped. completely. (COM2 system)

Normal PCV1 drive voltage ◎ O O O
stopped. control control control stopped. completely. (PCV1 )
When the trouble has been

Control Regular Regular Regular Control Reset 2·1·8 memorized as a past failure,
Normal PCV2 drive voltage ◎ O O O
stopped. control control control stopped. completely. (PCV2) the SERVICE ENGINE
SOON lamp lights up.
When the trouble has been

Control Regular Regular Regular Control Reset Held until ECU power source is 2·4·7 memorized as a past failure,
stopped. control control control stopped. completely. turned OFF. ◎ (PCV1) the SERVICE ENGINE O O O
SOON lamp lights up.
Control Regular Regular Regular Control Reset Held until ECU power source is 2·4·8
stopped. control control control stopped. completely. turned OFF. ◎ (PCV2) O O O
Regular Regular Regular Regular Regular Reset -

- 4·2·1 O O O
2-20
Backup control
diagnostic Judge
trouble Item Failure Contents Time DATA Control
code

Fuel temperature sensor output value is
211 Fuel temperature sensor system 1 sec. = 6SD,6WG, 6TE: -25°C
over 4.8V Control based on the backup value.
(Memorized) trouble continued Other controlled water temperature
or below 0.1V. = 6SD, 6WG:, 6T: E40°C

Fuel temperature sensor output value is
22 Atmospheric temperature sensor 1 sec. = 6SD,6WG, 6TE: -25°C
over 4.8V Control based on the backup value.
(Memorized) trouble continued Other controlled water temperature
or below 0.1V. = 6SD, 6WG:, 6T: E40°C
2
32 At the time of engine stall, boost relative 1 sec. Control boost relative pressure Control based on the backup value.
(Memorized) Boost sensor system Trouble pressure is over 20kPa or below 32 kPa. continued = 0kPa
42 0.5 sec.
(Memorized) High boost trouble High boost pressure was detected. - -
continued
65 25 sec.
(Memorized) Low boost trouble Low boost pressure was detected. - -
continued
Engine speed is more than specified.

543 6SD1: 2950rpm
(Memorized) Excessive high engine speed - - Power supply to TWV and PCV is stopped.
6WG1: 2950rpm
6TE1: 2950rpm
71 Atmospheric temperature sensor output

(Memorized) Atmospheric pressure sensor 1 sec.
value is over 4.7V Controlled atmospheric temperature = 100kPa Control based on the backup value.
trouble continued
or below 1.9V.
25 Vehicle speed sensor output value is 1 sec. Service engine soon lamp lights ON on
(Memorized) Vehicle speed sensor trouble -
below 0.5V continued vehicles equipped with NR control.
416 Main relay = OFF output (when key 5 sec.

Main relay trouble - -
(Not Memorized) SW=OFF, power supply to ECU is not cut off) continued
411 1.2 sec.

(Memorized) M/V:A drive system trouble Drive voltage trouble when M/V A=ON - M/V A control is stopped.
continued
412 1.2 sec.

(Memorized) M/V:B drive system trouble Drive voltage trouble when M/V B=ON - M/V A, B, and C control is stopped.
continued
415 1.2 sec.

(Memorized) M/V:C drive system trouble Drive voltage trouble when M/V C=ON - M/V A, B, and C control is stopped.
continued
Fail safe relay [A] system

418 trouble Improper relay drive voltage when F/S 1 sec. - M/V A, B, C, D and E control is stopped
(Memorized) (SD1: VGS M/V relay error REL A=ON. continued
6TE1: INT/S M/V relay error)
518 Learned accelerator voltage value data is

EOL data error - - Control based on the backup value.
(Not Memorized) not input.
Abnormal waveform (PWM) of ASR 10 sec.

- ASR signal error - ASRcontrol is stopped
communication was detected. continued
When PTO/SW=ON, the all speed When an error occurrence is judged, all speed accelerator opening is controlled (fixed to 0%).
- All speed accelerator sensor 1 sec. After that, when the accelerator pedal opening decreases below 5%, control is made as the all
accelerator sensor output value is over
error continued speed accelerator opening = accelerator pedal opening.
4.8V or below 0.1V.
417 When the engine speed exceeded 1.6sec.

(Memorized) Starter switch trouble 1000rpm, starter SW S signal was - -
continued
detected continuously.
33 Trouble of IC for CPU monitor was

(Memorized) IC for CPU monitor trouble - Control of fuel injection rate (60 mm3/st max.) Control based on the backup value.
detected trouble.
35 All analog input system is controlled by

(Memorized) A/D conversion error Trouble of A/D conversion was detected. - -
backup value.
35
(Memorized) Charge circuit trouble Incorrect charge voltage was detected. - - Power supply to TWV and PCV is stopped.
- CPU trouble CPU trouble - - Power supply to TWV and PCV is stopped.
Diagnostic trouble 42 displayed after 0.5 sec.

42·32 VGS is stopped, and M/V A, B, and C control
High boost trouble 0.5S, continued 10 S and then 32 10 sec. - is stopped.
displayed. continued
Low boost range is judged to be 2 sec.

65 Low boost trouble insufficient at ACC: more than 50% and - -
continued
continued for 25 sec.
2-21
Note: Failure indication symbols of the service engine soon lamp (in user mode) are listed in the table below.
O: Conditional lighting up (going out at a speed more than 650rpm and lighting up again when the engine speed below 650rpm continued for 20 seconds) ◎ : Lights up continuously. -: Does not light up.
EGR (co PTO SERVICE ENGINE SOON lamp Applicable engine

Intake
mmon to VGS CCS (common Auto cruise failure indication
shutter Control recovery conditions Remarks
all (6SD1) (6WG1) to all (6SD1) 6SD1 6WG1 6TE1
(6TE1) DIAG SW DIAG SW
engines) engines) open (user) short circuit (dealer)
Regular Regular Regular Regular Regular Regular Fuel temperature sensor output is over 2·1·1
control - O O O
control control control control control 0.1V or below 4.8V
Regular Regular Regular Regular Regular Regular Atmospheric temperature sensor 2·2
control O O O O
control control control control control output is over 0.1V and below 4.8V
Control
2
Regular Regular Regular Reset When the engine installs, boost relative 3·2
stopped. - O O O -
control control control completely. pressure is below 20kPa or over 16kPa.
Control Control - - Regular Reset 4·2

stopped. Held until ECU is turned OFF. ◎ O O -
stopped control completely.
Regular Regular Regular Regular Regular Regular 6·5
control Held until ECU is turned OFF. - O O -
control control control control control
When the engine speed decreases

Regular below specified value,
Regular Regular Regular Regular Reset 5·4·3
control 6SD1: 2750rpm -
control control control control completely. O O O
6WG1: 2750rpm
6TE1: 2750rpm
Control Regular Regular Reset Atmosphere sensor output is over 7·1
stopped. - - - O O
control control completely. 1.9V and below 4.7V. -
Regular Regular Regular Regular Regular Reset Vehicle speed sensor voltage is over - 2·5
control control control control control completely. 0.5V and vehicle speed pulse is input. O O O
Regular Regular Regular Regular Regular Reset 4·1·6
control Held until ECU is turned OFF. O O O O
control control control control completely.
Control Reset Control Control Control Reset 4·1·1
stopped. completely stopped Held until ECU is turned OFF. ◎ O O O
stopped. stopped. completely.
Control When the engine is turned ON

Control Control Control Reset 4·1·2
stopped. - Held until ECU is turned OFF. ◎ again with the key, failure is - O
stopped stopped stopped. completely. indicated.
Control Control Control Control Reset 4·1·5
stopped. - Held until ECU is turned OFF. ◎ O O O
stopped stopped stopped. completely.
Control Regular Regular Regular Regular Reset
stopped. Held until ECU is turned OFF. O 4·4·3 O O O
Control Regular Regular Regular Regular Reset 4·1·3
stopped. Held until ECU is turned OFF. O O O O
Control Control Control Control Control Reset When F/S REL A=ON, relay drive 4·1·8
stopped. O O O O
stopped. stopped. stopped stopped. completely. voltage is normal.
Control Regular Control Control Control Reset When F/S REL B=ON, relay drive 4·2·4
stopped. O O O O
control stopped. stopped.. stopped. completely. voltage is normal.
Regular Regular Regular Regular Regular Reset Leaned value data of accelerator 5·1·8
control control control control control completely. voltage was input to ECU. ◎ O O O
Regular Regular Regular Regular Regular Regular Normal waveform (PWM) of ASR -
control control control control control control communication was detected. - O O O
Control Regular Regular Regular Regular Regular - -

stopped. Held until ECU is turned OFF. O O
O
Regular Vehicles
Regular Normal waveform (PWM) of 5·1·1
control - - - - - equipped -
control ECOGIT was detected. - with
ECOGI
Regular Regular Regular Regular Regular Regular 4·1·7

control Starter SW=OFF - O O O
Regular Regular Regular Regular Regular Reset
control Held until ECU is turned OFF. ◎ 3·3 O O O
Control Control Regular Regular Regular Reset
stopped. Normal A/D conversion ◎ 3·5 O O O
stopped control control control completely.
Control Control Control Control Control Reset Once the engine installs, it does not
stopped. stopped stopped. stopped stopped. completely. install anymore. ◎ 3·5 O O O
Control Control Control Control Control Reset -

stopped. stopped. stopped. stopped. completely. - ◎ O O O
stopped.
Control (A) 42
- - - - - - ◎ (B) 32 O - -
stopped
- - - - - - - - 6·5 O - -
2-22
Chapter 3
Functional diagnosis
3
Chapter 3 Functional diagnosis
Preface
For the purpose of keeping engine operation normal or to restore the engine operation to normal condition,
functional diagnosis is made. If some engine control functions are not properly working, the engine control unit
diagnoses erroneously or some error showing no diagnostic trouble code occurs so that diagnosis cannot be made
correctly.
Follow the inspection procedure described on the following pages for diagnosis (check or repair) of functions.
3-2
Checking of SERVICE ENGINE SOON lamp lighting circuit
system (SERVICE ENGINE SOON lamp does not turn ON)
Engine control/SERVICE ENGINE SOON lamp circuit

ENGINE CONTROL UNIT CONNECTOR 120 PIN
40 PIN RL 0.5
80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
LgB 0.5
Brw 0.5
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
SDL 10 11 12 13 14 15 16 17 18 19 20 21
21 20 19 18 17 16 15 14 13 12 11 10
32 31 30 29 28 27 26 25 24 23 22
(BLACK) 22 23 24 25 26 27 28 29 30 31 32
Brw 0.5
1 2 3 4 5 6 7 8 9 10
111213141516 17 1819202122
ECU HARNESS
3
Brw 0.5
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 38
39 37
41 42 43 44
SMJ 44 43 42 41 1 2 3 4 5 6 7
(WHITE) 8 9 10 11 12 13 14 15
48 47 46 45
45 46 47 48
60 59 58 57 56 55 54 53 52 51 50 49
49 50 51 52 53 54 55 56 57 58 59 60
72 71 70 69 68 67 66 65 64 63 62 61
61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 84 83 82 81 80 79 78 77 76 75 74 73
INSTRUMENT (LOWER) INSTRUMENT (UPPER) HARNESS

HARNESS
LgB 0.5
1 1
DIAG. SWITCH
B 1.25
B 1.25
RL 0.5
ECU GND
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
CASE GND
1 1
MEMORIAL SWITCH
3-3
Checking of service engine soon lamp lighting circuit system
(SERVICE ENGINE SOON lamp does not turn ON)
Engine control unit power source, GND circuit
CASE GND POWER GND

40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
VW 1.25 RW 1.25
B 1.25
Y 0.5
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
1 2 3 4 5 6 7 8
19 20 B 1.25
9 10 11 12 13 14 15 16 17 18
22 23 24 25 26 27 28 29 30 31 32
LR 0.5 B 1.25
B 1.25
25
FUSE 20
1 2 3 4 5 6 7 8 9 10 11
3
12 13 14 15 16 17 18 19 20 21 22
5 1
4 2
9 8 7 6 5 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10
MAIN RELAY 32 31 30 29 28 27 26 25 24 23 22
ECU HARNESS SIDE

RW 1.25
1
25
LR 0.5
2 4
B2
3
Y 0.5
FUSE 45
O 1.25
8 7 6 5 4 3 2 1
10 9 8 7 6 5 4 3 2 1 20 19
18 17 16 15 14 13 12 11 10 9
20 19 18 17 16 15 14 13 12 11
1 2 3 4 5 6 7
8 9 10 11 12 13 14 B 1.25
15 16 17 18 19 20
21 22 23 24 B 1.25
25 26 27 28 DIAG. CONNECTOR
29 30 31 32 1 2 3 4 5 6 7 8 9 10 11
33 34 35 36
37 38 39 40 41 42 12 13 14 15 16 17 18 19 20 21 22
43 44 45 46 47 48 49
50 51 52 53 54 55 56
46
JOINT CONNECTOR (2)
INSTRUMENT (LOWER) HARNESS
7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
14 13 12 11 10 9 8
20 19 18 17 16 15 2221201918 17 16 1514131211
24 23 22 21
28 27 26 25
B2
32 31 30 29
36 35 34 33
42 41 40 39 38 37
49 48 47 46 45 44 43
56 55 54 53 52 51 50
1 2 3 4 5 6 7 8 9 10
46 111213141516 17 1819202122
BL 2 B2
FRAME HARNESS SIDE
3-4
Circuit description
Power to operate the meter (SERVICE ENGINE SOON lamp {enginge conrol}) is supplied through the fuse
No.11.
Lighting up and going out of the lamp are controlled with the engine control unit. (The engine control unit
is located in the circuit between the power source and GND (ground) circuit to operate the lamp control
switch in the control unit and light up or extinguish the lamp.)
Possible causes
⋅ Faulty power supply circuit (starter switch circuit, battery relay circuit, etc.)
⋅ Faulty main unit (indicator, communication circuit)
⋅ SERVICE ENGINE SOON lamp (bulb) burnt out
⋅ Faulty meter main assembly (including circuits)
⋅ Disconnected wire of meter power source circuit
⋅ Disconnected wire of lamp driving circuit
⋅ Faulty engine control unit
3
⋅ Faulty engine control unit power circuit (key ON)
⋅ Faulty engine control unit power source circuit (main relay circuit)
⋅ Faulty engine control unit GND circuit
3-5


1 Check the fuses. Fuses are normal Step 3 Step 2
Check if the fuse for meter power (No.11) and the fuses for Engine (OK) (NG)
Control Unit (No.17 for key ON signal and No.45 for main relay
power) are normal.
2 Replace the fuses, and check if the ENGINE CONTROL/SERVICE Lamp ON (operated) Step 18 Step 3
ENGINE SOON lamp turns on (operated) when the starter switch is (OK) (NG)
turned on again.
3 Check if the voltage is applied to respective fuses Battery voltage Step 4 Checking
1. Remove the fuses No.11, 17, and 45. (OK) the
2. Turn the starter switch on. power
3. Measure the voltage at each fuse mounting place. source
Is the voltage normal value? circuit
(NG)
4 1. Disconnect the harness from the Engine Control Unit. Lamp ON (operated) Step 10 Step 5
2.Ground (GND) the connector (No.105 pin) of the Engine Control (OK) (NG)
Unit.
3.Turn the starter switch on.
5 Check the connector and harness of the meter circuit. No fault is found Step 7 Step 6
1. Disconnect the harness from the meter. (OK) (NG)
2. Disconnect the harness from the Engine Control Unit.
3. Check the connectors for corrosion, looseness, opening, or fitting
conditions of pins.
4. Referring to the circuit diagrams, check the following circuits:
⋅ Between power source and meter
1) Fuse No.17 to instrument (upper) harness connector
2) Meter to instrument (lower) harness connector
⋅ Between Engine Control Unit and meter
1) Engine Control Unit to instrument (lower) harness connector
2) ECU harness connector to instrument (upper) harness
connector
3) Meter to instrument (lower) harness connector
Are the harnesses and connectors normal?
3-6

6 Repair faulty parts (connectors and harnesses) in the meter circuit. Lamp ON (operated) Step 18 Step 7
After repair, check if the lamps other than ENGINE (OK) (NG)
CONTROL/SERVICE ENGINE SOON lamp turn on (operate)
when the starter switch is turned on again.
7 Is multi-warming display attached to the meter? - Step 10 Step 8
8 Check the warning lamp bulb. Bulb is normal Step 10 Step 9
Is the bulb broken? (OK) (NG)
9 Replace the warning lamp bulb. Lamp ON (operated) Step 18 Step 10
After repair, check if the SERVICE ENGINE SOON lamp turns on (OK) (NG)
(operates) when the starter switch is turned on again.
Did the meter (lamp) operate?
10 Check the power source for the Engine Control Unit. Battery voltage Step 12 Step 11
2. Turn the starter switch on.
(OK) (NG) 3
3. Measure the voltage at the connector of Engine Control Unit
(No.13 and 23 pins).
Is the voltage normal value?
11 Repair the harness between fuse No.17 and Engine Control Unit. Lamp ON (operated) Step 18 Step 12
12 Check the main relay circuit (harnesses and connectors) and the No fault is found Step 14 Step 13
relays. (OK) (NG)
2. Remove the main relay.
conditions of pins.
⋅ Engine Control Unit to instrument (lower) harness connector
⋅ ECU harness connector to main relay
⋅ Fuse No.45 to main relay
⋅ Fuse No.45 to frame (Ft) harness connector
⋅ Instrument (lower) harness connector to ground point
5. Check the relays for function.
Are the harnesses, connectors, and relays normal?
3-7

13 Repair faulty harness, connector, or relay in the main relay circuit. Lamp ON (operated) Step 18 Step 14
14 Check the GND for Engine Control Unit. No fault is found Step 16 Step 15
1. Disconnect the harness from the Engine Control Unit. (OK) (NG)
conditions of pins.
⋅ ECU harness connector to frame (Ft) harness connector
⋅ Instrument (lower) harness connector to ground point
15 Repair faulty harnesses and connectors in the ground circuit for the Lamp ON (operated) Step 18 Step 16
Engine Control Unit. (OK) (NG)
After repair, check if the lamps other than ENGINE
16 Replace the meter assembly. Lamp ON (operated) Step 18 Step 17
17 Replace the Engine Control Unit. - Step 18 -
*After the Engine Control Unit was replaced, perform the
accelerator learning.
18 Restore the vehicle, and perform the repair check. - Check -
end
3-8
Connection of meter connector

<Vehicles with multi-warning>
Connector D
Connector F
Connector A
3
Connector B
Connector C
Connector E
Connector G
<Vehicles without multi-warning>
SERVICE ENGINE SOON Lamp
Connector D
Connector A
Connector B
Connector C
Connector E
For air suspension warning

Connector H Connector F
3-9
GND point
1
Legend
1 Battery Earth
3-10
Checking the SERVICE ENGINE SOON lamp flickering control system
(SERVICE ENGINE SOON lamp does not flicker)
Engine control/SERVICE ENGINE SOON lamp circuit

40 PIN RL 0.5
80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
LgB 0.5
Brw 0.5
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
SDL 10 11 12 13 14 15 16 17 18 19 20 21
21 20 19 18 17 16 15 14 13 12 11 10
32 31 30 29 28 27 26 25 24 23 22
(BLACK) 22 23 24 25 26 27 28 29 30 31 32
Brw 0.5
1 2 3 4 5 6 7 8 9 10
111213141516 17 1819202122
ECU HARNESS
3
Brw 0.5
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 38
39 37
41 42 43 44
SMJ 44 43 42 41 1 2 3 4 5 6 7
(WHITE) 8 9 10 11 12 13 14 15
48 47 46 45
45 46 47 48
60 59 58 57 56 55 54 53 52 51 50 49
49 50 51 52 53 54 55 56 57 58 59 60
72 71 70 69 68 67 66 65 64 63 62 61
61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 84 83 82 81 80 79 78 77 76 75 74 73
INSTRUMENT (LOWER) INSTRUMENT (UPPER) HARNESS

HARNESS
LgB 0.5
1 1
DIAG. SWITCH
B 1.25
B 1.25
RL 0.5
ECU GND
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
CASE GND
1 1
MEMORIAL SWITCH
3-11
Circuit description
Power to operate the meter (ENGINE CONTROL/SERVICE ENGINE SOON lamp{engine contorl}) is
supplied through the fuse No.11.
Lighting up and going out of the lamp flickering are controlled with the engine control unit. (The engine
control unit is located in the circuit between the power source and (GND), to operate the lamp control switch
in the engine control unit and lighting up or extinguish the lamp flicker.)
Possible causes
⋅ Faulty meter main assembly (including circuits)
⋅ Shorted lamp driving circuit
⋅ Faulty diagnostic switch circuit

1 Check the diagnostic switch (connector) circuit. No fault is found Step 3 Step 2
conditions of pins.
⋅ Between Engine Control Unit and diagnostic switch (connector)
2) ECU harness connector to diagnostic switch (connector)
⋅ Between diagnostic switch (connector) and ground (GND)
1) Diagnostic switch (connector) to frame (Ft) harness connector
2) Instrument (lower) harness connector and ground (GND)
2 Repair faulty harnesses and connectors in the diagnostic switch Flicker (operate) Step 9 Step 3
(connector) circuit. (OK) (NG)
After repair, check if the lamps other than ENGINE
CONTROL/SERVICE ENGINE SOON lamp flicker (operate) when
the starter switch is turned on again.
3-12

3 Check the connector and harness of the meter circuit. No fault is found Step 5 Step 4
1. Disconnect the harness from the meter. (OK) (NG)
conditions of pins.
⋅ ECU harness connector to instrument (upper) harness connector
⋅ Meter to instrument (lower) harness connector
4 Repair faulty parts (connectors and harnesses) in the meter circuit. Flicker (operated) Step 8 Step5
CONTROL/SERVICE ENGINE SOON lamp flicker (operate) when
3
5 Replace the meter assembly, and connect all harnesses for the Engine Starter switch ON: Step 6 Step 7
Control Unit, etc. Lamp ON (OK) (NG)
After repair, check if the lamps other than ENGINE Starter switch OFF:
CONTROL/SERVICE ENGINE SOON lamp operate normally Lamp OFF
6 After repair, check if the lamps other than ENGINE Flicker (operated) Step 8 Step 7
CONTROL/SERVICE ENGINE SOON lamp flicker (operate) when (OK) (NG)
*After the Engine Control Unit is replaced, perform the accelerator (OK)
learning.
Did corrective action complete?
8 Restore the vehicle, and perform the repair check. - Check
end
3-13
Diagnosis switch (connector)

Connectors 1 and 2 are always connected. To turn ON the lamp, disconnect 1 and 3.
Installing position
When the inspection cover is removed

1 2

6 Wound with PVC-Y tape
1 Black 20 pin connector
4
2 Black 20 pin connector
7
3 White 20 pin connector
5
8 9 10
12
11
13
3-14
Connection of meter connector

<Vehicles with multi-warning system>
Connector D
Connector F
Connector A
3
Connector B
Connector C
Connector E
Connector G
<Vehicles without multi-warning>
SERVICE ENGINE SOON Lamp
Connector D
Connector A
Connector B
Connector C
Connector E
For air suspension warning

Connector H Connector F
3-15
Checking the Tech II
Self-diagnosis circuit (Engine control unit)

40 PIN 80 PIN
MEMORY CLEAR SW. RL 0.5
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
DIAGNOSIS SW. 26 25 21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
61 62 63 64 65 66 67 68 69 70
71 72 73 74 75 76 77 78 79 80
101 102 103 104 105 106 107 108 109 110
111 112 113 114 115 116 117 118 119 120
RL 0.5
1 G 0.5
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
SDL
21 20 19 18 17 16 15 14 13 12 11 10 10 11 12 13 14 15 16 17 18 19 20 21
G 0.5 (BLACK)
1 32 31 30 29 28 27 26 25 24 23 22
22 23 24 25 26 27 28 29 30 31 32
LR 0.5 WR 0.5
WR 0.5 LR 0.5
25
JOINT CONNECTOR(2)
13
26
4
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 8 7 6 5 4 3 2 1 SDL 1 2 3 4 5 6 7 8
20 19 19 20
18 17 16 15 14 13 12 11 10 9 (WHITE) 9 10 11 12 13 14 15 16 17 18
B 1.25
B 1.25
13
ECU HARNESS
TO TECH II, TECH II SIGNAL (TRANSMISSION)
LR 0.5
LC TYPE FROM TECH II, TECH II SIGNAL (RECEIVED)
FUSE 22
(WHITE) V 0.5
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
WR 0.5
TECH II CONNECTOR
3-16
Circuit description
Two Tech II communication circuits are provided; one in the signal communication circuit from the engine
control unit to the Tech II and other in the signal reception circuit from the Tech II to the engine control unit.
The signal from the transmission side is used for the "monitor" mode to read the self-diagnosis codes or
engine data with the Tech II.
The signal from the reception side is used for the "communication mode" to erase the self-diagnosis codes,
etc., or for the "inspection mode" to check the accelerator learning or switches.
Possible causes
⋅ Faulty the circuit from the engine control unit connector to Tech II connector (disconnected wire, short
circuit, etc.)
⋅ Faulty Tech II connector power source
3
3-17

1 Check the fuse. Fuse is normal Step 3 Step 2
Is the power fuse (No.22) for Tech II normal? (OK) (NG)
2 Replace the fuse, and turn the starter switch on again to check the Lamp ON (operated) Step 15 Step 3
Tech II for function. (OK) (NG)
Does the Tech II operate?
3 Check the Tech II power supply. Battery voltage Step 7 Step 4
Check if the voltage is applied to the Tech II when the starter switch (OK) (NG)
is turned on.
Is the voltage applied?
4 Check if the voltage is applied to the fuse No.22 when the starter Battery voltage Step 5 Step 6
switch is turned on. (OK) (NG)
Is the voltage applied?
5 Repair the power supply circuit for the Tech II. Tech II operates Step 15 Step 6
After repair, check the Tech II operation when the starter switch is (OK) (NG)
turned on again.
6 Repair or replace the power supply circuit (fuse No.22). Tech II operates Step 15 Step 7
(See Section 6, Wiring check "power supply circuit") (OK) (NG)
After repair, check the Tech II operation when the starter switch is
turned on again.
7 Check the Tech II connector circuit. No fault is found Step 9 Step 8
conditions of pins.
⋅ Between Engine Control Unit and Tech II connector
2) ECU harness connector to Tech II connector
8 Repair faulty harnesses and connectors in the Tech II connector Tech II operates Step 15 Step 9
circuit. (OK) (NG)
After repair, check the Tech II operation when the starter switch is
turned on again.
9 Check the fuse (2A) inside the Tech II. No fault is found. Step 11 Step 10
Is the fuse (2A) normal? (OK) (NG)
10 Replace the fuse (2A) inside the Tech II. Tech II operates Step 15 Step 11
After repair, check the Tech II operation when the starter switch is (OK) (NG)
turned on again.
3-18

11 Check the diagnosis harness. No fault is found. Step 13 Step 12
Is the diagnosis harness normal? (OK) (OK)
12 Repair or replace the diagnosis harness. Tech II operates Step 15 Step 13
After repair or replacement, check again the Tech II operation. (OK) (NG)
13 Check the Tech II. Tech II turns on (starts) Step 15 Step 14
1. Remove the Tech II from the vehicle. (OK) (NG)
2. Install the 100V power adapter to the Tech II.
3. Turn the Tech II on.
Does the Tech II turn on (start)?
14 Replace the Tech II. - Step 15 -
15 Check the communicating condition between Engine Control Unit
and Tech II.
Communication enabled Step 19 Step 16
(OK) (NG)
3
1. Install the Tech II on the vehicle.
2. Communicate with the Engine Control Unit (IE system). (Two
kinds of program cards are provided, each for power train and for
chassis. For the IE system, use the card for power train.)
Is the communication with Engine Control Unit enabled?
16 Check the Tech II (program card). Communication enabled
1. Install the Tech II on the vehicle. Step 17 Step 14
2. Communicate with the systems (HSA, ABS, etc.) except the (OK) (NG)
engine. (Two kinds of program cards are provided, each for power
train and for chassis.)
Is the communication with the systems except engine enabled?
17 Replace the Tech II (program card for power train), and Communication enabled Step 19 Step 18
communicate with the Engine Control Unit (IE system). (OK) (NG)
Is the communication with Engine Control Unit enabled?
*After the Engine Control Unit is replaced, perform the accelerator
learning.
19 Communicate with the DMU (Data Memory Unit). Communication enabled Step 25 Step 20
Is the communication with the DMU (Data Memory Unit) enabled? (OK) (NG)
3-19

20 Referring to the circuit diagrams, check the harnesses and connectors No fault is found. Step 22 Step 21
in the DMU (Data Memory Unit) circuit. (OK) (NG)
⋅ Diagnosis connector, DMU switch, memory switch connector to
floor (left) harness connector
⋅ Fuse No.7, 50 to floor (left) harness connector
⋅ Sheet harness connector to instrument (lower) harness connector
⋅ DMU (Data Memory Unit) to floor (left) harness connector
Are the connectors and harnesses normal?
21 Repair or replace the DMU (Data Memory Unit) circuit. Communication enabled Step 25 Step 22
After the repair or replacement, communicate again with the DMU (OK) (NG)
(Data Memory Unit).
Is the communication with the DMU (Data Memory Unit) enabled?
22 Check the DMU (Data Memory Unit) for a checking method and - Step 23 -
using method.
(See Chapter 7, DMU (Data Memory Unit), switch box)
Did the corrective action complete?
23 Communicate with the DMU (Data Memory Unit). Communication enabled Step 25 Step 24
Is the communication with the DMU (Data Memory Unit) enabled? (OK) (NG)
24 Replace the DMU (Data Memory Unit). - Step 25 -
end
3-20
Checking the engine starting system
Possible causes
⋅ Faulty starting system (starter, starter relay, starter circuit, battery, etc.)
⋅ Engine control system down (faulty Engine Control Unit, power source, GND, etc.)
⋅ Faulty supply pump (main body, PCV, feed pump)
⋅ Faulty injectors
⋅ Faulty common rail
⋅ Faulty fuel system (empty fuel, faulty piping, filter, air mixing, frozen fuel, etc.)
⋅ Faulty intake system (filter, intake shutter, etc.)
⋅ Faulty exhaust system (exhaust brake, etc.)
⋅ Engine trouble

Steps
1
Checking and Corrective Actions
Check the battery voltage, and if faulty, recharge or replace the
Result
-
YES
Step 2
NO
-
3
battery.
Did the corrective action complete?
2 Check the starter operation. Starter operates Step 3 Checking
Does the starter operate? (OK) the starter
circuit
After
repair and
check, step
3 (NG)
3 Check the starter for function. - Step 4 Referring
1. Turn the starter switch off. to the
2. Remove the starter. engine
3. Check the starter, and repair or replace, if faulty. repair
Did corrective actions complete? manual,
check the
starter,
then after
repair or
replacement,
step 4
4 With the starter removed, check the flywheel (ring gear) and starter - Step 5 -
pinion, and repair or replace if faulty.
5 After repair, start the engine again. Engine starts Step 18 Step 6
Does the engine start? (OK) (NG)
3-21

6 Check the fuel system. (Go to "Checking the fuel system") - Step 7 Check
Did corrective action complete? (OK) the fuel
system,
and
after
repair
and
check,
step 7
(NG)
7 After repair or replacement, start the engine again. Engine starts Step 18 Step 8
8 Check the intake system. (Go to "Checking the intake system") - Step 9 Check
Did corrective action complete? (OK) the
intake
system,
and
after
repair
and
check,
step 9
(NG)
9 Check the exhaust system. (Go to "Checking the exhaust system") - Step 10 Check
Did corrective action complete? (OK) the
exhaust
system,
and
after
repair
and
check,
step 10
(NG)
11 Check the fuel injection timing. At flywheel: BTDC 0° Step 13 Step 12
Check the mechanical timing at two places of supply pump and At supply pump (OK) (NG)
flywheel. (coupling): Scribed line
Is the mechanical timing normal? coincides with pointer
12 Adjust the engine mechanical timing. Engine starts Step 18 Step 13
After adjustment, start the engine again. (OK) (NG)
3-22

13 Check if the diagnostic trouble codes have been detected. The specified diagnostic Step 14 Checking
(Diagnostic trouble codes that stop the engine by the backup control) trouble codes are not (OK) by
1. Connect the Tech II. detected diagnosti
2. Check if the following diagnostic trouble codes are detected. c trouble
Diagnostic trouble codes: 14, 15, 227, 118, 158, 159 code.
Are diagnostic trouble codes detected? After
repair
and
check,
step 14
(NG)
15
Replace the Engine Control Unit. -
(OK)
Step 16
(NG)
-
3
*After the Engine Control Unit is replaced, perform the accelerator
learning.
16 After repair, start the engine again. Engine starts Step 18 Step 17
17 Check mechanical parts of the engine, and repair if faulty. - Step 18 -
⋅ Valves
⋅ Compressive pressure
⋅ Timing gear
⋅ Piston and crank related parts
end
3-23
Checking the power supply circuit
Power Supply Circuit (including starter switch signal circuit)

3
5 1 40 PIN 80 PIN
MAIN RELAY 4 2
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
RW 1.25 21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
1 31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
RL 0.3 2 4
B 0.3
3
BW 0.5
5
CONTROL UMT POWER SUPPLY RW 1.25
Y 0.5
7 7
Y 0.5
1 2 3 4 5 6 7 8 9
MAIN RELAY
9 8 7 6 5 4 3 2 1
SDL
21 20 19 18 17 16 15 14 13 12 11 10
FUSE 45 (BLACK) 10 11 12 13 14 15 16 17 18 19 20 21
RW 1.25 32 31 30 29 28 27 26 25 24 23 22
22 23 24 25 26 27 28 29 30 31 32
ECU HARNESS
BW 0.85
1 2 3 4 5 6 7 7 6 5 4 3 2 1
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
21 22 23 24 24 23 22 21
25 26 27 28 28 27 26 25
SMJ
29 30 31 32
(WHITE) 32 31 30 29
33 34 35 36 36 35 34 33
37 38 39 40 41 42 42 41 40 39 38 37
BL2
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
BL2
1 2
3-24
Circuit description
The power is supplied to respective units through two systems; the one is battery direct power supplied via
the Slow Blow Fuse (SBF) No.1, and the other is the power supplied to the SBF via the battery relay that
operates when the starter switch is in ON position and then the power is supplied from the SBF to each unit.
The Engine Control Unit and meter are driven by the power supplied via the battery relay.
The starter switch and power tilt circuit are driven by the battery direct power.
Possible causes
⋅ Faulty battery (liquid quantity, specific gravity, etc.)
⋅ Blown slow blow fuse (SBF)
⋅ Blown fuses
⋅ Faulty battery relay (internal disconnection, sticking, etc.)
⋅ Faulty starter switch
⋅ Faulty harnesses (disconnection, shortcircuit, etc.)
1) SBF (SBF box harness) - Frame (Ft) harness - Starter switch/fuse box "instrument (lower) harness"
3
2) Battery relay (SBF box harness) - Ground point "frame (Ft) harness"
3) Faulty battery cables (loose connection, etc.)

1 Check the Slow Blow Fuses (SBF No.1 - 7). SBF’s are normal Step 3 Step 2
1. Turn the starter switch off. (not blown) (OK) (NG)
Remove the SBF box cover, and check SBF’s.
2 Replace the SBF’s. - Step 3 -
3 Check if the voltage is applied to the Slow Blow Fuse (SBF) No.1. Battery voltage Step 5 Step 4
Is the voltage applied to the SBF No.1? (OK) (NG)
4 Check the battery for voltage, cable condition or disconnection, and - Step 5 -
repair or replace if faulty.
5 Check if the voltage is applied to the fuse (No.28). Battery voltage Step 7 Step 6
(Power is supplied to the left terminal of the fuse) (OK) (NG)
Is the voltage applied to the fuse (No.28)?
3-25

6 Check the fuse power supply circuit for disconnection, and repair or - Step 7 -
replace faulty part. (OK)
1. Disconnect negative terminal of the battery.
2. Check the following circuit for continuity:
⋅ Power supply terminal of fuse No.28 to frame (Ft) harness
connector
⋅ Instrument (lower) harness connector to Slow Blow Fuse box
harness connector
⋅ Slow Blow Fuse No.1 to frame (Ft) harness connector
7 Check if the voltage is applied to the frame (Ft) harness connector, Starter switch OFF: 0V Step 8 Step 13
pin 1 "instrument (slow) harness" when the starter switch is turned Starter switch ON: (OK) (NG)
ON (OFF/0V to ON/battery voltage). (Battery relay power supply Battery voltage
circuit)
Is the battery voltage applied to the frame (Ft) harness connector?
8 Check if the voltage is applied to the battery relay connector "frame Starter switch OFF: 0V Step 9 Step 16
(Ft) harness" when the starter switch is turned ON (OFF/0V to Starter switch ON: (OK) (NG)
ON/battery voltage). Battery voltage
Is the battery voltage applied to the battery relay connector?
9 Check if the voltage is applied to the Slow Blow Fuses (SBF) No.2 - Starter switch OFF: 0V Step 10 Step 18
6 when the starter switch is turned ON (OFF/0V to ON/battery Starter switch ON: (OK) (NG)
voltage). Battery voltage
Is the battery voltage applied to the SBF No.2 - 6?
10 Check if the voltage is applied to the frame (Ft) harness connector Starter switch OFF: 0V Step 11 Step 19
(slow blow fuse box harness) when the starter switch is turned ON Starter switch ON: (OK) (NG)
(OFF/0V to ON/battery voltage). Battery voltage
11 Check if the voltage is applied to the instrument (lower) harness Starter switch OFF: 0V Step 12 Step 21
connector, pin 1 "frame (Ft) harness" when the starter switch is Starter switch ON: (OK) (NG)
turned ON (OFF/0V to ON/battery voltage). Battery voltage
12 Check if the voltage is applied to the fuses shown in the circuit Starter switch OFF: 0V Step 13 Step 23
diagram when the starter switch is turned ON (OFF/0V to Starter switch ON: (OK) (NG)
ON/battery voltage). Battery voltage
Is the battery voltage applied to each fuse?
3-26

13 Check the starter switch circuit for continuity. 0.5Ω or less Step 15 Step 14
⋅ Starter switch connector to frame (Ft) harness connector (OK) (NG)
⋅ Starter switch connector to fuse No.28
Is the circuit normal?
14 Repair or replace the starter switch circuit "instrument (lower) - Step 8 -
harness". (OK)
15 Replace the starter switch. - Step 8 -
Did the corrective action complete? (OK)
16 Check the battery relay circuit "frame (Ft) harness". 0.5Ω or less Step 9 Step 17
⋅ Confirm the continuity between instrument (lower) harness (OK) (NG)
connector and battery relay connector "frame (Ft) harness" to
check for disconnection in the circuit.
⋅ Check the circuit between battery relay connector and ground
3
point "frame (Ft) harness" for disconnection.
17 Repair or replace faulty circuit "frame (Ft) harness". - Step 9 -
18 Replace the battery relay. - Step 10 -
19 Check the Slow Blow Fuse (SBF) circuit (slow blow fuse box 0.5Ω or less Step 11 Step 20
harness). (OK) (NG)
⋅ Confirm the continuity between SBF 2-6 and frame (Ft) harness
connector (slow blow fuse box harness) to check for
disconnection in the circuit.
20 Repair or replace faulty circuit (slow blow fuse box harness). - Step 11 -
21 Check the frame (Ft) harness. 0.5Ω or less Step 12 Step 22
⋅ Confirm the continuity between instrument (lower) harness (OK) (NG)
connector and slow blow fuse box harness connector to check
for disconnection in the circuit. (SBF No.2 - 6 circuit)
3-27

22 Repair or replace the frame (Ft) harness in the circuit between - Step 12 -
instrument (lower) harness connector and slow blow fuse box
harness connector.
23 Check the power supply circuit for each fuse, and repair or replace if - Step 24 -
faulty.
⋅ Power supply terminal of each fuse to frame harness connector
(Power is supplied to the left terminal of the fuse)
24 Check for the continuity in the Engine Control Unit power circuit, - Step 26 Step 25
and repair or replace if disconnected. (OK) (NG)
⋅ Fuse No.45 - Main relay - Engine Control Unit
⋅ Fuse No.17 - Engine Control Unit
25 Repair or replace the Engine Control Unit power circuit "instrument - Step 26 -
(lower) harness". (OK)
end
3-28
Arrangement of fuses
1. HSA is reset by pulling out the HSA fuse 14 and semi-auto cluch fuse 20 and 44 . Be sure to pull the parking brake lever when replacing the fuse.
Notes: 2. Do not use any fuses other than specified; they may cause a fire or shutdown of functions. (Current of working load of spare power source should be 70% at the maximum of the rated value.)
Fuse box
1 11 26 38
Meter Wiper, washer
7.5A Head lamp (up direction, left side) 7.5A 15A Tail lamp, fog lamp, illumination 15A
2 12 Reverse lamp, Back up light, 27 39
Head lamp (up direction, right side) Stop lamp Collapsible mirror
7.5A 7.5A Sub starter horn 15A 15A
3 13 28 40
Head lamp (down direction, left side) P.T. O., exhaust brake Starter (relay) Cigarette light
7.5A 7.5A 15A 15A
4 14 29 41
Head lamp (down direction, right side) HSA Note 1 Auto T/M (relay) Electric outlet, cigar lighter 12V consent
7.5A 7.5A 15A 15A
5 Clock (tacho graph), Room light, 16 30
Turn signal
45
Engine ECU
7.5A Backup light 7.5A Transfer low 15A 15A
6 16 32
Engine stop 4WD Power window (right)
7.5A 7.5A 15A
7 17 33
Door lock Transfer high Power window (left)
7.5A 7.5A 15A
8 18 34
Radio, cassette Auto T/M ECU Auto T/M ECU
7.5A 7.5A 15A
3
9 20 Semi-auto cluch 36 Blower motor
Glow plug (relay) Engine ECU
7.5A 7.5A Note 1 15A
37 Condenser fan motor (air conditioning system)
15A Compressor (air conditioning system)
3-29
Layout of starter Relay
1 2 3 4
Legend
1 Battery Key (40A)
2 LAMP (40A)
3 Starter (60A)
4 A/C (40A)
3-30
Layout of Slow Blow Fuse (SBF) Box
1
Legend
1 Starter Relay
3-31
Checking the staring system
Starting circuit (including neutral signal circuit) (manual / ECOGIT Vehicle)

40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
11 31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
BG 0.5
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
SDL
21 20 19 18 17 16 15 14 13 12 11 10 10 11 12 13 14 15 16 17 18 19 20 21
(BLACK)
32 31 30 29 28 27 26 25 24 23 22 22 23 24 25 26 27 28 29 30 31 32 NEUTRAL SIGNAL
11 ECU HARNESS
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12 11
BG 0.5
NEUTRAL SWITCH
SWP
1 2
(GRAY)
BG 0.5
TRANSMISSION HARNESS
3-32
Circuit description
The power is supplied to the starter to start the engine when the starter relay in the starter circuit operates.
For manual transmission vehicles, the starter relay operates when the starter switch is turned to the "S"
position.
For ECOGIT/automatic transmission vehicles, the starter relay operates when the starter switch is turned to
the "S" position and the neutral relay operates.
In the sub starter circuit, the starter relay operates when the starter switch is turned to the "ON" position and
the neutral relay operates (regardless of the type of transmission).
Possible causes
⋅ Faulty starter circuit (starter, starter relay, starter circuit, battery, etc.)
⋅ Faulty starter switch
⋅ Faulty neutral relay
⋅ Faulty control unit (automatic, ECOGIT)
⋅ Faulty neutral switch
3
1 Check the starter circuit and Slow Blow Fuse (SBF). 0.5Ω or less Step 3 Step 2
Confirm the continuity in the following circuits to check for (OK) (NG)
disconnection:
⋅ Starter relay to Slow Blow Fuse (SBF) No. 3
⋅ Starter relay to starter (C Pin)
⋅ Starter relay to frame ground
⋅ Starter to battery relay
⋅ Starter to frame (starter ground)
⋅ Slow Blow Fuse (SBF) No. 3
2 Repair or replace the starter circuit. Starter starts Step 13 Step 3
After repair or replacement, check again if the starter starts. (OK) (NG)
Does the starter operate?
3 Check the starter relay circuit. Starter switch Step 13 Step 4
1. Turn the starter switch off. OFF: 0V (OK) (NG)
2. Disconnect the harness (relay coil side: 2-pin connector) from the Starter switch
starter relay. S: Battery voltage
Check if the voltage is applied to the starter relay connector (harness
side) when the starter switch is turned to the "S" position (OFF/0V to
S/battery voltage). (Starter relay power supply circuit)
Is the battery voltage applied to the starter relay connector?
3-33

4 Check the circuit between starter switch and starter. Starter switch Step 5 Step 6
1.Disconnect the instrument (lower) harness and the frame (Ft) OFF: 0V (OK) (NG)
harness. Starter switch
2.Check if the voltage is applied to the frame (Ft) harness connector S: Battery voltage
"instrument (lower) harness" when the starter switch is turned to
the "S" position (OFF/0V to S/battery voltage). (Starter relay
power supply circuit)
5 Repair or replace the circuit between instrument (lower) harness Starter operates Step 15 Step 6
connector and starter relay "frame (Ft) harness". (OK) (NG)
After repair or replacement, check again if the starter operates.
6 Check the continuity in the circuit between starter switch and frame 0.5Ω or less Step 8 Step 7
(Ft) harness connector "instrument (lower) harness" to check for (OK) (NG)
disconnection.
Manual vehicles:
⋅ Starter switch to frame (Ft) harness connector
ECOGIT, automatic vehicles:
⋅ Starter switch to neutral relay
⋅ Neutral relay to frame (Ft) harness connector
⋅ Neutral relay circuit (coil-side circuit)
7 Repair or replace the circuit between starter switch and frame (Ft) Starter operates Step 15 Step 8
harness connector "instrument (lower) harness" (OK) (NG)
8 Check the relays (neutral relay, etc.), and replace if faulty. Starter operates Step 15 Step 9
After repair or replacement, check again if the starter operates. (OK) (NG)
9 Check the starter switch. Step 11 Step 10
Check if the connector pins No.2 and 3 on the starter switch side are 0.5Ω or less (OK) (NG)
continuous when the starter switch is turned to the "S" position.
Are the pins continuous?
10 Replace the starter switch. Starter operates Step 15 Step 11
11 Check the type of transmission. - Step 13 Step 12
Is the transmission type, automatic/ECOGIT?
3-34

12 Check the automatic/ECOGIT system and neutral circuit, and repair Starter operates Step 5 Step 13
or replace if faulty. (OK) (NG)
13 Check the starter relays, and replace if faulty. Starter operates Step 15 Step 14
14 Replace the main starter. - Step 15 -
15 Restore the vehicle, and perform the repair check. Check
end
3-35
Layout of Slow Blow Fuse (SBF) Box
1 2 3 4
Legend
1 Battery Key (40A)
2 LAMP (40A)
3 Starter (60A)
4 A/C (40A)
Layout of Starter Relay
Legend
1 Starter Relay
3-36
Checking the fuel system
Possible causes
⋅ Empty fuel tank, or frozen fuel
⋅ Air mixing in fuel piping
⋅ Clogged fuel filters (main, pre, gose filters)
⋅ Fuel quality
⋅ Clogged supply pump gose filter, faulty feed pump
⋅ Faulty fuel piping (squeezed, bent, clogged, disconnected)
⋅ Faulty fuel tank (mixing of foreign materials, bent/cracked piping in tank)


1 Check the fuel quantity.
Is the fuel quantity enough?
Step 2
(OK)
Refill,
and go
3
to step 2
(NG)
2 Check the fuel quality. Engine starts Step 8 Step 3
1. Drain the fuel from the fuel tank.
2. Refill the specified fuel.
3. Bleed the air from the fuel piping.
4. Start the engine.
3 Bleed the air from the fuel piping (perform with the priming pump - Step 4 Bleed
only). (The air bleeding by a dry-shot operation of the injector is the air,
executed in step 4.) and go
(Air bleeding section: Fuel tank - Feed pump - Fuel filter - Supply to step 4
pump)
At this time, if no fuel comes to the fuel filter, check the overflow
valve on the supply pump and replace it if faulty. If the overflow
valve is normal, connect the fuel hose at the top of fuel tank reversely
(reversed IN and OUT) to bleed the air, and when the fuel comes,
check the fuel tank by referring to step 7.
4 Bleed the air from the fuel piping. (Bleed the air by a dry-shot - Step 5 Bleed
operation of the injector.) the air,
(Air bleeding section: Supply pump - Common rail - Injector) By this and go
operation, bleed the air from the piping. If the air bleeding failed, the to step 5
engine control may be faulty. Thus, check the diagnostic trouble
codes.
3-37
Checking the fuel system

5 Check if the fuel filters are normal. - Step 6
(Fuel filter and pre-fuel filter)
Clean or replace, if the filters are blocked with dust or clogged.
6 Check the fuel piping for abnormality and fuel leakage. - Step 7 -
Check if the pipes are squeezed, bent, cracked, or loose, or if dust is
present in the injector or pump filters. Repair or replace, if faulty.
7 Check the fuel tank. - Step 8 -
Check if:
⋅ Foreign materials mix in
(Foreign materials block the fuel suction port)
⋅ Fuel suction pipe is bent
⋅ Fuel suction pipe is cracked
⋅ Fuel tank is deformed
⋅ Fuel tank is installed properly
⋅ Air breather in the fuel tank cap is clogged
⋅ Water mixes in the fuel tank
Repair or replace the fuel tank, if faulty.
8 Restore the vehicle, and bleed the air again from the fuel piping and - Check -
perform the repair check. end
3-38
Checking the intake system
Possible causes
⋅ Blocked air cleaner
⋅ Faulty intake piping (squeezed or damaged intake duct, piping, intercooler, etc.)
⋅ Faulty intake shutter (intake shutter valve is kept closed, air cylinder does not return, etc.)
⋅ Faulty CCS (valve is kept closed, air cylinder does not return, etc.)
⋅ Faulty VGS turbo (operation failure, air cylinder does not return, etc.)

1 Check the air cleaner warning lamp condition in the meter. Lamp OFF Step 3 Step 2
Is the air cleaner warning lamp OFF?
2
3
Clean or replace the air cleaner
Check if the water or dust exists in the air cleaner case.
-
No water or dust exists

Step 3
Step 5
-
Step 4
3
Is the inside of case normal? (OK) (NG)
4 Clean the inside of air cleaner case. Check the water drain valve, and - Step 5 Step 9
if faulty, repair or replace.
5 Check if the intake piping is squeezed or damaged. No water or dust exists Step 7 Step 6
Is the intake piping normal? (OK) (NG)
6 Repair or replace the intake piping, if it is squeezed or damaged. - Step 7 -
7 Check if the intercooler piping is squeezed, damaged, or installed - Step 9 Step 8
improperly.
Is the intercooler piping normal?
8 Repair or replace the intercooler piping, if squeezed or damaged. - Step 9 -
9 Using the Tech II, check the VGS magnetic valve operation. Normal operation Step 11 Step 10
1. Connect the Tech II. (OK) (NG)
2. Turn the starter switch on. At this time, do not start the engine.
3. Operating the Tech II, check the magnetic valve operation.
(Refer to Section 7 How to use IE system checking tool.) Also, check
that the compressed air is fed to the air cylinder to move the rod, and
then the valve opens and closed when the magnetic valve operates.
Do the magnetic valve and VGS turbo operate normally?
10 Repair or replace faulty parts detected in step 9. - Step 11 -
11 Restore the vehicle, and perform the repair check - Check -
end
3-39
Checking the intake system
Intake shutter / VGS turbo air cylinder stroke
8-step type
3–0.2
6–0.2
9–0.4
Port 3 Port 2 Port 1 12–0.2
15–0.4
18–0.4
21–0.6 (Full stroke)
o: Air pressurized x: Released to atmosphere

Stroke
Port
0 3 6 9 12 15 18 21
Port 1 X O X O X O X O
Port 2 X X O O X X O O
Port 3 X X X X O O O O
Magnetic valve inspection procedure using Tech II

Select" M/V ABC instruction" in the "Test mode" as shown in
F0: Diagnostic Trouble code
the right figure and check the magnetic valve for operation F1: Data Display
according to the instructions on the display. F2: Snapshot

F3: Programming
F4: Special Function
F0: Engine Output
F1: Fuel System
F0: Exhaust Brake Control
F1: Solenoid Valve
3-40
Checking the exhaust system
Exhaust brake circuit

40 PIN LY 0.5
80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
18 18
CRUISE EXHAUST DRIVE OUTPUT SIGNAL
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
SDL 10 11 12 13 14 15 16 17 18 19 20 21
21 20 19 18 17 16 15 14 13 12 11 10
32 31 30 29 28 27 26 25 24 23 22
(BLACK) 22 23 24 25 26 27 28 29 30 31 32
LY 0.5
3
1 2 3 4
1 2 3 4 5 6 7 7 6 5 4 3 2 1
8 9 10 11 12 13 14 14 13 12 11 10 9 8 30
15 16 17 18 19 20 20 19 18 17 16 15
21 22 23 24 24 23 22 21
25 26 27 28
SMJ 28 27 26 25
(WHITE)
FUSE 13 1 29 30
33 34
31 32
35 36
32 31
36 35
30 29
34 33
2 3 4 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
5 50 51 52 53 54 55 56 56 55 54 53 52 51 50
30 46
46
3
5 1
GND EXHAUST BRAKE
4 2
MAGNETIC VALVE
1 2
3-41
Circuit description
In the exhaust brake circuit, the power is supplied from the fuse No.13, and when the exhaust brake switch
(combination switch) is turned on, the signals are sent to the brake integrated control unit. At the same time,
the signals (exhaust brake switch signals) are also sent to the Engine Control Unit. Upon signal reception, the
brake integrated control unit operates the exhaust brake magnetic valve, and this operating signal is also sent
to the Engine Control Unit.
Possible causes
⋅ Faulty exhaust brake (exhaust brake is kept closed, air cylinder does not return, etc.)
⋅ Faulty exhaust brake magnetic valve
⋅ Faulty brake integrated control unit
⋅ Faulty exhaust brake switch system

1 Check the exhaust brake operation. Engine starts, and exhaust Step 10 Step 2
1. Turn the starter switch on. brake operates (OK) (NG)
2. Start the engine and idle it.
3. Disconnect the connector (PA1 pin, green) inside the inspection
cover.
4. Turn on the exhaust brake switch lever.
Does the engine start? Does the exhaust brake operate?
2 Check the exhaust brake switch. ON ↔ OFF indication on Step 4 Step 3
1. Connect the Tech II. the screen is changed (OK) (NG)
2. Shift the gear to the neutral position. over by switch operation
4. Check the switch inputs with the Tech II.
5. Operate the exhaust brake switch.
6. Check if the ON/OFF indication on the Tech II screen is changed
over by the switch operation.
Is the ON/OFF indication changed by switch operation?
3-42

3 Check the exhaust brake switch circuit for the continuity, and repair Exhaust brake operates Step 10 Step 4
or replace faulty parts. (OK) (NG)
⋅ Combination switch itself
⋅ Fuse No.13 to combination switch
⋅ Combination switch to base harness connector
⋅ Base harness connector to Engine Control Unit
⋅ Combination switch to floor (left) harness connector
⋅ Instrument (lower) harness connector to sheet harness
connector
⋅ Floor (left) harness connector to brake integrated control unit
connector (A)
After repair or replacement, check again the exhaust brake operation
using the connector (PA1 pin, green) inside the inspection cover.
Does the exhaust brake operate?
3
4 Using the circuit tester, measure the resistance of exhaust brake Magnetic valve, Step 6 Step 5
magnetic valve. Pin to pin: 34 - 40 Ω (OK) (NG)
Is the resistance value normal? Pin to body: ∞Ω
5 Replace the exhaust brake magnetic valve. Exhaust brake operates Step 10 Step 6
After repair or replacement, check again the exhaust brake operation (OK) (NG)
6 Check the exhaust brake magnetic valve circuit for the continuity, Exhaust brake operates Step 10 Step 7
and repair or replace faulty parts. (OK) (NG)
⋅ Brake integrated control unit connector (A) to floor (left)
harness connector
⋅ Sheet harness connector to instrument (lower) harness
connector
⋅ Floor (left) harness connector to frame (Ft) harness connector
⋅ Floor (left) harness connector to engine control unit
⋅ Instrument (lower) harness connector to member harness
connector
⋅ Frame (Ft) harness connector to exhaust brake magnetic valve
⋅ Member harness connector to earth point
After repair or replacement, check again the exhaust brake operation
3-43

7 Check the operation of exhaust brake magnetic valve. ON ↔ OFF indication on Step 8 Step 9
2. Shift the gear in the neutral position. over by switch operation
4. Check the switch inputs with the Tech II.
over by disconnecting/connecting the connector (PA1 pin, green)
inside the inspection cover.
Is the ON/OFF indication changed by disconnecting/connecting the
connector (PA1 pin, green)?
8 Replace the exhaust brake valve Step 10
9 Replace the brake integrated control unit, and check the power Step 10
supply and GND circuit of the brake integrated control unit, and
10 Restore the vehicle, and perform the repair check. Check
end
3-44
External view, Pin assignment and resistance value of magnetic valve

<External view of magnetic valve> <Pin assignment of magnetic valve>
Pin No. Signal name
1 Magnetic valve (coil)
2 1 2 Magnetic valve (coil)
Z type
connector (gray),
2 pins
3
<Magnetic valve resistance value>
Pants checked Resistance value Remarks
1 2 34 40∞Ω Between magnetic valve coils
Z type connector
1 body ∞ Between magnetic valve coil and body
(gray) 2 poles
2 body ∞ Between magnetic valve coil and body
Note: The resistance value varies depending on the temperature of the magnetic valve main unit.
3-45
Checking the parking switch
Parking switch circuit (including low air pressure switch circuit)

40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
YG 0.5
AIR LOW
PRESSURE SW
BUZZER:AIR (SIG)
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
SDL 10 11 12 13 14 15 16 17 18 19 20 21 PARKING SW (SIG)
1 2 21 20 19 18 17 16 15 14 13 12 11 10
32 31 30 29 28 27 26 25 24 23 22
(BLACK) 22 23 24 25 26 27 28 29 30 31 32
LB 0.5 LB 0.5
FUSE 11
ECU HARNESS
1 2 3 4 5 6
18
7 8 9 10 11 12 13 14
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 4 3 2 1
FUSE 12
37 38 39 40 40 39 38 37 9 8 7 6 5
41 42 43 44 SMJ 44 43 42 41
45 46 47 48
(WHITE) 48 47 46 45
60 59 58 57 56 55 54 53 52 51 50 49
49 50 51 52 53 54 55 56 57 58 59 60
72 71 70 69 68 67 66 65 64 63 62 61
61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 84 83 82 81 80 79 78 77 76 75 74 73
6 5 4 3 2 1
1413 12 11 10 9 8 7 INSTRUMENT (UPPER) HARNESS

LB 0.5
1 2 3 4 5 6 7 7 6 5 4 3 2 1
8 9 10 12 13 14 14 13 12 11 10 9 8
11
15 16 17 18 19 20 20 19 18 17 16 15
21 22 23 24 24 23 22 21
25 26 27 28
SMJ 28 27 26 25
TO CONNECT
2 1 (WHITE) 32 31 30 29
4 3 29 30 31 32
SW: 33 34 35 36 36 35 34 33
42 41 40 39 38 37
PARKING 37
43
38
44
39
45 46
40
47
41
48
42
49 49 48 47 46 45 44 43
50 51 52 54 55 56 56 55 54 53 52 51 50
53
LB 0.3
GND
AIR LOW PRESSURE YG 0.5

2 1
SW SWP 4 3
(GRAY)
1 2
BL 0.5
1 2
SWP 3 4
(GRAY)
1 2
BL 0.5
SWP
(GRAY)
1 2
BL 0.5
SWP
(GRAY)
1 2
FVM/Z BL 0.5
AIR TANK HARNESS
3-46
Circuit description
The parking switch is installed in the vicinity of wheel park (frame (Ft) harness). The parking switch turns
on when the parking lever is pulled (when the air in the wheel park chamber is bled).
The wheel park switch circuit is supplied with the power from the parking lamp in the meter, and connected
to the frame (Ft) ground via the switch.
Possible causes
⋅ Faulty parking switch itself
⋅ Faulty parking switch circuit
⋅ Faulty meter itself
⋅ Faulty meter circuit
⋅ Faulty Engine Control Unit

3
1 Check if the voltage is applied to the parking switch. Lamp ON Step 7 Step 2
1. Disconnect the harness from the parking switch. (OK) (NG)
3. Ground the parking switch connector (pins on power supply side).
Does the parking lamp in the meter turn on?
2 Check the parking lamp in the meter for broken bulb. - Step 4 Step 3
Is the lamp normal?
3 Replace the parking lamp in the meter. Lamp ON Step 5 Step 4
After repair or replacement, check if the lamp turns on. (OK) (NG)
Does the lamp turn on?
4 Check the meter (lamp) power. Battery voltage Step 5 Check
1. Turn the starter switch on. (OK) the
2. Check if the voltage is applied to the meter connector. power
Is the voltage applied? supply
circuit
(NG)
3-47

5 Check for continuity of the following circuits between meter 0.5Ω or less Step 7 Step 6
(parking lamp) and parking switch. (OK) (NG)
⋅ Meter to instrument (lower) harness connector
⋅ Instrument (upper) harness connector to frame (Ft) harness
connector
⋅ Instrument (upper) harness connector to Engine Control Unit
connector
⋅ Instrument (lower) harness connector to wheel park switch
⋅ Instrument (lower) harness connector to frame (Rr) harness
connector
⋅ Frame (Ft) harness connector to wheel park switch
Are the circuits normal?
6 Repair or replace faulty meter (parking lamp) circuit. Lamp ON Step 15 Step 7
After repair or replacement, check if the lamp turns on when the (OK) (NG)
wheel park is operated.
7 Check the parking switch ground circuit. - Step 9 Step 8
Is the circuit normal? (OK) (NG)
8 Repair or replace the parking switch ground circuit. Lamp ON Step 15 Step 9
9 Check again if the voltage is applied to the parking switch. Lamp ON Step 11 Step 10
1. Disconnect the harness from the parking switch. (OK) (NG)
3. Ground the parking switch connector (pins on power supply side).
Does the parking lamp in the meter turn on?
10 Replace the meter. - Step 15 Step 11
3-48

11 Check the parking switch operation. Lamp ON (when the Step 13 Step 12
1. Check that the air pressure is normal. parking lever is pulled) (OK) (NG)
2. Check if the parking lamp turns on when the parking lever is
pulled.
3. Check if the parking lamp turns off when the parking lever is
released.
Does the parking lamp operate (on/off) normally?
12 Check the parking switch. Lamp ON Step 15 Step 13
13 Check the Parking Switch ON ↔ OFF indication on Step 15 Step 14
1. Connect the Tech II.
2. Shift the gear to the neutral position.
the screen is changed
over by switch operation
(OK) (NG) 3
4. Using the Tech II, check the inputs of each switch.
5. Operate the parking switch.
14 Replace the engine control unit. - Step 15 -
end
3-49
External view and operation of parking switch
Air pressure in wheel park 1 2 Switch

2
About 460kPa (4.7 kg/cm ) or less O O ON
2
About 460kPa (4.7 kg/cm ) or more OFF
3-50
Idling speed cannot be adjusted
Possible causes
⋅ Improper Idle control switch position
⋅ Faulty idle control switch (up/down)
⋅ Faulty idle control selector switch
⋅ Faulty switch input circuit (idle control switch, idle control selector switch, etc.)
⋅ Faulty sensor system (accelerator sensor, all speed accelerator sensor, etc.)
⋅ Faulty PTO
⋅ Engine Control Unit

1 Check the idle control selector switch for position. - Step 3 Step 2
2
Is the switch in "AUTO" position?
Set the idle control selector switch in "MANU" position, and adjust Adjustable
(OK)
Step 7
(NG)
Step 3
3
the idling speed by using the idle control switch (press up or down (OK) (NG)
side).
Is the idling speed adjustable?
3 Check the Engine Control Unit (each switch input circuit). ON ↔ OFF indication on Step 5 Step 4
5. Operate each switch:
⋅ Idle up switch (idle control switch)
⋅ Idle down switch (idle control switch)
4 Repair or replace the circuits by referring to each switch circuit Adjustable Step 7 Step 5
(Section 6, Wiring check "idle control switch, idle control selector (OK) (NG)
switch, and limp home switch circuits").
After repair or replacement, adjust again the idling speed.
5 Check the PTO. - Step 6 Check
Perform the "PTO check", and repair or replace if faulty. PTO
6 Check the Engine Control Unit. - Step 7 -
1. Turn the starter switch off.
2. Replace the Engine Control Unit.
3. Start the engine and check for operation.
7 Restore the vehicle and perform the repair check. - Check -
end
3-51
External view and operation of idling control switch
<External view of idling control switch>
Idling control switch
UP
2 1
3
Connector
DOWN
060HY00486
<Operation of idling control switch>
When With UP With DOWN

released side pressed side pressed
UP UP UP
DOWN DOWN DOWN
3 3 3
2 2 2
1 1 1
Measuring point Switch operating condition Resistance value Remarks

3 1 Released ∞
UP pressed 0.5Ω or less
2 3 UP circuit
Idling control switch Released ∞
DOWN pressed 0.5Ω or less
2 1 DOWN circuit
Released ∞
3-52
Idling speed cannot be decreased
Possible causes
⋅ Improper Idle control switch position
⋅ Faulty idle control switch (up/down)
⋅ Faulty idle control selector switch
⋅ Faulty switch input circuit (idle control switch, idle control selector switch, etc.)
⋅ Faulty sensor system (accelerator sensor, all speed accelerator sensor, etc.)
⋅ Faulty PTO
⋅ Engine Control Unit
⋅ Faulty injection (nozzle)

1 Check the idle control selector switch for position.
Is the switch in "AUTO" position?
Step 3
(OK)
Step 2
(NG)
3
2 Set the idle control selector switch in "MANU" position, and adjust Adjustable Step 8 Step 3
the idling speed by using the idle control switch (press up or down (OK) (NG)
side).
3 Check the Engine Control Unit (each switch input circuit). ON ↔ OFF indication on Step 5 Step 4
1. Connect the Tech II. the screen is changed (OK) (OK)
5. Operate each switch:
⋅ Idle up switch (idle control switch)
⋅ Idle down switch (idle control switch)
⋅ Idle control selector switch
4 Repair or replace the circuits by referring to each switch circuit Adjustable Step 5 -
(Section 6, Wiring check "idle control switch, idle control selector
switch, and limp home switch circuits").
After repair or replacement, adjust again the idling speed.
Check the PTO.
5 Perform the "PTO check", and repair or replace if faulty. - Step 6 Check
Did corrective actions complete? PTO
6 Check the water temperature sensor. Step 7 Chapter
Referring to the diagnostic trouble code "23", check the sensor, and 4
repair or replace if faulty. diagnostic
Did corrective actions complete? trouble
code
’’23’’
3-53
Idling speed cannot be decreased

7 Check the injection operation. Injector is normal Step 9 Step 8
1. Connect the Tech II. (Engine sound changes) (OK) (NG)
3. Using the Tech II, conduct the injector test.
(In the "Injection Power Balance" test, stop the injector every
cylinder, and the injector is normal if the engine sound changes
when the injection is stopped.)
Does the engine sound change?
8 Replace the injector of the cylinder where the engine sound does not - Step 9 -
change.
10 Restore the vehicle and perform the repair check. - Check -
end
3-54
External view and operation of idling control switch
<External view of idling control switch>
Idling control switch
UP
2 1
3
Connector
DOWN
060HY00486
3
<Operation of idling control switch>
When With UP With DOWN

released side pressed side pressed
UP UP UP
DOWN DOWN DOWN
3 3 3
2 2 2
1 1 1
Measuring point Switch operating condition Resistance value Remarks

3 1 Released ∞
UP pressed 0.5Ω or less
2 3 UP circuit
Idling control switch Released ∞
DOWN pressed 0.5Ω or less
2 1 DOWN circuit
Released ∞
3-55
Chapter 4
Checking procedure for each
diagnostic trouble code
4
Chapter 4 Checking procedure for each diagnostic trouble code
Preface
When any diagnostic trouble code is displayed, check and repair according to the flow chart on the following
pages.
Caution: Try to take notes of check results. To record information on customers, make use of the "IE
Check Sheet".
When no diagnostic trouble code is displayed, check and repair referring to Chapter 5, Checking Method for
Symptom.
After completion of inspections and repair, be sure to clear the memory in the DMU (data memory unit) and engine
control unit.
4-2
14 G sensor system trouble (1/5)
G sensor circuit (including NE sensor and fuel pressure sensor circuit)

40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
Gy 0.5
FUEL PRESSURE SENSOR (SIG)

FUEL PRESSURE SENSOR
FUEL PRESSURE SENSOR (POWER)

123 NE SENSOR (SHEILD)
1 2 3 4 4 3 2 1 Gy 0.5
B 0.5 5 6 7 8 SWP 8 7 6 5
9 10 11 12 (GRAY) 12 11 10 9 B 0.5
(GRAY)
WL 0.5 W 0.5
OL 0.5 G 0.5
W 0.5 R 0.5
B 0.5 O 0.5
NE SENSOR
NE SENSOR (SHEILD)
4
NE SENSOR (—)
1 2 NE SENSOR (+)
Y 0.5 W 0.5
Br 0.5 B 0.5
(WHITE) B 0.5 Gy 0.5
4 3 2 1 1 2 3 4
GyR 0.5
8 7 6 5 SWP 5 6 7 8
12 11 10 9 (GRAY) 9 10 11 12
G 0.5
B 0.5
G SENSOR R 0.5
1 2
G SENSOR (SHEILD)
P 0.5
G SENSOR (—)
L 0.5
(GREEN) G SENSOR (+)
ECU HARNESS
4-3
Circuit description
The G sensor detects the camshaft revolutions in the supply pump to judge the cylinders. The voltage is
generated to output the pulse signals, when the pulsar provided on the camshaft crosses the G sensor leading
end. The Engine Control Unit reads this pulse signals, and based on this signals, it judges the cylinders. In
case of G sensor trouble, the NE sensor installed on the flywheel judges the cylinders. Also, the sensor circuit
is shielded to prevent electrical noise invasion.
Vehicle behaviors in case of a trouble

• SERVICE ENGINE SOON lamp turns on (ON condition: when engine idles continuously for 20 seconds)
• Instantaneous revolution drop (0 rpm during diagnosis until switching to NE sensor)
• Low starting performance
• Varying revolutions (hunting)
• Rough idling
• When both NE sensor and G sensor failed, the SERVICE ENGINE SOON lamp turns on (continuous
ON)and the engine stops
Diagnostic conditions
At the engine revolutions over 400 rpm (idling), the pulses from the NE sensor are entered (at 450-time
input), but no pulses are entered from the G sensor. Under this condition, the control unit judges as "G sensor
system trouble" and displays "diagnostic trouble code: 14".
The judgment time varies depending on the number of engine revolutions. The judgment time becomes
longer when the engine revolutions are low, and it becomes shorter as the engine revolutions increase.
Warning during diagnosis (ENGINE CONTROL/SERVICE ENGINE SOON lamp ON)

In the event of G sensor system trouble, the ENGINE CONTROL lamp for the vehicles with the multi-
warning display, or the SERVICE ENGINE SOON lamp for the vehicles without the multi-warning display
turns on when the engine revolutions below 650 rpm continue for 20 seconds. The lamp turns off when the
engine revolutions exceed 650 rpm.
Possible causes
• Loose connection of connectors (faulty connectors between Engine Control Unit and ECU harness, ECU
harness and engine harness, engine harness and extension harness, or respective sensors)
• Disconnection or shortcircuit in G sensor (+) circuit (faulty vehicle harness or sensor harness of ECU
harnesses, engine harnesses or extension harnesses)
• Disconnection in G sensor (-) circuit (faulty vehicle harness or sensor harness of ECU harnesses, engine
harnesses or extension harnesses)
• Faulty sensor (faulty sensor inside or sensing block)
• Faulty cam shaft internal supply pump
• Internal trouble of Engine Control Unit
Diagnostic help
Check the connectors for loose connection, the harnesses for abrasion or folding, the wires inside harnesses
for abrasion or shortcircuit. Also, perform functional diagnosis to check the operation and control, and repair
if faulty.
4-4

1 Check the detected diagnostic trouble code. - Step 2 Refer to
1.Start the engine and idle it. Current diagnostic
2. Using the Tech II, check the detected diagnostic trouble code. trouble help, and
Is the detected diagnostic trouble code current trouble? go to
step 4
past
trouble
2 Measure resistance value of the G sensor circuit. Between pins 49 and 58: Step 6 Step 3
1. Turn the starter switch off. 185 - 2450Ω (OK) (NG)
2. Disconnect the harness from the Engine Control Unit. (at about 20°C)
3. Using a tester, measure resistance value of the sensor. Between pins 49-77 and
Is the resistance value normal? GND: ∞Ω
Between pins 58-77 and
GND: ∞Ω
3 Using a circuit tester, measure resistance value of the "G sensor". Between sensor pins: Step 5 Step 4
2. Disconnect the harness from the sensor.
1850 - 2450W
(at about 20°C)
(OK) (NG)
4
3. Using a tester, measure resistance value of the sensor. Between sensor body and
Is the resistance value normal? each pin: ∞Ω
4 Replace the G sensor - Step 6 -
5 Repair or replace the harnes of G sensor circuit. Also, check the - Step 6 -
connectors for connection.
⋅ Engine Control Unit to engine harness connector (ECU harness,
G sensor circuit)
⋅ ECU harness connector to G sensor connector "6WG1, 6SD1
engine"/extension harness connector "6TE1 engine" (engine
harness,G sensor circuit)
⋅ Engine harness to G sensor connector
(Extension harness, G sensor circuit "6TE1 engine")
6 Check the harnesses for shortcircuit. Voltage is applied Step 7 Step 8
2. Install the circuit tester between sensor each pin and GND
(frame or engine body).
Note: If the harness is disconnected from the G sensor, diagnostic
trouble code "14" may be detected, and therefore clear the
diagnostic trouble code after the check finished.
4. Check if the voltage is applied to the harnesses.
Is the voltage applied to each pin?
4-5

7 Repair or replace the G sensor circuit connector. - Step 8 -
⋅ Engine Control Unit to engine harness connector (ECU harness,
G sensor circuit)
⋅ ECU harness connector to G sensor connector "6WG1, 6SD1
engine"/extension harness connector "6TE1 engine" (engine
harness,G sensor circuit)
⋅ Engine harness connector to G sensor connector
(Extension harness, G sensor circuit "6TE1 engine")
heck the Engine Control Unit. - Step 10 Step 9
8 1. Turn the starter switch off. (OK) (NG)
2. Confirm that the harness is connected to the Engine Control
Unit.
3. Connect the Tech II and clear the diagnostic trouble codes.
Note: Be sure clear the diagnostic trouble codes, as the engine
stops if the codes 14 and 15 are detected simultaneously.
4. Disconnect the harness from the NE sensor.
Note: The diagnostic trouble code 15 is detected if the harness is
disconnected from the NE sensor, and thus clear the code
after the check finished.
5. Start the engine, and check the engine condition.
10 With the NE sensor removed, check if the idling is stable. - Step 14 Step 11
Using the Tech II, check with the "Engine Speed" of engine data that
the engine speed is stable, free from variations or hesitation.
Is the idling stable?
11 Check the G sensor installation. - Step 13 Step 12
1. Check the G sensor for evidence of play or floating.
Is the sensor installed correctly? - Step 10
12 Install the G sensor correctly. -
13 Replace the supply pump. - Step 10 -
4-6

14 Restore the vehicle. - Step 15 -
1. Stop the engine.
2. Connect the harnesses to the sensors.
4. Connect the Tech II, and clear the diagnostic trouble codes.
15 Confirm that the diagnostic trouble codes have been cleared, and - Repair After
conduct the test run again to check that no diagnostic trouble code is end referring
detected. (OK) to
Is diagnostic trouble code detected? diagnostic
help,
step 1
(NG)
Note: The accelerator learning must be executed after the Engine Control Unit was replaced.
External view, pin assignment, and resistance value of G sensor

<External view of G sensor> <Pin assignment of G sensor>
Pin No. Signal name Wire color/diameter 4

1 (-) L/0.5
2 (+) P/0.5
- Shield Shield
(-) (+)
<Resistance value of G sensor>

Parts checked Resistance value Remarks
2-pin 1 2 1850 - 2450Ω Between (-) and (+) at about 20°C
connector 1 Body ∞Ω Between (-) and shield
(white) 2 Body ∞Ω Between (-) and shield
Note: The resistance value varies depending on the temperature (engine warming condition).
4-7
15 NE sensor system trouble (1/5)
NE sensor circuit (including G sensor and fuel pressure sensor circuit)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
Gy 0.5


1 2 3 4 4 3 2 1 Gy 0.5
B 0.5 5 6 7 8 SWP 8 7 6 5
9 10 11 12 (GRAY) 12 11 10 9 B 0.5
(GRAY)
WL 0.5 W 0.5
OL 0.5 G 0.5
W 0.5 R 0.5
B 0.5 O 0.5
NE SENSOR (SHEILD)
NE SENSOR
NE SENSOR (—)
1 2 NE SENSOR (+)
Y 0.5 W 0.5
Br 0.5 B 0.5
4 3 2 1 1 2 3 4
GyR 0.5
8 7 6 5 SWP 5 6 7 8
12 11 10 9 (GRAY) 9 10 11 12
G 0.5
B 0.5
G SENSOR R 0.5
1 2
G SENSOR (SHEILD)
P 0.5
G SENSOR (—)
L 0.5
ECU HARNESS
4-8
Circuit description
The NE sensor detects the number of engine revolutions. The voltage is generated to output the pulse signals,
when the sensing hole provided in the flywheel crosses the NE sensor leading end. The Engine Control Unit
reads this pulse signals, and based on this signals, it recognizes the engine revolutions, injection timing, and
injection cylinders. In case of NE sensor trouble, the G sensor installed on the supply pump detects the
number of engine revolutions. Also, the sensor circuit is shielded to prevent electrical noise invasion.

• Instantaneous revolution drop (0 rpm during diagnosis until switching to G sensor)
• Low starting performance
• Rough idling
• When both NE sensor and G sensor failed, the SERVICE ENGINE SOON lamp turns on (continuous
ON)and the engine stops
At the engine revolutions over 400 rpm, the pulses from the G sensor are entered (at 40-time input), but no
pulses are entered from the NE sensor. Under this condition, the control unit judges as "NE sensor system
trouble" and displays "diagnostic trouble code: 15". The judgment time varies depending on the number of
engine revolutions. The judgment time becomes longer when the engine revolutions are low, and it becomes
4
shorter as the engine revolutions increase.

In the event of NE sensor system trouble, the ENGINE CONTROL lamp for the vehicles with the multi-
turns on when the engine revolutions (idling) below 650 rpm continue for 20 seconds. The lamp turns off
when the engine revolutions exceed 650 rpm.
Possible causes
harness and engine harness, or respective sensors)
• Disconnection or shortcircuit in NE sensor (+) circuit (faulty vehicle harness or sensor harness of ECU
harnesses or engine harnesses)
• Disconnection in NE sensor (-) circuit (faulty vehicle harness or sensor harness of ECU harnesses or
engine harnesses)
• Faulty sensor installation (gap, play)
• Faulty flywheel sensing hole (clogging, soil, scratch)
Diagnostic help
if faulty.
4-9

1. Start the engine and idle it. Current diagnostic
2. Using the Tech II, check the detected diagnostic trouble trouble help, and
code. go to
Is the detected diagnostic trouble code current trouble? step 4
past
trouble
2 Using a circuit tester, measure resistance value of the "NE Between sensor pins: Step 4 Step 3
sensor". 109 - 143Ω (OK) (NG)
1. Turn the starter switch off. (at about 20°C)
2. Disconnect the harness from the sensor. Between sensor body and
3. Using a tester, measure resistance value of the sensor. each pin: ∞Ω
Is the resistance value normal?
3 Replace the NE sensor - Step 4 -
4 Check the harnesses for shortcircuit. Voltage is applied Step 5 Step 6
2. Install the circuit tester between sensor each pin and GND
Note: If the harness is disconnected from the NE sensor,
diagnostic trouble code "15" may be detected, and
therefore clear the diagnostic trouble code after the
check finished.
4. Check if the voltage is applied to the harnesses.
5 Repair or replace the harnesses of NE sensor circuit. - Step 6 -
⋅ Engine Control Unit to engine harness connector (ECU
harness, NE sensor circuit)
⋅ ECU harness connector to NE sensor connector (engine
6 Check the harness for disconnection or shortcircuit. Between 48 and 57 pins: Step 8 Step 7
1. Turn the starter switch off. 109 - 143Ω (OK) (OK)
2. Confirm that the harness is connected to the NE sensor. (at about 20°C)
3. Disconnect the harness from the Engine Control Unit. Between 48 and 76 pins/GND
4. Using a tester, measure resistance value of the connector ∞Ω
for the Engine Control Unit. Between 57 and 76 pins/GND
Is the resistance value normal? ∞Ω
4-10

7 Repair or replace the harnesses of NE sensor circuit. Also, - Step 8 -
check the connectors for connection.
⋅ ECU harness connector to NE sensor connector (engine
8 Check the Engine Control Unit. - Step 10 Step 9
1. Turn the starter switch off. (OK) (NG)
2. Confirm that the harness is connected to the Engine
Control Unit.
3. Connect the Tech II and clear the diagnostic trouble
codes.
Note: Be sure clear the diagnostic trouble codes, as the
engine stops if the codes 14 and 15 are detected
simultaneously.
4. Disconnect the harness from the G sensor.
Note: The diagnostic trouble code 14 is detected if the
harness is disconnected from the G sensor, and thus
clear the code after the check finished.
4
5. Start the engine, and check the engine condition.
Did corrective actions complete? (OK)
10 With the G sensor removed, check if the idling is stable. - Step 14 Step 11
Using the Tech II, check with the "Engine Speed" of engine
data that the engine speed is stable, free from variations or
hesitation.
Is the idling stable?
11 Check the NE sensor installation. - Step 13 Step 12
1. Check the NE sensor for evidence of play or floating.
Is the sensor installed correctly?
12 Install the NE sensor correctly. - Step 10 -
13 Check the flywheel, and clean, repair, or replace if faulty. - Step 10 -
⋅ Check from sensor installation hole
OK -> Check by referring to diagnostic help
NG -> Flywheel
⋅ Faulty NE sensor (soil, scratch)
⋅ Faulty flywheel sensing hole (clogging, soil, scratch)
4-11

1. Stop the engine.
2. Connect the harnesses to the sensors.
4. Connect the Tech II, and clear the diagnostic trouble
codes.
15 Confirm that the diagnostic trouble codes have been cleared, - Repair After
and conduct the test run again to check that no diagnostic end referring
trouble code is detected. (OK) to
help,
step 1
(NG)
External view, pin assignment, and resistance value of NE sensor
<External view of NE sensor> <Pin assignment of G sensor>
Pin No. Signal name Wire color/diameter

1 (-) L/0.5
2 (+) P/0.5
- Shield Shield
(-) (+)
<Resistance value of NE sensor>

2-pin 1 2 1850 - 2450Ω Between (-) and (+) at about 20°C
connector 1 Body ∞Ω Between (-) and shield
(white) 2 Body ∞Ω Between (-) and shield
Note: The resistance value varies depending on the temperature (engine warming condition).
4-12
22 Atmospheric temperature sensor system trouble (1/6)
Atmospheric temperature sensor circuit (including fuel temperature sensor and water
temperature sensor circuit)
SWP FUEL TEMP. SENSOR (SIG)
2 1 1 2
FUEL TEMP. (WHITE)
SENSOR LB 0.5
L 0.85
LR 0.5
L 0.85

40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
YB 0.5
LW 0.5
LB 0.5
WATER TEMP. SENSOR (SIG)
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21
(BLACK)
32 31 30 29 28 27 26 25 24 23 22 22 23 24 25 26 27 28 29 30 31 32 ATMOSPHERIC TEMP. SENSOR (SIG)
YB 0.5
10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10
111213141516 17 1819202122
2221201918 17 16 1514131211
LB 0.5
LB 0.5
YB 0.5
4
14 ECU HARNESS
.WATER TEMP.
14 THERMISTOR
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
41 42 43 44 SMJ 44 43 42 41 RV
(GRAY) 1 2 3 (BLUE) 2
48 47 46 45
45 46 47 48
3
LB 0.5
60 59 58 57 56 55 54 53 52 51 50 49
YV 0.5
49 50 51 52 53 54 55 56 57 58 59 60
72 71 70 69 68 67 66 65 64 63 62 61
61 62 63 64 65 66 67 68 69 70 71 72
LW 0.5
73 74 75 76 77 78 79 80 81 82 83 84 84 83 82 81 80 79 78 77 76 75 74 73
ENGINE CONTROL
THERMISTOR
FRAME (Ft) HARNESS
YV 0.5 WATER TEMP. (MAIN)
19
1 2 3 4 5 6 7
7 6 5 4 3 2 1
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 1 2 3 4 5 6 7 8
21 22 23 24
24 23 22 21 9 10 11 12 13 14 15 16 17
25 26 27 28
SMJ 28 27 26 25
(WHITE) YV 0.5
29 30 31 32
32 31 30 29
33
37
34
38 39 40
35
41
36
42
36 35 34 33 METER CONNECTOR
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
FACIA HARNESS
LW 0.5
EJ MARK
(BLACK)
3 2 1 1
SMP 1 2 3
6 5 4 1 2
(GRAY) 4 5 6
2
LB 0.5
INSTRUMENT (LOWER) HARNESS DASH HARNESS ATMOSPHERIC TEMP.

SENSOR (MAIN)
4-13
Circuit description
The atmospheric temperature sensor detects the temperature (atmospheric temperature) outside the vehicles.
The voltage is applied to the atmospheric temperature sensor provided in the front lid, and that voltage value
is used as a signal. The Engine Control Unit reads variations in the applied voltage, and based on this signal,
it optimizes the fuel injection control. In the event of atmospheric temperature sensor trouble, the Engine
Control Unit performs the control with the backup values. Also, the sensor circuit GND is used in common
to respective temperature sensors.

• Trouble at cold engine
White smoke
The control unit judges as "atmospheric temperature sensor system trouble" and displays "diagnostic trouble
code: 22" when the voltage applied to the atmospheric temperature sensor exceeds 4.8V, or the voltage below
0.1V continues fore more than one second.

In the event of atmospheric temperature sensor system trouble, the ENGINE CONTROL lamp for the
vehicles with the multi-warning display, or the SERVICE ENGINE SOON lamp for the vehicles without the
multi-warning display turns on when the engine revolutions (idling) below 650 rpm continue for 20 seconds.
The lamp turns off when the engine revolutions exceed 650 rpm.
Possible causes
harness and instrument harness, instrument harness and dash harness, or dash harness and sensor
connectors)
• Disconnection or shortcircuit in atmospheric temperature sensor (SIG) circuit (faulty vehicle harness or
sensor harness of ECU harnesses, instrument harnesses or dash harnesses)
• Disconnection in atmospheric temperature sensor (GND) circuit (faulty vehicle harness or sensor harness
of ECU harnesses, instrument harnesses or dash harnesses)
Diagnostic help
if faulty.
4-14

step 2
past
trouble
2 Check if diagnostic trouble codes "23, 211" are detected - Step 3 Step 7
simultaneously.
Are diagnostic trouble codes "22" and "23, 211" detected
simultaneously?
3 Check the harness (GND) for disconnection or shortcircuit. Between pin 66 and Step 5 Step 4
1. Turn the starter switch off. GND:∞Ω (OK) (NG)
2. Disconnect the harness from the Engine Control Unit. (without jumpr)
3. Disconnect the harness from the atmospheric temperature Between pins 53 and 66:
sensor.
4. Using a jumper wire between connector pins on atmospheric
(Jumper: 2 - 1)
0.5Ω or less 4
temperature sensor side, measure resistance value of connector
on the Engine Control Unit side.
4 Repair or replace the harness of atmospheric temperature sensor - Step 5 -
circuit. Also, check the connectors for connection.
⋅ Engine Control Unit to instrument harness connector (ECU
harness, atmospheric temperature sensor circuit)
⋅ ECU harness to dash harness connector (instrument harness,
atmospheric temperature sensor circuit)
⋅ Instrument harness connector to atmospheric temperature
sensor connector (dash harness, atmospheric temperature
sensor circuit)
5 Check the atmospheric temperature sensor circuit (GND) for Voltage is applied Step 6 Step 7
shortcircuit.
4. Install the circuit tester between connector pin on sensor side
and GND (frame or engine body).
6. Measure voltage in the atmospheric temperature sensor circuit.
4-15

⋅ ECU harness connector to dash harness connector (instrument
⋅ Instrument harness connector to atmospheric temperature sensor
connector (dash harness, atmospheric temperature sensor circuit)
7 Check the harness (SIG) for disconnection or shortcircuit. Between pin 53 and Step 9 Step 8
1. Turn the starter switch off. GND: (OK) (NG)
2. Disconnect the harness from the Engine Control Unit. ∞Ω
3. Disconnect the harness from the atmospheric temperature sensor. (without jumper)
4. Using a jumper wire between connector pins on atmospheric Between pins 53 and 66:
temperature sensor side, measure resistance value of connector (Jumper: 2 - 1)
on the Engine Control Unit side. 0.5Ω or less
⋅ ECU harness connector to dash harness sensor connector
(instrument harness, atmospheric temperature sensor circuit)
⋅ Instrument harness connector to atmospheric temperature sensor
connector (dash harness, atmospheric temperature sensor circuit)
9 Check the atmospheric temperature sensor circuit (SIG) for shortcircuit. Voltage is applied Step 10 Step 11
10 Repair or replace the atmospheric temperature sensor circuit. Also, - Step 11 -
⋅ Engine Control Unit to instrument harness (ECU harness,
atmospheric temperature sensor circuit)
⋅ ECU harness to dash harness (instrument harness, atmospheric
⋅ Instrument harness to atmospheric temperature sensor (dash
4-16

11 Check the atmospheric temperature sensor. - Step 13 Step 12
Giving temperature changes to the atmospheric temperature sensor, (OK) (NG)
measure the sensor internal resistance. (At cold engine, compare
water temperature with atmospheric temperature using the Tech II.
Also, measure resistance by referring to the chart on the next page.)
Does the resistance value change according to the temperature, and
is the resistance value normal?
Replace the atmospheric temperature sensor.
12 Did corrective actions complete? - Step 13 -
Check the voltage applied to the atmospheric temperature sensor, "power".
13 1. Turn the starter switch off. Between sensor pin 1 and Step 15 Step 14
2. Install the harness to the engine control unit. GND: (OK) (NG)
3. Install the circuit tester between connector pins and GND 5V (4.75 - 5.25V)
(frame and engine body etc.) on the sensor side.
Note: If the harness is disconnected from the atmospheric
temperature sensor, diagnostic trouble code "22" may be
detected, and therefore clear the diagnostic trouble code after
the check finished.
5. Measure the voltage in the atmospheric temperature sensor
4
"power" circuit.
14 Is the applied voltage normal? - Step 15 -
Replace the Engine Control Unit.
15 Did corrective actions complete? Between sensor pin 2-1 Step 17 Step 16
Using the circuit tester, check the atmospheric temperature sensor and GND: (OK) (NG)
"GND" for continuity. 5V
1. Turn the starter switch off. (4.75 - 5.25V)
2. Confirm that the harness is connected to the engine control unit.
3. Install the circuit tester between connector pins on the sensor side.
Note: If the harness is disconnected from the atmospheric
temperature sensor, diagnostic trouble code "22" may be
detected, and therefore clear the diagnostic trouble code
after the check finished.
5. Measure the voltage in the atmospheric temperature sensor
"GND" circuit.
Is the applied voltage normal?
1. Stop the engine.
2. Connect the harnesses.
4-17

18 Did corrective actions complete? - Repair After
Confirm that the diagnostic trouble codes have been cleared, and end referring
conduct the test run again to check that no diagnostic trouble code is (OK) to
detected. diagnostic
Is diagnostic trouble code detected? help,
step 1
(NG)
Appearance, pin assignment and resistance value of atmospheric temperature sensor
<Pin assignment of atmospheric temperature sensor> <Name of terminals of atmospheric sensor>
Temperature-sensitive portion
Pin No. Signal name Wire color / wire dia.
1 SIG VR/0.5
2 GND YR/0.5
2 < Installation position of atmospheric temperature sensor>
1
100
EJ mark II
connector (black),
2 pins
Resistance value（kΩ）
<Resistance value of atmospheric temperature sensor>

10
1
0.1
-40 -30 -20 -10 0 10 20 30 40

Temperature（°C）
Legend 1
1 Starter Relay
<Resistance value of atmospheric temperature sensor>

Temperature of temperature-
Parts checked Resistance value sensitive portion
Remarks
1 2 3.74kΩ 20°C Between thermistors for IE
EJ mark II
9.77kΩ 0°C
connector
1 Body ∞ - Between thermistor for IE and body
(black), 2 pins
2 Body ∞ - Between thermistor for IE and body
Note: Resistance value varies depending on the temperature of the temperature-sensitive portion.
4-18
23 Water temperature sensor system trouble (1/6)
Water temperature sensor circuit (including fuel temperature sensor and water
temperature sensor circuit).
2 1 1 2
FUEL TEMP. (WHITE)
SENSOR LB 0.5
L 0.85
LR 0.5
L 0.85

40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
YB 0.5
LW 0.5
LB 0.5
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21
(BLACK)
YB 0.5
10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10
111213141516 17 1819202122
2221201918 17 16 1514131211
4
LB 0.5
LB 0.5 YB 0.5
14 ECU HARNESS
.WATER TEMP.
14 THERMISTOR
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
41 42 43 44 SMJ 44 43 42 41 RV
(GRAY) 1 2 3 (BLUE) 2
48 47 46 45
45 46 47 48
3
LB 0.5
60 59 58 57 56 55 54 53 52 51 50 49
YV 0.5
49 50 51 52 53 54 55 56 57 58 59 60
72 71 70 69 68 67 66 65 64 63 62 61
61 62 63 64 65 66 67 68 69 70 71 72
LW 0.5
73 74 75 76 77 78 79 80 81 82 83 84 84 83 82 81 80 79 78 77 76 75 74 73
ENGINE CONTROL
THERMISTOR
FRAME (Ft) HARNESS
19
1 2 3 4 5 6 7
7 6 5 4 3 2 1
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 1 2 3 4 5 6 7 8
21 22 23 24
24 23 22 21 9 10 11 12 13 14 15 16 17
25 26 27 28
SMJ 28 27 26 25
(WHITE) YV 0.5
29 30 31 32
32 31 30 29
33
37
34
38 39 40
35
41
36
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
FACIA HARNESS
LW 0.5
EJ MARK
(BLACK)
3 2 1 1
SMP 1 2 3
6 5 4 1 2
(GRAY) 4 5 6
2
LB 0.5

SENSOR (MAIN)
4-19
Circuit description
The water temperature sensor detects the engine cooling water temperature. The voltage is applied to the
water temperature sensor provided on the cylinder body or housing, and that voltage value is used as a signal.
The Engine Control Unit reads variations in the applied voltage, and based on this signal, it optimizes the fuel
injection control. In the event of water temperature sensor trouble, the Engine Control Unit performs the
control with the backup values. Also, the sensor circuit GND is used in common to respective temperature
sensors.

• ERVICE ENGINE SOON lamp turns on (ON condition: when engine idles continuously for 20 seconds)
• Trouble at cold engine
Low starting performance
White smoke
Rough idling
The control unit judges as "water temperature sensor system trouble" and displays "diagnostic trouble code:
23" when the voltage applied to the atmospheric temperature sensor exceeds 4.8V, or the voltage below 0.1V
continues fore more than one second.

In the event of water temperature sensor system trouble, the ENGINE CONTROL lamp for the vehicles with
the multi-warning display, or the SERVICE ENGINE SOON lamp for the vehicles without the multi-warning
display turns on when the engine revolutions (idling) below 650 rpm continue for 20 seconds. The lamp turns
off when the engine revolutions exceed 650 rpm.
Possible causes
harness and instrument harness, instrument harness and frame harness, or frame harness and sensor
connectors)
• Disconnection or shortcircuit in water temperature sensor (SIG) circuit (faulty vehicle harness or sensor
harness of ECU harnesses, instrument harnesses or frame harnesses)
• Disconnection in water temperature sensor (GND) circuit (faulty vehicle harness or sensor harness of ECU
harnesses, instrument harnesses or frame harnesses)
Diagnostic help
if faulty.
4-20

step 2
past
trouble
simultaneously.
simultaneously?
1. Turn the starter switch off. GND:∞Ω (OK) (NG)
2. Disconnect the harness from the Engine Control Unit. (without jumpr)
3. Disconnect the harness from the water temperature sensor. Between pins 30 and 66:
4. Using a jumper wire between connector pins on water
(Jumper: 3 - 1)
0.5Ω or less 4
4 Repair or replace the harness of water temperature sensor circuit. - Step 5 -
Also, check the connectors for connection.
harness, water temperature sensor circuit)
⋅ ECU harness connector to frame harness connector (instrument
⋅ Instrument harness connector to water temperature sensor
connector (frame harness, water temperature sensor circuit)
5 Check the water temperature sensor circuit (GND) for shortcircuit. Voltage is applied Step 6 Step 7
6. Measure voltage in the water temperature sensor circuit.
4-21

6 Repair or replace the harness of water temperature sensor circuit. - Step 7 -
2. Disconnect the harness from the Engine Control Unit. ∞Ω (without jumpr)
3. Disconnect the harness from the water temperature sensor. Between pins 30 and 66:
4. Using a jumper wire between connector pins on water (Jumper: 3 - 1)
temperature sensor side, measure resistance value of connector 0.5Ω or less
8 Repair or replace the harness of water temperature sensor circuit. Step 9 -
Also, check the connectors for connection. -
9 Check the water temperature sensor circuit (SIG) for shortcircuit. Step 10 Step 11
1. Turn the starter switch off. Voltage is applied
10 Repair or replace the harness of water temperature sensor circuit. Step 11 -
Also, check the connectors for connection. -
⋅ Engine Control Unit to instrument harness connector(ECU
⋅ Instrument harness connector to water temperature senso
connector r (frame harness, water temperature sensor circuit)
4-22

11 Check the water temperature sensor. About 40 C: 1.25kW Step 13 Step 12
Giving temperature changes to the water temperature sensor, About 80 C: 350W (OK) (NG)
measure the sensor internal resistance. (Put the sensor in the beaker (See chart)
and heat it to measure resistance. Or, with all harnesses connected,
start the engine and check the water temperature with the Tech II.
When the temperature reached the specified value, stop the engine,
disconnect the harness from the Engine Control Unit, and measure
the resistance at the connector.)
12 Replace the water temperature sensor. - Step 13 -
13 Check the voltage applied to the water temperature sensor, "power" Between sensor pin 1 and Step 15 Step 14
pin. GND: (OK) (NG)
1. Turn the starter switch off. 5V (4.75 - 5.25V)
2. Install the harness on the engine control unit.
3. Install the circuit tester between connector pins and GND
(frame and engine body etc.) on the sensor side.
Note: If the harness is disconnected from the water temperature
sensor, diagnostic trouble code "23" may be detected, and
therefore clear the diagnostic trouble code after the check
finished.
4
5. Measure the voltage in the water temperature sensor "power"
circuit.
15 Using the circuit tester, check the water temperature sensor "GND" Between sensor pin 3-1 Step 17 Step 16
for continuity. and GND: (OK) (NG)
3. Install the circuit tester between connector pins on the sensor
side.
Note: If the harness is disconnected from the water temperature
sensor, diagnostic trouble code "23" may be detected, and
therefore clear the diagnostic trouble code after the check
finished.
5. Measure the voltage in the water temperature sensor "GND"
circuit.
Is the voltage normal?
1. Stop the engine.
4-23

detected. (OK) to
diagnostic
Is diagnostic trouble code detected?
help,
step 1
(NG)
Appearance, pin assignment and resistance value of water temperature sensor

< Appearance of water temperature sensor> < pin assignment of water temperature sensor>
Temperature-sensitive Pin No. Signal name Wire color / wire dia.

portion for meter 1 SIG (For engine) Y/0.5
2 SIG (For meter) YG/0.5
Temperature-sensitive
portion for IE 3 GND (For engine) YR/0.5
<Resistance characteristic of water temperature sensor>

3 2
100
RV connector (blue),
3 pins
Resistance value（kΩ）
10
1
0.1
3 2 1 -50 0 50 100
Temperature（°C）
060HY00017
060MX157
<Resistance characteristic of water temperature sensor>

Temperature of temperature-
Parts checked Resistance value sensitive portion Remarks
RV connector 1 2 ∞ - Between thermistor for IE and thermistor
(blue), 3 pins 1 3 350Ω 80°C Between thermistors for IE
1.25kΩ 40°C
1 body ∞ - Between thermistor for IE and body
2 3 ∞ - Between thermistor for IE and thermistor
2 body 52Ω 80°C Between thermistorfor IE and body
3 body ∞ - Between meter for IE and body
Note: Resistance value varies depending on the temperature of the temperature-sensitive portion.
4-24
24 Accelerator sensor system trouble (1/6)
Accelerator sensor circuit (including accelerator switch circuit)

40 PIN GyG 0.5 80 PIN

L 0.5
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
VW 1.25
Y 0.5
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
VW 0.5 21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
Gy 0.5
R 0.5
VW 1.25 W 0.5
FUSE 20
VW 1.25 LO 0.5
1 2 3 4 5 6 7 8 9 9 8 7 6 5 4 3 2 1
SDL
10 11 12 13 14 15 16 17 18 19 20 21 21 20 19 18 17 16 15 14 13 12 11 10
(BLACK) ACCELERATOR SENSOR 2 (SIG)
32 31 30 29 28 27 26 25 24 23 22
22 23 24 25 26 27 28 29 30 31 32
ACCELERATOR SENSOR 2 (POWER)
ACCELERATOR SENSOR 2 (GND)
ACCELERATOR SENSOR 1 (SIG)
1 2 3 4 5 6 7 8
19 20
9 10 11 12 13 14 15 16 17 18
GyG 0.5
L 0.5 4
LO 0.5
Y 0.5
ECU HARNESS
1
2 8 7 6 5 4 3 2 1
20 19
18 17 16 15 14 13 12 11 10 9
ACCELERATOR SWITCH
FUSE 11
Y 0.5
Y 0.5
G 0.5
L 0.5
L 0.5 5V Main
G 0.5 Ground Main
1 2 SDL 2 1
3 4 5 6 (WHITE) 6 5 4 3
R 0.5 5V sub Main

Y 0.5 signal Main B 0.5
W 0.5 single sub W 0.5
B 0.5 Grand sub R 0.5
ACCELERATOR SENSOR
4-25
Circuit description
The accelerator sensor detects the throttle opening. The voltage is applied to the accelerator sensor provided
on the accelerator pedal link, and the voltage value returned to the Engine Control Unit is used as a signal.
The Engine Control Unit reads the voltage changes from the accelerator sensor, and based on this signals, it
optimizes the throttle opening and fuel injection control. In the event of accelerator sensor trouble, the Engine
Control Unit makes control using the accelerator switch signal and backup value.
Also, the accelerator learning must be executed when the accelerator was repaired or replaced.

• SERVICE ENGINE SOON lamp turns on (continuous ON)
• Lack of output power
• Faulty accelerator pedal reaction (responsibility)
The control unit judges as "accelerator temperature sensor system trouble" and displays "diagnostic trouble
code: 24" when the output voltage applied to the accelerator temperature sensor exceeds 4.8V, or the voltage
below 0.1V continues fore more than one second.

In the event of accelerator sensor system trouble, the ENGINE CONTROL lamp for the vehicles with the
multi-warning display, or the SERVICE ENGINE SOON lamp for the vehicles without the multi-warning
display turns on, regardless of engine running condition. (Continuous ON)
Possible causes
harness and instrument harness or instrument harness and sensor connectors)
• Disconnection or shortcircuit in accelerator sensor (power) circuit (faulty vehicle harness or sensor harness
of ECU harnesses or instrument harnesses)
• Disconnection or shortcircuit in accelerator sensor (SIG) circuit (faulty vehicle harness or sensor harness
• Disconnection or shortcircuit in accelerator sensor (GND) circuit (faulty vehicle harness or sensor harness
• Faulty accelerator installation (disordered, loose)
• Faulty accelerator pedal (disordered, loose, faulty link, faulty spring)
Diagnostic help
if faulty.
4-26

1 Check the detected diagnostic trouble code. Current Step 2 Refer to
1. Start the engine and idle it. trouble: 24 Current diagnostic
step 4
past
trouble
2 Check the harness for disconnection or shortcircuit. Pins 41 - 44: 0.5Ω or less Step 4 Step 3
1. Turn the starter switch off. (Jumper: 4 - 1) (OK) (NG)
2. Disconnect the harness from the Engine Control Unit. Pins 41 - 45: 0.5Ω or less
3. Disconnect the harness from the accelerator sensor. (Jumper: 4 - 2)
4. Using a jumper wire between connector pins on accelerator Pins 44 - 45: 0.5Ω or less
sensor side, measure resistance value of connector on the (Jumper: 2 - 1)
Engine Control Unit side. Pins 42 - 54: 0.5Ω or less
Is the resistance value normal? (Jumper: 5 - 3)
Pins 42 - 46: 0.5Ω or less
(Jumper: 5 - 6) 4
Pins 54 - 46: 0.5Ω or less
(Jumper: 3 - 6)
Each pin - body (GND):
∞Ω (Without jumpr)
3 Repair or replace the accelerator sensor circuit. Also, check the - Step 4 -
⋅ ECU harness connector to accelerator sensor harness connector
(instrument harness, water temperature sensor circuit)
4 Check the accelerator sensor circuit for shortcircuit. Voltage is applied Step 5 Step 6
4. Install the circuit tester between connector each pin on sensor
side and GND (frame or engine body).
6. Measure the voltage in the accelerator sensor circuit.
4-27

5 Repair or replace the accelerator sensor circuit. Also, check the - Step 6 -
harness, accelerator sensor circuit)
⋅ ECU harness connector to accelerator sensor harness connector
(instrument harness, accelerator sensor circuit)
6 Check the voltage applied to the accelerator sensor, "power" pin. Between sensor pin Step 8 Step 7
1. Turn the starter switch off. 1and GND: (OK) (NG)
2. Install the harness on the engine control unit. 5V(4.75 - 5.25V)
3. Install the circuit tester between connector pins on the sensor Between sensor pin
side and GND (frame and engine body etc.). 3and GND:
4. Turn the starter switch on. 5V (4.75 - 5.25V)
Note: If the harness is disconnected from the accelerator sensor,
diagnostic trouble code "24" may be detected, and therefore
clear the diagnostic trouble code after the check finished.
5. Measure the voltage in the accelerator sensor "power" circuit.
8 Using the circuit tester, check the accelerator sensor "GND" for Between sensor pin Step 10 Step 9
continuity. 1 - 2 and GND: (OK) (NG)
2. Confirm that the harness is connected to the engine control unit. Between sensor pin
3. Install the circuit tester between connector pins on the sensor 3 - 6 and GND:
side. 5V (4.75 - 5.25V)
Note: If the harness is disconnected from the accelerator sensor,
5. Measure the voltage in the accelerator sensor circuit.
10 Check the accelerator pedal link, bracket, and spring for installation - Step 11 -
or trouble, and repair or replace if faulty.
4-28

11 Using the Tech II, check the accelerator sensor. - Step 13 Step 12
4. Connect the Tech II, and perform "Accelerator sensor, SW
check" in "Inspection" menu to check if the sensor is normal.
Is the accelerator sensor normal?
12 Replace the accelerator sensor. - Step 13 -
13 Confirm that the diagnostic trouble codes are cleared, and conduct - Step 15 Step 14
the test run again to check that no diagnostic trouble code is detected. (OK) (NG)
1. Stop the engine.
4
detected. (OK) to
help,
step 1
(NG)
Note:Be sure to execute the accelerator learning after the Engine Control Unit or accelerator sensor was
repaired or replaced.
4-29
External view, pin assignment and resistance value of accelerator sensor

< External view of accelerator sensor > < Pin assignment of accelerator sensor >
1 +5V main L/0.5

2 GND main G/0.5
3 +5V sub R/0.5
4 SIG main Y/0.5
1 2 W/0.5
3456
5 SIG sub
6 GND sub B/0.5
SDL connector
(white) 6 pins
< External view of bracket assembly >
<Accelerator sensor output voltage>

Output voltage in the table below is that when the sensor is connected to the engine control unit.
Accelerator
Parts checked Output voltage Remarks
pedal position
SDL connector 1, 3 2, 6 - 5.07 - 5.17V
(white), 6 pins 4, 5 2, 6 Idling position 0.35 - 0.65V New sensor
0.31 - 0.69V Used sensor
Full-throttle (Idling voltage Permissible if the full
position + 3.5V - 4.80V) voltage is below 4.8V and
the difference between the
full voltage and idling
voltage is "more than 3.5V".
4-30
25 Vehicle speed sensor system trouble (1/7)
Vehicle speed sensor circuit (including pulse matching device circuit (except for ECOGIT vehicle)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 VEHICLE SPEED SENSOR (SIG)
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21 (FROM PULSE MATCHING DEVICE)
(BLACK)
32 31 30 29 28 27 26 25 24 23 22 22 23 24 25 26 27 28 29 30 31 32
PL 0.5
ECU HARNESS
Y 0.5 PL 0.5
4 3 2 1 12 PIN
12 1110 9 8 7 6 5
W 0.5
4
B 0.5
VEHICLE SPEED SENSOR POWER

1 2 3 4 5 6 7 7 6 5 4 3 2 1
8 9 10 11 12 13 14 14 13 12 11 10 9 8 VEHICLE SPEED SENSOR SIG
15 16 17 18 19 20 20 19 18 17 16 15
21 22 23 24 24 23 22 21
25 26 27 28 28 27 26 25 VEHICLE SPEED SENSOR GND
SMJ Y 0.5
(WHITE) 1 2 3
29 30 31 32 32 31 30 29
W 0.5
33 34 35 36 36 35 34 33
37 38 39 40 41 42 42 41 40 39 38 37
B 0.5
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
INSTRUMENT (LOWER) HARNESS FRAME (Ft) HARNESS
4-31
Circuit description
The vehicle speed sensor detects the vehicle speed. The vehicle speed sensor is installed on the transmission
or transfer output. The vehicle speed sensor is driven via the drive gears and the sensor shaft rotates. When
the shaft rotates, the voltage is generated by the magnet (magnetic force) attached to the sensor, and the pulse
signals are outputted. For the sensor output signals, the time (frequency) between pulse signals changes
according to the vehicle speeds (sensor shaft revolutions). (Low frequency pulses are outputted when the
sensor shaft revolutions are low, or high frequency pulses if high. The pulses per one shaft revolution are 25
pulses for other than ECOGIT, or 6 pulses for ECOGIT.) The Engine Control Unit converts the vehicle speed
sensor signals into the vehicle speeds, which are used for the auto cruise or NR control. As the pulse signals
(frequencies) from the vehicle speed sensor vary depending on the type of vehicles because of different
transmissions, differential gear ratios, or tire radii, the pulse matching device is installed to correct the pulse
signals so that the vehicle speed information can be used exactly for meters and various controls. (It corrects
the vehicle speed sensor shaft revolutions to 637 rpm when the vehicle speed is 60 km/h.) For the pulse
signals, the voltage changes between high level (about 14V) and low level (about 2V).
he control unit judges as "vehicle speed sensor trouble" and displays "diagnostic trouble code: 25", when the
vehicle speed pulse signal voltage level is high and the state below 0.5V continues for more than one second,
or when no vehicle speed pulse signals are entered during auto cruise operation.

In the event of vehicle speed sensor system trouble, the ENGINE CONTROL lamp for the vehicles with the
display turns on, regardless of engine running condition if NR is attached to the vehicles. (Continuous ON)
For the vehicles without NR, the ENGINE CONTROL lamp or the SERVICE ENGINE SOON lamp does
not turn on, but the trouble is indicated with the diagnostic trouble code only.
Possible causes
• Loose connection of connectors (faulty connectors between Engine Control Unit and instrument harness,
ECU harness and frame harness, instrument harness and transmission harness, or frame harness and sensor
connectors)
• Faulty vehicle speed sensor circuit (power supply, SIG, GND, pulse matching device) (Faulty vehicle
harness or sensor harness of ECU harnesses, instrument harnesses, frame harnesses or transmission
harnesses)
• Faulty sensor installation condition (loose, faulty shaft)
• Faulty drive gear for vehicle speed sensor shaft rotation (transmission, etc.)
• Faulty internal circuit of pulse matching device
Diagnostic help
if faulty. (For the ECOGIT vehicles, see the ECOGIT Troubleshooting Manual.)
4-32

step 2
past
trouble
2 Check the speedometer operation. Normal operation Step 3 Step 9
Does the meter operate normally during the vehicle running?
3 Check the harnesses for disconnection or shortcircuit. Pulse matching device: Step 5 Step 4
1. Turn the starter switch off. 12-pin connector (OK) (NG)
2. Disconnect the harness from the Engine Control Unit. (Bt. pulse matching
3. Disconnect the harness from the pulse matching device. device pin 2 and Engine
4. Using a jumper wire, connect between connector pin on the Control Unit - pin 75)
pulse matching device side and GND (frame or body). Jumper: 0.5Ω or less
Without jumper: ∞Ω
5. Install the circuit tester between connector pin on the Engine
Control Unit side and GND (frame or body), and measure 4
resistance.
4 Repair or replace the vehicle speed sensor circuit. Also, check the - Step 5 -
harness, vehicle speed sensor circuit)
⋅ ECU harness connector to pulse matching device connector
(instrument harness, vehicle speed sensor circuit)
5 Check the pulse matching device power circuit for disconnection. Pulse matching device: Step 7 Step 6
1. Turn the starter switch off. 12-pin connector, (OK) (NG)
2. Install the circuit tester between connector pin on sensor side Between. pin 4 and GND:
and GND (frame or engine body). Battery voltage
4. Measure voltage in the pulse matching device power circuit.
Is the voltage applied normal?
6 Repair or replace the pulse matching device power circuit. Also, - Step 7 -
4-33

7 Check the harness for disconnection or shortcircuit. Pulse matching device: Step 9 Step 8
1. Turn the starter switch off. 12-pin connector, (OK) (NG)
2. Disconnect the harness from the vehicle speed sensor. Bt. pins 3 and 10
3. Disconnect the harness from the pulse matching device device. (Jumper bt. vehicle speed
4. Using a jumper wire between connector pins on vehicle speed sensor⋅POW and SIG):
sensor side, measure resistance value of connector on the pulse 0.5Ω or less
matching device side. (Without jumper): ∞Ω
Is the resistance value normal? Between pins 3 and 12
(Jumper bt. vehicle speed
sensor POW and GND):
0.5Ω or less
(Without jumper): ∞Ω
Between pins 10 and 12
(Jumper bt. vehicle speed
sensor SIG and GND):
0.5Ω or less
(Without jumper): ∞Ω
8 Repair or replace the vehicle speed sensor circuit. Also, check the - Step 9 -
⋅ Pulse matching device to frame harness connector (instrument
harness, vehicle speed sensor circuit)
⋅ Instrument harness connector to transmission harness
connector (frame harness, vehicle speed sensor circuit)
⋅ Frame harness connector to vehicle speed sensor connector
(transmission harness, vehicle speed sensor circuit)
9 Check the vehicle speed sensor condition. - Step 11 Step 10
2. Remove the vehicle sensor.
3. Check the shaft for wear, damage, or disengagement.
Is the vehicle sensor shaft normal?
4-34

10 Replace the vehicle speed sensor shaft. - Step 19 -
11 Check again the diagnostic trouble code. - Step 19 Step 12
1. Connect the Tech II, and clear the diagnostic trouble code.
2. Start the engine and conduct the test.
3. Connect the Tech II, and check the diagnostic trouble code.
Is the diagnostic trouble code detected?
12 Replace the vehicle speed sensor, and check again if the diagnostic - Step 19 Step 13
trouble code is detected.
1. Replace the vehicle speed sensor.
13 Check if the diagnostic trouble code is detected in other systems Diagnostic trouble code is Step 14 Step 18
besides IE system. detected in other systems
Is the diagnostic trouble code "25" detected in the HSA system? besides IE system
14 Check the vehicle speed sensor drive gears. - Step 16 Step 15
15
Are the drive gears normal?
Repair or replace the vehicle speed sensor drive gears. -
(OK)
Step 17
(NG)
-
4
16 Replace the pulse matching device. - Step 17 -
1. Stop the engine.
2. Connect the harnesses on the boost sensor.
detected. (OK) to
help,
step 1
(NG)
4-35
External view, pin assignment and output voltage of vehicle speed sensor
< External view of vehicle speed sensor > < Pin assignment of accelerator sensor >
1 power source Y/0.5

2 GND B/0.5
3 SIG W/0.5
3 2 1
060HY00276
<Output voltage of vehicle speed sensor>

Output voltage in the table below is obtained when the vehicle speed sensor is connected to the vehicle.
Parts checked Shaft condition Output voltage Remarks
090II 1 2 - battery voltage (28V)
water-proof 3 2 Not rotating 1.0 - 3.0V Vehicle stop
connector, 3 pins or
Sensor side: 12.0 - 15.0V
(Black) Not rotating Pulse signal that the voltage Vehicle
Harness side: changes between 1.0 - 3.0V and traveling
(gray) 12.0 - 15.0V
<Checking the output voltage of vehicle sensor>
The vehicle sensor is designed so that the output voltage is changed according to the shaft rotating angle. The
output voltage during the "Vehicle traveling" in the above table can be checked by turning the shaft by hand.
(The output voltage changes between 1.0-3.0V and 12.0-15.0V by turning the shaft by 7.2°.)
* The pulse matching device converts the input signal before outputting it. Therefore, it cannot be checked
in the same manner as the vehicle speed sensor. (The output voltage of the pulse matching device cannot
be checked with a circuit tester. Oscilloscope or other similar measuring instrument which can check
waveform is required.)
1 Remove the vehicle speed sensor.

2 Connect the vehicle sensor connector.
3 Turn the starter switch off.
4 Turn the vehicle sensor shaft slowly using a circuit tester and
measure the output voltage.
Vehicle speed sensor tightening torque Shaft

Tighten the vehicle speed sensor with the specified tightening torque as shown below.
* If the tightening torque more than specified is applied, the sensor may be damaged or fail.
Specified tightening torque: 24.52 - 34.32 N-m (2.5 - 3.5 kgf⋅m)

4-36
External view, pin assignment and output voltage of pulse matching device
<External view of pulse matching device> <Pin assignment of pulse matching device>
Pin No. Pin No. Signal name
(12 pins) (8 pins)
1 1 8-pulse signal output (SIG)
2 4 25-pulse signal output (SIG)
3 7 Power supplied to vehicle speed sensor
4 8 Pulse matching device power source
10 2 Pulse signal input
12 5 GND
1 2 3 4
1 2 3 4 5 6 7 8
5 6 7 8 9 10 1112
4
060H1000120
<Pulse matching device output voltage>

Output voltage in the table below is obtained when the pulse matching device is connected to the vehicle.
Parts checked Vehicle sensor Output voltage Remarks

shaft condition
Pulse matching 12 pins 4 w - Battery voltage (28V)
device connector 8 pins 5 8
(12 pins 12 pins 3 w - Battery voltage (28V)
8 pins 5 7
or 8 pins)
12 pins 0 w Not rotating 1.0 - 3.0V or 10PIN:
8 pins 2 5 (vehicle stop) 12.0 - 15.0V Measurement of 25-
Rotating Pulse signal which changes between pulse input signal
(vehicle traveling) 1.0 - 3.0V and 12.0 - 15.0V from vehicle speed
sensor
12 pins 2 w Not rotating 1.0 - 3.0V 2PIN:
8 pins 4 5 (vehicle stop) Measurement of
Rotating Pulse signal which changes between 25-pulse output
(vehicle traveling) 1.0 - 3.0V and 12.0 - 15.0V signal
12 pins 1 w Not rotating 0 - 1.5V Measurement of

8 pins 1 5 (vehicle stop) 8-pulse output
Rotating Pulse signal which changes between signal
(vehicle traveling) 0 - 1.5V and meter power source
(8.0V) - 0.5V
4-37
32 Boost sensor system trouble ... 6S series, 6W series (1/6)
Boost sensor circuit

40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
BOOST, ALL SPEED

ACCEL SENSOR (GND)
4 3 2 1 1 2 3 4
SWP BOOST SENSOR (SIG)
8 7 6 5 5 6 7 8
(GRAY) BOOST, ALL SPEED
12 11 10 9 9 10 11 12
ACCEL SENSOR (POWER)
B 0.5 16 15 14 13 13 14 15 16
GyB 0.5
B 0.5
B 0.5
B 0.5
W 0.5
B 0.5
R 0.5
6SD1 ENGINE
BOOST SENSOR
EJ MARK ECU HARNESS
123
(BLACK)
R 0.5
B 0.5
W 0.5
ENGINE HARNESS
4-38
Circuit description
The boost sensor is detects the intake manifold inside pressure. The boost sensor is installed on the intake
manifold. The boost sensor output voltage changes (the output voltage is low when the intake manifold inside
pressure is low, and it becomes high as the pressure rises) if the intake manifold inside pressure changes
according to the engine (turbocharger) condition.
The Engine Control Unit reads this output voltage change and converts it into the boost pressure for control.
The boost sensor power supply (5V) and GND circuit is common to the all speed accelerator sensor, and it is
connected to the Engine Control Unit. The sensor circuit is shielded to protect from electrical noise.

• SERVICE ENGINE SOON lamp turns on (ON condition: when engine idling continues for 20 seconds)
• Black smoke
The control unit judges as "boost sensor trouble" and displays "diagnostic trouble code: 32", if the relative
boost pressure exceeds 20kPa or if the state below -32kPa continues for one second, when the engine stalls.
If the "high boost trouble (diagnostic trouble code: 42)" is also displayed, the boost pressure is faulty, and
accordingly check and repair by referring to "high boost trouble (diagnostic trouble code: 42)".

4
In the event of boost sensor system trouble, the ENGINE CONTROL lamp for the vehicles with the multi-
Possible causes
• Loose connection of connectors (faulty connectors between Engine Control Unit and engine harness, or
ECU harness and respective sensors)
• Disconnection or shortcircuit in boost sensor (5V, SIG, GND) circuit (faulty vehicle harness or sensor
harness of ECU harnesses or engine harnesses)
• Faulty sensor installation condition (loose)
• Faulty intake system (intercooler, intake pipe, air cleaner, etc.)
Diagnostic help
Check the intake system including air cleaner for clogging, the connectors for loose connection, the harnesses
for abrasion or folding, the wires inside harnesses for abrasion or shortcircuit. Also, perform functional
diagnosis to check the operation and control, and repair if faulty.
4-39

step 2
past
trouble
2 Check the harness for disconnection or shortcircuit. Between pins 61 and 72: Step 4 Step 3
2. Disconnect the harness from the Engine Control Unit. 0.5Ω or less
3. Disconnect the harness from the boostr sensor. (Without jumper) ∞Ω
4. Using a jumper wire between connector pins on boost sensor Between pins 61 and 56:
side, measure resistance value of connector on the Engine (Jumper: 1 - 2)
Control Unit side. 0.5Ω or less
Is the resistance value normal? (Without jumper) ∞Ω
Between pins 72 and 56:
(Jumper: 3 - 2)
0.5Ω or less
(Without jumper) ∞Ω
3 Repair or replace the harness of boost sensor circuit. Also, check the - Step 4 -
harness, boost sensor circuit)
⋅ ECU harness connector to boost sensor connector (engine
4 Check the boost sensor circuit for shortcircuit. Voltage is applied Step 5 Step 6
6. Measure voltage in the boost sensor circuit.
5 Repair or replace the harness of boost sensor circuit. - Step 6 -
⋅ ECU harness connector to boost sensor connector (engine
4-40

6 Check the voltage applied to the boost sensor, "power" pin. Between sensor pin 3 and Step 8 Step 7
1. Turn the starter switch off. GND: 5V (OK) (NG)
2. Install the harness on the engine control unit. (4.75 - 5.25V)
side. and GND (frame and engine body etc.)
Note: If the harness is disconnected from the boost sensor,
5. Measure the voltage in the boost sensor "power" circuit.
7 Using the circuit tester, check the boost sensor "GND" for continuity. Between sensor pin 2 and Step 9 Step 8
1. Turn the starter switch off. GND: 0.5Ω or less (OK) (NG)
side.
4
5. Measure the resistance value in the boost sensor circuit.
9 Check the boost sensor. - Step 10 Step 11
2. Remove the boost sensor.
3. Check the boost sensor for clogging or presence of foreign
materials.
Are foreign materials present on the boost sensor?
10 Clean the boost sensor and install it again. - Step 12 -
4-41

11 Replace the boost sensor. - Step 12 -
13 Check the intake system. - Step 14 See
Did corrective actions complete? functional
diag:
Intake
system
to check,
then step
14
1. Stop the engine.
detected. (OK) to
help,
step 1
(NG)
4-42
External view, pin assignment and output voltage of boost sensor

<External view of boost sensor> <Pin assignment of boost sensor>
1 SIG W/0.5
2 GND B/0.5
3 2 1
3 5V R/0.5
EJ mark II connector
(black), 3 pins <Boost sensor output characteristic diagram>
4.5
Output voltage
Connector
Air intake port 2.5
0.5
66.7 200 333.3(kPa)
500 1500 2500(mmHg) 4

Boost pressure
(absolute voltage)
<Boost sensor output voltage>
The output voltage shown in the table below are obtained when the boost sensor is connected with the engine
control unit. Refer to the "Boost sensor output characteristic diagram" for the relation between the voltage
and output voltage.
Parts checked Boost pressure Output voltage Remarks
EJ mark II connector 3 2 - 5.07 - 5.17V
(black), 3 pins 1 2 101.3kPa {760mmHg} 0.8 - 1.2V Equivalent to
atmospheric pressure
4-43
33 CPU monitoring IC trouble (1/2)
Description of diagnostic trouble code

The central processing unit (CPU), memory (RAM), and CPU monitoring IC are built in the Engine Control
Unit.
If this diagnostic trouble code occurred, whether the CPU in the Engine Control Unit operates normally
(including calculation and various controls) is not sure, and thus this diagnostic trouble code "CPU
monitoring IC trouble" is displayed.
Vehicle behaviors in the event of this diagnostic trouble code

In the event of CPU monitoring IC trouble, the Engine Control Unit judges as "CPU monitoring IC trouble"
and displays "diagnostic trouble code: 33".

In the event of CPU monitoring IC trouble, the ENGINE CONTROL lamp for the vehicles with the multi-
turns on, regardless of the engine running condition. (Continuous ON)
Possible cause
• Internal trouble of EngineControl Unit

1 Check the detected diagnostic trouble code. - Step 2 Step 6
1. Using the Tech II, check the detected diagnostic trouble code.
Is the detected diagnostic trouble code current trouble?
2 Check the diagnostic trouble code. - Step 6 Step 3
2. Turn the starter switch off once.
4. Connect the Tech II and check the diagnostic trouble code.
3 Check the battery voltage and Engine Control Unit connector for - Step 5 Step 4
abnormality. (OK) (NG)
Is any abnormality found?
4 Repair faulty parts found in step 3. - Step 2 -
5 Replace Engine Control Unit. - Step 6 -
4-44
32 CPU monitoring IC trouble (2/2)

1. Stop the engine.
7 Confirm that the diagnostic trouble codes have been cleared, and - Repair Step 2
conduct the test run again to check that no diagnostic trouble code is end (NG)
detected.
4-45
35 A/D conversion error/charger circuit trouble (1/2)

The engine control unit converts signals from switches and sensors (analog signal) to digital signals to be
used for various calculation and control. When this conversion (A/D conversion) is not successful, a
diagnostic trouble code "A/D conversion error" is indicated.
A power source pressure-up circuit for the injector is provided in the engine control unit. If a trouble is
detected in this circuit, the diagnostic trouble code, "charge circuit trouble" is indicated.
Vehicle behavior in case of a trouble

• A/D conversion error
Service engine soon lamp lights up (continuous ON).
Lack of output power
Rough idling
• Charging circuit trouble
Service engine soon lamp lights up (continuous ON).
Engine stops.
When a trouble of IC for monitoring CPU in the engine control unit is detected, it is diagnosed as "A/D
conversion error/charge circuit trouble" and "diagnostic trouble code: 35" is indicated.
Warning during diagnosis (ENGINE CONTROL / SERVICE ENGINE SOON lamp light ON)
In the event of failure in the engine control unit, "Engine Control" lights up for the vehicles equipped with
the multi-warning function and "Service engine soon lamp" for other vehicles.
(continuous ON)
Possible causes
• Internal trouble of engine control unit
• Faulty injector system circuit
4-46
35 A/D conversion error/charger circuit trouble (2/2)

1 Check the detected diagnostic trouble code. - Step 2 Step 8
1. Using the Tech II, check the detected diagnostic trouble code. Current
Is the detected diagnostic trouble code current trouble? trouble
2 Check the diagnostic trouble code. - Step 6 Step 3
2. Turn the starter switch off once.
4. Connect the Tech II and check the diagnostic trouble code.
3 Check the battery voltage and Engine Control Unit connector for - Step 5 Step 4
abnormality. (OK) (NG)
Is any abnormality found?
4 Repair faulty parts found in step 3. - Step 2 -
5 Referring to diagnostic trouble codes "158, 159", check the injector Step 7 Step 6
system circuit. (OK) (NG)
6
Is the injector system circuit normal?
Repair the injector system circuit. - Step 2 - 4
1. Stop the engine.
9 Confirm that the diagnostic trouble codes have been cleared, and - Repair Step 2
conduct the test run again to check that no diagnostic trouble code is end (NG)
detected. (OK)
4-47
42 High boost trouble ... 6S series, 6W series (1/6)
Boost sensor circuit (including all speed accelerator sensor circuit)

40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
BOOST, ALL SPEED

ACCEL SENSOR (GND)
4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8
12 11 10 9 9 10 11 12
B 0.5 16 15 14 13 13 14 15 16
GyB 0.5
B 0.5
B 0.5
B 0.5
W 0.5
B 0.5
R 0.5
6SD1 ENGINE
BOOST SENSOR
EJ MARK ECU HARNESS
123
(BLACK)
R 0.5
B 0.5
W 0.5
ENGINE HARNESS
4-48
Circuit description

• SERVICE ENGINE SOON lamp turns on (Continuous ON)
• Black smoke
The control unit judges as "high boost trouble" and displays "diagnostic trouble code: 42", if the state where
actual boost pressure is higher than reference boost pressure continues for more than 0.5 second though the
boost pressure always changes during the engine running.
Further, if an abnormal state continues for more than 10 seconds, "diagnostic trouble code: 42" is also
displayed.
4
In the event of boost pressure trouble, the ENGINE CONTROL lamp for the vehicles with the multi-warning
display, or the SERVICE ENGINE SOON lamp for the vehicles without the multi-warning display turns on,
regardless of the engine running conditions. (Continuous ON)
Possible causes
• Faulty sensor (faulty sensor internal circuit, detector (diaphragm))
• Faulty sensor installation (loose)
• Faulty turbocharger (main body, VGS (air cylinder, magnetic valve, air piping, shaft, etc.))
• Faulty exhaust brake (main body, control air cylinder, etc.)
Diagnostic help
4-49

step 2
past
trouble
diag:
Intake
system
to check,
then
step 3
3 Check the exhaust system. - Step 4 See
diag:
Intake
system
to check,
then
step 4
(Jumper: 3 - 2)
0.5Ω or less
⋅ ECU harness connector to boost sensor harness connector
(engine harness, boost sensor circuit)
4-50

6. Measure voltage in the boosg sensor circuit.
8 Check the voltage applied to the boost sensor, "power" pin. Between sensor pin Step 10 Step 9
1. Turn the starter switch off. 3 and GND: (OK) (NG)
2. Install the harness on the engine control unit. 5V (4.75 - 5.25V)
3. Install the circuit tester between connector each pins on the
sensor side and GND (frame and engine body etc.).
4
9 Using the circuit tester, check the boost sensor "GND" for continuity. Between sensor pin Step 11 Step 10
2. Confirm that the harness is connected to the engine control unit. 0.5W or less
side.
4-51

11 Check the boost condition. -4 to 4kPa Step 15 Step 12
2. Connect the harness to the boost sensor.
4. Connect the Tech II, and check the "relative boost" of the
engine data.
5. Start the engine and idle it.
Is the data normal?
materials.
1. Stop the engine.
2 Turn the starter switch on.
detected. (OK) to
help,
step 1
(NG)
4-52

1 SIG W/0.5
2 GND B/0.5
3 2 1
3 +5V R/0.5
4.5
Output voltage
Connector
Air intake port 2.5
0.5
66.7 200 333.3(kPa)
500 1500 2500(mmHg) 4

Boost pressure
(absolute voltage)
and output voltage.
4-53
65 Low boost trouble ... 6S series, 6W series (1/6)
Boost sensor circuit
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
BOOST, ALL SPEED

ACCEL SENSOR (GND)
4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8
12 11 10 9 9 10 11 12
B 0.5 16 15 14 13 13 14 15 16
GyB 0.5
B 0.5
B 0.5
B 0.5
W 0.5
B 0.5
R 0.5
6SD1 ENGINE
BOOST SENSOR
EJ MARK ECU HARNESS
123
(BLACK)
R 0.5
B 0.5
W 0.5
ENGINE HARNESS
4-54
Circuit description

• Black smoke
The control unit judges as "low boost trouble" and displays "diagnostic trouble code: 65", if the state where
actual boost pressure is lower than reference boost pressure continues fore more than about 25 seconds,
though the boost pressure always changes during the engine running when the throttle opening is over 80%.

In the event of boost pressure trouble, the ENGINE CONTROL lamp for the vehicles with the multi-warning
display, or the SERVICE ENGINE SOON lamp for the vehicles without the multi-warning display does not
4
turn on, but the trouble is indicated with the diagnostic trouble code only.
Possible causes
• Faulty sensor (faulty sensor internal circuit, detector (diaphragm))
• Faulty turbocharger (main body, VGS (air cylinder, magnetic valve, air piping, shaft, etc.))
• Faulty exhaust brake (main body, control air cylinder, etc.)
Diagnostic help
4-55

step 2
past
trouble
diag:
Intake
system
to check,
then
step 3
diag:
Intake
system
to check,
then
step 4
(Jumper: 3 - 2)
0.5Ω or less
4-56

6. Measure voltage in the boosg sensor circuit.
8 Check the voltage applied to the boost sensor, "power" pin. Between sensor pin Step 10 Step 9
2. Install the harness on the engine control unit. 5V (4.75 - 5.25V)
3. Install the circuit tester between connector each pins on the
sensor side and GND (frame and engine body etc.).
4
9 Using the circuit tester, check the boost sensor "GND" for continuity. Between sensor pin Step 11 Step 10
2. Confirm that the harness is connected to the engine control unit. 0.5Ω or less
side.
4-57

11 Check the boost condition. -4 to 4kPa Step 15 Step 12
2. Connect the harness to the boost sensor.
4. Connect the Tech II, and check the "relative boost" of the
engine data.
5. Start the engine and change the engine speed from idling to high
speed range. Also, conduct the test run and check numeric value.
Is the data normal?
materials.
1. Stop the engine.
2 Turn the starter switch on.
detected. (OK) to
diagnostic
help,
step 1
(NG)
4-58

1 SIG W/0.5
2 GND B/0.5
3 2 1
3 +5V R/0.5
4.5
Output voltage
Connector
Air intake port 2.5
0.5
66.7 200 333.3(kPa)
500 1500 2500(mmHg) 4

Boost pressure
(absolute voltage)
and output voltage.
4-59
71 Atmospheric pressure sensor trouble ... 6S series, 6W series (1/2)
Atmospheric pressure sensor circuit (built in Engine Control Unit)
060MX113
Circuit description
The atmospheric pressure sensor detects the atmospheric pressure. The atmospheric pressure sensor is
installed in the Engine Control Unit.
Upon change of atmospheric pressure due to the altitude or weather conditions, the output voltage of the
atmospheric pressure sensor changes (the output voltage is low when atmospheric pressure is low, and it
becomes high as the atmospheric pressure rises). The Engine Control Unit reads this change in output voltage
and converts it into the atmospheric pressure, and based on this signal, it optimizes the fuel injection control
and calculates relative pressure of the boost pressure.
In the event of atmospheric pressure sensor trouble, the Engine Control Unit makes control with the backup
value.
Note: The Engine Control Unit cannot be disassembled. Replace the Engine Control Unit if the atmospheric
pressure sensor is faulty.

• During the running at a highland
White smoke
The control unit judges as "atmospheric pressure sensor trouble" and displays "diagnostic trouble code: 71",
when the voltage applied to the atmospheric pressure sensor exceeds 4.7V or when the state below 1.9V
continues for more than one second.

In the event of atmospheric pressure sensor system trouble, the ENGINE CONTROL lamp for the vehicles
with the multi-warning display, or the SERVICE ENGINE SOON lamp for the vehicles without the multi-
warning display does not turn on, but the trouble is indicated with the diagnostic trouble code only.
4-60
71 Atmospheric pressure sensor trouble ... 6S series, 6W series (2/2)
Possible causes
• Faulty sensor (faulty sensor internal circuit, detector, or installation)
• Internal trouble of Engine Control Circuit
Diagnostic help
Clear the diagnostic trouble code and conduct the test run, and if the diagnostic trouble code is again
displayed, replace the Engine Control Unit, as the atmospheric pressure sensor is built in the Engine Control
Unit. Also, in the test run, run the vehicle from a lowland up to a highland to check if a trouble is detected.


step 2
past
2 Check again the diagnostic trouble code. - Step 4

trouble
Step 3 4
2. Start the engine and conduct the test run. (Run vehicle at a
highland, if possible)
3 3. Connect the Tech II, and check the diagnostic trouble code. - Step 4 -
4 Replace the Engine Control Unit. - Repair After
Did corrective actions complete? end referring
Confirm that the diagnostic trouble codes have been cleared, and (OK) to
conduct the test run again to check that no diagnostic trouble code is diagnostic
detected. help,
Is diagnostic trouble code detected? step 1
(NG)
4-61
115 Fuel pressure sensor output fixed (1/5)
Fuel pressure sensor circuit (including NE sensor and G sensor circuit)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
Gy 0.5


1 2 3 4 4 3 2 1 Gy 0.5
B 0.5 5 6 7 8 SWP 8 7 6 5
9 10 11 12 (GRAY) 12 11 10 9 B 0.5
(GRAY)
WL 0.5 W 0.5
OL 0.5 G 0.5
W 0.5 R 0.5
B 0.5 O 0.5
NE SENSOR (SHEILD)
NE SENSOR
NE SENSOR (—)
1 2 NE SENSOR (+)
Y 0.5 W 0.5
Br 0.5 B 0.5
4 3 2 1 1 2 3 4
GyR 0.5
8 7 6 5 SWP 5 6 7 8
12 11 10 9 (GRAY) 9 10 11 12
G 0.5
B 0.5
G SENSOR R 0.5
1 2
G SENSOR (SHEILD)
P 0.5
G SENSOR (—)
L 0.5
ECU HARNESS
4-62
Circuit description
The fuel pressure sensor detects the common rail inside pressure. The fuel pressure sensor is installed on the
common rail.
The fuel pressure sensor output voltage changes (the output voltage is low when the fuel pressure inside
common rail is low, and it becomes high as the pressure rises) if the fuel pressure inside common rail changes
according to the engine condition. The Engine Control Unit reads this output voltage change and converts it
into the fuel pressure inside common rail for control.
The fuel pressure sensor power supply (5V), SIG, and GND circuit is independent, and it is connected to the
Engine Control Unit.
The sensor circuit is shielded to protect from electrical noise.

• White smoke/black smoke
• Rough idling
• Poor starting performance
If the state where the common rail fuel pressure (over 10MPa) continues for more than about 9 seconds when 4
the diagnostic trouble code "245" is not detected and the supply pump is normal (not fail-safe mode), the
Engine Control Unit judges as "fuel pressure sensor output fixed" and displays "diagnostic trouble code:
115".

In the event of fuel pressure trouble, the ENGINE CONTROL lamp for the vehicles with the multi-warning
regardless of the engine running condition. (Continuous ON)
Possible causes
• Disconnection or shortcircuit in fuel pressure sensor (5V, SIG, GND) circuit (faulty vehicle harness or
sensor harness of ECU harnesses or engine harnesses)
• Faulty sensor (faulty sensor internal circuit, detector)
Diagnostic help
if faulty.
4-63

step 2
past
trouble
2 Check the harness for disconnection or GND for shortcircuit. Between pins 62 and 71: Step 4 Step 3
1. Turn the starter switch off. 0.5Ω or less (OK) (NG)
2. Disconnect the harness from the Engine Control Unit. (Without jumper)
3. Disconnect the harness from the fuel pressure sensor. Between pins 73 and 55:
. Using a jumper wire between connector pins on fuel pressure (Jumper: 3 - 1)
sensor side, measure resistance value of connector on the 0.5Ω or less
Engine Control Unit side. (Without jumper) ∞Ω
Is the resistance value normal? Between pins 62 and 55:
(Jumper: 2 - 1)
0.5Ω or less
(Jumper: 2 - 1)
0.5Ω or less
(Jumper: 2 - 3)
0.5Ω or less
(Jumper: 2 - 3)
0.5Ω or less
3 Repair or replace the fuel pressure sensor circuit. Also, check the - Step 4 -
⋅ Engine Control Unit to engine harness connector(ECU harness,
fuel pressure sensor circuit)
⋅ ECU harness connector to fuel pressure sensor connector
(engine harness, fuel pressure sensor circuit)
4-64

4 Check the fuel pressure sensor circuit for shortcircuit. Voltage is applied Step 5 Step 6
4. Install the circuit tester between connector each pin on sensor
side and GND (frame or engine body).
6. Measure voltage in the fuel pressure sensor circuit.
5 Repair or replace the harness of fuel pressure sensor circuit. - Step 6 -
⋅ Engine Control Unit to engine harness
(ECU harness, fuel pressure sensor circuit)
(Engine harness, fuel pressure sensor circuit)
6 Check the fuel pressure inside common rail. Followed Step 10 Step 7
1. Start the engine. (OK) (NG)
2. Using the Tech II, conduct the "Fuel Pressure Control" test to
check if actual pressure follows the specified pressure.
Did actual pressure follow the specified pressure?
4
7 Check the fuel pressure sensor. - Step 8 Step 9
2. Remove the fuel pressure sensor from the common rail.
3. Check the fuel pressure sensor for presence of foreign
materials.
Are foreign materials present on the fuel pressure sensor?
8 Clean the fuel pressure sensor and install it on the common rail. - Step 6 -
9 Replace the fuel pressure sensor. - Step 6 -
2. Bleed the air mixing in the fuel.
3. Start the engine and conduct the test run.
1. Stop the engine.
4-65

detected. (OK) to
help,
step 1
(NG)
External view, pin assignment, and output voltage of fuel pressure sensor
<External view of fuel pressure sensor> <Pin assignment of fuel pressure sensor>
1 GND WL/0.5
2 SIG B/0.5
3 5V OL/0.5
3 2 1
060MX044
<Output characteristic chart of fuel pressure sensor>

0.84
Output voltage
0.6
(Vout / Vc)
0.2
MPa
0 100 160
2
kgf/cm
0 1019 1631
Pressure
At Vc=5V, actual reading ON 4.2V(160MPa)
OFF 1.0V( 0MPa)
4-66
118 Common-rail pressure trouble (1/7)

40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
Gy 0.5


1 2 3 4 4 3 2 1 Gy 0.5
B 0.5 5 6 7 8 SWP 8 7 6 5
9 10 11 12 (GRAY) 12 11 10 9 B 0.5
(GRAY)
WL 0.5 W 0.5
OL 0.5 G 0.5
W 0.5 R 0.5
B 0.5 O 0.5
NE SENSOR
NE SENSOR (SHEILD)
4
NE SENSOR (—)
1 2 NE SENSOR (+)
Y 0.5 W 0.5
Br 0.5 B 0.5
4 3 2 1 1 2 3 4
GyR 0.5
8 7 6 5 SWP 5 6 7 8
12 11 10 9 (GRAY) 9 10 11 12
G 0.5
B 0.5
G SENSOR R 0.5
1 2
G SENSOR (SHEILD)
P 0.5
G SENSOR (—)
L 0.5
ECU HARNESS
4-67
Circuit description
common rail.

• Rough idling
• Engine stops
The Engine Control Unit judges as "common rail pressure trouble" and displays "diagnostic trouble code:
118" when diagnostic trouble code "245" is not detected and the state where actual common rail pressure
exceeds about 125MPa continues for more than 0.2 second.
(The Engine Control Unit stops the engine when actual common rail pressure exceeds about 130MPa.)

Possible causes
• Injector internal trouble
• Supply pump internal trouble
• Flow damper operated
• Pressure limiter not operated yet
• Faulty piping (clogging, squeezed) in fuel system (on leak side)
4-68
Diagnostic help
Check the connectors for loose connection, the harnesses for abrasion or folding, the wires inside harnesses for
abrasion or shortcircuit. Also, perform functional diagnosis to check the operation and control, and repair if
faulty.
The fuel pressure rises over the specified value, if the pressure limiter does not operate. Replace the pressure
limiter, when the diagnosis could not find out a faulty part but the diagnostic trouble code is detected frequently.

step 2
past
trouble
4
4. Connect the Tech II, and check the diagnostic trouble code. -
3 Check the supply pump for mounting condition. Step 5 Step 4
2. Run the engine to position the No.1 cylinder in the top dead center.
3. Check the mating mark on the supply pump. -
Is the mating mark on the supply pump in correct position?
4 Adjust the supply pump mounting condition. - Step 5 -
5 Check the injectors for fuel injecting operation. Step 9 Step 6
Note: At this time, if the injector related trouble code has been (OK) (NG)
detected, check and repair the injector related parts before
this checking.
2. Using the Tech II, conduct the "Cylinder Power Balance" test
and stop each cylinder injector to check if fuel is injected
normally.
The engine speed and sound will vary if the injector is stopped
when the injector injects fuel normally.
The engine speed and sound will not vary if the injector is
stopped when the injector is faulty and does not inject fuel.
Does the injector inject fuel normally?
4-69

6 Check the fuel piping system. - Step 8 Step 7
1. Stop the engine. (OK) (NG)
2. Check the fuel piping of the cylinder where the engine speed
and sound did not vary in step 5. (Clogged or squeezed high
pressure piping, leak side piping)
Is the fuel piping system normal?
7 Check the fuel piping system, and repair or replace. - Step 9 -
(Repair or replace the fuel piping of the cylinder where the engine
speed and sound did not vary in step 5.)
8 Replace the injector. - Step 9 -
(Replace the injector of the cylinder where the engine speed and
sound did not vary in step 5.)
9 Check again the fuel system including piping and filters, and repair - Step 10 -
or replace if faulty.
4. Using a jumper wire between connector pins on fuel pressure (Jumper: 3 - 1)
(Jumper: 2 - 1)
0.5Ω or less
(Jumper: 2 - 1)
0.5Ω or less
(Jumper: 2 - 3)
0.5Ω or less
(Jumper: 2 - 3)
0.5Ω or less
4-70

11 Repair or replace the harness of fuel pressure sensor circuit. Also, - Step 12 -
harness, fuel pressure sensor circuit)
4. Install the circuit tester between each pin on the sensor
connector and GND (frame or engine body).
4
3. Check the fuel pressure sensor for presence of foreign materials.
18 Check again the fuel pressure. - Step 21 Step 19
1. Perform again the steps 14 to 16. (OK) (NG)
2. Check the fuel pressure.
Are data normal, and also does actual pressure follow the specified
value?
4-71

19 Check the supply pump. - Step 20 Step 21
2. Disconnect the fuel high pressure piping between supply pump
and common rail.
Note: As the fuel flows out, prevent the fuel from running out and
wipe the fuel that flowed out with waste cloth.
3. Disconnect the harnesses from PCV1 and PCV2.
Note: If the harnesses are disconnected from the PCV, the
diagnostic trouble codes "247, 248" will be detected, and thus
clear the trouble codes after the check finished.
4. Start the starter.
Note: As the fuel may flow out suddenly, prevent the fuel from
running out and wipe the fuel that flowed out with waste cloth.
5. Check if the fuel is discharged from the supply pump (delivery
valve).
Is the fuel discharged from the supply pump (delivery valve)?
Did correction actions complete?
21 Check the flow damper operation. Number of flow damper Step 22 Step 24
1. Connect the Tech II. operating times increases
2. Start the engine and change the engine speed.
3. Using the Tech II, check how many times the flow damper
operates.
4. Does the number of flow damper operating times increase
during engine running?
22 Check the fuel piping where the number of flow damper operating - Step 24 Step 23
times increases (between common rail and injector) for leakage.
Does the fuel leak?
23 Repair or replace the fuel piping (between common rail and injector). - Step 25 -
24 Replace the flow damper. - Step 25 -
25 Bleed the air mixing in the fuel. - Step 26 -
4-72

2. Restore the vehicle.
detected. (OK) to
help,
step 1
(NG)
1
2
GND
SIG
WL/0.5
B/0.5 4
3 5V OL/0.5
3 2 1
060MX044

0.84
Output voltage
0.6
(Vout / Vc)
0.2
MPa
0 100 160
2
kgf/cm
0 1019 1631
Pressure
OFF 1.0V( 0MPa)
4-73
151 Common rail pressure trouble (pump excessive pressure feed) (1/7)

40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
Gy 0.5


1 2 3 4 4 3 2 1 Gy 0.5
B 0.5 5 6 7 8 SWP 8 7 6 5
9 10 11 12 (GRAY) 12 11 10 9 B 0.5
(GRAY)
WL 0.5 W 0.5
OL 0.5 G 0.5
W 0.5 R 0.5
B 0.5 O 0.5
NE SENSOR (SHEILD)
NE SENSOR
NE SENSOR (—)
1 2 NE SENSOR (+)
Y 0.5 W 0.5
Br 0.5 B 0.5
4 3 2 1 1 2 3 4
GyR 0.5
8 7 6 5 SWP 5 6 7 8
12 11 10 9 (GRAY) 9 10 11 12
G 0.5
B 0.5
G SENSOR R 0.5
1 2
G SENSOR (SHEILD)
P 0.5
G SENSOR (—)
L 0.5
ECU HARNESS
4-74
Circuit description
common rail.

• Rough idling
The Engine Control Unit judges as "common rail pressure trouble (pump excessive pressure feed)" and
displays "diagnostic trouble code: 151" if the difference between actual common rail fuel pressure and target 4
common rail fuel pressure is over 10MPa (PC differential pressure) and this state continues for more than
about 9 seconds during the engine running or if the PCV close timing is 217.5°CA and this state continues
for more than about 9 seconds at the water temperature over 60°C when the diagnostic trouble codes "245,
115" are not detected and the supply pump and NE sensor are operating normally (not fail-safe mode).

Possible causes
• Injector internal trouble
• Supply pump internal trouble
• Flow damper operated
• Pressure limiter not operated yet
• Faulty piping (clogging, squeezed) in fuel system (on leak side)
4-75
Diagnostic help
Check the connectors for loose connection, the harnesses for abrasion or folding, the wires inside harnesses for
abrasion or shortcircuit. Also, perform functional diagnosis to check the operation and control, and repair if faulty.
The fuel pressure rises over the specified value, if the pressure limiter does not operate. Replace the pressure
limiter, when the diagnosis could not find out a faulty part but the diagnostic trouble code is detected frequently.


step 2
past
trouble
3 Check the supply pump for mounting condition. - Step 5 Step 4
2. Run the engine to position the No.1 cylinder in the top dead center.
3. Check the mating mark on the supply pump.
Is the mating mark on the supply pump in correct position?
4 Adjust the supply pump mounting condition. - Step 5 -
5 Check the injectors for fuel injecting operation. - Step 9 Step 6
Note:At this time, if the injector related trouble code has been (OK) (NG)
detected, check and repair the injector related parts before
this checking.
2. Using the Tech II, conduct the "Injection Power Balance" test
and stop each cylinder injector to check if fuel is injected
normally.
The engine speed and sound will vary if the injector is stopped
when the injector injects fuel normally.
The engine speed and sound will not vary if the injector is
stopped when the injector is faulty and does not inject fuel.
Does the injector inject fuel normally?
4-76
151 Common rail pressure trouble (pump excessive pressure feed) (4//7)

6 Check the fuel piping system. - Step 8 Step 7
2. Check the fuel piping of the cylinder where the engine speed
and sound did not vary in step 5. (Clogged or squeezed high
pressure piping, leak side piping)
Is the fuel piping system normal?
7 Check the fuel piping system, and repair or replace. - Step 9 -
(Repair or replace the fuel piping of the cylinder where the engine
speed and sound did not vary in step 5.)
8 Replace the injector. - Step 9 -
(Replace the injector of the cylinder where the engine speed and
sound did not vary in step 5.)
9 Check again the fuel system including piping and filters, and repair - Step 10 -
or replace if faulty.
0.5Ω or less
(Without jumper)
(OK) (NG) 4
(Jumper: 2 - 1)
0.5Ω or less
(Jumper: 2 - 1)
0.5Ω or less
(Jumper: 2 - 3)
0.5Ω or less
(Jumper: 2 - 3)
0.5Ω or less
4-77

4. Install the circuit tester between each pin on the sensor
connector side and GND (frame or engine body).
3. Check the fuel pressure sensor for presence of foreign
materials.
18 Check again the fuel pressure. - Step 21 Step 19
1. Perform again the steps 14 to 16. (OK) (NG)
2. Check the fuel pressure.
Are data normal, and also does actual pressure follow the specified
value?
4-78

19 Check the supply pump. - Step 20 Step 21
2. Disconnect the fuel high pressure piping between supply pump
and common rail.
Note: As the fuel flows out, prevent the fuel from running out and
wipe the fuel that flowed out with waste cloth.
3. Disconnect the harnesses from PCV1 and PCV2.
Note: If the harnesses are disconnected from the PCV, the
diagnostic trouble codes "247, 248" will be detected, and
thus clear the trouble codes after the check finished.
4. Start the starter.
Note: As the fuel may flow out suddenly, prevent the fuel from
running out and wipe the fuel that flowed out with waste cloth.
5. Check if the fuel is discharged from the supply pump (delivery
valve).
Is the fuel discharged from the supply pump (delivery valve)?
21 Repair or replace the fuel piping (between common rail and injector).
- Step 23 -
4
22 Replace the flow damper. - Step 23 -
23 Bleed the air mixing in the fuel. - Step 24 -
2. Restore the vehicle.
4-79

detected. (OK) to
Is diagnostic trouble code detected? possible
causes,
step 1
(NG)
1 GND WL/0.5
2 SIG B/0.5
3 5V OL/0.5
3 2 1
060MX044

0.84
Output voltage
0.6
(Vout / Vc)
0.2
MPa
0 100 160
2
kgf/cm
0 1019 1631
Pressure
OFF 1.0V( 0MPa)
4-80
158 TWV power system trouble (Common 1 "Injector 1, 3, 5 systems") (1/5)
Injector circuit
ECU, Engine harness (6SD1 engine)
INJECTOR 6 INJECTOR 1
L 1.25 GR 1.25
L 1.25 GR 1.25
LW 1.25 GW 1.25
LW 1.25 GW 1.25
LR 1.25 G 1.25
LR 1.25 G 1.25
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100 RY 1.25
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110 RY 1.25
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
INJECTOR NO. 6 40 PIN 80 PIN

1 2
(CYLINDER #4)
RL 1.25
RL 1.25
R 0.85
G 0.85 B 1.25
INJECTOR NO. 4 1 2
(CYLINDER #6)
Y 0.85
L 0.85
4 3 2 1
SWP 1 2 3 4
8 7 6 5 (GRAY) 5 6 7 8
4
12 11 10 9 9 10 11 12
W 0.85
B 0.85
Y 0.85
INJECTOR NO. 2 1 2 R 0.85
(CYLINDER #5) G 0.85
B 0.85 L 0.85
4 3 2 1 1 2 3 4
W 0.85
8 7 6 5 5 6 7 8 B 0.5
SWP
12 11 10 9 9 10 11 12
16 15 14 13 (GRAY) 13 14 15 16
B 0.5
G 0.85
B 1.25
R 0.85
B 0.5
INJECTOR NO. 5 W 0.85

1 2 B 0.85
(CYLINDER #2)
L 0.85
R 0.85 Y 0.85
G 0.85 1 2 3 4
SWP 4 3 2 1
5 6 7 8 (GRAY) 8 7 6 5
9 10 11 12 12 11 10 9
INJECTOR NO. 3 1 2
(CYLINDER #3)
Y 0.85
L 0.85
Gy 0.5
Gy 0.5
INJECTOR NO. 1 1 2
(CYLINDER #1) B 1.25
B 0.85
W 0.85 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
ENGINE HARNESS
JOINT CONNECTOR (1)
GND POINT (CASE GND)
ECU HARNESS
4-81
Circuit description
The fuel injection quantity and injection timing of the injectors are controlled by the energizing time. The
voltage (over 100V) raised in the Engine Control Unit is applied to the TWV (Two Way Valve) in the
injectors provided on the engine block or head, and the signals are returned to the Engine Control Unit via
the injectors to control the switches in the Engine Control Unit, so as to make various controls.
CAUTION:
The injector driving voltage exceeds 100V, and therefore the starter switch must be turned OFF to prevent an
electric shock during the checking and repair.

• Engine stops
The control unit judges as "TWV Power System Trouble (Common 1 "Injector 1, 3, 5 Systems")" and
displays "diagnostic trouble code: 158" when battery voltage is shortcircuited to the TWV (Two Way Valve)
drive circuit in the injector.

In the event of injector power system trouble, the ENGINE CONTROL lamp for the vehicles with the multi-
Possible causes
harness and engine harness, ECU harness and injector harness, or middle connector, injector connector)
• Disconnection or shortcircuit in injector (power side) circuit (faulty vehicle harness of ECU harnesses,
engine harnesses, or injector harnesses)
• Disconnection or shortcircuit in injector (driving side) circuit (faulty vehicle harness of ECU harnesses,
• Faulty TWV (faulty shortcircuit of internal coil)
if faulty.
Injector (TWV) numbers and cylinder numbers

• TWV1 All engines No.1 cylinder
• TWV2 6WG1, 6SD1: No.5 cylinder 6TE1: No.6 cylinder
4-82

1 Check the diagnostic trouble code. - Step 2 If
1. Try to start the engine (perform cranking). Current started,
<Engine cannot start, if current code 158 has been detected> trouble refer to
2. Using the Tech II, check the diagnostic trouble code. diagnostic
Is the detected diagnostic trouble code current trouble? help,
then
step 2
2 Check the harness for disconnection or shortcircuit. Between pins 100 and Step 4 Step 3
1. Turn the starter switch off. 110: 0.5Ωor less (OK) (NG)
2. Disconnect the harness from the Engine Control Unit. Between pin 100 and
3. Disconnect the harness from the TWV1, 3, 5. each pin: ∞Ω
4. Measure resistance value of connector on the Engine Control Between pin 110 and
Unit side. each pin: ∞Ω
Is the resistance value normal? Between pin 100 and
body (GND): ∞Ω
Between pin 110 and
body (GND): ∞Ω
0.5Ω or less
Between pin 90 and each
4
pin: ∞Ω
pin: ∞Ω
Between pin 90 and body
(GND): ∞Ω
(GND): ∞Ω
0.5Ω or less
pin: ∞Ω
pin: ∞Ω
(GND): ∞Ω
(GND): ∞Ω
0.5W or less
pin: ∞Ω
pin: ∞Ω
(GND): ∞Ω
(GND): ∞Ω
4-83

3 Repair or replace the harness of TWV circuit. Also, check the - Step 2 -
⋅ Engine Control Unit to TWV connector (power supply side)
(Faulty vehicle harness of ECU harness, engine harness, or
injector harness)
4 Check the harness in power supply system and TWV system for Between pin 100 and Step 6 Step 5
shortcircuit. GND: 0V (OK) (NG)
1. Turn the starter switch off. Between pin 110 and
2. Disconnect the harness from the Engine Control Unit. GND: 0V
3. Disconnect the harness from the TWV 1, 3, 5. Between pin 90 and
4. Turn the starter switch on. GND: 0V
5. Measure potential difference of the connector on the Engine Between pin 99 and
Control Unit. GND: 0V
Is the voltage applied? Between pin 88 and
GND: 0V
Between pin 97 and
GND: 0V
Between pin 86 and
GND: 0V
Between pin 95 and
GND: 0V
⋅ Engine Control Unit to TWV connector
injector harness)
6 Using a circuit tester, measure the resistance of TWV. Between TWV pins: 0.3 - Step 8 Step 7
1. Turn the starter switch off. 1.3Ω (at about 20°C) (OK) (NG)
2. Using a circuit tester, measure internal resistance of TWV. Between TWV body and
7 Replace the TWV. - Step 9 -
9 estore the vehicle. - Step 10 -
1. Stop the engine.
detected. (OK) to
help,
step 1
(NG)
4-84
External view, pin assignment and resistance value of injector
<External view of injector>

Because the valve is of the two-way type, pins are not identified.
6SD1 6WG1 6TE1
<Resistance value of injector>
Resistance value between pins 0.3 - 1.3Ω
4-85
Injector circuit
ECU, Engine harness (6SD1 engine)
L 1.25 GR 1.25
L 1.25 GR 1.25
LW 1.25 GW 1.25
LW 1.25 GW 1.25
LR 1.25 G 1.25
LR 1.25 G 1.25
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100 RY 1.25
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110 RY 1.25
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120

1 2
(CYLINDER #4)
RL 1.25
RL 1.25
R 0.85
G 0.85 B 1.25
INJECTOR NO. 4 1 2
(CYLINDER #6)
Y 0.85
L 0.85
4 3 2 1
SWP 1 2 3 4
8 7 6 5 (GRAY) 5 6 7 8
12 11 10 9 9 10 11 12
W 0.85
B 0.85
Y 0.85
B 0.85 L 0.85
4 3 2 1 1 2 3 4
W 0.85
8 7 6 5 5 6 7 8 B 0.5
SWP
12 11 10 9 9 10 11 12
16 15 14 13 (GRAY) 13 14 15 16
B 0.5
G 0.85
B 1.25
R 0.85
B 0.5

1 2 B 0.85
(CYLINDER #2)
L 0.85
R 0.85 Y 0.85
G 0.85 1 2 3 4
SWP 4 3 2 1
5 6 7 8 (GRAY) 8 7 6 5
9 10 11 12 12 11 10 9
INJECTOR NO. 3 1 2
(CYLINDER #3)
Y 0.85
L 0.85
Gy 0.5
Gy 0.5
INJECTOR NO. 1 1 2
B 0.85
W 0.85 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
ENGINE HARNESS
JOINT CONNECTOR (1)
ECU HARNESS
4-86
Circuit description
injectors provided on the engine block or head, and the signals are returned to the Engine Control Unit via
the injectors to control the switches in the Engine Control Unit, so as to make various controls.
CAUTION:
The injector driving voltage exceeds 100V, and therefore the starter switch must be turned OFF to prevent an
electric shock during the checking and repair.

• Engine stops
The control unit judges as "TWV Power System Trouble (Common 2 "Injector 2, 4, 6 Systems")" and
displays "diagnostic trouble code: 159" when battery voltage is shortcircuited to the TWV (Two Way Valve)
drive circuit in the injector.
In the event of injector system trouble, the ENGINE CONTROL lamp for the vehicles with the multi-warning
regardless of the engine running condition. (Continuous ON) 4
Possible causes
• Disconnection or shortcircuit in injector (power side) circuit (faulty vehicle harness of ECU harnesses,
• Disconnection or shortcircuit in injector (driving side) circuit (faulty vehicle harness of ECU harnesses,
• Faulty TWV (faulty shortcircuit of internal coil)
Diagnostic help
if faulty.

• TWV1 All engines No.1 cylinder
4-87

1 Check the diagnostic trouble code. - Step 2 If
1. Try to start the engine (perform cranking). Current started,
<Engine cannot start, if current code 159 has been detected> trouble refer to
2. Using the Tech II, check the diagnostic trouble code. diagnostic
Is the detected diagnostic trouble code current trouble? help,
then
step 2
Step 3
(NG)
2 Check the harness for disconnection or shortcircuit. Between pins 119 and Step 4
1. Turn the starter switch off. 120: 0.5Ω or less (OK)
4. Measure resistance value of connector on the Engine Control each pin: ∞Ω
Unit side. Between pin 120 and
Between pin 119 and
body (GND): ∞Ω
Between pin 120 and
body (GND): ∞Ω
0.5Ω or less
pin: ∞Ω
pin: ∞Ω
(GND): ∞Ω
(GND): ∞Ω
0.5Ω or less
pin: ∞Ω
pin: ∞Ω
(GND): ∞Ω
(GND): ∞Ω
0.5Ω or less
pin: ∞Ω
pin: ∞Ω
(GND): ∞Ω
(GND): ∞Ω
4-88

⋅ Engine Control Unit to TWV connector (power supply side)
injector harness)
4 Check the harness in power supply system and TWV system for Between pin 119 and Step 6 Step 5
shortcircuit. GND: 0V (OK) (NG)
1. Turn the starter switch off. Between pin 120 and
2. Disconnect the harness from the Engine Control Unit. GND: 0V
3. Disconnect the harness from the TWV 2, 4, 6. Between pin 89 and
4. Turn the starter switch on. GND: 0V
5. Measure potential difference of the connector on the Engine Between pin 98 and
Control Unit. GND: 0V
Is the voltage applied? Between pin 87 and
GND: 0V
Between pin 96 and
GND: 0V
Between pin 85 and
GND: 0V
Between pin 94 and
5 Repair or replace the harness of TWV circuit. Also, check the

GND: 0V
- Step 4 -
4
⋅ Engine Control Unit to TWV connector
injector harness)
6 sing a circuit tester, measure the resistance of TWV. Between TWV pins: 0.3 - Step 8 Step 7
2. Using a circuit tester, measure internal resistance of TWV. Between TWV body and
1. Stop the engine.
2. Connect the harnesses. -
detected. (OK) to
help,
step 1
(NG)
4-89

6SD1 6WG1 6TE1
4-90
211 Fuel temperature sensor trouble (1/6)
Fuel temperature sensor circuit (including water temperature sensor and atmospheric
temperature sensor circuits)

2 1 1 2
FUEL TEMP. (WHITE)
SENSOR LB 0.5
L 0.85
LR 0.5
L 0.85

40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
YB 0.5
LW 0.5
LB 0.5
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21
(BLACK)
YB 0.5
10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10
111213141516 17 1819202122
4
2221201918 17 16 1514131211
LB 0.5
LB 0.5 YB 0.5
14 ECU HARNESS
.WATER TEMP.
14 THERMISTOR
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
41 42 43 44 SMJ 44 43 42 41 RV
(GRAY) 1 2 3 (BLUE) 2
48 47 46 45
45 46 47 48
3
LB 0.5
60 59 58 57 56 55 54 53 52 51 50 49
YV 0.5
49 50 51 52 53 54 55 56 57 58 59 60
72 71 70 69 68 67 66 65 64 63 62 61
61 62 63 64 65 66 67 68 69 70 71 72
LW 0.5
73 74 75 76 77 78 79 80 81 82 83 84 84 83 82 81 80 79 78 77 76 75 74 73
ENGINE CONTROL
THERMISTOR
FRAME (Ft) HARNESS
19
1 2 3 4 5 6 7
7 6 5 4 3 2 1
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 1 2 3 4 5 6 7 8
21 22 23 24
24 23 22 21 9 10 11 12 13 14 15 16 17
25 26 27 28
SMJ 28 27 26 25
(WHITE) YV 0.5
29 30 31 32
32 31 30 29
33
37
34
38 39 40
35
41
36
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
FACIA HARNESS
LW 0.5
EJ MARK
(BLACK)
3 2 1 1
SMP 1 2 3
6 5 4 1 2
(GRAY) 4 5 6
2
LB 0.5

SENSOR (MAIN)
4-91
Circuit description
The fuel temperature sensor detects the fuel temperature. The voltage is applied to the fuel temperature sensor
provided on the fuel leak pipe, and that voltage value is used as a signal. The Engine Control Unit reads
variations in the applied voltage, and based on this signal, it optimizes the fuel injection control. In the event
of fuel temperature sensor trouble, the Engine Control Unit performs the control with the backup values.
Also, the sensor circuit GND is used in common to respective temperature sensors.

• Not bodily sensory
The control unit judges as "fuel temperature sensor system trouble" and displays "diagnostic trouble code:
211", when the voltage applied to the fuel temperature sensor exceeds 4.8V or when the state below 0.1V
continues for more than one second.

In the event of fuel temperature sensor system trouble, the ENGINE CONTROL lamp for the vehicles with
display does not turn on, but the trouble is indicated with the diagnostic trouble code only.
Possible causes
• Loose connection of connectors (faulty connectors between Engine Control Unit and ECU harness, or
respective sensors)
• Disconnection or shortcircuit in fuel temperature sensor (SIG) circuit (faulty vehicle harness or sensor
harness of ECU harnesses)
• Disconnection in fuel temperature sensor (GND) circuit (faulty vehicle harness or sensor harness of ECU
harnesses)
Diagnostic help
if faulty.
4-92

step 2
past
trouble
simultaneously.
simultaneously?
1. Turn the starter switch off. GND: ∞Ω (OK) (NG)
2. Disconnect the harness from the Engine Control Unit. (without jumper)
3. Disconnect the harness from the fuel temperature sensor. Between pins 52 and 66:
4. Using a jumper wire between connector pins on fuel
(Jumper: 2 - 1)
0.5Ω or less 4
4 Repair or replace the harness of fuel temperature sensor circuit. Also, Step 5 -
check the connectors for connection. -
⋅ Engine Control Unit to instrument harness connector(ECU
harness, fuel temperature sensor circuit)
harness, fuel temperature sensor circuit)
⋅ Instrument harness connector to fuel temperature sensor
connector (frame harness, fuel temperature sensor circuit)
5 Check the fuel temperature sensor circuit (GND) for shortcircuit. Voltage is applied Step 6 Step 7
6. Measure voltage in the fuel temperature sensor circuit.
6 Repair or replace the harness of fuel temperature sensor circuit. Also, - Step 7 -
⋅ Engine Control Unit to sensor connectors (ECU harness, fuel
4-93

1. Turn the starter switch off. GND: ∞Ω (OK) (NG)
2. Disconnect the harness from the Engine Control Unit. (without jumper)
3. Disconnect the harness from the fuel temperature sensor. Between pins 52 and 66:
4. Using a jumper wire between connector pins on fuel (Jumper: 2 - 1)
temperature sensor side, measure resistance value of connector 0.5Ω or less
8 Repair or replace the harness of fuel temperature sensor circuit. Also, - Step 9 -
9 Check the fuel temperature sensor circuit (SIG) for shortcircuit. Voltage is applied Step 10 Step 11
6. Measure voltage in the fuel temperature sensor circuit.
10 Repair or replace the harness of fuel temperature sensor circuit. - Step 11 -
11 Check the fuel temperature sensor. About 40°C: 1.21kΩ Step 13 Step 12
Giving temperature changes to the fuel temperature sensor, measure About 10°C: 3.45kW (OK) (NG)
the sensor internal resistance. (Put the sensor in the beaker and heat (See chart)
it to measure resistance. Or, with all harnesses connected, start the
engine and check the water temperature with the Tech II. When the
temperature reached the specified value, stop the engine, disconnect
the harness from the Engine Control Unit, and measure the resistance
at the connector.)
12 Replace the fuel temperature sensor. - Step 13 -
4-94

13 Check the voltage applied to the fuel temperature sensor, "power" Between sensor pin 1 and Step 15 Step 14
pin. GND: 5V (4.75 - 5.25V) (OK) (NG)
2. Install the harness on the engine control unit.
side and GND (frame and engine body etc.).
Note: If the harness is disconnected from the fuel temperature sensor,
5. Measure the voltage in the fuel temperature sensor "power" circuit.
15 Using the circuit tester, check the fuel temperature sensor "GND" for Between sensor pin 2-1 Step 17 Step 16
continuity. and GND: (OK) (NG)
3. Install the circuit tester between connector pins on the sensor side.
4
Note: If the harness is disconnected from the fuel temperature sensor,
5. Measure the voltage in the fuel temperature sensor "GND" circuit.
1. Stop the engine.
detected. (OK) to
help,
step 1
(NG)
4-95
External view, pin assignment and resistance value of fuel pressure sensor
< External view of fuel temperature sensor > <Name of terminals of fuel temperature sensor >
1 SIG LR/0.5
2 GND LB/0.5
2 1
SWP connector
(white), 2 pins
Temperature-sensitive portion
< Resistance characteristic of fuel temperature sensor (Ref.)>
30
20
10
8
6
5
Resistance value (kΩ)
4
3
2
1
0.8
0.6
0.5
0.4
0.3
0.2
0.1
-20 0 20 40 60 80 100120
Temperature (5°ΩC)
<Resistance value of fuel temperature sensor>

Temperature of
Parts checked Resistance value temperature-sensitive Remarks
portion
EJ mark II 1 2 1.21kΩ 40 Between thermistors for IE
connector 3.45kΩ 10
1 Body
(black), 2 pins ∞Ω - Between thermistor for IE and body
2 Body ∞Ω - Between thermistor for IE and body
4-96
217 PCV1 system short circuit (battery and power supply circuit) trouble (1/4)
PCV circuit (including the PCV relay circuit)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
VW 1.25
PCV1 (SIG) VW 0.5
BrB 1.25
BrB 1.25
Br 1.25
KEY SW [ON] SIG
PCV2 PCV1 Br 1.25
4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8
12 11 10 9
SWP 9 10 11 12 PCV2 (SIG)
1 2 1 2 16 15 14 13 (GRAY) 13 14 15 16
RW 1.25
WL 1.25 WL 1.25
1 2 3 4 4 3 2 1
5 6 7 8 SWP 8 7 6 5
9 10 11 12 (GRAY) 12 11 10 9
RB 1.25
WL 1.25
3
ENGINE HARNESS 4
PCV RELAY
5 1
4 2
1
P 0.3 2 3 4 B 0.3
5
O 1.25
8 7 6 5 4 3 2 1 SDL 1 2 3 4 5 6 7 8
20 19 19 20
FUSE 45 18 17 16 15 14 13 12 11 10 9 (WHITE) 9 10 11 12 13 14 15 16 17 18
O 1.25
B 1.25 G 1.25 G 1.25
DIODE(P.CV) ECU HARNESS
1 2 3 4
FUSE 20
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21
32 31 30 29 28 27 26 25 24 23 22 (BLACK) 22 23 24 25 26 27 28 29 30 31 32
VW 0.5
BASE HARNESS CONNECTOR (A)

FUSE 17 VW 1.25
1 2 3 4 5 6 7 7 6 5 4 3 2 1
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
21 22 23 24 24 23 22 21
25 26 27 28 28 27 26 25
SMJ B8
29 30 31 32 (WHITE) 32 31 30 29
33 34 35 36 36 35 34 33
37 38 39 40 41 42 42 41 40 39 38 37 BL 5
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
FRAME GND
B2
ACG E TERMINAL
FRAME (Ft) HARNESS
4-97
Circuit description
The Pump Control Valve (PCV) controls the fuel feedrate to the common rail. Upon signal (voltage)
transmission to the PCV provided on the supply pump, the PCV valve closes and the fuel is compressively
fed from the supply pump to the common rail.
The Engine Control Unit operates the PCV, using the switch function. The longer PCV operation time causes
more fuel to be fed to the common rail, and the common rail internal pressure to be increased.
Two PCV’s are installed on the supply pump, and if either PCV failed, another PCV operates the engine to
prevent engine stop.
CAUTION:
If the harnesses for PCV1 and PCV2 are connected reversely, the diagnostic trouble code is not detected but
the engine stops.

• SERIVCE ENGINE SOON lamp turns on (continuous ON)
• Rough idling
The control unit judges as "PCV1 system short (battery, power supply system circuit) trouble" and displays
"diagnostic trouble code: 217" if the signal voltage from the PCV1 is high when the starter switch is turned
on and the supply pump is normal.

In the event of PCV system trouble, the ENGINE CONTROL lamp for the vehicles with the multi-warning
Possible causes
harness and engine harness, or engine harness and PCV connectors)
• Shortcircuit in PCV circuit (faulty vehicle harness of ECU harnesses, engine harnesses, or instrument
harnesses)
• Faulty PCV (faulty internal shortcircuit)
Diagnostic help
if faulty.
4-98

step 2
past
trouble
2 Check the harness for shortcircuit or disconnection. Between pins 21 and 22: Step 4 Step 3
2. Disconnect the harness from the Engine Control Unit. Between pin 21 and each
3. Disconnect the harness from the PCV1. pin: ∞Ω
4. Measure resistance value of the connector on the Engine Between pin 22 and each
Control Unit side. pin: ∞Ω
Is the resistance value normal? Between pin 21 and body
(GND): ∞Ω
3 Repair or replace the harness of PCV circuit. Also, check the

(GND): ∞Ω
- Step 4 - 4
⋅ Engine Control Unit to PCV connector
(Faulty vehicle harness of ECU harness or engine harness)
4 Using a circuit tester, measure the resistance of PCV1. Between PCV pins: 2.6 - Step 6 Step 5
2. Using a circuit tester, measure internal resistance of PCV1. Between PCV body and
5 Replace the PCV1 (supply pump). - Step 7 -
1. Stop the engine.
detected. (OK) to
help,
step 1
(NG)
4-99
External view, pin assignment and resistance value of PCV
<External view of PCV> Because the PCV, pins are not identified.
<Resistance value of PCV>
<Arrangement of PCV>
・6WG1-TC PCV2 PCV1 ・6SD1-TC PCV2 PCV1
・6TE1
Fr
on
t
PCV1
PCV2
4-100
PCV circuit (including the PCV relay circuit)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
VW 1.25
PCV1 (SIG) VW 0.5
BrB 1.25
BrB 1.25
Br 1.25
KEY SW [ON] SIG
PCV2 PCV1 Br 1.25
4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8
12 11 10 9
SWP 9 10 11 12 PCV2 (SIG)
1 2 1 2 16 15 14 13 (GRAY) 13 14 15 16
RW 1.25
WL 1.25 WL 1.25
1 2 3 4 4 3 2 1
5 6 7 8 SWP 8 7 6 5
9 10 11 12 (GRAY) 12 11 10 9
RB 1.25
WL 1.25
3
PCV RELAY
ENGINE HARNESS
4
5 1
4 2
1
P 0.3 2 3 4 B 0.3
5
O 1.25
8 7 6 5 4 3 2 1 SDL 1 2 3 4 5 6 7 8
20 19 19 20
FUSE 45 18 17 16 15 14 13 12 11 10 9 (WHITE) 9 10 11 12 13 14 15 16 17 18
O 1.25
B 1.25 G 1.25 G 1.25
1 2 3 4
FUSE 20
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21
32 31 30 29 28 27 26 25 24 23 22 (BLACK) 22 23 24 25 26 27 28 29 30 31 32
VW 0.5

FUSE 17 VW 1.25
1 2 3 4 5 6 7 7 6 5 4 3 2 1
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
21 22 23 24 24 23 22 21
25 26 27 28 28 27 26 25
SMJ B8
29 30 31 32 (WHITE) 32 31 30 29
33 34 35 36 36 35 34 33
37 38 39 40 41 42 42 41 40 39 38 37 BL 5
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
FRAME GND
B2
ACG E TERMINAL
FRAME (Ft) HARNESS
4-101
Circuit description
CAUTION:
the engine stops.

• Rough idling
The control unit judges as "PCV2 system short (battery, power supply system circuit) trouble" and displays
"diagnostic trouble code: 218" if the signal voltage from the PCV2 is high when the starter switch is turned
on and the supply pump is normal.

Possible causes
harness and engine harness, or engine harness and PCV connectors)
harnesses)
Diagnostic help
if faulty.
4-102

step 2
past
trouble
2 Check the harness for shortcircuit or disconnection. Between pins 31 and 32: Step 4 Step 3
2. Disconnect the harness from the Engine Control Unit. Between pin 31 and each
3. Disconnect the harness from the PCV2. pin: ∞Ω
4. Measure resistance value of the connector on the Engine Between pin 32 and each
Control Unit side. pin: ∞Ω
Is the resistance value normal? Between pin 31 and body
(GND): ∞Ω
3 Repair or replace the harness of PCV circuit. Also, check the

(GND): ∞Ω
- Step 4 - 4
⋅ Engine Control Unit to PCV connector
(Faulty vehicle harness of ECU harness or engine harness)
1. Stop the engine.
detected. (OK) to
help,
step 1
(NG)
4-103
<Arrangement of PCV>
・6TE1
Fr
on
t
PCV1
PCV2
4-104
226 Supply pump no pressure feed or pressure limiter operated (1/5)
Fuel system diagram

6WG1-TC, 6SD1-TC engine
Fuel filter
Common rail Injector
Flow
Fuel pressure sensor damper
Fuel temperature sensor
PCV Overflow valve

Pressure limiter
Feed pump
4
Supply pump Fuel tank
Pre-filter
6TE1 engine
Left bank Right bank

Fuel filter
Pressure
Injector limiter
Injector
Common rail Flow

damper
Fuel pressure sensor Overflow valve
Feed pump
Supply pump
Fuel tank 51659A 青

Priming pump 01/09/21 01/0
Pre-filter 170 230
DOM
4-105
Circuit description
The Engine Control Unit supervises the common rail internal pressure based on the fuel pressure sensor
signals, and if the pressure is low, it controls the Pump Control Valve (PCV) on the supply pump to raise the
common rail internal pressure. The common rail internal pressure cannot be raised if the fuel feed to the
supply pump failed or the supply pump troubled.
In the event that the common rail internal pressure rises over the specified value, the pressure limiter installed
on the common rail operates to reduce the fuel pressure so as to prevent the engine mechanical troubles.

• Lack of output power ( after the failure diagnostic, fuel injection is limited )
The control unit judges as "common rail pressure trouble (pump no pressure feed)" and displays "diagnostic
trouble code: 226", if the state where the PCV close timing to the PCV close timing limit is below +1°CA or
common rail internal fuel pressure F/B control amount is below -60°CA continues for more than one second,
when diagnostic trouble codes 245, 217, 218, 247, and 248 are not detected.
(If actual fuel pressure is lower than the target common rail internal fuel pressure of Engine Control Unit)

In the event of diagnostic trouble code "226" detection, the ENGINE CONTROL lamp for the vehicles with
Possible causes
• Air mixing in high pressure fuel piping
• Pressure limiter operated (operated at the pressure below specified value, deteriorated internal sealing)
• Internal trouble of injector
• Internal trouble of supply pump, faulty installation
• Faulty piping of fuel system (fuel leakage, clogging, squeezed, etc.)
• Faulty fuel filters (main, pre goes) (clogging overflow valve trouble, etc.)
• Faulty fuel tank (clogging, low fuel level, extended tank, etc.)
• Engine Control Unit trouble
Diagnostic help
Check the fuel feed piping to the supply pump for abnormality, the fuel fed from the supply pump for leakage,
the supply pump for abnormally, and the Engine Control Unit for abnormality in this order.
4-106

step 2
past
trouble
2 Check the fuel quantity, and refill if less. - Step 3 -
1. Stop the engine.
2. Check the fuel quantity.
3 Clear the diagnostic trouble code, and again conduct the test run to - Step 26 Step 4
confirm that the diagnostic trouble code is not detected. (OK) (NG)
4 Exchange the IN and OUT of fuel hose on the fuel tank (reverse connection). - Step 5 -
5
Clear the diagnostic trouble code, and again conduct the test run to - Step 6 Return 4
confirm that the diagnostic trouble code is not detected. (OK) the fuel
Is the diagnostic trouble code detected? hose to
origin,
and go to
Step 7
(NG)
6 Restore the fuel hose as original, and check and clean the fuel tank. - Step 26 Step 7
Clear the diagnostic trouble code, and again conduct the test run to (OK) (NG)
confirm that the diagnostic trouble code is not detected.
7 Check the fuel piping for leakage or squeezing. - Step 8 Step 10
Check the pre-filter, fuel filter, gose filter (inlet of supply pump) for
clogging.
Is fuel leakage from piping or filter clogging detected?
8 Repair or replace the fuel piping. - Step 9 -
Clean the pre-filter and gose filter, and replace the fuel filter. Perform
the air bleeding (air bleeding including dry-shot of injectors).
10 Replace the overflow valve for the fuel filter. - Step 11 -
4-107
226 Supply pump no [ressure feed or pressure limiter operated (4/5)

11 Confirm that the diagnostic trouble codes have been cleared, and conduct - Step 26 Step 12
the test run again to check that no diagnostic trouble code is detected. (OK) (NG)
12 Check for fuel leakage from the fuel high pressure piping and - Step 13 Step 14
common rail.
raise the specified pressure.
3. Stop the engine, and check the fuel high pressure piping and
common rail for fuel leakage.
Is fuel leakage detected?
13 Repair or replace the parts where the fuel leaks. - Step 14 -
14 Check with the oil level gauge if the oil level rises and you smell light oil. - Step 15 Step 16
Was abnormality detected?
15 Fuel leaks from some injectors. Check the pipe joints, and replace - Step 16 -
faulty injectors.
16 Perform the air bleeding (air bleeding including dry-shot of - Step 17 -
injectors). (Between supply pump, common rail, and injectors)
17 Confirm that the diagnostic trouble code has been cleared, then conduct - Step 26 Step 18
again the test run to check that no diagnostic trouble code is detected. (OK) (NG)
18 Check the injectors for fuel injecting operation. - Step 19 See diag.
Note: At this time, if the injector related trouble code has been (OK) codes
detected, check and repair the injector related parts before this "271 -
checking. 276" and
1. Start the engine. Sec. 3
2. Using the Tech II, conduct the "Injection Power Balance" test "Checking
and stop each cylinder injector to check if fuel is injected Fuel
normally. System"
The engine speed and sound will vary if the injector is stopped when to check
the injector injects fuel normally. and
The engine speed and sound will not vary if the injector is stopped replace
when the injector is faulty and does not inject fuel. injector
Does the injector inject fuel normally? and fuel
piping,
then
step 16
(NG)
19 Replace the pressure limiter. - Step 20 -
Perform the air bleeding (air bleeding including dry-shot of
4-108

20 Confirm that the diagnostic trouble code has been cleared, then - Step 26 Step 21
conduct again the test run to check that no diagnostic trouble code is (OK) (NG)
detected.
21 Check the supply pump (PCV). - Step 22 Step 23
2. Disconnect the harness from PCV1.
Note: If the harness is disconnected from PCV1, the diagnostic
trouble code "247" is detected, and thus clear the diagnostic
trouble code after the check finished.
Does the engine run?
22 Check the supply pump (PCV). Step 25 Step 23
1. Stop the engine. - (OK) (NG)
2. Connect the harness to the PCV1.
4
23 Replace the supply pump. Step 24 -
Perform the air bleeding (air bleeding including dry-shot of - (OK)
injectors).
24 Confirm that the diagnostic trouble code has been cleared, then Step 26 Step 25
conduct again the test run to check that no diagnostic trouble code is - (OK) (NG)
detected.
25 Replace the Engine Control Unit. Step 26 -
Did corrective actions complete? -
26 Restore the vehicle. Step 27 -
1. Stop the engine. -
4. Connect the Tech II to clear the diagnostic trouble codes.
27 Confirm that the diagnostic trouble code has been cleared, then Repair -
conduct again the test run to check that no diagnostic trouble code is - end
detected. (OK)
4-109
227 Pump no pressure feed (Fuel outflow) (1/5)
Fuel system diagram

6WG1-TC, 6SD1-TC engine
Fuel filter
Common rail Injector
Flow
Fuel pressure sensor damper
PCV Overflow valve

Pressure limiter
Feed pump
Supply pump Fuel tank
Pre-filter
6TE1 engine
Left bank Right bank
Fuel filter
Pressure
Injector limiter
Injector
Common rail Flow

damper
Fuel pressure sensor Overflow valve
Feed pump
Supply pump
Fuel tank 51659A 青柳

Priming pump 01/09/21 01/0
Pre-filter 170 230
DOM
4-110
Circuit description
The Engine Control Unit supervises the common rail internal pressure based on the fuel pressure sensor
signals, and if the pressure is low, it controls the Pump Control Valve (PCV) on the supply pump to raise the
common rail internal pressure. The common rail internal pressure cannot be raised if the fuel feed to the
supply pump failed or the supply pump troubled.
In the event that the common rail internal pressure rises over the specified value, the pressure limiter installed
on the common rail operates to reduce the fuel pressure so as to prevent the engine mechanical troubles.

• Engine stops
• Lack of output power ( after the failure diagnostic, fuel injection is limited)
The control unit judges as "pump no pressure feed (fuel outflow)" and displays "diagnostic trouble code:
227", if the state where actual common rail pressure is below the target common rail pressure +5MPa and the
PCV close timing is below the PCV close timing limit +1°CA or common rail pressure F/B control amount
is below -50°CA continues for more than 8.4 seconds, when diagnostic trouble code "226" is detected and
also the codes 245, 217, 218, 247, and 248 are not detected.
(If actual fuel pressure is lower than the target common rail internal fuel pressure of Engine Control Unit)
4
In the event of diagnostic trouble code "227" detection, the ENGINE CONTROL lamp for the vehicles with
Possible causes
• Air mixing in high pressure fuel piping
• Pressure limiter operated (operated at the pressure below specified value, deteriorated internal sealing)
• Internal trouble of injector
• Internal trouble of supply pump, faulty installation
• Faulty piping of fuel system (fuel leakage, clogging, squeezed, etc.)
• Faulty fuel filters (main, pre goes) (clogging overflow valve trouble, etc.)
• Faulty fuel tank (clogging, low fuel level, extended tank, etc.)
• Engine Control Unit trouble
Diagnostic help
Check the fuel feed piping to the supply pump for abnormality, the fuel fed from the supply pump for leakage,
the supply pump for abnormally, and the Engine Control Unit for abnormality in this order. The content of
checking is same as diagnostic trouble code "226".
4-111

step 2
past
trouble
2 Check the fuel quantity, and refill if less. - Step 3 -
1. Stop the engine.
2. Check the fuel quantity.
4 Exchange the IN and OUT of fuel hose on the fuel tank (reverse connection). - Step 5 -
5 Clear the diagnostic trouble code, and again conduct the test run to - Step 6 Return
confirm that the diagnostic trouble code is not detected. (OK) the hose
Is the diagnostic trouble code detected? to origin,
and go to
Step 7
(NG)
6 Restore the fuel hose as original, and check and clean the fuel tank. - Step 26 Step 7
Clear the diagnostic trouble code, and again conduct the test run to (OK) (NG)
confirm that the diagnostic trouble code is not detected.
7 Check the fuel piping for leakage or squeezing. - Step 8 Step 10
Check the pre-filter, fuel filter, gose filter (inlet of supply pump) for
clogging.
Is fuel leakage from piping or filter clogging detected?
8 Repair or replace the fuel piping. - Step 9 -
Clean the pre-filter and gose filter, and replace the fuel filter.
injectors).
10 Replace the overflow valve for the fuel filter. - Step 11 -
11 Confirm that the diagnostic trouble codes have been cleared, and Step 26 Step 12
conduct the test run again to check that no diagnostic trouble code is - (OK) (NG)
detected.
4-112

12 Check for fuel leakage from the fuel high pressure piping and - Step 13 Step 14
common rail.
raise the specified pressure.
3. Stop the engine, and check the fuel high pressure piping and
common rail for fuel leakage.
Is fuel leakage detected?
13 Repair or replace the parts where the fuel leaks. - Step 14 -
14 Check with the oil level gauge if the oil level rises and you smell light - Step 15 Step 16
oil.
Was abnormality detected? -
15 Fuel leaks from some injectors. Check the pipe joints, and replace Step 16 -
faulty injectors.
16 Perform the air bleeding (air bleeding including dry-shot of Step 17 -
17 Confirm that the diagnostic trouble code has been cleared, then conduct
again the test run to check that no diagnostic trouble code is detected.
Step 26 Step 18
(OK) (NG)
4
Is the diagnostic trouble code detected? -
18 Check the injectors for fuel injecting operation. Step 19 See diag.
Note: At this time, if the injector related trouble code has been (OK) codes
detected, check and repair the injector related parts before "271 -
this checking. 276" and
1. Start the engine. Sec. 3
2. Using the Tech II, conduct the "Injection Power Balance" test "Checkin
and stop each cylinder injector to check if fuel is injected g Fuel
normally. System"
The engine speed and sound will vary if the injector is stopped to check
when the injector injects fuel normally. and
The engine speed and sound will not vary if the injector is replace
stopped when the injector is faulty and does not inject fuel. injector
Does the injector inject fuel normally? and fuel
piping,
then
step 16
- (NG)
19 Replace the pressure limiter. Step 20 -
injectors).
(Between supply pump, common rail, and injectors)
4-113

detected.
21 Check the supply pump (PCV). - Step 22 Step 23
22 Check the supply pump (PCV). - Step 25 (NG)
1. Stop the engine. (OK)
2. Connect the harness to the PCV1.
injectors).
detected.
1. Stop the engine. -
4. Connect the Tech II to clear the diagnostic trouble codes. - -
27 Confirm that the diagnostic trouble code has been cleared, then - Repair -
conduct again the test run to check that no diagnostic trouble code is end
detected. (OK)
4-114
241 Accelerator switch off trouble (1/5)
Accelerator circuit (including accelerator sensor circuit)

L 0.5
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
VW 1.25
Y 0.5
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
VW 0.5 21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
Gy 0.5
R 0.5
VW 1.25 W 0.5
FUSE 20
VW 1.25 LO 0.5
1 2 3 4 5 6 7 8 9 9 8 7 6 5 4 3 2 1
SDL
10 11 12 13 14 15 16 17 18 19 20 21 21 20 19 18 17 16 15 14 13 12 11 10
32 31 30 29 28 27 26 25 24 23 22
22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8
19 20
9 10 11 12 13
GyG 0.5
L 0.5
14 15 16 17 18
4
LO 0.5
Y 0.5
ECU HARNESS
1
2 8 7 6 5 4 3 2 1
20 19
18 17 16 15 14 13 12 11 10 9
ACCELERATOR SWITCH
FUSE 11
Y 0.5
Y 0.5
G 0.5
L 0.5
L 0.5 5V Main
G 0.5 Ground Main
1 2 SDL 2 1
3 4 5 6 (WHITE) 6 5 4 3
R 0.5 5V sub Main

ACCELERATOR SENSOR
4-115
Circuit description
The accelerator switch detects the accelerator pedal stroke. When the voltage is applied to the accelerator
switch provided on the accelerator link and the switch turns on (the accelerator pedal in idle position), the
voltage is applied to the Engine Control Unit as a signal.
The Engine Control Unit reads the change in voltage from the accelerator switch, and based on this signal, it
judges the accelerator pedal position. (When the switch turns off, the control unit judges the accelerator pedal
is in other than idle position.)
In the event of accelerator switch trouble, the Engine Control Unit makes control with the accelerator sensor
signals and backup values. Also, the accelerator learning must be executed after the accelerator switch was

The control unit judges as "accelerator switch OFF trouble" and displays "diagnostic trouble code: 241" if
the state where no voltage is applied from the accelerator switch continues for more than one second when
the accelerator sensor is normal and the accelerator sensor signal voltage is below 0.65V.

In the event of accelerator switch trouble, the ENGINE CONTROL lamp for the vehicles with the multi-
turns on, regardless of engine running condition. (Continuous ON)
Possible causes
harness and instrument harness or instrument harness and switch connectors)
• Disconnection or shortcircuit in accelerator switch (power) circuit (faulty vehicle harness or sensor
harness of ECU harnesses or instrument harnesses)
• Disconnection or shortcircuit in accelerator switch (SIG) circuit (faulty vehicle harness or sensor harness
• Faulty switch (faulty switch inside or rod)
• Faulty accelerator switch installation (disordered, loose)
• Faulty accelerator sensor
Diagnostic help
if faulty.
4-116

1 Check the detected diagnostic trouble code. - Step 2 See
1. Start the engine and run it in the idling state. Current diagnostic
2. Using the Tech II, check the diagnostic trouble code detected. code help,
Is the detected diagnostic trouble code a current code? then step
2 Past
code
2 Check the harness for disconnection or GND short. ⋅ With starter SW OFF, Step 8 Step 3
1. Turn the starter switch off. and pedal in idle position, (OK) (NG)
3. Install the circuit tester between connector pin and GND (frame GND: 0V
or engine body). ⋅ With starter SW ON,
4. Measure voltage of the accelerator switch circuit. and pedal in idle position,
Is the applied voltage normal? Between pin 20 and
GND: Battery voltage
⋅ With starter SW OFF,
and pedal in other than
idle position, 4
Between pin 20 and
GND: 0V
⋅ With starter SW ON,
idle position,
Between pin 20 and
GND: 0V
Between pin 2 and GND:
Battery voltage
0V
3 Check the accelerator switch circuit (power). - Step 5 Step 4
3. Disconnect the harness from the accelerator switch.
4. Install the circuit tester between switch connector pin and GND
5. Measure voltage of the accelerator switch circuit.
Is the applied voltage normal? -
4-117

4 Repair or replace the harness of accelerator switch circuit (power). Step 5 -
⋅ Accelerator switch to fuse connector
(Instrument harness, accelerator switch)
⋅ Power supply circuit up to fuse
(Instrument harness, frame harness, relays, etc.)
5 Check the accelerator switch. Step 7 Step 6
1. Turn the starter switch off. - (OK) (NG)
3. Install the circuit tester between the switch connector pins.
4. Check if the switch functions (continuous) when the accelerator
switch is operated.
Is the switch function normal?
6 Replace the accelerator switch. - Step 8 -
7 Repair or replace the harness of the accelerator switch circuit - Step 8 -
(between switch and Engine Control Unit). Also, check the
connector for connection.
⋅ Accelerator switch to Engine Control Unit connector
(Instrument harness, accelerator switch circuit)
8 Check the accelerator pedal link, bracket, spring, accelerator sensor, - Step 9 -
etc. for installation or any trouble, and repair or replace if faulty.
9 Adjust the accelerator switch. - Step 10 -
1. Stop the engine.
12 Confirm that the diagnostic trouble code has been cleared, then - Repair See
conduct again the test run to check that no diagnostic trouble code is end diagnostic
detected. (OK) help,
Is the diagnostic trouble code detected? then
step 1
(NG)
Note: The accelerator learning must be executed after the Engine Control Unit or accelerator switch was
4-118
External view, pin assignment and resistance value of accelerator switch
<External view of accelerator switch> Because of the switch, pins are not distinguished.
1
2
S type connector
(white), 2 pins
Connector
Rod
<External view of bracket assembly> <Accelerator switch resistance value>
4
Rod is Rod is
pushed, not pushed,
"contact point ON" "contact point OFF
Idling condition Accelerator is pressed on
101HY00002
<Accelerator switch resistance value>
Accelerator pedal condition

Parts checked Remarks
(accelerator switch rod condition)
S type 1 2 Idling position 0.5Ω or less
connector (with rod pressed on)
(white), 2 pins
Full-throttle position ∞
(rod not pressed on)
1 Body - ∞
2 Body - ∞
4-119
242 Accelerator switch on trouble (1/5)
Accelerator switch circuit(including accelerator sensor circuit)

L 0.5
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
VW 1.25
Y 0.5
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
VW 0.5 21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
Gy 0.5
R 0.5
VW 1.25 W 0.5
FUSE 20
VW 1.25 LO 0.5
1 2 3 4 5 6 7 8 9 9 8 7 6 5 4 3 2 1
SDL
10 11 12 13 14 15 16 17 18 19 20 21 21 20 19 18 17 16 15 14 13 12 11 10
32 31 30 29 28 27 26 25 24 23 22
22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8
19 20
9 10 11 12 13 14 15 16 17 18
GyG 0.5
L 0.5
LO 0.5
Y 0.5
ECU HARNESS
1
2 8 7 6 5 4 3 2 1
20 19
18 17 16 15 14 13 12 11 10 9
ACCELERATOR SWITCH
FUSE 11
Y 0.5
Y 0.5
G 0.5
L 0.5
L 0.5 5V Main
G 0.5 Ground Main
1 2 SDL 2 1
3 4 5 6 (WHITE) 6 5 4 3
R 0.5 5V sub Main

ACCELERATOR SENSOR
4-120
Circuit description
The accelerator switch detects the accelerator pedal stroke. When the voltage is applied to the accelerator
switch provided on the accelerator link and the switch turns on (the accelerator pedal in idle position), the
voltage is applied to the Engine Control Unit as a signal.
The Engine Control Unit reads the change in voltage from the accelerator switch, and based on this signal, it
judges the accelerator pedal position. (When the switch turns off, the control unit judges the accelerator pedal
is in other than idle position.)
In the event of accelerator switch trouble, the Engine Control Unit makes control with the accelerator sensor
signals and backup values. Also, the accelerator learning must be executed after the accelerator switch was

• Faulty accelerator pedal reaction (responsibility)
The control unit judges as "accelerator switch ON trouble" and displays "diagnostic trouble code: 242" if the
state where no voltage is applied from the accelerator switch continues for more than 0.5 second when the
accelerator sensor is normal and the accelerator sensor signal voltage is below 3.06V.

4
In the event of accelerator switch trouble, the ENGINE CONTROL lamp for the vehicles with the multi-
Possible causes
harness and instrument harness or instrument harness and switch connectors)
• Disconnection or shortcircuit in accelerator switch (power) circuit (faulty vehicle harness or sensor
harness of ECU harnesses or instrument harnesses)
• Disconnection or shortcircuit in accelerator switch (SIG) circuit (faulty vehicle harness or sensor harness
• Faulty switch (faulty switch inside or rod)
• Faulty accelerator switch installation (disordered, loose)
• Faulty accelerator sensor
Diagnostic help
if faulty.
4-121

1 Check the detected diagnostic trouble code. - Step 2 See
2. Using the Tech II, check the diagnostic trouble code detected. code help,
Is the detected diagnostic trouble code a current code? then step
2 Past
code
2 Check the harness for disconnection or short. ⋅ With starter SW OFF, Step 8 Step 3
1. Turn the starter switch off. and pedal in idle position, (OK) (NG)
3. Install the circuit tester between connector pin and GND (frame GND: 0V
or engine body). ⋅ With starter SW ON,
4. Measure voltage of the accelerator switch circuit. and pedal in idle position,
Is the applied voltage normal? Between pin 20 and
GND: Battery voltage
idle position,
Between pin 20 and
GND: 0V
idle position,
Between pin 20 and
GND: 0V
Battery voltage
0V
3 Check the accelerator switch circuit (power). - Step 5 Step 4
4. Install the circuit tester between switch connector pin and GND
5. Measure voltage of the accelerator switch circuit.
4-122

4 Repair or replace the harness of accelerator switch circuit (power). - Step 5 -
⋅ Accelerator switch to fuse connector
(Instrument harness, accelerator switch)
⋅ Power supply circuit up to fuse
(Instrument harness, frame harness, relays, etc.)
5 Check the accelerator switch. - Step 7 Step 6
2. Disconnect the harness from the accelerator switch. -
3. Install the circuit tester between the switch connector pins.
4. Check if the switch functions (continuous) when the accelerator
switch is operated.
Is the switch function normal?
6 Replace the accelerator switch. Step 8 -
7 Repair or replace the harness of the accelerator switch circuit Step 8 -
(between switch and Engine Control Unit). Also, check the
connector for connection.
⋅ Accelerator switch to Engine Control Unit connector
4
(Instrument harness, accelerator switch circuit)
8 Check the accelerator pedal link, bracket, spring, accelerator sensor, - Step 9 -
etc. for installation or any trouble, and repair or replace if faulty.
9 Adjust the accelerator switch. Step 10 -
10 Replace the Engine Control Unit. Step 11 -
1. Stop the engine.
3. Turn the starter switch on. -
12 Confirm that the diagnostic trouble code has been cleared, then Repair See
Is the diagnostic trouble code detected? then
step 1
(NG)
4-123
External view, pin assignment and resistance value of accelerator switch
<External view of accelerator switch> Because of the switch, pins are not distinguished.
1
2
S type connector
(white), 2 pins
Connector
Rod
<External view of bracket assembly> <Accelerator switch resistance value>
Rod is Rod is
pushed, not pushed,
"contact point ON" "contact point OFF
Idling condition Accelerator is pressed on
101HY00002
<Accelerator switch resistance value>
Accelerator pedal condition

Parts checked Remarks
(accelerator switch rod condition)
S type 1 2 Idling position 0.5Ω or less
connector (with rod pressed on)
(white), 2 pins
Full-throttle position ∞
(rod not pressed on)
1 Body - ∞
2 Body - ∞
4-124
245 Fuel pressure sensor trouble (1/5)
Fuel pressure sensor (including NE sensor and G sensor circuit)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
Gy 0.5


1 2 3 4 4 3 2 1 Gy 0.5
B 0.5 5 6 7 8 SWP 8 7 6 5
9 10 11 12 (GRAY) 12 11 10 9 B 0.5
(GRAY)
WL 0.5 W 0.5
OL 0.5 G 0.5
W 0.5 R 0.5
B 0.5 O 0.5
4
NE SENSOR (SHEILD)
NE SENSOR
NE SENSOR (—)
1 2 NE SENSOR (+)
Y 0.5 W 0.5
Br 0.5 B 0.5
4 3 2 1 1 2 3 4
GyR 0.5
8 7 6 5 SWP 5 6 7 8
12 11 10 9 (GRAY) 9 10 11 12
G 0.5
B 0.5
G SENSOR R 0.5
1 2
G SENSOR (SHEILD)
P 0.5
G SENSOR (—)
L 0.5
ECU HARNESS
4-125
Circuit description
common rail.
Vehicle behaviors
• Rough idling
The Engine Control Unit judges as "fuel pressure sensor trouble" and displays "diagnostic trouble code: 245",
if the state where the voltage detected by the Engine Control Unit is over 4.7V (VB/5V SIG shortcircuit) or
below 0.7V (disconnected) or GND shortcircuit continues for 0.1 second.

In the event of fuel pressure sensor system trouble, the ENGINE CONTROL lamp for the vehicles with the
Possible causes
ECU harness and sensors)
Diagnostic help
if faulty.
4-126

step 2
past
trouble
(Jumper: 2 - 1)
0.5Ω or less
4
(Jumper: 2 - 1)
0.5Ω or less
(Jumper: 2 - 3)
0.5Ω or less
(Jumper: 2 - 3)
0.5Ω or less
6. Measure voltage in the pressure sensor circuit.
4-127

⋅ Engine Control Unit to engine harness (ECU harness, fuel
pressure sensor circuit)
⋅ ECU harness to fuel pressure sensor connector (Engine
6 Check for the voltage applied to the fuel pressure sensor "power". Between sensor pin 3 and Step 8 Step 7
1. Turn the starter switch off. GND: 5V (4.75 - 5.25V) (OK) (NG)
2. Connect the harness to the Engine Control Unit.
3. Install the circuit tester between sensor connector pin and GND
Note: If the harness is disconnected from the fuel pressure sensor,
the diagnostic trouble code "245" is detected, and thus clear the
diagnostic trouble code after the check finished.
5. Measure the voltage of the fuel pressure sensor "power" circuit.
7 With the circuit tester, check for continuity of fuel pressure sensor "GND". Between sensor pin 1 and Step 9 Step 8
2. Confirm that the harness has been connected to the Engine
Control Unit.
3. Install the circuit tester between sensor connector pins.
Note: If the harness is disconnected from the fuel pressure sensor,
the diagnostic trouble code "245" is detected, and thus
5. Measure the resistance of the fuel pressure sensor circuit.
1.Turn the starter switch off.
2.Remove the fuel pressure sensor from the common rail.
3.Check the fuel pressure sensor for presence of forreign matelils.
4-128

1. Stop the engine.
2. Connect the harnesses to the fuel pressure sensor.
14 Confirm that the diagnostic trouble code has been cleared, then - Repair See
Is the diagnostic trouble code detected? then step
1
(NG)
1
2
GND
SIG
WL/0.5
B/0.5
4
3 5V OL/0.5
3 2 1
060MX044

0.84
Output voltage
0.6
(Vout / Vc)
0.2
MPa
0 100 160
2
kgf/cm
0 1019 1631
Pressure
OFF 1.0V( 0MPa)
4-129
247 PCV1 system harness, short (GND circuit) trouble (1/5)
PCV circuit (including PCV relay circuit)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
VW 1.25
PCV1 (SIG) VW 0.5
BrB 1.25
BrB 1.25
Br 1.25
KEY SW [ON] SIG
PCV2 PCV1 Br 1.25
4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8
12 11 10 9
SWP 9 10 11 12 PCV2 (SIG)
1 2 1 2 16 15 14 13 (GRAY) 13 14 15 16
RW 1.25
WL 1.25 WL 1.25
1 2 3 4 4 3 2 1
5 6 7 8 SWP 8 7 6 5
9 10 11 12 (GRAY) 12 11 10 9
RB 1.25
WL 1.25
ENGINE HARNESS
3
PCV RELAY
5 1
4 2
1
P 0.3 2 3 4 B 0.3
5
O 1.25
8 7 6 5 4 3 2 1 SDL 1 2 3 4 5 6 7 8
20 19 19 20
FUSE 45 18 17 16 15 14 13 12 11 10 9 (WHITE) 9 10 11 12 13 14 15 16 17 18
O 1.25
B 1.25 G 1.25 G 1.25
1 2 3 4
FUSE 20
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21
32 31 30 29 28 27 26 25 24 23 22 (BLACK) 22 23 24 25 26 27 28 29 30 31 32
VW 0.5

FUSE 17 VW 1.25
1 2 3 4 5 6 7 7 6 5 4 3 2 1
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
21 22 23 24 24 23 22 21
25 26 27 28 28 27 26 25
SMJ B8
29 30 31 32 (WHITE) 32 31 30 29
33 34 35 36 36 35 34 33
37 38 39 40 41 42 42 41 40 39 38 37 BL 5
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
FRAME GND
B2
ACG E TERMINAL
FRAME (Ft) HARNESS
4-130
Circuit description
CAUTION:
the engine stops.

• Rough idling
The control unit judges as "PCV1 system short (GND circuit) trouble" and displays "diagnostic trouble code:
4
247" if the signal voltage from the PCV1 is low when the starter switch is turned on and the supply pump,
NE sensor is normal.

Possible causes
harness and instrument harness, ECU harness and engine harness, engine harness and PCV, or instrument
harness and PCV relay)
harnesses)
• Faulty PCV relay
Diagnostic help
if faulty.
4-131

step 2
past
trouble
1. Turn the starter switch off. 0V (without jumper) (OK) (NG)
2. Disconnect the harness from the Engine Control Unit. Between pin 21 and body
3. Disconnect the harness from the PCV1. (GND): (jumper: 1-2)
4. Using a jumper wire between PCV1 connector pins, measure Battery voltage
resistance of the connector on the Engine Control Unit. (without jumper) 0V
5. Turn the starter switch on. Between pin 22 and body
Is the voltage value normal? (GND): (jumper 1-2)
Battery voltage
(without jumper) 0V
3 Check the harness for disconnection or shortcircuit. Between pins 1 and 2: 0V Step 5 Step 4
1. Turn the starter switch off. Between pin 1 and body (OK) (NG)
2. Disconnect the harness from the Engine Control Unit. (GND): battery voltage
3. Disconnect the harness from the PCV1. Between pin 2 and body
4. Measure voltage value of the connector on the PCV1 side. (GND): 0V
Is the voltage value normal?
4 Repair or replace the harness of PCV relay and PCV relay to PCV1. - Step 6 -
5 Repair or replace the harness of Engine Control Unit to PCV1. Also, - Step 6 -
1. Turn the starter switch off. 3.8W (at about 20°C) (OK) (NG)
4-132

1. Stop the engine.
detected. (OK) to
help,
step 1
(NG)
4
4-133
<Arrangement of PCV >
・6TE1
Fr
on
t
PCV1
PCV2
External view, pin assignment and resistance value of PCV relay
<External view of PCV relay > <Circuit of PCV relay >
5 1
4 4 2
3
2
5
* ISO relay
4-134
<Pin assignment of PCV relay >
Pin No. Signal name

1 Relay contact point (normal open): secondary side
1
2 Relay coil: secondary side
2 3 4
3 Relay contact point (normal close) : secondary side
5 4 Relay coil: primary side
5 Relay contact point: primary side
< Installing position of PCV relay >
Relay box (B)
R/L R/L
HEAD (HI) TAIL
AB D
R/L R/L R/L
FOG RAMP HEAD (LOW) STOP LAMP
C
R/L R/L R/L
CIGAR HORN EXH BRAKE
LIGHTER
Relay box (C)

4
R/L R/L R/L
COND MAIN MAG. V. CUT
E
R/L R/L R/L
COMP W/PARK P. C. V
BRAKE
R/L R/L
FAN WASHER
< Resistance value of PCV relay >

Single 2 4 240 290Ω
unit of 1 5 ∞ No power supplied to relay coil
relay 0.5Ω or less Power supplied to relay coil
3 5 0.5Ω or less No power supplied to relay coil
∞ Power supplied to relay coil
4-135
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
VW 1.25
PCV1 (SIG) VW 0.5
BrB 1.25
BrB 1.25
Br 1.25
KEY SW [ON] SIG
PCV2 PCV1 Br 1.25
4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8
12 11 10 9
SWP 9 10 11 12 PCV2 (SIG)
1 2 1 2 16 15 14 13 (GRAY) 13 14 15 16
RW 1.25
WL 1.25 WL 1.25
1 2 3 4 4 3 2 1
5 6 7 8 SWP 8 7 6 5
9 10 11 12 (GRAY) 12 11 10 9
RB 1.25
WL 1.25
ENGINE HARNESS
3
PCV RELAY
5 1
4 2
1
P 0.3 2 3 4 B 0.3
5
O 1.25
8 7 6 5 4 3 2 1 SDL 1 2 3 4 5 6 7 8
20 19 19 20
FUSE 45 18 17 16 15 14 13 12 11 10 9 (WHITE) 9 10 11 12 13 14 15 16 17 18
O 1.25
B 1.25 G 1.25 G 1.25
1 2 3 4
FUSE 20
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21
32 31 30 29 28 27 26 25 24 23 22 (BLACK) 22 23 24 25 26 27 28 29 30 31 32
VW 0.5

FUSE 17 VW 1.25
1 2 3 4 5 6 7 7 6 5 4 3 2 1
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
21 22 23 24 24 23 22 21
25 26 27 28 28 27 26 25
SMJ B8
29 30 31 32 (WHITE) 32 31 30 29
33 34 35 36 36 35 34 33
37 38 39 40 41 42 42 41 40 39 38 37 BL 5
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
FRAME GND
B2
ACG E TERMINAL
FRAME (Ft) HARNESS
4-136
Circuit description
CAUTION:
the engine stops.

• Rough idling
The control unit judges as "PCV2 system short (GND circuit) trouble" and displays "diagnostic trouble code:
4
248" if the signal voltage from the PCV2 is low when the starter switch is turned on and the supply pump,
NE sensor is normal.

Possible causes
harness and instrument harness, ECU harness and engine harness, engine harness and PCV, or instrument
harness and PCV relay)
harnesses)
Diagnostic help
if faulty.
4-137

step 2
past
trouble
1. Turn the starter switch off. 0V (without jumper) (OK) (NG)
2. Disconnect the harness from the Engine Control Unit. Between pin 31 and body
3. Disconnect the harness from the PCV2. (GND): (jumper: 1-2)
4. Using a jumper wire between PCV2 connector pins, measure Battery voltage
resistance of the connector on the Engine Control Unit. (without jumper) 0V
5. Turn the starter switch on. Between pin 32 and body
Is the voltage value normal? (GND): (jumper 1-2)
Battery voltage
(without jumper) 0V
3 Check the harness for disconnection or shortcircuit. Between pins 1 and 2: 0V Step 5 Step 4
1. Turn the starter switch off. Between pin 1 and body (OK) (NG)
2. Disconnect the harness from the Engine Control Unit. (GND): battery voltage
3. Disconnect the harness from the PCV2. Between pin 2 and body
4. Measure voltage value of the connector on the PCV2 side. (GND): 0V
4 Repair or replace the harness of PCV relay and PCV relay to PCV2. - Step 6 -
5 Repair or replace the harness of Engine Control Unit to PCV2. Also, - Step 6 -
4-138

1. Stop the engine.
detected. (OK) to
help,
step 1
(NG)
4
4-139
<Arrangement of PCV >
・6TE1
Fr
on
t
PCV1
PCV2
<External view of PCV relay > <Circuit of PCV relay >
5 1
4 2
4
3
2
5
* ISO relay
060HY00472
4-140
<Pin assignment of PCV relay >
Pin No. Signal name

1
2 3 4
5 Relay contact point: primary side
< Installing position of PCV relay >
Relay box (B)
R/L R/L
HEAD (HI) TAIL
AB D
R/L R/L R/L
C
R/L R/L R/L
LIGHTER
Relay box (C)

4
R/L R/L R/L
E
R/L R/L R/L
COMP W/PARK P. C. V
BRAKE
R/L R/L
FAN WASHER

Single 2 4 240 290Ω
unit of 1 5 ∞ No power supplied to relay coil
relay 0.5Ω or less Power supplied to relay coil
4-141
271 No.1 cylinder injector drive system trouble (1/5)
Injector circuit (1)

ECU, engine harness (6SD1 engine)
L 1.25 GR 1.25
L 1.25 GR 1.25
LW 1.25 GW 1.25
LW 1.25 GW 1.25
LR 1.25 G 1.25
LR 1.25 G 1.25
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100 RY 1.25
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110 RY 1.25
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120

1 2
(CYLINDER #4)
RL 1.25
RL 1.25
R 0.85
G 0.85 B 1.25
INJECTOR NO. 4 1 2
(CYLINDER #6)
Y 0.85
L 0.85
4 3 2 1
SWP 1 2 3 4
8 7 6 5 (GRAY) 5 6 7 8
12 11 10 9 9 10 11 12
W 0.85
B 0.85
Y 0.85
B 0.85 L 0.85
4 3 2 1 1 2 3 4
W 0.85
8 7 6 5 5 6 7 8 B 0.5
SWP
12 11 10 9 9 10 11 12
16 15 14 13 (GRAY) 13 14 15 16
B 0.5
G 0.85
B 1.25
R 0.85
B 0.5

1 2 B 0.85
(CYLINDER #2)
L 0.85
R 0.85 Y 0.85
G 0.85 1 2 3 4
SWP 4 3 2 1
5 6 7 8 (GRAY) 8 7 6 5
9 10 11 12 12 11 10 9
INJECTOR NO. 3 1 2
(CYLINDER #3)
Y 0.85
L 0.85
Gy 0.5
Gy 0.5
INJECTOR NO. 1 1 2
B 0.85
W 0.85 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
ENGINE HARNESS
JOINT CONNECTOR (1)
ECU HARNESS
4-142
Circuit description
injectors provided on the cylinder head, and the signals are returned to the Engine Control Unit via the
injectors to control the switches in the Engine Control Unit, so as to make various controls.
CAUTION:The injector driving voltage exceeds 100V, and therefore the starter switch must be turned OFF
to prevent an electric shock during the checking and repair.

• Rough idling
The control unit judges as "No.1 cylinder injector drive system trouble" and displays "diagnostic trouble
code: 271" when no signal (voltage) is entered to the TWV (Two Way Valve) drive circuit in the injector.

4
Possible causes
• Disconnection or GND shortcircuit in injector (power side) circuit (faulty vehicle harness of ECU
harnesses, engine harnesses, or injector harnesses)
• Disconnection or GND shortcircuit in injector (driving side) circuit (faulty vehicle harness of ECU
• Faulty TWV (faulty disconnection of internal coil)
Diagnostic help
if faulty.

• TWV1 All engines TWV1
4-143

2. Using the Tech II, check the diagnostic trouble code. trouble help, and
step 2
past
trouble
2. Disconnect the harness from the Engine Control Unit. Between pins 100 and
3. Install the circuit tester between connector pins. 110: 0.5Ω or less
4. Measure resistance of the No.1 cylinder injector (TWV) circuit. Between pins 90 and 100:
Is the resistance value normal? 0.3 - 1.3Ω
0.3 - 1.3Ω
0.3 - 1.3Ω
0.3 - 1.3Ω
Between each pin and
GND: ∞Ω
injector body: ∞Ω
3 Using the circuit tester, measure the resistance of the No.1 cylinder Between TWV pins: 0.3 - Step 5 Step 4
injector (TWV) circuit. 1.3Ω (at about 20°C) (OK) (NG)
1. Turn the starter switch off. Between TWV body and
2. Disconnect the harness from the injector (TWV). each pin: ∞Ω
3. Using a circuit tester, measure internal resistance of TWV.
4-144

2. Disconnect the harness from the Engine Control Unit. Between pins 100 and 110:
3. Disconnect the harness from the TWV. 0.5Ω or less
4. Using a jumper wire between TWV connector pins, measure Between pins 90 and 100:
resistance of the connector on the Engine Control Unit. 0.5Ω or less (with jumper)
0.5Ω or less (with jumper)
GND: ∞Ω
6 Repair or replace the harness of injector (TWV) circuit. Also, check - Step 5 -
the connectors for connection.
⋅ Engine Control Unit to TWV connector (power side)
injector harness)
4
⋅ Engine Control Unit to TWV connector (drive side)
(Faulty vehicle harness of ECUharness, engine harness, or
injector harness)
1. Stop the engine.
detected. (OK) to
help,
step 1
(NG)
4-145

6SD1 6WG1 6TE1
4-146
Injector circuit (1)

L 1.25 GR 1.25
L 1.25 GR 1.25
LW 1.25 GW 1.25
LW 1.25 GW 1.25
LR 1.25 G 1.25
LR 1.25 G 1.25
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100 RY 1.25
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110 RY 1.25
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120

1 2
(CYLINDER #4)
RL 1.25
RL 1.25
R 0.85
G 0.85 B 1.25
INJECTOR NO. 4 1 2
(CYLINDER #6)
Y 0.85
L 0.85
4 3 2 1
SWP 1 2 3 4
8 7 6 5 (GRAY) 5 6 7 8
12 11 10 9 9 10 11 12
INJECTOR NO. 2
(CYLINDER #5)
1 2
W 0.85
B 0.85
Y 0.85
R 0.85
G 0.85
L 0.85
4
B 0.85
4 3 2 1 1 2 3 4
W 0.85
8 7 6 5 5 6 7 8 B 0.5
SWP
12 11 10 9 9 10 11 12
16 15 14 13 (GRAY) 13 14 15 16
B 0.5
G 0.85
B 1.25
R 0.85
B 0.5

1 2 B 0.85
(CYLINDER #2)
L 0.85
R 0.85 Y 0.85
G 0.85 1 2 3 4
SWP 4 3 2 1
5 6 7 8 (GRAY) 8 7 6 5
9 10 11 12 12 11 10 9
INJECTOR NO. 3 1 2
(CYLINDER #3)
Y 0.85
L 0.85
Gy 0.5
Gy 0.5
INJECTOR NO. 1 1 2
B 0.85
W 0.85 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
ENGINE HARNESS
JOINT CONNECTOR (1)
ECU HARNESS
4-147
Circuit description

• Rough idling

Possible causes
Diagnostic help
if faulty.

4-148

step 2
past
trouble
2 Check the harness for disconnection or shortcircuit. ⋅ 6WG1, 6SD1 engine Step 5 Step 3
1. Turn the starter switch off. ⋅ Between pins 86 and 95: (OK) (NG)
3. Install the circuit tester between connector pins. ⋅ Between pins 100 and
4. Measure resistance of the No.2 cylinder injector (TWV) circuit. 110: 0.5Ω or less
Is the resistance value normal? ⋅ Between pins 86 and
100: 03 - 1.3Ω
⋅ Between pins 86 and
110: 03 - 1.3Ω
100: 03 - 1.3Ω
110: 0.5W or less
4
⋅ Between each pin and
GND: ∞Ω
⋅ 6TE1 engine
⋅ Between pins 85 and 94:
0.5Ω or less
120: 0.5Ω or less
119: 03 - 1.3Ω
120: 03 - 1.3Ω
119: 03 - 1.3W
120: 03 - 1.3Ω
GND: ∞Ω
1. Turn the starter switch off. Between TWV body
2. Disconnect the harness from the injector (TWV). and each pin: ∞Ω
4-149

1. Turn the starter switch off. Between pins 86 and 95: (OK) (NG)
3. Disconnect the harness from the TWV. Between pins 100 and
4. Using a jumper wire between TWV connector pins, measure 110:
resistance of the connector on the Engine Control Unit. 0.5Ω or less
0.5Ω or less (jumper)
GND: ∞W
⋅ 6TE1 engine
0.5Ω or less
Between pins 119 and
120:
0.5Ω or less
Between pins 94 and
1200. 5Ω or less
(jumper)
GND: ∞Ω
(Faulty vehicle harness of ECU harness, engine harness, or injector harness)
(Faulty vehicle harness of ECUharness, engine harness, or injector harness)
4-150

1. Stop the engine.
detected. (OK) to
help,
step 1
(NG)

Because the valve is of the two-way type, pins are not identified. 4
6SD1 6WG1 6TE1
4-151
Injection circuit (1)

L 1.25 GR 1.25
L 1.25 GR 1.25
LW 1.25 GW 1.25
LW 1.25 GW 1.25
LR 1.25 G 1.25
LR 1.25 G 1.25
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100 RY 1.25
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110 RY 1.25
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120

1 2
(CYLINDER #4)
RL 1.25
RL 1.25
R 0.85
G 0.85 B 1.25
INJECTOR NO. 4 1 2
(CYLINDER #6)
Y 0.85
L 0.85
4 3 2 1
SWP 1 2 3 4
8 7 6 5 (GRAY) 5 6 7 8
12 11 10 9 9 10 11 12
W 0.85
B 0.85
Y 0.85
B 0.85 L 0.85
4 3 2 1 1 2 3 4
W 0.85
8 7 6 5 5 6 7 8 B 0.5
SWP
12 11 10 9 9 10 11 12
16 15 14 13 (GRAY) 13 14 15 16
B 0.5
G 0.85
B 1.25
R 0.85
B 0.5

1 2 B 0.85
(CYLINDER #2)
L 0.85
R 0.85 Y 0.85
G 0.85 1 2 3 4
SWP 4 3 2 1
5 6 7 8 (GRAY) 8 7 6 5
9 10 11 12 12 11 10 9
INJECTOR NO. 3 1 2
(CYLINDER #3)
Y 0.85
L 0.85
Gy 0.5
Gy 0.5
INJECTOR NO. 1 1 2
B 0.85
W 0.85 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
ENGINE HARNESS
JOINT CONNECTOR (1)
ECU HARNESS
4-152
Circuit description

• Rough idling

4
Possible causes
Diagnostic help
if faulty.

4-153

step 2
past
trouble
3. Install the circuit tester between connector pins. Between pins 100 and
03 - 1.3Ω
03 - 1.3Ω
03 - 1.3Ω
0.5Ω or less
GND: ∞Ω
⋅ 6TE1 engine
0.5Ω or less
120: 0.5Ω or less
03 - 1.3Ω
03 - 1.3Ω
03 - 1.3Ω
03 - 1.3Ω
GND: ∞Ω
injector (TWV) circuit. 1.3W (at about 20°C) (OK) (NG)
4-154

4.Using a jumper wire between TWV connector pins, measure 110:
resistance of the connector on the Engine Control Unit. 0.5Ω or less
GND: ∞Ω
⋅ 6TE1 engine
0.5Ω or less 4
110: 0.5Ω or less
GND: ∞Ω
-
6 Repair or replace the harness of injector (TWV) circuit. Also, check - Step 5
injector harness)
injector harness)
4-155

1. Stop the engine.
detected. (OK) to
help,
step 1
(NG)

6SD1 6WG1 6TE1
4-156

L 1.25 GR 1.25
L 1.25 GR 1.25
LW 1.25 GW 1.25
LW 1.25 GW 1.25
LR 1.25 G 1.25
LR 1.25 G 1.25
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100 RY 1.25
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110 RY 1.25
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120

1 2
(CYLINDER #4)
RL 1.25
RL 1.25
R 0.85
G 0.85 B 1.25
INJECTOR NO. 4 1 2
(CYLINDER #6)
Y 0.85
L 0.85
4 3 2 1
SWP 1 2 3 4
8 7 6 5 (GRAY) 5 6 7 8
12 11 10 9 9 10 11 12
4
W 0.85
B 0.85
Y 0.85
B 0.85 L 0.85
4 3 2 1 1 2 3 4
W 0.85
8 7 6 5 5 6 7 8 B 0.5
SWP
12 11 10 9 9 10 11 12
16 15 14 13 (GRAY) 13 14 15 16
B 0.5
G 0.85
B 1.25
R 0.85
B 0.5

1 2 B 0.85
(CYLINDER #2)
L 0.85
R 0.85 Y 0.85
G 0.85 1 2 3 4
SWP 4 3 2 1
5 6 7 8 (GRAY) 8 7 6 5
9 10 11 12 12 11 10 9
INJECTOR NO. 3 1 2
(CYLINDER #3)
Y 0.85
L 0.85
Gy 0.5
Gy 0.5
INJECTOR NO. 1 1 2
B 0.85
W 0.85 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
ENGINE HARNESS
JOINT CONNECTOR (1)
ECU HARNESS
4-157
Circuit description

• Rough idling

Possible causes
Diagnostic help
if faulty.

4-158

step 2
past
trouble
0.3 - 1.3Ω
0.3 -1.3Ω
0.3 - 1.3Ω
0.3 - 1.3Ω
4
GND: ∞Ω
⋅ 6TE1 engine
0.5Ω or less
120: 0.5Ωor less
0.3 - 1.3Ω
0.3 - 1.3Ω
0.3 -1.3Ω
0.3 -1.3Ω
GND: ∞Ω
injector (TWV) circuit. 1.3W (at about 20°C) (OK) (NG)
4-159

4. Using a jumper wire between TWV connector pins, measure 120: 0.5Ω or less
resistance of the connector on the Engine Control Unit. Between pins 85 and 119:
Is the resistance value normal? 0.5Ω or less
(without jumper)
0.5Ω or less
(without jumper)
0.5Ω or less
(without jumper)
0.5Ω or less
(without jumper)
GND: ∞Ω
⋅ 6TE1 engine
0.5Ω or less
120: 0.5Ω or less
0.5Ω or less
(without jumper)
0
.5Ω or less
(without jumper)
0.5Ω or less
(without jumper)
0.5Ω or less
(without jumper)
GND: ∞Ω
injector harness)
injector harness)
4-160

1. Stop the engine.
detected. (OK) to
help,
step 1
(NG)
4
6SD1 6WG1 6TE1
4-161

L 1.25 GR 1.25
L 1.25 GR 1.25
LW 1.25 GW 1.25
LW 1.25 GW 1.25
LR 1.25 G 1.25
LR 1.25 G 1.25
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100 RY 1.25
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110 RY 1.25
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120

1 2
(CYLINDER #4)
RL 1.25
RL 1.25
R 0.85
G 0.85 B 1.25
INJECTOR NO. 4 1 2
(CYLINDER #6)
Y 0.85
L 0.85
4 3 2 1
SWP 1 2 3 4
8 7 6 5 (GRAY) 5 6 7 8
12 11 10 9 9 10 11 12
W 0.85
B 0.85
Y 0.85
B 0.85 L 0.85
4 3 2 1 1 2 3 4
W 0.85
8 7 6 5 5 6 7 8 B 0.5
SWP
12 11 10 9 9 10 11 12
16 15 14 13 (GRAY) 13 14 15 16
B 0.5
G 0.85
B 1.25
R 0.85
B 0.5

1 2 B 0.85
(CYLINDER #2)
L 0.85
R 0.85 Y 0.85
G 0.85 1 2 3 4
SWP 4 3 2 1
5 6 7 8 (GRAY) 8 7 6 5
9 10 11 12 12 11 10 9
INJECTOR NO. 3 1 2
(CYLINDER #3)
Y 0.85
L 0.85
Gy 0.5
Gy 0.5
INJECTOR NO. 1 1 2
B 0.85
W 0.85 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
ENGINE HARNESS
JOINT CONNECTOR (1)
ECU HARNESS
4-162
Circuit description

• Rough idling

4
Possible causes
Diagnostic help
if faulty.

4-163

step 2
past
trouble
Is the resistance value normal? 120: 0.5Ω or less
0.3 - 1.3Ω
0.3 - 1.3Ω
0.3 - 1.3Ω
0.3 - 1.3Ω
GND: ∞Ω
⋅ 6TE1 engine
0.5Ω or less
110: 0.5Ω or less
0.3 - 1.3Ω
0.3 - 1.3Ω
0.3 - 1.3Ω
0.3 - 1.3Ω
GND: ∞Ω
1.Turn the starter switch off. Between TWV body and
4-164

(without jumper)
0.5Ω or less
(without jumper)
0.5Ω or less
(without jumper)
0.5Ω or less
(without jumper)
GND: ∞Ω
⋅ 6TE1 engine
Between pins 88 and 97: 4
0.5Ω or less
110: 0.5Ω or less
0.5Ω or less
(without jumper)
0.5Ω or less (without
jumper)
0.5Ω or less
(without jumper)
0.5W or less
(without jumper)
GND: ∞Ω
injector harness)
⋅ Engine Control Unit to TWV connector (driving side)
injector harness)
4-165

1. Stop the engine.
detected. (OK) to
help,
step 1
(NG)

6SD1 6WG1 6TE1
4-166

L 1.25 GR 1.25
L 1.25 GR 1.25
LW 1.25 GW 1.25
LW 1.25 GW 1.25
LR 1.25 G 1.25
LR 1.25 G 1.25
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100 RY 1.25
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110 RY 1.25
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120

1 2
(CYLINDER #4)
RL 1.25
RL 1.25
R 0.85
G 0.85 B 1.25
INJECTOR NO. 4 1 2
(CYLINDER #6)
Y 0.85
L 0.85
4 3 2 1
SWP 1 2 3 4
8 7 6 5 (GRAY) 5 6 7 8
12 11 10 9 9 10 11 12
4
W 0.85
B 0.85
Y 0.85
B 0.85 L 0.85
4 3 2 1 1 2 3 4
W 0.85
8 7 6 5 5 6 7 8 B 0.5
SWP
12 11 10 9 9 10 11 12
16 15 14 13 (GRAY) 13 14 15 16
B 0.5
G 0.85
B 1.25
R 0.85
B 0.5

1 2 B 0.85
(CYLINDER #2)
L 0.85
R 0.85 Y 0.85
G 0.85 1 2 3 4
SWP 4 3 2 1
5 6 7 8 (GRAY) 8 7 6 5
9 10 11 12 12 11 10 9
INJECTOR NO. 3 1 2
(CYLINDER #3)
Y 0.85
L 0.85
Gy 0.5
Gy 0.5
INJECTOR NO. 1 1 2
B 0.85
W 0.85 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
ENGINE HARNESS
JOINT CONNECTOR (1)
ECU HARNESS
4-167
Circuit description

• Rough idling

Possible causes
Diagnostic help
if faulty.

4-168

step 2
past
trouble
0.5Ω or less
0.5Ω or less
0.5Ω or less
0.5Ω or less
4
GND: ∞Ω
⋅ 6TE1 engine
0.5Ω or less
120: 0.5Ω or less
0.3 -1.3Ω
0.3 - 1.3Ω
0.3 -1.3Ω
0.3 - 1.3Ω
GND: ∞Ω
injector (TWV) circuit. 1.3Ω (at about 20° C) (OK) (NG)
1.Turn the starter switch off. Between TWV body and
4-169

1. Turn the starter switch off. Between pins 87 and 96: (OK) (OK)
(without jumper)
0.5Ω or less
(without jumper)
0.5Ω or less
(without jumper)
0.5Ω or less
(without jumper)
GND: ∞Ω
⋅ 6TE1 engine
0.5Ω or less
120: 0.5Ω or less
0.5Ω or less
(without jumper)
0.5Ω or less
(without jumper)
0.5Ω or less
(without jumper)
0.5Ω or less
(without jumper)
GND: ∞Ω
injector harness)
injector harness)
4-170

1. Stop the engine.
detected. (OK) to
help,
step 1
(NG)
4
6SD1 6WG1 6TE1
4-171
411 Magnetic valve "A" drive system trouble (1/8)
Magnetic valve circuit (1)

C**23 vehicle
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
PL 0.5
Sb 0.5
YBr 0.5
YG 0.5
YV 0.5
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
10 11 12 13 14 15 16 17 18 19 20 21
SDL
21 20 19 18 17 16 15 14 13 12 11 10
(BLACK)
22 23 24 25 26 27 28 29 30 31 32 32 31 30 29 28 27 26 25 24 23 22
3
5 1
4 2
FUSE 19 1
2 4
Sb 0.5 ECU HARESS
3
4 4
1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1
19 20 20 19
9 10 11 12 13 14 15 16 17 18 18 17 16 15 14 13 12 11 10 9
11 12
12 YBr 0.5 11
YV 0.5
YG 0.5
10 9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 10
111213141516 17 1819202122 2221201918 17 16 1514131211
VGS1 MAGNETIC VALVE

Z TYPE
(MAGNETIC VALVE A) (GRAY)
YG 0.5 PL 0.5
1 2
VGS2 MAGNETIC VALVE

Z TYPE
(MAGNETIC VALVE B) (GRAY)
YV 0.5 PL 0.5
1 2
VGS3 MAGNETIC VALVE

Z TYPE
(MAGNETIC VALVE C) (GRAY)
YBr 0.5 PL 0.5
1 2
FRAME (Ft) HARNESS
4-172
Circuit description
The magnetic valve "A" is used to supply air to the air cylinder for VGS, CCS, or intake shutter. By
controlling the air supply to the air cylinder, the air cylinder for VGS, CCS, or intake shutter is controlled
properly.
The power is supplied to the magnetic valves via magnetic valve fail-safe relays (EGR, (VGS, INT/S) M/V
relays), and further it is connected to the Engine Control Unit via magnetic valves.
The Engine Control Unit controls each magnetic valve, and in the event of a trouble detection, it control the
magnetic valve fail-safe relays to stop the power supply to the magnetic valves and thus to stop each control.

• 6SD1
Lack of output power/slow response
• 6WG1
• 6TE1
Large sound of exhaust brake
• When magnetic valve "A" is not driven
The control unit judges as "magnetic valve "A" drive system trouble" and displays "diagnostic trouble
4
code: 411" when the state where the operating voltage from magnetic valve "A" is faulty (no power
supply or low potential) continues for 1.2 seconds. (Circuit disconnection, GND short, etc.)
• When magnetic valve "A" is driven
The control unit judges as "magnetic valve "A" drive system trouble" and displays "diagnostic trouble
code: 411" when the state where the operating voltage from magnetic valve "A" is faulty (high potential)
continues for 1.2 seconds. (Power supply short, engine control unit GND disconnection, etc.)

In the event of magnetic valve system trouble, the ENGINE CONTROL lamp for the vehicles with the multi-
4-173
Possible causes
harness and frame harness, ECU harness and member harness, ECU harness and instrument harness, or
member harness and magnetic valve connector)
• Disconnection or shortcircuit in magnetic valve (power side) circuit (faulty vehicle harness of ECU
harnesses, instrument harnesses, frame harnesses, or member harnesses)
• Disconnection or GND shortcircuit in magnetic valve (driving side) circuit (faulty vehicle harness of
ECU harnesses, frame harnesses, or member harnesses)
• Faulty magnetic valve (faulty disconnection of internal coil)
• Faulty magnetic valve fail safe relay (EGR, (VSG, INT/S) M/V relay)
Diagnostic help
if faulty.
Magnetic valve numbers and cylinder numbers

• Magnetic valve (A) 6SD1:VGS1 6TE1Intake shutter 1 6WG1: CCS
• Magnetic valve (B) 6SD1:VGS2 6TE1Intake shutter 2 6WG1:Not used
• Magnetic valve (C) 6SD1:VGS3 6TE1Intake shutter 3 6WG1: Not used


step 2
past
trouble
2 Check the harness for disconnection or shortcircuit. ⋅ 6SD1, 6TE1 Step 6 Step 3
2. Disconnect the harness from the Engine Control Unit. 34 - 40Ω
3. Install the circuit tester between connector pins.
4. Measure resistance of the magnetic valve (A) circuit.
3 Measure the resistance of the magnetic valve (A). Between pins: 34 - 40Ω Step 5 Step 4
1.Turn the starter switch off. Between each pin and (OK) (NG)
2. Disconnect the harness from the magnetic valve (A). body (GND): ∞Ω
3. Using a circuit tester, measure internal resistance of magnetic
valve (A).
4 Replace the magnetic valve (A). - Step 6 -
4-174

5 Repair or replace the magnetic valve (A). Also, check the connectors - Step 6 -
for connection.
⋅ Engine Control Unit to magnetic valve (A) connector (driving
side)
(Faulty vehicle harness of ECU harness, frame harness, or
member harness)
⋅ Engine Control Unit to magnetic valve (A) connector (power
side, fly back circuit)
(Faulty vehicle harness of ECU harness, frame harness,
member harness, or instrument harness)
1. Turn the starter switch off. Between pin 115 and (OK) (NG)
2. Disconnect the harness from Engine Control Unit. GND: Starter switch
3. Install the circuit tester between Engine Control Unit pin and OFF: 0V
GND (frame or body). ON: Battery voltage
4. Measure voltage value in the fail safe relay circuit. ⋅ 6WG1
Is the voltage value normal? Between pin 115 and
GND: Starter switch
OFF: 0V
ON: Battery voltage
7 Check the harness for disconnection or shortcircuit.
⋅ ISO relay
Between pin relay 2 and
Step 9
(OK)
Step 8
(NG) 4
2. Disconnect the fail safe relay. GND:
3. Install the circuit tester between fail safe relay pin and GND Between pin relay 5 and
(frame or body). GND:
4. Measure voltage value in the fail safe relay circuit. Starter switch OFF: 0V
Is the voltage value normal? ON: Battery voltage
⋅ Micro ISO relay
GND:
GND:
Starter switch OFF: 0V
ON: Battery voltage
8 Repair or replace the fail safe relay circuit (power side). Also, check - Step 10 -
⋅ Fail safe relay to fuse, power circuit.
9 Replace the fail safe relay. - Step 10 -
10 Check the harness for disconnection or shortcircuit. Jumper position Step 12 Step 11
1. Turn the starter switch off. (Engine Control Unit) (OK) (NG)
2. Connect the fail safe relay. 6SD1, 6TE1: pin 115
3. Disconnect the harness from magnetic valve (A). 6WG1: pin 117
4. Disconnect the harness from Engine Control Unit. Between M/V pin 2 and
5. Using a jumper wire, connect the circuit tester between Engine GND: Starter switch
Control Unit pin and GND (frame or body). OFF: 0V
6. Install the circuit tester between magnetic valve (A) pin and ON: Battery voltage
GND (frame or body).
7. Measure voltage value in the magnetic valve (A) circuit.
4-175

11 Repair or replace the fail safe relay or the magnetic valve (A) power - Step 12 -
side circuit.
12 Check the harness for disconnection or shortcircuit. Between pin 81 and Step 14 Step 13
2. Disconnect the harness from Engine Control Unit. Between pin 82 and
3. Install the circuit tester between Engine Control Unit pin and GND: 0.5Ω or less
GND (frame or body). Between pin 102 and
4. Measure resistance value in the Engine Control Unit (GND) GND: 0.5Ω or less
circuit. Between pin 111 and
Is the resistance value normal? GND: 0.Ω or less
Between pin 59 and
GND: 0.5Ω or less
Between pin 59 and other
pin (power/SIG): ∞Ω
13 Repair or replace the Engine Control Unit (GND) circuit. - Step 14 -
1. Stop the engine.
detected. (OK) to
help,
step 1
(NG)
4-176
External view, pin assignment and resistance value of magnetic valve
<External view of magnetic valve >
2 1
Z type connector
(gray) 2 pins
060HY00469
<Installation of magnetic valve >
1 2 3
Legend
1 M/V (C)
2 M/V (B)
3 M/V (A)
Resistance value of magnetic valve >
Resistance value between pins 34 - 40Ω
4-177
External view, pin assignment and resistance value of fail safe relay
<External view of fail safe relay > <Circuit of fail safe relay >
⋅ ISO relay ⋅ Micro ISO relay ⋅ ISO relay ⋅ Micro ISO relay
1 1
3
4
2
5 1
1 2
4 2
3 5
4
3
2 5
4
5 3
<Installation position of fail safe relay >

⋅ ISO relay ⋅ Micro ISO relay
Pin No.
ISO Micro Signal name
1
1
relay relay
2 3 4
2 1 2 Relay contact point (normal open): secondary side
3 4 5
2 5
3 4 Relay contact point (normal close) : secondary side
5 1 Relay contact point: primary side
<Circuit of fail safe relay >
Relay box (B)
R/L R/L
HEAD (HI) TAIL
AB
R/L R/L R/L
C
R/L R/L R/L
LIGHTER
Relay box (C)
R/L R/L R/L

E
R/L R/L R/L
COMP W/PARK P. C. V
BRAKE
R/L R/L
FAN WASHER
4-178
< Resistance value of Fail safe relay >

Parts checked
ISO relay Micro Resistance value Remarks
ISO relay
Single unit 2 4 3 5 240 - 290Ω
of relay 1 5 1 2 ∞ No power supplied to relay coil
0Ω (0.5Ω or less) Power supplied to relay coil
3 5 1 4 ∞ No power supplied to relay coil
4-179
412 Magnetic valve "B" drive system trouble (1/8)

Model C**23 vehicle
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
PL 0.5
Sb 0.5
YBr 0.5
YG 0.5
YV 0.5
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
10 11 12 13 14 15 16 17 18 19 20 21
SDL
21 20 19 18 17 16 15 14 13 12 11 10
(BLACK)
22 23 24 25 26 27 28 29 30 31 32 32 31 30 29 28 27 26 25 24 23 22
3
5 1
4 2
FUSE 19 1
2 4
Sb 0.5 ECU HARESS
3
4 4
1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1
19 20 20 19
9 10 11 12 13 14 15 16 17 18 18 17 16 15 14 13 12 11 10 9
11 12
12 YBr 0.5 11
YV 0.5
YG 0.5
10 9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 10
111213141516 17 1819202122 2221201918 17 16 1514131211
VGS1 MAGNETIC VALVE

Z TYPE
YG 0.5 PL 0.5
1 2
VGS2 MAGNETIC VALVE

Z TYPE
YV 0.5 PL 0.5
1 2
VGS3 MAGNETIC VALVE

Z TYPE
YBr 0.5 PL 0.5
1 2
FRAME (Ft) HARNESS
4-180
Circuit description
The magnetic valve "B" is used to supply air to the air cylinder for VGS, or intake shutter. By controlling the
air supply to the air cylinder, the air cylinder for VGS, or intake shutter is controlled properly.
The power is supplied to the magnetic valves via magnetic valve fail-safe relays ((VGS, INT/S) M/V relays),
and further it is connected to the Engine Control Unit via magnetic valves.

• 6SD1 engine
Lack of output power/slow response
• When magnetic valve "B" is not driven
The control unit judges as "magnetic valve "B" drive system trouble" and displays "diagnostic trouble
code: 412" when the state where the operating voltage from magnetic valve "B" is faulty (low potential)
continues for 1.2 seconds. (Circuit disconnection, GND short, etc.)
• When magnetic valve "B" is driven
The control unit judges as "magnetic valve "B" drive system trouble" and displays "diagnostic trouble
code: 412" when the state where the operating voltage from magnetic valve "B" is faulty (no power 4
supply or high potential) continues for 1.2 seconds. (Power supply short, engine control unit GND
disconnection, etc.)

Possible causes
• Faulty magnetic valve fail safe relay ((VGS, INT/S) M/V relay)
Diagnostic help
if faulty.
4-181
Injector magnetic valve numbers and cylinder numbers



step 2
past
trouble
2 Check the harness for disconnection or shortcircuit. 6SD1, 6TE1 Step 6 Step 3
1. Turn the starter switch off. Between pins 3and 93: (OK) (NG)
3. Install the circuit tester between connector pins. Between each pin and
4. Measure resistance of the magnetic valve (B) circuit. body (GND):∞Ω
3 Measure the resistance of the magnetic valve (B). Between pins: 34 - 40Ω Step 5 Step 4
2. Disconnect the harness from the magnetic valve (B). body (GND): ∞Ω
valve (B).
4 Replace the magnetic valve (B). - Step 6 -
5 Repair or replace the magnetic valve (B). Also, check the connectors - Step 6 -
for connection.
⋅ Engine Control Unit to magnetic valve (B) connector (driving
side)
member harness)
⋅ Engine Control Unit to magnetic valve (B) connector (power
4-182

6 Check the harness for disconnection or shortcircuit. ⋅ SD1, 6TE1 Step 10 Step 7
1. Turn the starter switch off. Between pin 115 and (OK) (OK)
4. Measure voltage value in the fail safe relay circuit.
7 Check the harness for disconnection or shortcircuit. Between pin relay 5 and Step 9 Step 8
2. Disconnect the fail safe relay. Between pin relay 1 and
3. Install the circuit tester between fail safe relay pin and GND GND:
(frame or body). Starter switch OFF: 0V
4. Measure voltage value in the fail safe relay circuit. ON: Battery voltage
9 Replace the fail safe relay.
- Step 10 -
4
3. Disconnect the harness from magnetic valve (B). Between M/V pin 2 and
5. Using a jumper wire, connect the circuit tester between Engine OFF: 0V
Control Unit pin and GND (frame or body). ON: Battery voltage
6. Install the circuit tester between magnetic valve (B) pin and
7. Measure voltage value in the magnetic valve (B) circuit.
11 Repair or replace the fail safe relay or the magnetic valve (C) power - Step 12 -
side circuit.
4-183

Is the resistance value normal? GND: 0.5Ω or less
Between pin 59 and
GND: 0.5Ω or less
13 Repair or replace the Engine Control Unit (GND) circuit. - Step 14 -
1. Stop the engine.
detected. (OK) to
help,
step 1
(NG)
4-184
2 1
Z type connector
(gray) 2 pins
060HY00469
<Installation position of magnetic valve >
1 2 3
Legend
1 M/V (C)
2 M/V (B)
3 M/V (A)
<Resistance value of magnetic valve >

4-185
1
2 4
1 2
3 5
5
4
3
* Micro ISO relay
<Circuit of fail safe relay >

Pin No. Signal name
3 4 5 4 Relay contact point (normal close) : secondary side
Relay box (B)
R/L R/L
HEAD (HI) TAIL
AB
R/L R/L R/L
C
R/L R/L R/L
LIGHTER
Relay box (C)
R/L R/L R/L

E
R/L R/L R/L
COMP W/PARK P. C. V
BRAKE
R/L R/L
FAN WASHER
4-186

Single unit 3 5 240 - 290Ω∞
of relay 1 2 ∞ No power supplied to relay coil
1 4 ∞ No power supplied to relay coil
4-187
415 Magnetic valve "C" drive system trouble (6S series and 6T series engines) (1/8)

Model C∗∗ 23 vehicle
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
PL 0.5
Sb 0.5
YBr 0.5
YG 0.5
YV 0.5
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
10 11 12 13 14 15 16 17 18 19 20 21
SDL
21 20 19 18 17 16 15 14 13 12 11 10
(BLACK)
22 23 24 25 26 27 28 29 30 31 32 32 31 30 29 28 27 26 25 24 23 22
3
5 1
4 2
FUSE 19 1
2 4
Sb 0.5 ECU HARESS
3
4 4
1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1
19 20 20 19
9 10 11 12 13 14 15 16 17 18 18 17 16 15 14 13 12 11 10 9
11 12
12 YBr 0.5 11
YV 0.5
YG 0.5
10 9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 10
111213141516 17 1819202122 2221201918 17 16 1514131211
VGS1 MAGNETIC VALVE

Z TYPE
YG 0.5 PL 0.5
1 2
VGS2 MAGNETIC VALVE

Z TYPE
YV 0.5 PL 0.5
1 2
VGS3 MAGNETIC VALVE

Z TYPE
YBr 0.5 PL 0.5
1 2
FRAME (Ft) HARNESS
4-188
Circuit description
The magnetic valve "C" is used to supply air to the air cylinder for VGS, or intake shutter. By controlling the
air supply to the air cylinder, the air cylinder for VGS, or intake shutter is controlled properly.

• 6SD1 engine
• When magnetic valve "C" is not driven
The control unit judges as "magnetic valve "C" drive system trouble" and displays "diagnostic trouble
code: 415" when the state where the operating voltage from magnetic valve "C" is faulty (no power
supply or low potential) continues for 1.2 seconds. (Circuit disconnection, GND short, etc.)
• When magnetic valve "C" is driven
The control unit judges as "magnetic valve "C" drive system trouble" and displays "diagnostic trouble
code: 415" when the state where the operating voltage from magnetic valve "C" is faulty (high
4
potential)continues for 1.2 seconds. (Power supply short, engine control unit GND disconnection, etc.)

Possible causes
• Faulty magnetic valve fail safe relay ((VGS, INT/S) M/V relay)
Diagnostic help
if faulty.
4-189
Magnetic valve numbers and cylinder numbers


step 2
past
trouble
1. Turn the starter switch off. Between pins 39and 93: (OK) (NG)
3. Install the circuit tester between connector pins. Between each pin and
4. Measure resistance of the magnetic valve (C) circuit. body (GND): ∞Ω
3 Measure the resistance of the magnetic valve (C). Between pins: 34 - 40Ω Step 5 Step 4
2. Disconnect the harness from the magnetic valve (C). body (GND): ∞Ω
valve (C).
4 Replace the magnetic valve (C). - Step 6 -
5 Repair or replace the magnetic valve (C). Also, check the connectors - Step 6 -
for connection.
⋅ Engine Control Unit to magnetic valve (C) connector (driving
side)
member harness)
⋅ Engine Control Unit to magnetic valve (C) connector (power
4-190

1. Turn the starter switch off. Between pin 115 and (OK) (NG)
4. Measure voltage value in the fail safe relay circuit.
7 Check the harness for disconnection or shortcircuit. Between pin relay 5 and Step 9 Step 8
2. Disconnect the fail safe relay. Between pin relay 1 and
3. Install the circuit tester between fail safe relay pin and GND GND:
(frame or body). Starter switch OFF: 0V
4. Measure voltage value in the fail safe relay circuit. ON: Battery voltage
9 Replace the fail safe relay.
- Step 10 -
4
3. Disconnect the harness from magnetic valve (B). Between M/V pin 2 and
5. Using a jumper wire, connect the circuit tester between Engine OFF: 0V
Control Unit pin and GND (frame or body). ON: Battery voltage
6. Install the circuit tester between magnetic valve (C) pin and
7. Measure voltage value in the magnetic valve (C) circuit.
11 Repair or replace the fail safe relay or the magnetic valve (C) power - Step 12 -
side circuit.
4-191

Is the resistance value normal? GND: 0.5Ω or less
Between pin 59 and
GND: 0.5Ω or less
13 Repair or replace the Engine Control Unit (GND) circuit. - Step 14
1. Stop the engine.
detected. (OK) to
help,
step 1
(NG)
4-192
2 1
Z type connector
(gray) 2 pins
<Installation position of magnetic valve >
1 2 3
Legend
1 M/V (C)
2 M/V (B)
3 M/V (A)
<Resistance value of magnetic valve >

4-193
4
2
1 2
3 5
5
4
3
<Pin assignment of fail safe relay >

Pin No. Signal name
3 4 5 4 Relay contact point (normal close) : secondary side
Relay box (B)
R/L R/L
HEAD (HI) TAIL
AB
R/L R/L R/L
C
R/L R/L R/L
LIGHTER
Relay box (C)
R/L R/L R/L

E
R/L R/L R/L
COMP W/PARK P. C. V
BRAKE
R/L R/L
FAN WASHER
4-194

Single unit 3 5 240 - 290Ω
0W (0.5Ω or less) Power supplied to relay coil
0W (0.5Ω or less) Power supplied to relay coil
4-195
416 Main relay system trouble (1/5)
Main relay circuit (including engine control unit GND circuit)
CASE GND POWER GND

40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
VW 1.25 RW 1.25
B 1.25
Y 0.5
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
1 2 3 4 5 6 7 8
19 20 B 1.25
9 10 11 12 13 14 15 16 17 18
22 23 24 25 26 27 28 29 30 31 32
LR 0.5 B 1.25
B 1.25
25
FUSE 20
1 2 3 4 5 6 7 8 9 10 11
3
12 13 14 15 16 17 18 19 20 21 22
5 1
4 2
9 8 7 6 5 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10
MAIN RELAY 32 31 30 29 28 27 26 25 24 23 22
ECU HARNESS SIDE

RW 1.25
1
25
LR 0.5
2 4
B2
3
Y 0.5
FUSE 45
O 1.25
8 7 6 5 4 3 2 1
10 9 8 7 6 5 4 3 2 1 20 19
18 17 16 15 14 13 12 11 10 9
20 19 18 17 16 15 14 13 12 11
1 2 3 4 5 6 7
8 9 10 11 12 13 14 B 1.25
15 16 17 18 19 20
21 22 23 24 B 1.25
29 30 31 32 1 2 3 4 5 6 7 8 9 10 11
33 34 35 36
37 38 39 40 41 42 12 13 14 15 16 17 18 19 20 21 22
43 44 45 46 47 48 49
50 51 52 53 54 55 56
46
JOINT CONNECTOR (2)
7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
14 13 12 11 10 9 8
20 19 18 17 16 15 2221201918 17 16 1514131211
24 23 22 21
28 27 26 25
B2
32 31 30 29
36 35 34 33
42 41 40 39 38 37
49 48 47 46 45 44 43
56 55 54 53 52 51 50
1 2 3 4 5 6 7 8 9 10
46 111213141516 17 1819202122
BL 2 B2
FRAME HARNESS SIDE
4-196
Circuit description
The main relay supplies the power to the Engine Control Unit. When the starter switch is in "ON" or "S"
position, the Engine Control Unit turns on the main relay to supply the main power to the Engine Control
Unit.

• SERVICE ENGINE SOON lamp turns on (ON condition: when the engine idling lasts for 20 seconds)
• Large battery consumption in the event of relay trouble
The control unit judges as "main relay system trouble" and displays "diagnostic trouble code: 416" when the
voltage is applied from the main relay after the starter switch turned off.

In the event of main relay system trouble, the ENGINE CONTROL lamp for the vehicles with the multi-
Possible causes
4
harness and instrument harness, or ECU harness and main relay connectors)
• Disconnection or shortcircuit in main relay circuit (faulty vehicle harness of ECU harnesses or instrument
harnesses)
• Faulty main relay
Diagnostic help
if faulty.
4-197

step 2
past
trouble
2 Check the main relay circuit (coil side) for shortcircuit. Between pin 109 and Step 4 Step 3
1. Turn the starter switch off. body (GND): 0V (OK) (NG)
2. Disconnect the main relay. Between pin 118 and
3. Disconnect the harness from Engine Control unit. body (GND): 0V
5. Measure voltage value of the connector pins on the Engine
Control Unit.
3 Repair or replace the harness between main relay (coil side) and - Step 4 -
Engine Control Unit. Also, check the connectors for connection.
4 Check the main relay. Starter switch OFF: 0V Step 6 Step 5
1. Connect the main relay. ON: Battery voltage (OK) (NG)
2. Measure voltage on the Engine Control Unit connector when (Pin 91 to GND/pin 111
starter switch operates. or 101 to GND)
5 Is the voltage value normal?
Repair or replace the main relay or main relay power side circuit. - Step 7 -
7 Restore the vehicle. - Step 8
1. Stop the engine.
detected. (OK) to
help,
step 1
(NG)
4-198
External view, pin assignment and resistance value of main relay
<External view of main relay > <Circuit of main relay >
1
3
5 1
4 2
4
3 Pin No. Signal name
2
5
* ISO relay
3 Relay contact point (normal close): secondary side
4 Relay coil: primary side
<Pin assignment of main relay > 5 Relay contact point: primary side
2
1
3 4 4
5
<Installation position of main relay >
Relay box (B)
R/L R/L
HEAD (HI) TAIL
AB
R/L R/L R/L
C
R/L R/L R/L
LIGHTER
Relay box (C)
R/L R/L R/L

E
R/L R/L R/L
COMP W/PARK P. C. V
BRAKE
R/L R/L
FAN WASHER
4-199
< Resistance value of main relay >

0.5Ω or less Power supplied to relay coil
4-200
417 Starter switch trouble (1/5)
Starter switch [engine control unit power source] circuit

(including engine control unit GND circuit) (1)
3
5 1 40 PIN 80 PIN
MAIN RELAY 4 2
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
RW 1.25 21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
1 31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
RL 0.3 2 4
B 0.3
3
BW 0.5
5
Y 0.5
7 7
Y 0.5
1 2 3 4 5 6 7 8 9
MAIN RELAY
9 8 7 6 5 4 3 2 1
SDL
21 20 19 18 17 16 15 14 13 12 11 10
FUSE 45 (BLACK) 10 11 12 13 14 15 16 17 18 19 20 21
RW 1.25 32 31 30 29 28 27 26 25 24 23 22
22 23 24 25 26 27 28 29 30 31 32
ECU HARNESS
4
BW 0.85
1 2 3 4 5 6 7 7 6 5 4 3 2 1
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
21 22 23 24 24 23 22 21
25 26 27 28 28 27 26 25
SMJ
29 30 31 32
(WHITE) 32 31 30 29
33 34 35 36 36 35 34 33
37 38 39 40 41 42 42 41 40 39 38 37
BL2
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
BL2
1 2
4-201
Starter switch [engine control unit power source] circuit (2)

(including engine control unit GND circuit)
CASE GND POWER GND

40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
VW 1.25 RW 1.25
B 1.25
Y 0.5
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
1 2 3 4 5 6 7 8
19 20 B 1.25
9 10 11 12 13 14 15 16 17 18
22 23 24 25 26 27 28 29 30 31 32
LR 0.5 B 1.25
B 1.25
25
FUSE 20
1 2 3 4 5 6 7 8 9 10 11
3
12 13 14 15 16 17 18 19 20 21 22
5 1
4 2
9 8 7 6 5 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10
MAIN RELAY 32 31 30 29 28 27 26 25 24 23 22
ECU HARNESS SIDE

RW 1.25
1
25
LR 0.5
2 4
B2
3
Y 0.5
FUSE 45
O 1.25
8 7 6 5 4 3 2 1
10 9 8 7 6 5 4 3 2 1 20 19
18 17 16 15 14 13 12 11 10 9
20 19 18 17 16 15 14 13 12 11
1 2 3 4 5 6 7
8 9 10 11 12 13 14 B 1.25
15 16 17 18 19 20
21 22 23 24 B 1.25
29 30 31 32 1 2 3 4 5 6 7 8 9 10 11
33 34 35 36
37 38 39 40 41 42 12 13 14 15 16 17 18 19 20 21 22
43 44 45 46 47 48 49
50 51 52 53 54 55 56
46
JOINT CONNECTOR (2)
7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
14 13 12 11 10 9 8
20 19 18 17 16 15 2221201918 17 16 1514131211
24 23 22 21
28 27 26 25
B2
32 31 30 29
36 35 34 33
42 41 40 39 38 37
49 48 47 46 45 44 43
56 55 54 53 52 51 50
1 2 3 4 5 6 7 8 9 10
46 111213141516 17 1819202122
BL 2 B2
FRAME HARNESS SIDE
4-202
Circuit description
here are two kinds of starter switch signals, key positions "ON" and "S", and each key position is detected.
According to the key position, the voltage is applied to the Engine Control Unit as a signal.
With the starter switch in "ON" position, the battery relay operates to supply the power, and the Engine
Control Unit reads the voltage of the supplied power via fuses, and with this voltage it drives various sensors,
relays, injectors and magnetic valves.
With the starter switch in "S" position, the Engine Control Unit uses this signal for fuel injection control at
the start of the engine.

• Starter malfunction
• Starter switch misoperation
The control unit judges as "starter switch trouble" and displays "diagnostic trouble code: 417" if state where
the voltage of starter switch (key position "S") signal is applied is detected continuously when the engine
speed exceeds 1000 rpm.

The ENGINE CONTROL lamp or SERVICE ENGINE SOON lamp does not turn on even if the starter
switch system failed, but the trouble is indicated with the diagnostic trouble code only.
4
Possible causes
harness and instrument harness, or instrument harness and switch connectors)
• Shortcircuit in starter switch circuit (faulty vehicle harness of ECU harnesses or instrument harnesses)
• Faulty switch
• Faulty internalswitch
Diagnostic help
if faulty.
4-203

1 Check if diagnostic trouble code other than "417" is detected. - Step 2 See
Is diagnostic trouble code other than "417" detected? check
steps by
diag.
trouble
code,
and after
check,
step 2
2 Check the starter operation. - Step 3 Step 7
Does the starter operate when the starter switch is in "ON" position?
3 Check the harness for GND short. ⋅ Starter SW other than Step 7 Step 4
1. Turn the starter switch off. "S" position, Between pin (OK) (NG)
2. Disconnect the harness from the Engine Control Unit. 24 and GND: 0V
3. Install the circuit tester between connector pin and GND (frame ⋅ Starter SW "S" position,
or engine body). Between pin 24 and
4. Measure voltage of the starter switch circuit. GND: Battery voltage
4 Check the harness for shortcircuit. Between pins 24 and 13: Step 5 Step 6
1. Turn the starter switch off. ∞Ω (OK) (NG)
2. Disconnect the harness from the starter switch. Between pins 24 and 23:
3. Measure resistance of the connector on Engine Control Unit ∞Ω
side. Between pin 24 and other
Is the resistance value normal? pins: ∞Ω
0.5Ω or less
5 Replace the starter switch. - Step 7 -
6 Repair or replace the harnesses of starter switch circuit. Also, check - Step 7 -
⋅ Engine Control Unit to instrument harness connector
(ECU harness, starter switch circuit)
⋅ Starter switch to ECU harness connector
(Instrument harness, starter switch circuit)
4-204

7 Check the starter for abnormality. - Step 8 See engine
1. Turn the starter switch off. repair
2. Remove the starter. manual to
3. Check the starter, and repair or replace if faulty. check the
Did corrective actions complete? starter, and
after repair
or
replacement,
step 8
8 With the starter removed, check the flywheel (ring gear) and starter - Step 9 -
pinion, and repair or replace if faulty.
11
Restore the vehicle. - Step 12 -
4
1. Stop the engine.
2. Connect the harnesses to boost sensor
conduct the test run again to check that no diagnostic trouble code is end referring to
detected. (OK) diagnostic
Is diagnostic trouble code detected? help, step 1
(NG)
4-205
418 Fail-safe (Magnetic valve cut) relay "A" system trouble ... 6S and 6T series (1/5)

Model C**23 Vehicle
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
PL 0.5
Sb 0.5
YBr 0.5
YG 0.5
YV 0.5
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
10 11 12 13 14 15 16 17 18 19 20 21
SDL
21 20 19 18 17 16 15 14 13 12 11 10
(BLACK)
22 23 24 25 26 27 28 29 30 31 32 32 31 30 29 28 27 26 25 24 23 22
3
5 1
4 2
FUSE 19 1
2 4
Sb 0.5 ECU HARESS
3
4 4
1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1
19 20 20 19
9 10 11 12 13 14 15 16 17 18 18 17 16 15 14 13 12 11 10 9
11 12
12 YBr 0.5 11
YV 0.5
YG 0.5
10 9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 10
111213141516 17 1819202122 2221201918 17 16 1514131211
VGS1 MAGNETIC VALVE

Z TYPE
YG 0.5 PL 0.5
1 2
VGS2 MAGNETIC VALVE

Z TYPE
YV 0.5 PL 0.5
1 2
VGS3 MAGNETIC VALVE

Z TYPE
YBr 0.5 PL 0.5
1 2
FRAME (Ft) HARNESS
4-206
Circuit description

• SERVICE ENGINE SOON lamp turns on (ON condition: when the engine idling lasts for 20 seconds)
• Auto cruise does not operate
• 6SD1 engine
• Fail-safe relay "A" (Disconnection, GND short) (when the relay does not operate)
The control unit judges as "fail-safe relay "A" system trouble" and displays "diagnostic trouble code:
418" when the state where the operating voltage from fail-safe relay "A" is faulty (no power supply or
low potential) continues for one second.
• Fail-safe relay "A" (Power supply short) (when the relay operates)
The control unit judges as "fail-safe relay "A" system trouble" and displays " diagfrom fail-safe relay
"A" is faulty (high potential) continues for one second.
4
In the event of fail-safe relay system trouble, the ENGINE CONTROL lamp for the vehicles with the multi-
when the engine revolutions exceed 650 rpm. (Conditional ON)
Possible causes
• Loose connection of connectors
(Faulty connection between E/ngine Control Unit and instrument harness, or ECU harness and fail-safe
relay)
• Fail-safe relay circuit
(Faulty vehicle harness of ECU harness or instrument harness)
• Faulty fail-safe relay itself (disconnection of internal coil, etc.)
• Internal trouble of engine control unit
Diagnostic help
if faulty.
4-207
Fail-safe relay "A" and applications

• 6SD1 engine: For VGS magnetic valve cut
step 2
past
trouble
2 Check the fail safe relay circuit (coil side) for shortcircuit. Between pin 115 and Step 4 Step 3
2. Disconnect the fail safe relay.
3. Disconnect the harness from Engine Control unit.
5. Measure voltage value of the connector pins on the Engine
Control Unit.
3 Repair or replace the harness between fail safe relay (coil side) and - Step 4
Engine Control Unit. Also, check the connectors for connection. (OK)
4 Check the fail safe relay. Starter switch OFF: 0V Step 6 Step
1. Connect the fail safe relay. ON: Battery voltage (OK) 5(NG)
2. Measure voltage on the Engine Control Unit connector when (Pin 115 to GND)
starter switch operates.
5 Repair or replace the fail safe relay or fail safe relay power side - Step 7
circuit.
6 Replace the Engine Control Unit. - Step 7
1. Stop the engine.
8 Confirm that the diagnostic trouble codes have been cleared, and - Repair No:
conduct the test run again to check that no diagnostic trouble code is end After
detected. (OK) referring
Is diagnostic trouble code detected? to
diagnostic
help,
step 1
(NG)
4-208
4
2
1 2
3 5
5
4
3
* Micro ISO relay
Pin No. Signal name
<Pin assignment of fail safe relay > 1 Relay contact point: primary side
3 Relay coil: primary side
1 4 Relay contact point (normal close) : secondary side
2
3 4 5
4
Relay box (B)
R/L R/L
HEAD (HI) TAIL
AB
R/L R/L R/L
C
R/L R/L R/L
LIGHTER
Relay box (C)
R/L R/L R/L

E
R/L R/L R/L
COMP W/PARK P. C. V
BRAKE
R/L R/L
FAN WASHER
4-209
< Resistance value of fail safe relay >

4-210
421 PCV relay system trouble (1/5)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
VW 1.25
PCV1 (SIG) VW 0.5
BrB 1.25
BrB 1.25
Br 1.25
KEY SW [ON] SIG
PCV2 PCV1 Br 1.25
4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8
12 11 10 9
SWP 9 10 11 12 PCV2 (SIG)
1 2 1 2 16 15 14 13 (GRAY) 13 14 15 16
RW 1.25
WL 1.25 WL 1.25
1 2 3 4 4 3 2 1
5 6 7 8 SWP 8 7 6 5
9 10 11 12 (GRAY) 12 11 10 9
RB 1.25
WL 1.25
ENGINE HARNESS
5
4
3
1
2
PCV RELAY 4
1
P 0.3 2 3 4 B 0.3
5
O 1.25
8 7 6 5 4 3 2 1 SDL 1 2 3 4 5 6 7 8
20 19 19 20
FUSE 45 18 17 16 15 14 13 12 11 10 9 (WHITE) 9 10 11 12 13 14 15 16 17 18
O 1.25
B 1.25 G 1.25 G 1.25
1 2 3 4
FUSE 20
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21
32 31 30 29 28 27 26 25 24 23 22 (BLACK) 22 23 24 25 26 27 28 29 30 31 32
VW 0.5

FUSE 17 VW 1.25
1 2 3 4 5 6 7 7 6 5 4 3 2 1
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
21 22 23 24 24 23 22 21
25 26 27 28 28 27 26 25
SMJ B8
29 30 31 32 (WHITE) 32 31 30 29
33 34 35 36 36 35 34 33
37 38 39 40 41 42 42 41 40 39 38 37 BL 5
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
FRAME GND
B2
ACG E TERMINAL
FRAME (Ft) HARNESS
4-211
Circuit description

• Large battery consumption when the relay troubled
The control unit judges as "PCV relay system trouble" and displays "diagnostic trouble code: 421" when the
voltage is applied from the PCV1 or PCV2 after the starter switch turned off.

Possible causes
harness and instrument harness, ECU harness and engine harness, engine harness and PCV connectors,
or instrument harness and PCV relays)
• Disconnection and shortcircuit in PCV circuit (faulty vehicle harness of ECU harnesses, engine
harnesses, or instrument harnesses)
• Faulty PCV (faulty internal circuit)
Diagnostic help
if faulty.
4-212

step 2
past
trouble
2 Check the PCV relay circuit for shortcircuit. Between pin 115 and Step 4 Step 3
2. Disconnect the PCV relay. Between pin 2 and body
3. Disconnect the harness from Engine Control unit. (GND): 0V
4. Disconnect the harness from PCV1 or PCV2.
5. Measure voltage value of the connector pins on the PCV.
3 Repair or replace the harness between PCV relay and PCV or PCV - Step 4 -
and Engine Control Unit. Also, check the connectors for connection.
4 Check the PCV relay.
1. Connect the PCV relay.
Starter switch OFF: 0V
ON: Battery voltage
Step 6
(OK)
Step 5
(NG)
4
2. Measure voltage on the PCV connector when starter switch
operates.
5 Repair or replace the PCV relay or PCV relay coil side circuit. - Step 7 -
1. Stop the engine.
detected. (OK) to
help,
step 1
(NG)
4-213
<External view of PCV relay > <Circuit of fail PCV relay >
1
3
5 1
4 2
4
3 Pin No. Signal name
2
5 1 Relay contact point (normal open): secondary side
* Micro ISO relay 2 Relay coil: primary side
<Pin assignment of PCV relay > 5 Relay contact point: primary side
2 3 4
<Installation position of PCV relay >
Relay box (B)
R/L R/L
HEAD (HI) TAIL
AB D
R/L R/L R/L
C
R/L R/L R/L
LIGHTER
Relay box (C)
R/L R/L R/L

E
R/L R/L R/L
COMP W/PARK P. C. V
BRAKE
R/L R/L
FAN WASHER
4-214

0.5Ω or less Power supplied to relay coil
4-215
518 EOL data error (1/2)

This "diagnostic trouble code: 518 (EOL data error)" does not indicate the detection of IE system trouble.
It has been set to ensure the accelerator learning situation.
If this diagnostic trouble code occurred, execute the "accelerator learning" using the Tech II.
For the "accelerator learning", see Chapter 1 IE System General Description and Chapter 7 How to Use IE
System Inspection Tools.

• Poor accelerator feeling
(The fuel injection amount varies with the accelerator pedal operation.)
The Engine Control Unit immediately judges as "EOL data error" and displays "diagnostic trouble code: 518"
if it recognized that the accelerator learning has not been executed.

If the accelerator learning has not been executed, the ENGINE CONTROL lamp for the vehicles with the
display turns on, regardless of engine running condition. (Conditional ON)
Possible causes
• Accelerator learning has not been executed
• Engine Control Unit internal trouble
• Tech II related troubles (harness, Tech II itself, program card)
Diagnostic help
If the accelerator learning failed or other troubles occur, check diagnostic trouble codes, or the connectors for
loose connection, the harnesses for abrasion or folding, the wires inside harnesses for abrasion or short with
other circuits. Also, perform functional diagnosis to check the operation and control, and repair if faulty.
4-216
518 EOL data error (2/2)

1 Check if diagnostic trouble code other than "518" is detected. - Step 2 See the
Is diagnostic trouble code other than "518" detected? check
steps by
diag.
trouble
code, and
after
Step 5 check,
(OK) step 2
2 Execute the accelerator learning. - Step 4 Step 3
Did the accelerator learning complete normally? (OK) (NG)
3 Execute the accelerator learning using other vehicle. - See Tech
Did the accelerator learning complete normally? II check
in
functional
inspection,
and after
check,
step 4
4
(NG)
4 Adjust, repair, or replace the parts judged as faulty during the - Step 5 -
accelerator learning.
1. Stop the engine.
detected. (OK) to
help, step
1 (NG)
4-217
543 Excessive high revolution error (1/2)

This "diagnostic trouble code: 543 (excessive high revolution error)" does not indicate the detection of IE
system trouble.
It has been set to confirm whether faulty engine running state (overrun) occurred in the past, and it helps you
find out causes when the engine troubled (seizure, damage, etc.).
The Engine Control Unit judges as "excessive high revolution error" and displays "diagnostic trouble code:
543" if the number of engine revolutions recognized by the Engine Control Unit exceeds the specified value.
⋅ Specified revolutions All engines: 2950 rpm

If the even of excessive high revolution detection, the ENGINE CONTROL lamp for the vehicles with the
display does not turn on, but the trouble is indicated with the diagnostic trouble code only.
Possible causes
• Transmission shifting failure by driver
• Misoperation at downhill
Diagnostic help
if faulty.
4-218
518 Excessive high revolution error (2/2)

1 Check the operating conditions (for misoperation that caused engine - Step 2 Step 3
overrun). (Ask the driver about past operating conditions)
Was there misoperation?
2 Tell the driver that there was engine overrun due to misoperation, - Step 3 -
and instruct proper operation.
3 Check if there is any influence of engine overrun (faulty engine - Step 4
itself), and repair or replace faulty parts.
1. Stop the engine.
5 Did corrective actions complete?
Confirm that the diagnostic trouble codes have been cleared, and
conduct the test run again to check that no diagnostic trouble code is
detected.
- Repair
end
(OK)
After
referring
to
4
help,
step 1
(NG)
4-219
Chapter 5
Checking method for symptom
5
Chapter 5 Checking method for symptom
Preface
Method for symptom and repair according to the flow chart as shown on the following pages. At this time, give
consideration to the presumed factors and refer to the description of functional checks and checking methods
for each diagnostic trouble code.
Caution: Try to take notes of check results. Make use of the "IE Check Sheet" when recording
information on customers.
After completion of check and repair, be sure to clear the memory in the DMU (data memory unit) and engine
control unit.
5-2
Engine stall (1/3)
Possible causes
• Faulty fuel system (empty tank, frozen fuel, air mixing in fuel piping, faulty filters (clogged, main, pre, gose
filters), faulty piping, fuel quality, fuel tank (dust, faulty duel suction port, etc.))
• Faulty intake system (clogged filters, faulty intake shutter, faulty intake piping, etc.)
• Faulty supply pump (including feed pump) (fuel no pressure feed)
• Faulty common rail (flow damper, pressure limiter operated/deteriorated internal sealing)
• Faulty injectors (no fuel injection)
• System backup due to trouble (fail-safe), system down
• Faulty engine (seizure, low compression pressure, other mechanical troubles)
• ACG trouble
• Chassis related troubles (clutch, transmission, brake, etc.)
• Influence of retrofit electrical parts (radio equipment, lamps, etc.)
• Engine Control Unit troubles (main body, power supply, GND, etc.)
Diagnostic help
if faulty.


1 Check if the ENGINE CONTROL lamp or SERVICE ENGINE Lamp ON Step 2 See
SOON lamp turns on. (OK) "Check
1. Turn the starter switch on. SERVIC
(At this time, do not start the engine.) E
Does the ENGINE CONTROL lamp or SERVICE ENGINE SOON
lamp turn on?
ENGINE
SOON
5
lamp
lighting
circuit
system",
and after
repair and
check,
step 2
(NG)
2 Check if the ENGINE CONTROL lamp or SERVICE ENGINE Flicker Step 3 See
SOON lamp flickers. (OK) "Sec.3
1. Turn the starter switch on. Check
(At this time, do not start the engine.) SERVIC
2. Connect the diagnostic switch (connector). E
Does the ENGINE CONTROL lamp or SERVICE ENGINE SOON ENGINE
lamp flicker? SOON
lamp
flicker
circuit
system",
and after
repair and
check,
step 3
(NG)
5-3
Engine stall (2/3)

3 Check the diagnostic trouble code. Diagnostic trouble code is See Step 4
1. Connect the Tech II. detected "Sec.4
2. Turn the starter switch on. Check
3. Check the diagnostic trouble code. by
Is the diagnostic trouble code detected? trouble
code"
and after
repair
and
check,
step 4
4 Start the engine. Engine starts Step 5 See
Does the engine start? (OK) "Sec.3
Check
engine
starting
system"
and after
repair
and
check,
step 5
(NG)
5 Check the fuel system. - Step 17 See
1. Perform "check fuel system", and repair or replace if faulty. (OK) "Sec.3
2. Start the engine, and run the vehicle to check for trouble. Check
Has the engine trouble been fixed? fuel
system"
and after
repair
and
check,
step 6
(NG)
1. Perform "check intake system", and repair or replace if faulty. (OK) "Sec.3
Has the engine trouble been fixed? intake
system"
and after
repair
and
check,
step 7
(NG)
7 Check the ACG. - Step 9 Step 8
Check if the charge warning lamp in the meter lights up during the (OK) (NG)
engine running.
Is the charge warning lamp OFF?
5-4
Engine stall (3/3)

8 Replace the ACG. Also, check the charge warning lamp system, and - Step 9 -
9 Check retrofit electrical parts such as radio equipment and line-stop - Step 10 Step 11
alarm lamp display for condition.
Does the engine stall when retrofit electrical parts turn off?
10 Reinstall electrical parts, or remove them. - Step 11 -
Does the engine stall?
12 Return the Engine Control Unit to the home position. - Step 13 -
13 Check the supply pump (feed pump). - Step 15 Step 14
1. Operate the priming pump through the air bleeding procedure, (OK) (NG)
and check if the fuel is forcibly fed to the fuel filter.
Is the fuel fed forcibly to the fuel filter?
14 Replace the supply pump (feed pump). - Step 15 -
15 Check the engine mechanical parts, and repair if faulty. - Step 16 -
Valve system
Injection nozzles
Compression pressure
Timing gears
Pistons and crank related parts
16
Check the chassis related parts (clutch, transmission, etc.) and repair - Step 17 -
5
if faulty.
17 Restore the vehicle, and perform repair check. - Check -
end
5-5
Engine hunting, rough idle (1/4)
Possible causes
• Faulty switch (reverse, neutral) input circuit system (switches, harnesses, etc.)
• Faulty sensor (NE, G, fuel pressure) input circuit system (sensors, harnesses, etc.)
• Faulty accelerator sensor, all speed accelerator sensor system (sensors, harnesses, etc.)
• Faulty engine (mechanical troubles of supply pump, flywheel, injectors, common rail, etc.)
• System backup due to troubles (fail-safe)
Diagnostic help
if faulty.

1 Check the fuel. - Step 24 Step 2
1. Replace fuel in the fuel tank and piping. (OK) (NG)
2. Start the engine, and run the vehicle to check for trouble.
Has the engine hunting trouble been fixed?
2 Bleed the air from the fuel, and check again if the trouble recurs. - Step 24 Step 3
Has the engine hunting trouble been fixed? (OK) (NG)
3 Check the intake system. - Step 24 No: See
Has the engine hunting trouble been fixed? intake
system"
and after
repair
and
check,
step 4
(NG)
Has the engine hunting trouble been fixed? fuel
system"
and after
repair
and
check,
step 5
(NG)
5-6

alarm lamp display for condition. (OK) (NG)
Does the engine hunting when retrofit electrical parts turn off?
7 Check retrofit electrical parts such as additional lamps (triple tail - Step 9 Step 8
lamps) for condition. (OK) (NG)
Is harness normal (no shortcircuit), or is the ground wire connected
to the frame properly?
8 Reinstall retrofit electrical parts such as additional lamps (triple tail - Step 9 -
lamps) for condition.
9 Is the engine type 6W family? - Step 10 Step 12
10 Check the reverse switch input circuit. ON ↔ OFF indication on Step 12 Step 11
1. Connect the Tech II. the screen is changed over (OK) (NG)
2. Shift the gear to the neutral position. by switch operation
4. Using the Tech II, check the switch inputs.
5. Shift the gear to the reverse position.
6.Check if the ON/OFF indication on the Tech II screen is changed
11 Referring to the reverse switch circuit (Chapter 6 Wiring check - Step 12 -
"reverse circuit"), repair or replace the circuit.
12 Check the neutral switch input circuit. ON ↔ OFF indication on Step 14 Step 13
2. Shift the gear to the neutral position.
the screen is changed over (OK)
by switch operation
(NG)
5
5. Shift the gear to without neutral position.
6. Check if the ON/OFF indication on the Tech II screen is
changed over by the switch operation.
13 Referring to the neutral switch circuit (Section 6 Wiring check - Step 14 -
"neutral circuit"), repair or replace the circuit.
14 Check the NE sensor and G sensor. - Step 16 Step 15
Check the NE sensor and G sensor for play or loose connection. (OK) (NG)
Are sensors installed normally?
15 Reinstall the NE sensor and G sensor. - Step 16 -
16 Check the NE sensor for signal detection. - Step 24 Step 17
2. Disconnect the harness from the NE sensor.
(For this work, the diagnostic trouble code is detected, and thus be
sure to clear the trouble code after restoring the vehicle.)
5-7

17 Check the flywheel and NE sensor, and repair or replace if they are - Step 18 -
damaged, rust, or dirty.
18 Check the accelerator sensor for signal detection. - Step 19 Sec.4
Referring to the diagnostic trouble code "24", check the accelerator "Check
sensor. by
Did corrective actions complete? diagnostic
trouble
code",
and after
repair
and
check,
step 19
19 Check the external accelerator (all speed accelerator sensor) for - Step 20 -
signal detection.
Referring to the "external accelerator check", check the accelerator
sensor.
20 Check the common rail system. - Step 24 Step 21
1. Referring to the diagnostic trouble codes "14, 15" (checking (OK) (NG)
engine timing sensors), "271 - 276" (checking injector related
parts), and "115, 118, 151, 245, 226, 227" (checking common
rail fuel pressure related parts and supply pump), perform
checking, and repair or replace if faulty.
2. Start the engine, and check for trouble.
3. Start the engine and check for trouble.
⋅ Valve system (valve clearance, etc.)
⋅ Compression pressure
⋅ Mechanical timing
end
5-8
Lack output power of engine, insufficient blow up,
pulsating combustion
Possible causes
• Faulty exhaust system (exhaust brake, faulty exhaust piping, etc.)
• Faulty. EGR
• Faulty PTO
• Faulty engine (mechanical troubles of compress pressure, valve clearance, turbo charger , EGR, supply
pump, injectors, common rail, etc.)
• Switch (exhaust brake) faulty input circuit system (switch, harness)
Diagnostic help
if faulty.

1 Check the fuel. - Step 28 Step 2
1. Replace fuel in the fuel tank and piping. (OK) (NG)
2. Start the engine, and run the vehicle to check for trouble.
5
Has the engine hunting trouble been fixed? intake
system"
and after
repair
and
check,
step 3
(NG)
Has the engine hunting trouble been fixed? fuel
system"
and after
repair
and
check,
step 4
(NG)
5-9
Lack output power of engine, insufficient blow up, pulsating combustion

4 Check the supply pump (feed pump). - Step 6 Step 5
1. Operate the priming pump through the air bleeding procedure, (OK) (NG)
and check if the fuel is forcibly fed to the fuel filter.
Is the fuel fed forcibly to the fuel filter?
5 Replace the supply pump (feed pump). - Step 6 -
1. Perform "check exhaust system", and repair or replace if faulty. (OK) "Sec.3
Has the engine hunting trouble been fixed? exhaust
system"
and after
repair
and
check,
step 7
(NG)
7 Check the exhaust pipe for clogging or squeezing. - Step 9 Step 8
Is the exhaust pipe normal? (OK) (NG)
8 Repair or replace the exhaust pipe. - Step 9 -
9 Is the engine type 6W or 6S family? - Step 10 Step 14
10 Check the boost sensor. - Step 11 Sec.4
Referring to the diagnostic trouble code "32", perform checking, and "Check
repair or replace if faulty. by
trouble
code",
and after
repair
and
check,
step 11
11 Check if there are squeezed portions or holes in the intercooler - Step 13 Step 12
(visual check). (OK) (NG)
Is the intercooler normal?
12 Repair or replace the intercooler. - Step 13 -
13 Referring to the boost cut signal circuit (Chapter 6 Wiring check - Step 14 -
"simple fuel economy/simple deadweight control unit communication
circuit), check the circuit (particularly for short with other circuit
(power system: VB, 5V system)) and repair or replace if faulty.
14 Check the accelerator pedal for full stroke position. Clearance: 1 - 2 mm Step 16 Step 15
With the starter switch in OFF position, check if the clearance to the (OK) (NG)
floor stopper bolt is proper when the accelerator pedal is depressed
fully.
Is the clearance to the floor stopper bolt proper?
5-10

15 Adjust the floor stopper bolt. - Step 16 -
16 Execute the accelerator learning. - Step 17 -
17 Check the single parts performance of accelerator sensor. - Step 18 Sec.4
Referring to the diagnostic trouble code "24", perform the checking "Check
accelerator, and repair or replace if faulty. by
trouble
code",
and after
repair
and
check,
step 18
alarm lamp display for condition.
Does the engine hunting trouble been fixed when retrofit electrical
parts turn off?
20 Check the vehicle speed sensor system of vehicle speed sensor and - Step 21 Sec.4
pulse matching device, etc. "Check
Referring to the diagnostic trouble code "25", perform the checking by
vehicle speed sensor, and repair or replace if faulty. diagnostic
Did corrective actions complete? trouble
code",
and after
5
repair
and
check,
step 21
21 Check the PTO. - Step 28 See
1. Perform "check PTO", and repair or replace if faulty. (OK) "Sec.3
Has the engine hunting trouble been fixed? PTO"
and after
repair
and
check,
step 22
(NG)
5-11

23 Check the ERG. - Step 28 See
1. Perform "check ERG", and repair or replace if faulty. (OK) "Sec.3
Has the engine hunting trouble been fixed? ERG"
and after
repair
and
check,
step 24
(NG)
Has the white smoke (large) trouble been fixed?
⋅ Valve system (valve clearance. etc,)
⋅ Turbo charger (6S, 6S engine)
27 Check the chassis related parts and repair if faulty. - Step 28 -
⋅ Clutch
⋅ Transmission
⋅ Brake related. etc,
end
5-12
White smoke (Large)
Possible causes
• Fuel quality (use of other than standard product)
• Air mixing in fuel system
• Faulty water temperature sensor, fuel temperature sensor, atmospheric temperature sensor, or boost sensor
• Faulty air breather pipe (clogging)
• Engine troubles (low compression pressure, pistons, turbocharger, oil coming up or down, etc.)
Diagnostic help
if faulty.


1 Check the fuel. - Step 12 See
Has the white smoke (large) trouble been fixed? fuel
system"
and after
repair
and
check,
2 Check the water temperature sensor. - Step 3

step 2
(NG)
Sec.4
5
Referring to the diagnostic trouble code "23", perform the checking, "Check
and repair or replace if faulty. by
trouble
code",
and after
repair
and
check,
step 3
5-13
White smoke (Large)

3 Check the fuel temperature sensor. - Step 4 Sec.4
Referring to the diagnostic trouble code "211", perform the "Check
checking, and repair or replace if faulty. by
trouble
code",
and after
repair
and
check,
step 4
4 Check the atmospheric temperature sensor. - Step 5 Sec.4
trouble
code",
and after
repair
and
check,
step 5
trouble
code",
and after
repair
and
check,
step 7
7 Check the atmospheric pressure sensor. - Step 8 Sec.4
trouble
code",
and after
repair
and
check,
step 8
5-14
White smoke (Large)

Has the white smoke (large) trouble been fixed?
⋅ Piston system (ring abrasion)
⋅ Faulty air breather pipe (clogging)
⋅ Oil coming up or down, etc.
11 Check the engine mechanical parts, and repair if faulty. - Step 12
⋅ Piston system (ring abrasion)
⋅ Faulty air breather pipe (clogging)
⋅ Oil coming up or down, etc.
end
5-15
Black smoke (large)
Possible causes
• Fuel quality (use of other than standard product)
• Faulty exhaust system (exhaust brake, faulty exhaust piping, etc.)
• Faulty. EGR
• Engine troubles (valve clearance, turbocharger, oil coming up, etc.)
• Faulty boost sensor, neutral switch input circuit system (sensors, switches, harnesses, etc.)
• Engine oil deterioration
Diagnostic help
if faulty.

Has the black smoke (large) trouble been fixed? intake
system"
and after
repair
and
check,
step 2
(NG)
2 Check the engine oil. - Step 15 After
1. Replace the engine oil and oil filter. (OK) replace
2. Start the engine, and run the vehicle to check for trouble. the
Has the black smoke (large) trouble been fixed? engine
oil step 3
(NG)
Has the black smoke (large) trouble been fixed? fuel
system"
and after
repair
and
check,
step 4
(NG)
5-16
Black smoke (large)

4 Check the ERG. - Step 15 See
1. Perform "check ERG", and repair or replace if faulty. (OK) "Sec.3
Has the black smoke (large) trouble been fixed? ERG"
and after
repair
and
check,
step 24
(NG)
Has the black smoke (large) trouble been fixed? fuel
system"
and after
repair
and
check,
step 7
(NG)
trouble
code",
5
and after
repair
and
check,
step 8
8 Check the neutral switch input circuit. ON ↔ OFF indication on Step 10 Step 9
1. Connect the Tech II. the screen is changed over (OK) (NG)
2. Shift the gear to the neutral position. by switch operation
5. Shift the gear to without neutral position.
6. Check if the ON/OFF indication on the Tech II screen is
changed over by the switch operation.
9 Referring to the neutral switch circuit (Chapter 6 Wiring check - Step 10 -
"neutral circuit"), repair or replace the circuit.
5-17
Black smoke (large)
Steps Checking and Corrective Actions Result YES YES

Has the black smoke (large) trouble been fixed?
Valve system (valve clearance. etc,)
Has the black smoke (large) trouble been fixed?
Compression pressure
Turbo charger (6S, 6S engine)
end
5-18
Chapter 6
Wiring check
6
Chapter 6 Wiring check
1. Preface
Identification of wires
Since wires of a large number of circuits are bound in a wiring harness, circuits are identified by colors and
patterns of the wires to facilitate correct wiring. The alphabet in the table below indicates abbreviations of
the identification and used also in the wiring diagram.
Refer to the table below for the abbreviations indicating wire colors.
Symbol B W R G Lg Y L O Br Sb P V Gy
Color of Black White Red green Light Yellow Blue Orange Brown Light Pink Violet Gray
wire green blue
Black, the base cover, is used for the earth circuit. e.g.: 3BW
B base color
W trace color
3 sizes
Wiring specifications
Wiring size is respectively determined according to the load to be applied to it. Size and allowable load
stipulated by the JIS standard are shown in the table below. When installing optional parts or units, select
wiring size based on the load. Never connect a power source or GND of different units to the IE system or
other electric systems.
Table of wiring harness size

Sectional area Outside dia. Allowable current
Nominal size
(mm ) 2
(mm) (ampere)
0.3 0.372 1.8 9
0.5 0.563 2.0 12
0.85 0.849 2.2 15
1.25 1.287 2.5 21
2 2.091 2.9 27
3 3.291 3.6 37
5 5.228 4.4 50
8 7.952 5.5 66
15 13.36 7.0 92
20 20.61 8.2 121
6-2
Preface
Fuse
A fuse is usually installed in series to the automobile circuit to be protected.
It is designed so that, if over-current flows to the circuit due to short-circuit or some other reason, the fuse
melts to shut off the current in the circuit and protect the units in the circuit. Before replacing the fuse, be
sure to find out the cause of the fuse blown out and use a fuse of the same amperage as the former one.
If a fuse of different amperage is used, fire or other significant troubles may result.
Normal Fuse blown out Specifications
15 15
Capacity (A) Color of housing
7.5 Transparent brown
10 Transparent red
15 Transparent blue
20 Transparent yellow
Relay
Battery, electrical parts and their control switches are usually forced to be positioned separately at a certain
distance. For this reason, long wires are required and voltage drop takes place (example 1 in the figure
below). Using a relay between the battery and electric load, the voltage drop can be avoided (example 2 in
the figure below). The switch controls the relay only so that the current through the switch can be reduced
and the switch can be more compact.
Load Load
1
2
Relay 6
6-3
Preface
Handling of connectors and harness
(1) Pulling out the connector

1. Pull out the connector after releasing the lock, if any.
In the left figure:
1 Pull up the lock to unlock.
1 2 Push in the lock to unlock.
2
2. Hold the connector and housing positively with both

hands, pull them to separate.
OK 3. Do not hold or pull the wire at this time.
NG
(2) Inserting the connector

1. Hold the both halves of the connector housing securely
and insert them into each other.
2. Make sure of the connector installing direction, align
NG
pins and insert fully.
3. When lock is provided, make sure the connector is
securely locked. (Snapping sound indicates that the
connector is fully locked).
* If no sound is heard, reconnect the connector again.
OK
6-4
Preface
(3) Inspection of connector

1. Check the continuity of the connectors with a circuit
OK
tester. Insert the lead rod of the circuit tester from the
harness side of the connector as shown in the left
figure.
Lead rod
2. Never insert the lead rod from the connector

connecting port since the connector pin is damaged.
Lead rod
4) Water-proof type connector

inspection procedure
In case of water-proof type connectors, the lead rod of the
1 circuit tester cannot be inserted from the wiring side for the
reason of structure.
6
Connect a connector 1 for test use prepared beforehand to
the connector 2 as shown in the left figure, connect the
2 lead rod of the circuit tester to the harness of the testing
connector and check for continuity.
Lead rod
6-5
Preface
5 Removing the connector terminal

- Lock incorporating type
1. Insert some slender metal rod such as a driver into the
Slender metal rod Lock connector opening as shown in the left figure.
2. Push up the lock with the metal rod in the arrow mark
direction and unlock. At this condition, pull out the
harness together with the pin.
Terminal
Connector housing Harness
opening
Pin lock type

1. Insert the metal rod into the connector opening.
Slender metal rod 2. Push the pin lock against the harness side and remove
Lock Harness
and pull out the harness together with the pin.
Pin
Connector housing
opening
(6) Installing the connector pin

1. Make sure that the lock of the pin is fully up and can
be locked.
Lock Harness
2. Inset the pin from the harness side of the connector and
push the lock pin until it clicks and locks.
3. Pull the wiring harness lightly to check that the pin is
fully locked in the connector.
Pin
6-6
Preface
(7) Applying the circuit tester
OK
When checking the continuity using a circuit tester, be sure
to apply the lead rod of the circuit tester from the harness
side (in case of a female pin only).
* Never apply the lead rod to the pin side.

Secondary fault may be caused.
Lead rod
Lead rod In case of a water-proof connector, preparing the connector

for test use beforehand will help you.
(8) Replacing the fuse

When the fuse melts, be sure to use a new one of the same
30A 60A capacity.
If a fuse of large capacity is used, the fuse does not
function as desired when over-current flows. As a result,
parts, wires, etc. may be burnt and a fire may break out in
the car.
10
15
D08HW074
(9) Handling of parts

Handle the electrical parts with sufficient care not to drop
or throw to avoid their damage.
6
D08RV704
6-7
; ;
Preface
(10) Cable harness

1. When installing electrical parts, take care not to bite
the harness somewhere and do not push in the parts
forcibly.
2. Allow all contact parts to be in proper and positive
contact with the mating surface.
3. If the harness is in contact with a sharp edge or surface
of other parts, protect the harness with grommet or
tube to avoid damage resulting from contact.
NG
OK
4. When routing the wire avoiding other parts, provide

NG sufficient allowance to the harness and prevent the
wires from coming in direct contact with parts nearby
using a protection tube or clip.
Vinyl tube
OK
Clip
6-8
Preface
5. Use a wiring of enough length between the engine and

chassis to prevent wear off or other damage due to
vibration.
NG
OK
6-9
2. Vehicle wiring harness
Vehicle equipped with 6S or 6T engine Vehicle equipped with 6S or 6T engine

(model C**) (model E**)
Instrument (upper) Instrument (upper)

harness harness
Instrument(lower) Instrument (lower) Member harness
harness Member harness (right)
harness
Member
harness (left)
To engine To engine
Frame harness Frame harness

Connector box Connector box
ECU harness ECU harness

Engine control unit Engine control unit
Vehicle equipped with 6S or 6T engine

(model C** E**)
Instrument (upper)
harness
Instrument (lower)
harness Member
harness
To engine
Frame harness
Connector box
ECU harness Engine control unit
Note: Wires are connected with the sensors, switches or control units through multiple harnesses. Refer
to "Collection of GIGA wiring diagrams" for details.
6-10
3. Wiring check
Engine control unit power source, GND circuit

CASE GND POWER GND

40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
VW 1.25 RW 1.25
B 1.25
Y 0.5
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18 19 20 21
1 2 3 4 5 6 7 8
19 20 B 1.25
9 10 11 12 13 14 15 16 17 18
22 23 24 25 26 27 28 29 30 31 32
LR 0.5 B 1.25
B 1.25
25
FUSE 20
1 2 3 4 5 6 7 8 9 10 11
3
12 13 14 15 16 17 18 19 20 21 22
5 1
4 2
9 8 7 6 5 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10
MAIN RELAY 32 31 30 29 28 27 26 25 24 23 22
ECU HARNESS SIDE

RW 1.25
1
25
LR 0.5
2 4
B2
3
Y 0.5
FUSE 45
O 1.25
8 7 6 5 4 3 2 1
10 9 8 7 6 5 4 3 2 1 20 19
18 17 16 15 14 13 12 11 10 9
20 19 18 17 16 15 14 13 12 11
1 2 3 4 5 6 7
8 9 10 11 12 13 14 B 1.25
15 16 17 18 19 20
21 22 23 24 B 1.25
29 30 31 32 1 2 3 4 5 6 7 8 9 10 11
33 34 35 36
37 38 39 40 41 42 12 13 14 15 16 17 18 19 20 21 22
43 44 45 46 47 48 49
50 51 52 53 54 55 56
46
JOINT CONNECTOR (2)
INSTRUMENT (LOWER) HARNESS 6

7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
14 13 12 11 10 9 8
20 19 18 17 16 15 2221201918 17 16 1514131211
24 23 22 21
28 27 26 25
B2
32 31 30 29
36 35 34 33
42 41 40 39 38 37
49 48 47 46 45 44 43
56 55 54 53 52 51 50
1 2 3 4 5 6 7 8 9 10
46 111213141516 17 1819202122
BL 2 B2
FRAME HARNESS SIDE
6-11
Wiring check
NE, G and fuel pressure sensor circuit

40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
Gy 0.5


1 2 3 4 4 3 2 1 Gy 0.5
B 0.5 5 6 7 8 SWP 8 7 6 5
9 10 11 12 (GRAY) 12 11 10 9 B 0.5
(GRAY)
WL 0.5 W 0.5
OL 0.5 G 0.5
W 0.5 R 0.5
B 0.5 O 0.5
NE SENSOR (SHEILD)
NE SENSOR
NE SENSOR (—)
1 2 NE SENSOR (+)
Y 0.5 W 0.5
Br 0.5 B 0.5
4 3 2 1 1 2 3 4
GyR 0.5
8 7 6 5 SWP 5 6 7 8
12 11 10 9 (GRAY) 9 10 11 12
G 0.5
B 0.5
G SENSOR R 0.5
1 2
G SENSOR (SHEILD)
P 0.5
G SENSOR (—)
L 0.5
ECU HARNESS
6-12
Wiring check
Boost, all speed accelerator sensor circuit
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
BOOST, ALL SPEED

ACCEL SENSOR (GND)
4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8
12 11 10 9 9 10 11 12
B 0.5 16 15 14 13 13 14 15 16
GyB 0.5
B 0.5
B 0.5
B 0.5
W 0.5
B 0.5
R 0.5
6SD1 ENGINE
BOOST SENSOR
EJ MARK ECU HARNESS
123
(BLACK)
R 0.5
B 0.5
W 0.5
ENGINE HARNESS
6-13
Wiring check
Accelerator sensor and accelerator switch circuit


L 0.5
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
VW 1.25
Y 0.5
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
VW 0.5 21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
Gy 0.5
R 0.5
VW 1.25 W 0.5
FUSE 20
VW 1.25 LO 0.5
1 2 3 4 5 6 7 8 9 9 8 7 6 5 4 3 2 1
SDL
10 11 12 13 14 15 16 17 18 19 20 21 21 20 19 18 17 16 15 14 13 12 11 10
32 31 30 29 28 27 26 25 24 23 22
22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8
19 20
9 10 11 12 13 14 15 16 17 18
GyG 0.5
L 0.5
LO 0.5
Y 0.5
ECU HARNESS
1
2 8 7 6 5 4 3 2 1
20 19
18 17 16 15 14 13 12 11 10 9
ACCELERATOR SWITCH
FUSE 11
Y 0.5
Y 0.5
G 0.5
L 0.5
L 0.5 5V Main
G 0.5 Ground Main
1 2 SDL 2 1
3 4 5 6 (WHITE) 6 5 4 3
R 0.5 5V sub Main

ACCELERATOR SENSOR
6-14
Wiring check
Water temperature, fuel temperature and atmospheric temperature sensor circuit

2 1 1 2
FUEL TEMP. (WHITE)
SENSOR LB 0.5
L 0.85
LR 0.5
L 0.85

40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 YB 0.5 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
LW 0.5
LB 0.5
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21
(BLACK)
YB 0.5
10 9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 10
111213141516 17 1819202122
2221201918 17 16 1514131211
LB 0.5
LB 0.5 YB 0.5
14 ECU HARNESS
.WATER TEMP.
14 THERMISTOR
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
41 42 43 44 SMJ 44 43 42 41 RV
(GRAY) 1 2 3 (BLUE) 2
48 47 46 45
45 46 47 48
3
LB 0.5
60 59 58 57 56 55 54 53 52 51 50 49
YV 0.5
49 50 51 52 53 54 55 56 57 58 59 60
72 71 70 69 68 67 66 65 64 63 62 61
61 62 63 64 65 66 67 68 69 70 71 72
LW 0.5
73 74 75 76 77 78 79 80 81 82 83 84 84 83 82 81 80 79 78 77 76 75 74 73
ENGINE CONTROL
THERMISTOR
FRAME (Ft) HARNESS
6
19
1 2 3 4 5 6 7
7 6 5 4 3 2 1
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 1 2 3 4 5 6 7 8
21 22 23 24
24 23 22 21 9 10 11 12 13 14 15 16 17
25 26 27 28
SMJ 28 27 26 25
(WHITE) YV 0.5
29 30 31 32
32 31 30 29
33
37
34
38 39 40
35
41
36
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
FACIA HARNESS
LW 0.5
EJ MARK
(BLACK)
3 2 1 1
SMP 1 2 3
6 5 4 1 2
(GRAY) 4 5 6
2
LB 0.5

SENSOR (MAIN)
6-15
Wiring check
PCV (pump control valve), PCV relay circuit
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
VW 1.25
PCV1 (SIG) VW 0.5
BrB 1.25
BrB 1.25
Br 1.25
KEY SW [ON] SIG
PCV2 PCV1 Br 1.25
4 3 2 1 1 2 3 4
8 7 6 5 5 6 7 8
12 11 10 9
SWP 9 10 11 12 PCV2 (SIG)
1 2 1 2 16 15 14 13 (GRAY) 13 14 15 16
RW 1.25
WL 1.25 WL 1.25
1 2 3 4 4 3 2 1
5 6 7 8 SWP 8 7 6 5
9 10 11 12 (GRAY) 12 11 10 9
RB 1.25
WL 1.25
ENGINE HARNESS
3
PCV RELAY
5 1
4 2
1
P 0.3 2 3 4 B 0.3
5
O 1.25
8 7 6 5 4 3 2 1 SDL 1 2 3 4 5 6 7 8
20 19 19 20
FUSE 45 18 17 16 15 14 13 12 11 10 9 (WHITE) 9 10 11 12 13 14 15 16 17 18
O 1.25
B 1.25 G 1.25 G 1.25
1 2 3 4
FUSE 20
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21
32 31 30 29 28 27 26 25 24 23 22 (BLACK) 22 23 24 25 26 27 28 29 30 31 32
VW 0.5

FUSE 17 VW 1.25
1 2 3 4 5 6 7 7 6 5 4 3 2 1
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
21 22 23 24 24 23 22 21
25 26 27 28 28 27 26 25
SMJ B8
29 30 31 32 (WHITE) 32 31 30 29
33 34 35 36 36 35 34 33
37 38 39 40 41 42 42 41 40 39 38 37 BL 5
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
FRAME GND
B2
ACG E TERMINAL
FRAME (Ft) HARNESS
6-16
Wiring check
Injector (TWV) circuit (6SD1 engine)

L 1.25 GR 1.25
L 1.25 GR 1.25
LW 1.25 GW 1.25
LW 1.25 GW 1.25
LR 1.25 G 1.25
LR 1.25 G 1.25
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100 RY 1.25
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110 RY 1.25
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120

1 2
(CYLINDER #4)
RL 1.25
RL 1.25
R 0.85
G 0.85 B 1.25
INJECTOR NO. 4 1 2
(CYLINDER #6)
Y 0.85
L 0.85
4 3 2 1
SWP 1 2 3 4
8 7 6 5 (GRAY) 5 6 7 8
12 11 10 9 9 10 11 12
W 0.85
B 0.85
Y 0.85
B 0.85 L 0.85
4 3 2 1 1 2 3 4
W 0.85
8 7 6 5 5 6 7 8 B 0.5
SWP
12 11 10 9 9 10 11 12
16 15 14 13 (GRAY) 13 14 15 16
B 0.5
G 0.85
B 1.25
R 0.85
B 0.5

1 2 B 0.85
(CYLINDER #2)
L 0.85
R 0.85 Y 0.85
G 0.85 1 2 3 4
SWP 4 3 2 1
5 6 7 8 (GRAY) 8 7 6 5
9 10 11 12 12 11 10 9
INJECTOR NO. 3 1 2
(CYLINDER #3)
Y 0.85
L 0.85
6
Gy 0.5
Gy 0.5
INJECTOR NO. 1 1 2
B 0.85
W 0.85 1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22
ENGINE HARNESS
JOINT CONNECTOR (1)
ECU HARNESS
6-17
Wiring check
Magnetic valve, magnetic valve fail safe relay circuit (C∗∗ 23 model vehicle)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
PL 0.5
Sb 0.5
YBr 0.5
YG 0.5
YV 0.5
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
10 11 12 13 14 15 16 17 18 19 20 21
SDL
21 20 19 18 17 16 15 14 13 12 11 10
(BLACK)
22 23 24 25 26 27 28 29 30 31 32 32 31 30 29 28 27 26 25 24 23 22
3
5 1
4 2
FUSE 19 1
2 4
Sb 0.5 ECU HARESS
3
4 4
1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1
19 20 20 19
9 10 11 12 13 14 15 16 17 18 18 17 16 15 14 13 12 11 10 9
11 12
12 YBr 0.5 11
YV 0.5
YG 0.5
10 9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 10
111213141516 17 1819202122 2221201918 17 16 1514131211
VGS1 MAGNETIC VALVE

Z TYPE
YG 0.5 PL 0.5
1 2
VGS2 MAGNETIC VALVE

Z TYPE
YV 0.5 PL 0.5
1 2
VGS3 MAGNETIC VALVE

Z TYPE
YBr 0.5 PL 0.5
1 2
FRAME (Ft) HARNESS
6-18
Wiring check
Vehicle speed sensor circuit (Except ECOGIT vehicle)
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 VEHICLE SPEED SENSOR (SIG)
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21 (FROM PULSE MATCHING DEVICE)
(BLACK)
32 31 30 29 28 27 26 25 24 23 22 22 23 24 25 26 27 28 29 30 31 32
PL 0.5
ECU HARNESS
Y 0.5 PL 0.5
4 3 2 1 12 PIN
12 1110 9 8 7 6 5
W 0.5
B 0.5
VEHICLE SPEED SENSOR POWER

1 2 3 4 5 6 7 7 6 5 4 3 2 1
8 9 10 11 12 13 14 14 13 12 11 10 9 8 VEHICLE SPEED SENSOR SIG
15 16 17 18 19 20 20 19 18 17 16 15
21 22 23 24 24 23 22 21
25 26 27 28 28 27 26 25 VEHICLE SPEED SENSOR GND
SMJ Y 0.5
(WHITE) 1 2 3
29 30 31 32 32 31 30 29
W 0.5
33 34 35 36 36 35 34 33
37 38 39 40 41 42 42 41 40 39 38 37
B 0.5
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
INSTRUMENT (LOWER) HARNESS FRAME (Ft) HARNESS
6-19
Wiring check
Starting circuit (battery relay, key switch, slow blow fuse and fuse circuit)

3
5 1 40 PIN 80 PIN
MAIN RELAY 4 2
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
RW 1.25 21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
1 31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
RL 0.3 2 4
B 0.3
3
BW 0.5
5
Y 0.5
7 7
Y 0.5
1 2 3 4 5 6 7 8 9
MAIN RELAY
9 8 7 6 5 4 3 2 1
SDL
21 20 19 18 17 16 15 14 13 12 11 10
FUSE 45 (BLACK) 10 11 12 13 14 15 16 17 18 19 20 21
RW 1.25 32 31 30 29 28 27 26 25 24 23 22
22 23 24 25 26 27 28 29 30 31 32
ECU HARNESS
BW 0.85
1 2 3 4 5 6 7 7 6 5 4 3 2 1
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
21 22 23 24 24 23 22 21
25 26 27 28 28 27 26 25
SMJ
29 30 31 32
(WHITE) 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
SWP
2 1
(BLACK) 1 2
6-20
Wiring check
Meter circuit (SERVICE ENGINE SOON lamp, tachometer output)

40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
12
RB 0.5
9 8 7 6 5 4 3 2 1 SDL 1 2 3 4 5 6 7 8 9
21 20 19 18 17 16 15 14 13 12 11 10 (BLACK) 10 11 12 13 14 15 16 17 18 19 20 21
TACHOMETER(SIG)OUTPUT
32 31 30 29 28 27 26 25 24 23 22
22 23 24 25 26 27 28 29 30 31 32
27
RB 0.5
Brw 0.5
BrW 0.5 SERVICE ENGINE SOON LAMP(SIG)
6 ECU HARNESS
6
16
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
16 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 38
39 37
41 42 43 44
SMJ 44 43 42 41
(WHITE)
48 47 46 45
45 46 47 48
60 59 58 57 56 55 54 53 52 51 50 49
49 50 51 52 53 54 55 56 57 58 59 60
72 71 70 69 68 67 66 65 64 63 62 61
61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 84 83 82 81 80 79 78 77 76 75 74 73
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16 17
1 2 3 4 5 6 7
8 9 10 11 12 13 14 15
BrW 0.5 YR 0.5
METER CONNECTOR METER CONNECTOR
6-21
Wiring check
Self-diagnosis circuit (diagnosis switch, memory clear switch and Tech II connector circuit)
40 PIN 80 PIN
MEMORY CLEAR SW. RL 0.5
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
DIAGNOSIS SW. 26 25 21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
61 62 63 64 65 66 67 68 69 70
71 72 73 74 75 76 77 78 79 80
101 102 103 104 105 106 107 108 109 110
111 112 113 114 115 116 117 118 119 120
RL 0.5
1 G 0.5
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
SDL
21 20 19 18 17 16 15 14 13 12 11 10 10 11 12 13 14 15 16 17 18 19 20 21
G 0.5 (BLACK)
1 32 31 30 29 28 27 26 25 24 23 22
22 23 24 25 26 27 28 29 30 31 32
LR 0.5 WR 0.5
WR 0.5 LR 0.5
25
JOINT CONNECTOR(2)
13
26
4
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19 20 21 22 8 7 6 5 4 3 2 1 SDL 1 2 3 4 5 6 7 8
20 19 19 20
18 17 16 15 14 13 12 11 10 9 (WHITE) 9 10 11 12 13 14 15 16 17 18
B 1.25
B 1.25
13
ECU HARNESS
TO TECH II, TECH II SIGNAL (TRANSMISSION)
LR 0.5
LC TYPE FROM TECH II, TECH II SIGNAL (RECEIVED)
FUSE 22
(WHITE) V 0.5
10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
WR 0.5
TECH II CONNECTOR
6-22
Wiring check
Neutral circuit (Except automatic transmission vehicles)

40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
11 31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
BG 0.5
9 8 7 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9
SDL
21 20 19 18 17 16 15 14 13 12 11 10 10 11 12 13 14 15 16 17 18 19 20 21
(BLACK) NEUTRAL SIGNAL
32 31 30 29 28 27 26 25 24 23 22 22 23 24 25 26 27 28 29 30 31 32
11 ECU HARNESS
10 9 8 7 6 5 4 3 2 1
22 21 20 19 18 17 16 15 14 13 12 11
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20 21 22
BG 0.5
NEUTRAL SWITCH
SWP
1 2
(GRAY)
BG 0.5
TRANSMISSION HARNESS
6-23
Wiring check
Clutch switch circuit

40 PIN RG 0.5
80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
10 10
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
SDL 10 11 12 13 14 15 16 17 18 19 20 21
21 20 19 18 17 16 15 14 13 12 11 10
32 31 30 29 28 27 26 25 24 23 22
(BLACK) 22 23 24 25 26 27 28 29 30 31 32
ECU HARNESS
RG 0.5
FUSE 11
1 2
3 4 5
CLUTCH SWITCH
6-24
Wiring check
Brake switch circuit

40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
19
G 0.5
1 2 3 4 5 6 7 8 9
19
9 8 7 6 5 4 3 2 1
21 20 19 18 17 16 15 14 13 12 11 10
SDL 10 11 12 13 14 15 16 17 18 19 20 21
32 31 30 29 28 27 26 25 24 23 22
(BLACK)
22 23 24 25 26 27 28 29 30 31 32
BRAKE SWITCH 2 (SIG)
ECU HARNESS
BRAKE SWITCH 2
SWP
2 1
(GRAY)
FUSE 27
DIODE
1 2
3 1
5 1 R 1.25 2 3 4 GY 0.3 GY 0.3
1 2
4 2
5
R 1.25
STOP LAMP RELAY
1 2 3 4 5 6 7 7 6 5 4 3 2 1
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
21 22 23 24 24 23 22 21
25 26 27 28 28 27 26 25
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
G 0.85 48
1 2 3 4 4 3 2 1
6
5 6 7 8 8 7 6 5
9 10 11 12 12 11 10 9
G 0.85
G 0.85
3 2 1 3 2 1
6 5 4 6 5 4
9 8 7 9 8 7
REAR COMB LAMP
6-25
Wiring check
Reverse circuit
40 PIN 80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
RL 0.5
REVERSE SWITCH (SIG)

1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
SDL 10 11 12 13 14 15 16 17 18 19 20 21
21 20 19 18 17 16 15 14 13 12 11 10
32 31 30 29 28 27 26 25 24 23 22
(BLACK)
22 23 24 25 26 27 28 29 30 31 32
22 22
ECU HARESS
FUSE 12
Br 0.85
BASE HARNESS CONNECTOR(B)

1 2 3 4 5 6 7 7 6 5 4 3 2 1
8 9 10 11 12 13 14 14 13 12 11 10 9 8 29
15 16 17 18 19 20 20 19 18 17 16 15
10 9 8 7 6 5 4 3 2 1
SDL 1 2 3 4 5 6 7 8 9 10 21 22
25 26
23 24
27 28
24 23
28 27
22 21
26 25
111213141516 17 1819202122
2221201918 17 16 1514131211
(WHITE) SMJ
29 30 31 32 (WHITE) 32 31 30 29
33 34 35 36 36 35 34 33
RL 0.5 37 38 39 40 41 42 42 41 40 39 38 37
17 17 43 44 45
50 51 52
46
53
47 48 49
54 55 56
49 48 47
56 55 54
46
53
45 44 43
52 51 50
RL 0.5
29
RL 0.85
1 2 3 4 4 3 2 1
5 6 7 8 8 7 6 5
9 10 11 12 12 11 10 9
RL 0.85
1 2
SWP
(GRAY) RL 0.85
BACK LAMP SWITCH
1 2 3 1 2 3
4 5 6 4 5 6
7 8 9 7 8 9
REAR (CMB) REAR (CMB)

LAMP (LH) LAMP (RH)
6-26
Wiring check
Idling control switch and idling control selector switch circuit

40 PIN 80 PIN
PG 0.5
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
PB 0.5
P 0.5
PB 0.5
PB 0.5
P 0.5
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
SDL 10 11 12 13 14 15 16 17 18 19 20 21
21 20 19 18 17 16 15 14 13 12 11 10
(BLACK)
32 31 30 29 28 27 26 25 24 23 22 22 23 24 25 26 27 28 29 30 31 32
ECU HARNESS
PB 0.5
FUSE 11
1 2 3 S TYPE
4 5 6
(WHITE)
6
P 0.5
IDLE CONTROL SW
6-27
Wiring check
Exhaust brake circuit

40 PIN LY 0.5
80 PIN
1 2 3 4 5 6 7 8 9 10 41 42 43 44 45 46 47 48 49 50 81 82 83 84 85 86 87 88 89 90
11 12 13 14 15 16 17 18 19 20 51 52 53 54 55 56 57 58 59 60 91 92 93 94 95 96 97 98 99 100
21 22 23 24 25 26 27 28 29 30 61 62 63 64 65 66 67 68 69 70 101 102 103 104 105 106 107 108 109 110
31 32 33 34 35 36 37 38 39 40 71 72 73 74 75 76 77 78 79 80 111 112 113 114 115 116 117 118 119 120
18 18
CRUISE EXHAUST DRIVE OUTPUT SIGNAL
1 2 3 4 5 6 7 8 9
9 8 7 6 5 4 3 2 1
SDL 10 11 12 13 14 15 16 17 18 19 20 21
21 20 19 18 17 16 15 14 13 12 11 10
32 31 30 29 28 27 26 25 24 23 22
(BLACK) 22 23 24 25 26 27 28 29 30 31 32
LY 0.5
1 2 3 4
1 2 3 4 5 6 7 7 6 5 4 3 2 1
8 9 10 11 12 13 14 14 13 12 11 10 9 8 30
15 16 17 18 19 20 20 19 18 17 16 15
21 22 23 24 24 23 22 21
25 26 27 28
SMJ 28 27 26 25
(WHITE)
FUSE 13 1 29 30
33 34
31 32
35 36
32 31
36 35
30 29
34 33
2 3 4 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
5 50 51 52 53 54 55 56 56 55 54 53 52 51 50
30 46
46
3
5 1
GND EXHAUST BRAKE
4 2
MAGNETIC VALVE
1 2
6-28
Chapter 7
How to use IE system
inspection tools
7
Chapter 7 How to use IE system inspection tools
1. Tech II
Tech II
Tech II is used to check the control unit for each signal reading condition and self-diagnosis condition.
As shown in the figure below, connect the Tech II to the diagnostic connector.
Installing position
Instrument lower harness

3
When inspection cover is removed

1 2
6 Wound with PVC-Y tape 6 White 20-pin connector
8 9 10
12
11
13
7-2
Tech II
Inspecting the switch input

Check each switch for normal input.
Data Display
Check that data values on the Tech II data display are
(C＊, E＊, L＊, F＊) Heavy, Medium Duty changed when switches, levers, etc. are operated.
Engine: (IE) 6SD1 (Common Rail)
Key Switch
Starter Switch
Parking Switch
Idle Control Switch
Idle Up Switch
Idle Down Switch
Brake 2 Switch
Clutch Switch
Neutral Switch
Units DTC Quick More
Switch condition (ON/OFF) is indicated in the area
Snapshot
shown by .
Refer to the next page for items.
7-3
Tech II
Switch input inspection item
Start switch ON/OFF Turns ON when the starter switch is at the "S" position.
Key switch ON/OFF Turned ON when the starter switch is at the "ON" position.
Air low pressure switch ON/OFF Turn ON when the air tank internal switch reduces below 490 kPa (5 kgf/cm2).
Parking switch ON/OFF/ Turns ON when the parking lever is pulled.
Diagnosis switch ON/OFF Turns ON when the diagnosis switch (connector) is connected.
Memory clear switch ON/OFF Turns ON when the memory clear switch (connector) is connected.
Idle UP switch ON/OFF Turns ON when the "UP" side of the idle control switch is pushed.
Idle DOWN switch ON/OFF Turns ON when the "DOWN" side of the idle control switch is pushed.
Idle manual switch MANU/AUTO Changes depending on the idling control switch select switch.
Scroll
MANUAL side: "MANU" is selected.

AUTO side: "AUTO" is selected.
Clutch switch ON/OFF Turns OFF when the clutch pedal is stepped on.
Accelerator switch ON/OFF Turns ON when the accelerator pedal is at the idle position.
Brake switch 2 ON/OFF Turns ON when the brake pedal is stepped on.
Exhaust brake ON/OFF/ Turns ON when the exhaust brake switch (combination switch lever) is
operated.
Neutral switch ON/OFF Turns ON when the N of the shift lever is selected.
Reverse switch ON/OFF/ Turns ON when R of the shift lever is selected.
Exhaust brake operation ON/OFF/ Turns ON when the exhaust brake is operated.
Completion
7-4
Tech II
Special functions
The magnetic valve operating condition and the injection system are inspected by sending the magnetic valve
operating signal from the Tech II to the control unit and operating the control unit forcedly.
(The special functions are inspected by stopping or starting the engine.)
Menu F4: Special function of the menu and press the

F0: Diagnostic Trouble Codes
F1: Data Display ENTER key.
F2: Snap Shot
F3: Programming
F4: Special Functions
F0: Engine Output Controls Items of the Special Functions are displayed.
F0: Exhaust Brake Control Note: After selecting the items, refer to each menu.
F1: Solenoid Valve
F1: Fuel System
F0: Cylinder Power Balance
F1: RPM Control
F2: Pilot Injector Stop
F3: Fuel Pressure Control
F4: Injection Timing
F5: Injection Stop
Fuel Pressure Control • Fuel pressure control

Actual Rail Pressure 50.8 MPa Change the fuel pressure in the common rail and check if
Desired Rail Pressure MPa
the actual pressure follows the set pressure and check for
Desired Rail Pressure MPa leak from the fuel piping when the pressure is increased.
Quit Decrease Increase
Injection Timing
• Injection timing
Main Injection Timing
Basic Injection Timing
5.6 ¡CA
¡CA
Change the fuel injection timing and check the exhaust
gas condition or engine condition.
7
Basic Injection Timing ¡CA
7-5
Tech II
RPM Control • RPM control

Change the idling speed and check if the actual speed
Engine Speed 639 RPM
Desired Idle Speed RPM follows up the set values.
Desired Idle Speed RPM
• Cylinder power balance

Cylinder Power Balance
Inspect the fuel injection condition from the injector by
Engine Speed RPM stopping the injectors in succession for each cylinder.
Desired Idle Speed 550 RPM
For normal injectors, the engine sound is changed when
Injector 1 On the fuel injection is stopped. Select the injectors with
the software key, "Next".
Quit Off Next
Pilot Injector Stop • Pilot injection stop

Inspect the fuel injection control (pilot injection) at the
Amount Of Goal Pilot In mm3
idling speed by stopping the pilot injection.
Pilot Injection On
Quit Off
Injection Stop • Injection stop

Inspect the engine stop control. When the test is carried
Engine Speed RPM
Fuel Rate mm3
out at the start of the engine, the engine stops.
Amount Of Goal Pilot In mm3
Injectors On
Quit Off
7-6
Tech II
• Exhaust brake control

Exhaust Brake Control
Inspect the exhaust brake operating condition while the
engine stops. At this time, the EXH. lamp (on the
installation panel) lights up.
Quit Active
Solenoid Valve
• Solenoid valve
Inspect the operation of the magnetic valves A, B and C
M/V A (VGS) Inactive while the engine stops.
Select the M/V with the software key, "Next".
6SD1 A: VGS B: VGS C: VGS
Quit On Next
Programming
Set up the accelerator learning. Communicate with Tech II and control unit and write the set values into the
control unit.
Menu F3: Programming on the menu and press the ENTER

F0: Diagnostic Trouble Codes
F1: Data Display key.
F2: Snap Shot
F3: Programming
F4: Special Functions
Programming Programming items are displayed.

Note) After electing the following items, refer to each
F0: Upload Fuel Delivery Rate Data
F1: Download Fuel Delivery Rate Data
F2: Accelerator Learning Data
menu.
• Upload Fuel Delivery Rate Data
7
• Download Fuel Delivery Rate Data
• Acceleraror learning Data
7-7
Tech II
Accelerator learning
Have the control unit memorize the idling position and full-throttle position of the accelerator pedal.
This accelerator learning should be carried out always after:
o replacing the control unit
o replacing the accelerator sensor
o Replacing the accelerator bracket assembly.
(Set the starter switch to "ON" and stop the engine during the accelerator learning.)
Programming
A. Menu F2: Accelerator learning Data on the menu and
press the ENTER key.
F2: Accelerator Learning Data
B. Enter the current date and press the software key,

Accelerator Learning Data
"Program".
Engine: (IE) 6SD1 (Common Rail)
Use up/down arrow keys to change value.

Use left/right arrow keys to select field.
Date Setting
01-01-2001
Program Abort
C. Set up the Full-stroke position for the accelerator pedal

Stepping the accelerator pedal all the way through the
Engine: (IE) 6SD1 (Common Rail) stroke and press the software key "Program".
Current Accel Learn Voltage (Full)
Note) Check that there is a gap of 1 - 2mm between the
Current Accel Learn Voltage (Idle) pedal and floor stopper bolt when the pedal is
Press [Program] to Store Voltage (Full) fully stepped on.
Shaded values indicates learning values before

Program Abort
changing. (Full/Idle)
These values can be checked on the data display.
7-8
Tech II

D. Set the idle position of the accelerator pedal.
(C＊, E＊, L＊, F＊) Heavy, Medium Duty Leave the foot from the accelerator pedal and press the
Engine: (IE) 6SD1 (Common Rail) software key, "Program".
Current Accel Learn Voltage (Full)
Shaded values indicates accelerator learning values to
Current Accel Learn Voltage (Idle) be set up
Press [Program] to Store Voltage (Full)
Press [Program] to Store Voltage (Idle)
Program Abort
E. When the "Programming Completed" is indicated, the

accelerator learning has completed.
Engine: (IE) 6SD1 (Common Rail) Check that the learning values set up as described above
are the same as the accelerator position learning value
Programming Completed!
(Full/Idle) in the data display.
Confirm
7-9
Chapter 8
Others
8
O
ECU power source system (including fuse and relay) (416, 421) O
Starter switch
O O
Battery, starter related
O O
Use this chart when repairing damages. (Refer to "Troubleshooting Manual", for details.)
Control system (including wiring harness)
Control unit 33, 35

Vehicle speed sensor 25
G sensor 14 O O
O O
NE (engine rotation) sensor 15
Atmospheric temperature sensor 22
O O
Inspection item chart for IE system condition
Water temperature sensor 23

Boost sensor 32
O O O
O
Fuel pressure sensor 245, 115
O
Accelerator sensor switch 24, 241, 242
O
M/V : D, E 443, 413
M/V :A - C 411, 412, 415
Note: Self-diagnosis codes in ( ) indicate that they may be caused in that item.
Short circuit of injector (+B⋅GND) 158, 159
O O
O
Disconnected wire of injector 271 - 276
O
Disconnected wire or short circuit of PCV 217, 218,
O
(contents of pump) 247, 248
Supply pump excessive pressure feed 151, 118
O O O
O O O O O O O O
O
Supply pump no pressure feed pressure limiter operated 226, 227
(42)
O
Abnormal turbo (including excessively high boost)
Disconnected, leaking or clogged boost sensor hose
Engine mechanical
Clogged or leaking inter cooler
O O
Defective EGR/intake valve
O
O
O
O O
Defective injector (including flow damper operation)
Chapter 8 Others
Clogged air cleaner
O
Clogged fuel clogged fuel hose (226, 227)
( )
O
O
O
O
O
system foreign substance in the fuel tank
fuel filter, (226, 227)
Clogged filter ( )
O
O
O
O
O
pre-filter, etc.
Air mixed (improper air vent, fuel shortage) (226, 227)
O
O
O
DTC
Inspection
item
White smoke large
Pulsating combustion
Black smoke large
Engine hunting
Failure condition
Defective start
Engine stall
8-2
Abbreviation list
Abbreviation
ABDC After Bottom Dead Center GSU Gear Shift Unit
ABS Antilock Brake System GVW, (GVM) Gross Vehicle Weight, (Mass)
AC Alternating Current HC Hydrocarbon
ACC Accessory HID High Intensity Discharge
ACG Alternating Current Generator H-Gear Hypoid Gear
AOH Brake Air Over Hydraulic Brake HSA Hill Start Aide
ACT Air Control Transmission / Actuator HT Hypoid Tandem
API American Petrol Institute HUD Head Up Display
ASM (Assy) Assembly IC Integrated Circuit
ASR Anti Slip Regulator ID Plate Identification Plate
ASSIT Assistant IE System ISUZU Economy System
ATDC After Top Dead Center IGN Ignition
ATF Automatic Transmission Fluid IN Intake, Inlet
A/C Air Conditioner INT/S Intake Shutter
A/T, AT Automatic Transmission / Air Tank ISC Idle Speed Control
A/F Air Fuel Ratio ISO International Standardization Organization
BAT, BATT Battery I/PUMP Injection Pump
BBDC Before Bottom Dead Center JIS Japanese Industrial Standard
BRG, Brg Bearing J/C Joint Connector
BKT, BRKT Bracket K/D Kick Drive
BTDC Before Top Dead Center LCD Liquid Crystal Display
CAN Control Area Network LED Light Emitting Diode
CAS Cab Air Suspension LIM Linesman
CCS Combined Charging System LSD Limited Slip Differential
CLU Change Lever Unit LSPV Load Sensing Proportioning Valve
CNG Compression Natural Gas LT Leading & Trailing
CO Carbon Oxide LTD Limited
CONN Connector L/H, LH Left Hand
CPU Central Processing Unit MPV Multi Protection Valve
C/U Control Unit M/T, MT Manual Transmission
DC Direct Current M/V Magnetic Valve
DD Direct Drive NC Normal Close
DI Direct Injection NE Number of Engine
DLC Data Link Connector NR Noise Reducer
DTC Diagnostic Trouble Code NO Normal Open
D2L Dual Two Leading NOx Nitrogen Oxide
EBS Electronic Brake System N-TDC Number - Top Dead Center
ECU Engine Control Unit / Electronic Control Unit OD Over Drive
ECM Engine Control Module OPT Option
ECS Electronic Control Suspension P Pole(S)
EGR Exhaust Gas Recirculation PCV Pump Control Valve/Positive Crankcase Ventilation
EHT Electrical & Hydraulic Timer PM Particulate Matter
EMI Electro Magnetic Interference POS Position
EVT Electronic Variable Timer PS Pre-Stroke
Exh, EXH Exhaust PTO Power Take Off
Ft, FRT Front PWM Pulse Width Modulation
FWD Forward PWR Power Source
F⋅Ft-Axle Forward Front - Axle P/L Pilot Lamp
F⋅Rr-Axle Forward Rear - Axle P/S Power Steering
F/B Feedback QOS Quick On System
F/C
F/L, FL
Fuel Cut
Fusible Link
Rr, RR
R⋅Ft-Axle
Rear
Rearward Front - Axle
8
GND Ground R⋅Rr-Axle Rearward Rear - Axle
8-3
Abbreviation list
Abbreviation
REF Reference
RET Retarder
RP Rail Pressure
RWD Rearward
R/H, RH Right Hand
R/L Relay
SAE Society of Automotive Engineers
SBF Slow Blow Fuse
S-Gear Spiral Gear
SIG Signal
SLD Shield
SRS Supplemental Restraint System
SSPS Speed Sensing Power Steering
ST Starter / Start
STD Standard
STRG Steering
SW Switch
TCM Transmission Control Module
TICS Timing & Injection rate Control System
TWV Two Way Valve
VGS Turbo Variable Geometry turbocharger System
WOT Wide Open Throttle
W/B, WB Wheel Base
W/L Warning Lamp
2L 2 (Two) Leading
8-4
Programming / Upload / Download Fuel Delivery Rate Data
Upload the Q data (1-3) stored in the ECM to Tech II and download that data from Tech II to ECM.
This process is required in the following cases.
⋅ After replacing the ECM, store the Q data which has been in the former ECM to new ECM.
Programming
⋅ Select "Upload Fuel Delivery Rate Data" in the
menu and press the ENTER key.
Upload Fuel Delivery Rate Data

⋅ Press the software key, Yes .
*1
Engine: (IE) 6S01 (Common Rail)
Do you want Upload data?
No Yes
⋅ Press the software key, Confirm .

Now the uploading has been completed.
*1
Upload Successful
Confirm
⋅ By pressing the EXIT key, the menu is displayed

again
*1
Cycle Ignition, Then Press Exit
8
8-5
Programming
Programming ⋅ Select "Download Fuel Delivery Rate Data" in the

menu and press the ENTER key.
Download Fuel Delivery Rate Data

⋅ Press the software key, Yes .
*1
Engine: (IE) 6S01 (Common Rail)
Do you want Download data?
No Yes
⋅ Now downloading has been completed.

By pressing the software key, Confirm , the menu
*1
is displayed again.
Check that the Q data in the former ECM and that
Programming Completed: in the new ECM are the same with the Fuel Rate
Data of the Data Display.
Confirm
Caution: Programming is possible only when the following conditions are met:
⋅ No DTC is displayed.
⋅ Engine is stop.
⋅ SW21 of Tech II Adapter is on the reception (RXD) side.
(Set the SW21 to the reception side when clearing DTC also.)
8-6
6SD1-WE-0115HK
You are requested to order this manual using the

manual number that is shown above.
This manual is applicable for vehicles in Hong Kong.
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 Dec., 2001

No.6SD1-WE-0115HK

Engine Emission: Workshop Manual

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WORKSHOP MANUAL

International Service & Parts

Chapter 1 Overview of IE system Checking the parking switch . . . . . . . . . . . . 3-46

273 No.3 cylinder injector drive PCV (pump control valve),

Chapter 4 Checking procedure for each diagnostic trouble code

Chapter 6 Wiring check

Chapter 7 How to use IE system inspection tools

1. Overview and specifications of IE system

Electronically controlled fuel

Auxiliary brake-linked function

Electronically controlled fuel injection system (common-rail type)

System schematic diagram

Atmospheric temperature sensor

System control schematic diagram

Engine control unit (ECU)

Accelerator sensor input

Compensation Water temperature sensor input,

ASR demand signal (fuel cut signal)

Fuel pressure sensor

VGS (Variable Geometry Turbo System)

Magnetic valve drive circuit

= Idling control switch

Output of idle position signal to brake intensive control unit

Output of engine rotations to tachometer

External view of engine control unit

Engine control unit input/output list

12 - - - - 57 NE sensor (-) signal (SIG) O O O

16 PTO switch signal (SIG ) Œ Œ Œ 61 Boost sensor signal (SIG) O O -

Pin Engine model

99 Injector 1 (6S, 6W: 1st cylinder, 6T: 1st cylinder) O O O

M/V ; EXB. BRAKE 88 TWV3

DAIG LAMP 89 TWV5

P/L ; RETARDER 108

SIG 53 ATMOSPHERIC TEMP. SENSOR

3. Control unit/sensor/switch installing position

<Right below the steering wheel>

<At the rear of passenger seat>

⋅ Engine control unit

Note: Only control units related with the engine

Clutch Idle control switch

SERVICE ENGINE SOON lamp

CRUISE HSA SRS AIR AUTO

A/T ABS POWER

Cab rear member (6S series)

Engine (6S series)

Fuel temperature sensor Fuel pressure sensor

4. Functions of input/output and vehicle behavior upon failure (influence)

<Self-diagnosis taking place>

Magnetic valve 411, 412,

Terminal Diagnostic trouble

= Accelerator learning procedure

= Accelerator link mechanism

Adjust the floor bolt as illustrated below.

When the accelerator

Q adjustment data No. Timing compensation

Q adjustment value T compe.

Control No. in plant

Diagnostic trouble codes can be checked or erased in the following procedure.

SERVICE ENGINE SOON lamp