GROUP 13E

ELECTRONICALLY
CONTROLLED FUEL SYSTEM

SPECIFICATIONS ............................................................................. 13E-2

STRUCTURE AND OPERATION

1. Overview .................................................................................... 13E-4
2. Electronic Control System .......................................................... 13E-5
3. Electronic Control Unit Connection Diagram .............................. 13E-8

TROUBLESHOOTING
1. Diagnosis Procedure ................................................................ 13E-10
2. Diagnostic Precautions ............................................................ 13E-11
3. Inspections Based on Diagnosis Codes ................................... 13E-12
4. Multi-Use Tester Service Data ................................................... 13E-18
5. Actuator Tests Performed Using Multi-Use Tester..................... 13E-19
6. TDC Check Mode by Multi-Use Tester ....................................... 13E-20
7. Inspections Performed on Electronic Control Unit
Connectors ............................................................................... 13E-20

INSPECTION OF ELECTRICAL EQUIPMENT............................... 13E-22

INSTALLED LOCATIONS OF PARTS ............................................ 13E-28

ELECTRIC CIRCUIT DIAGRAM ..................................................... 13E-32

13E-1
SPECIFICATIONS
Item Specifications
Manufacturer Bosch
Model VP 44
Electronically controlled distribution type
Type
(with built-in pump electronic control unit)
Injection pump
Max. injection pressure
assembly Approx. 100 {1000}
MPa {kgf/cm2}
Timer Hydraulic type
Timer control valve Duty solenoid type
Feed pump Vane type
Engine electronic Manufacturer Bosch
control unit Rated voltage V 12

13E-2
 13E
M E M O

13E-3
STRUCTURE AND OPERATION
1. Overview

The fuel is pressurized by means of the radial plunger high pressure pump. The fuel injection quantity and timing
are precisely controlled electronically through two control units (the engine electronic control unit in the cab and
the pump electronic control unit built into the injection pump).
The engine electronic control unit receives vehicle information from the engine speed sensor, accelerator pedal
position sensor, etc. outside of the injection pump and effects adjustments necessary to make on the engine side.
The pump electronic control unit receives output signals from the pump revolution (cam ring angle) sensor, fuel
temperature sensor, etc. in the injection pump and determines necessary fuel injection quantity and timing de-
pending on these data and the settings on the engine electronic control unit.
This method of engine control (by means of two separate control units) allows the high pressure solenoid valve
driving circuit to be placed near the solenoid valve, preventing electromagnetic disturbance signals from being
emitted.
The fuel drawn up from the fuel tank by the feed pump passes the fuel filter into the injection pump.
The fuel is then sent to the distributor head from the feed pump. A regulator valve is provided in this fuel passage
to prevent a rise in fuel delivery pressure due to the increase of engine speed, thus maintaining it at an optimum
level.
The fuel feed to the radial plunger high pressure pump is controlled by the high pressure solenoid valve so that
fuel injection takes place in the adequate condition required by the engine.
The pump revolution sensor performs the following functions:
Detection of injection pump speed
Determination of timer position
Determination of cam ring angular position in radial plunger high pressure pump

13E-4
 13E
2. Electronic Control System
2.1 System block diagram

Input Signal Output Signal

Pump revolution sensor

Injection pump

Fuel temperature sensor (built into Pump electronic con- High pressure solenoid
the injection pump) trol unit (built into in- valve
jection pump) Timer control valve

Pump electronic
control unit commu-
nication signal

Engine speed sensor Engine warning lamp

Engine

Engine electronic
Boost pressure sensor
Control Unit
Water temperature sensor Tachometer

Fuel injection Exhaust shutter 3-way

Starter switch quantity control magnetic valve
Accelerator pedal position sensor
Accelerator pedal switch Fuel injection Exhaust gas recirculation
(built into the accelerator pedal posi- timing control 3-way magnetic valve
tion sensor)
Clutch switch
Exhaust gas
Transmission neutral switch recirculation control
Vehicle

Vehicle speed sensor function

Intake air temperature sensor (See Gr17.)
Exhaust brake switch
Diagnosis switch Exhaust brake
Memory clear switch control function
Multi-Use Tester connector
Fuel injection rate adjustment resis- Fault diagnosis
tor function

13E-5
STRUCTURE AND OPERATION
Part names
Pump revolution sensor
Fuel temperature sensor (built into the injection pump) Sensing of fuel temperature
Engine speed sensor
Boost pressure sensor
Water temperature sensor
Starter switch
Accelerator pedal position sensor
Accelerator pedal switch (built into the accelerator
pedal position sensor)
Clutch switch
Transmission neutral switch
Vehicle speed sensor
Intake air temperature sensor
Exhaust brake switch
Diagnosis switch
Memory clear switch
Multi-Use Tester connector
Fuel injection rate adjustment resistor
Pump electronic
Pump control
control unit com-
unit
munication
High pressure solenoid valve
Timer control valve
Engine warning lamp
Tachometer
Exhaust shutter 3-way magnetic valve
Exhaust gas recirculation 3-way magnetic valve
13E-6
Major function or operation
Sensing of injection pump speed
Sensing of engine speed
Sensing of change air (boost) pressure
Sensing of water temperature
Senses that the engine is in starting condition with the starter switch in
START position.
Sensing of extent of accelerator pedal pressure
Sensing of released/pressed condition of accelerator pedal (ON with
pedal released)
Sensing of released/pressed condition of clutch switch (OFF with pedal
released)
Detection of transmission neutral condition (OFF with transmission in
neutral)
Detection of vehicle speed
Sensing of intake air temperature
Exhaust brake ON/OFF control
Output of diagnosis code
Detection of diagnosis codes; output of past diagnosis codes
Communication between Multi-Use Tester and engine control system
Correction of fuel injection rate control unit
Control area net-
work communi- Injection timing command to pump
cation signal
Engine speed
Output of engine speed to pump electronic control unit
pulse signal
Engine stop sig-
Engine stop
nal
Control of injection quantity and timing
Injection of system abnormalities
Injection of engine speed
ON/OFF control of exhaust shutter 3-way magnetic valve
ON/OFF control of exhaust gas recirculation 3-way magnetic valve
 13E
M E M O

13E-7
STRUCTURE AND OPERATION
3. Electronic Control Unit Connection Diagram

13E-8
13E

13E-9
TROUBLESHOOTING
1. Diagnosis Procedure

System inspection can be performed most effectively using a Multi-Use Tester. Types of system inspection are
broadly classified in accordance with fault symptoms and diagnosis codes as follows:
Inspection based on diagnosis code memorized by electronic control unit
Inspection performed on assumption of intermittent fault

Vehicle enters workshop.

Diagnosis code(s) is read.

Error code Normal code

output Normal code output
output after
deletion of
error code

Ascertain cause of Take steps on

diagnosis code generation; assumption of
perform inspection. intermittent fault.

Perform test drive.

If diagnosis code is generated during test drive, ascertain cause of code generation again and perform inspection.
If diagnosis code memorized by electronic control unit is not generated during test drive, perform inspection based
on diagnosis code and on assumption of intermittent fault.

Delete diagnosis code.

13E-10
 13E
2. Diagnostic Precautions

The battery voltage must be the standard voltage.

Make sure no harness connector or component connector is loose. Before disconnecting any connector, place the
starter switch in the LOCK position and wait 20 seconds.
After making a repair, delete the diagnosis code using the Multi-Use Tester or memory clear switch.
As a general rule, inspection work should be performed with the starter switch in the LOCK position.
However, it may be necessary to perform certain tasks with the starter switch in the ON position. At these times,
be careful not to cause short circuits between connector terminals and between terminals and the vehicle body.
Indicated component resistances may not fall within the standard ranges if they are unduly affected by the tem-
perature and/or by the accuracy of the tester. Standard values in the text are given on the assumption of room
temperature (10 to 35C).
After rectification of an abnormality, the systems ability or inability to automatically return to normal control from
the control during fault that begins when a fault occurs depends upon the diagnosis code, i.e., the fault location.
When the system resumes normal control, the warning lamp goes off.
Even when an abnormality has been rectified and the system has automatically returned to normal control, the di-
agnosis code corresponding to the fault location remains in the memory of the electronic control unit as a past di-
agnosis code.
Following a fault that does not permit an automatic return to normal control from the control during fault that begins
when a fault occurs, it is necessary to clear the diagnosis code from memory in order for the system to recover.

13E-11
TROUBLESHOOTING
3. Inspections Based on Diagnosis Codes
3.1 Diagnosis code list

Code Message Code Message

06 INJ.VALVE 32 BOOST SNSR
11 PUMP ECU 33 ECU SYSTEM
12 PUMP REV.SNSR 34 Q RESISTOR
15 ENG REV.SNSR 41 FUEL TMP.SNSR
19 ATM PERS SNSR 44 AIR TMP.SNSR
21 WATR TMP SNSR 65 ACCEL SW
22 SHUT OFF INJ. 66 STARTER SW (M)
23 TCV 79 EGR SOL
24 ACCEL SENSOR1 87 MAIN RELAY
25 CAR SPED SNSR 88 BATT.VOLTAGE
26 CAN

3.2 Diagnosis code generation conditions and inspection items

06: INJ.VALVE
The code is issued when the pump electronic control unit finds high pressure so-
Generation condition
lenoid valve current abnormal.
Recoverability When the solenoid valve current returns to normal, a reset is made.
Control effected by electronic control unit Fuel injection is limited to a certain rate or shut off.
Check fuel injection pump.
Inspection Electrical equipment
(Have work performed by Bosch.)

11: PUMP ECU

Diagnosis trouble code is issued when:
There is no message sent from the pump electronic control unit to the engine
Generation condition control unit through control area network.
The pump electronic control unit finds its internal electronic circuit abnormal
as a result of its self-diagnosis check.
Recoverability Fuel injection is limited to a certain rate or shut off.
Control effected by electronic control unit Spill valve operation stopped.
Check the fuel injection pump.
Inspection Electrical equipment
(Have work performed by Bosch.)

12: PUMP REV.SNSR

Diagnosis trouble code is issued when:
The pump electronic control unit finds the pump speed sensor abnormal as a
Generation condition
result of its self-diagnosis check.
The pump speed sensor detects an overspeed.
Recoverability When existing status returns to normal, a reset is made.
Ordinary control using data from engine speed sensor alone.
Control effected by electronic control unit High pressure solenoid valve inoperative if the engine speed sensor is also
faulty.
Check fuel injection pump.
Inspection Electrical equipment
(Have work performed by Bosch.)

13E-12
 13E
15: ENG REV.SNSR
Diagnosis trouble code is issued when:
1: The signal from the engine speed sensor is not input the specified number of
Generation condition
times to the electronic control unit while the engine is in operation.
2: The engine speed is excessive.
1: When the signal from the engine speed sensor returns to normal, a reset is
Recoverability made.
2: When the engine returns to specified speed, a reset is made.
1: Ordinary controls are continued through the pump speed sensor.
Control effected by electronic control unit
2: Fuel injection is shut off.
Service data 02: ENG SPEED
Electronic control unit connector 02 : Engine speed sensor
Inspection
Electrical equipment #263: Engine speed sensor
Electric circuit diagram Engine speed sensor system

19: ATM PRES SNSR

Diagnosis trouble code is intended for checking the atmospheric pressure sensor
(built into the electronic control unit) for anything abnormal. The code is issued
Generation condition
when a voltage signal from the atmospheric pressure sensor is out of the speci-
fied limits.
When the output voltage of the atmospheric pressure sensor falls within the
Recoverability
specified range, a reset is made.
Control effected by electronic control unit Controls achieved on the assumption that atmospheric pressure is 100 kPa.
Inspection Service data 12: ATM. PRESSURE

21: WATR TMP SNSR

Diagnosis trouble code is intended for checking for open or short circuit in the
harness of the water temperature sensor or anything abnormal in water tempera-
Generation condition
ture sensor. The code is issued when the output voltage from the water tempera-
ture sensor is out of the specified limits.
When the output voltage of the water temperature sensor falls within the speci-
Recoverability
fied range, a reset is made.
Control effected by electronic control unit Controls are continued through the fuel temperature sensor.
Service data 11: WATER TEMP.
Inspection Electrical equipment #262: Water temperature sensor
Electric circuit diagram Water temperature sensor system

22: SHUT OFF INJ.

Diagnosis trouble code is issued when:
1: The engine electronic control unit does not recognize injection shutoff signal
Generation condition
as HIGH but the pump electronic control unit does.
2: The starting switch is turned to OFF but the engine remains on.
Recoverability
Control effected by electronic control unit Fuel injection is shut off.
Check fuel injection pump.
Inspection Electrical equipment
(Have work performed by Bosch.)

13E-13
TROUBLESHOOTING
23: TCV
Diagnosis trouble code is issued when the pump electronic control unit finds the
Generation condition
injection timing out of the specified limits as a result of its self-diagnosis check.
Recoverability
Control effected by electronic control unit Fuel injection is limited to a certain rate.
0A: TCV DUTY
Service data
0D: TIMING DIFF.
Inspection
Check fuel injection pump.
Electrical equipment
(Have work performed by Bosch.)

24: ACCEL SENSOR 1

Diagnosis trouble code is issued when:
The accelerator pedal position sensor power voltage (+5 V) exceeds the spec-
Generation condition
ified limit.
The accelerator pedal switch is faulty.
Recoverability When the accelerator pedal position sensor returns to normal, a reset is made.
Controls are made on the assumption that the pedal is pressed 30 % when ac-
Control effected by electronic control unit
celerator pedal switch is OFF and 0 % when accelerator pedal switch is ON.
Service data 03: ACCEL SNSR (%), 04: ACCEL +5(V), 05: ACCEL SNSR (V)
Electronic control unit connector 04 : Accelerator pedal position sensor 1
Inspection
Electrical equipment #324: Accelerator pedal position sensor
Electric circuit diagram Accelerator pedal position sensor system

25: CAR SPED SNSR

Diagnosis trouble code is intended for checking the harness of the vehicle speed
sensor for open/short circuit and checking the vehicle speed sensor for anoma-
Generation condition
lies. The code is issued when there are no pulse inputs from the vehicle speed
sensor to the control unit in the specified time duration.
Recoverability When a pulse is input, a reset is made.
Control effected by electronic control unit Ordinary fuel injection control
Service data 13: VEHICLE SPEED
Inspection Electronic control unit connector 05 : Vehicle speed sensor
Electric circuit diagram Vehicle speed sensor system

26: CAN
Diagnosis trouble code is issued when:
The control area network is open or short circuited.
Generation condition
The engine control unit or pump electronic control unit has an internal circuit
failure.
Recoverability There is no reset condition.
Control effected by electronic control unit Injection is shut off.
Electric circuit diagram Pump electronic control unit system
Inspection Check engine control unit or pump electronic control unit. (Have work performed
Electrical equipment
by Bosch.)

13E-14
 13E
32: BOOST SNSR
Diagnosis trouble code is issued when the boost pressure sensor power voltage
Generation condition
(+5 V) exceeds the specified limit.
When the voltage of the boost pressure sensor re-enters the specified range, a
Recoverability
reset is made.
Control effected by electronic control unit Controls are made on the assumption that the boost pressure is 100 kPa.
Service data 0F: BOOST PRESS.
Inspection Electrical equipment #318: Boost pressure sensor
Electric circuit diagram Boost pressure sensor system

33: ECU SYSTEM

Diagnosis trouble code is issued in the following cases.
Generation condition 1: Mutual monitoring error of microcomputer
2: Internal (ROM) error of the control unit
Recoverability There is no reset condition
1: Injection is shut off.
Control effected by electronic control unit
2: All Fail Safe functions against a faulty A/D input are activated.
Inspection Electrical equipment Faulty electronic control unit

34: Q RESISTOR
Diagnosis trouble code is intended for checking the harness of the fuel injection
rate adjustment resistor for open or short circuit and checking the fuel injection
rate adjustment resistor for anomalies.
Generation condition
The code is issued when the output voltage of the fuel injection rate adjustment
resistor continues to be out of the specified limits for the predetermined period of
time.
When the voltage of the fuel injection rate adjustment resistor re-enters the spec-
Recoverability
ified range, a reset is made.
Control effected by electronic control unit The injection rate correction value is fixed to No.1 value.
Service data 0E: Q ADJ.RESISTR
Inspection Electrical equipment #828: Fuel injection rate adjustment resistor
Electric circuit diagram Fuel injection rate adjustment resistor system

41: FUEL TMP.SNSR

Diagnosis trouble code is issued when the pump electronic control unit detects
Generation condition
an abnormal fuel temperature rise or drop.
When the voltage of the fuel temperature sensor re-enters the specified range, a
Recoverability
reset is made.
Control effected by electronic control unit Control is made on the assumption that fuel temperature is 75C
Service data 16: FUEL TEMP.
Inspection Check engine control unit or pump electronic control unit. (Have work performed
Electrical equipment
by Bosch.)

13E-15
TROUBLESHOOTING
44: AIR TMP.SNSR
Diagnosis trouble code is intended for checking the harness of the intake air tem-
Generation condition perature sensor for open or short circuit and checking the intake air temperature
sensor for anomalies.
When the voltage of the intake air temperature sensor re-enters the specified
Recoverability
range, a reset is made.
Control effected by electronic control unit Control is made on the assumption that intake air temperature is 25C
Electrical equipment #303: Intake air temperature sensor
Inspection
Electric circuit diagram Intake air temperature sensor system

65: ACCEL SW
Diagnosis trouble code is intended for checking the harness of the accelerator
Generation condition pedal switch for open or short circuit and checking the accelerator pedal switch
for anomalies.
If the accelerator pedal switch turns OFF when the accelerator pedal position
Recoverability
sensor shows an opening of more than 0.1 %, a reset is made.
Control effected by electronic control unit Ordinary controls continued
Service data 47: ACCEL SW
Electronic control unit connector 09 : Accelerator pedal switch
Inspection
Electrical equipment #324: Accelerator pedal switch (built into the accelerator pedal position sensor.)
Electric circuit diagram Accelerator pedal switch system

66: STARTER SW (M)

Diagnosis trouble code is issued when:
1: The engine control unit finds its internal circuit abnormal as a result of its self-
Generation condition diagnosis check.
2: The control unit determines that the starter switch is OFF as soon as it is
turned ON.
1: There is no reset condition.
Recoverability
2: When starter switch ON is recognized, a reset is made.
Control effected by electronic control unit Fuel injection is shut off.
Service data 4D: STARTER SW (M)
Electronic control unit connector 13 : Starter switch
Inspection
Electrical equipment #002: Starter switch
Electric circuit diagram Starter switch system

79: EGR SOL

Diagnosis trouble code is intended for checking the harness of the exhaust gas
Generation condition recirculation 3-way magnetic valve for open or short circuit and the exhaust gas
recirculation 3-way magnetic valve for anomalies.
Automatic reset takes place when the harness is open circuited but not when
Recoverability
short circuited.
Control effected by electronic control unit Exhaust gas recirculation 3-way magnetic valve disabled.
Service data 44: EGR SOLENOID
Inspection Electrical equipment #565: 3-way magnetic valve
Electric circuit diagram Exhaust gas recirculation 3-way magnetic valve system

13E-16
 13E
87: MAIN RELAY
Diagnosis trouble code is intended for checking the harness of the electronic
Generation condition control unit main relay for open or short circuit and checking the electronic control
unit main relay for anomalies.
Recoverability There is no reset condition.
Control effected by electronic control unit
Electrical equipment #201: Electronic control unit main relay
Inspection
Electric circuit diagram Electronic control unit main relay system

88: BATT.VOLTAGE
Generation condition Diagnosis trouble code is issued when the battery voltage is too high or too low.
Recoverability
Control effected by electronic control unit Control is effected on the assumption the battery voltage is 9 V.
Service data 01: BATT. VOLTAGE
Inspection
Electric circuit diagram Battery system

13E-17
TROUBLESHOOTING
4. Multi-Use Tester Service Data
NOTE
It is possible to see service data and actuator tests simultaneously.

No. Item Data Inspection condition Requirement

01 BATT. VOLTAGE . V Starter switch ON Matches battery voltage
Synchronized with tachom-
02 ENG SPEED .rpm Racing (engine running)
eter
Accelerator pedal released 0%
03 ACCEL SNSR (%) . % Slowly pressed Slowly increased
Accelerator pedal fully pressed 100%
04 ACCEL +5V (V) . V Starter switch ON 4.8 to 5.2 V
Accelerator pedal slowly pressed from
05 ACCEL SNSR (V) . V 0.85 to 4.15 V
released position
No fuel injection 100 %
08 DEMAND FUEL Q . %
Maximum fuel injection 0%
0A TCV DUTY . % During idling 10 to 50 %

0D TIMING DIFF. . CA During idling 0 CA

Matches No. marked on in-
0E Q ADJ. RESISTR jection rate adjustment re-
sistor
0F BOOST PRESS. . kPa Engine speed 3700 rpm 148 kPa
Equivalent to atmospheric
Engine cold
temperature
11 WATER TEMP. . C Engine warmup in progress Slowly increased
Engine stopped after warmup Slowly decreased
Altitude 0 m 101 kPa
12 ATM. PRESSURE . kPa
Altitude 600 m 95 kPa
. km/h Synchronized with speed-
13 VEHICLE SPEED During driving
ometer
Equivalent to atmospheric
Engine cold
temperature
16 FUEL TEMP. . C Engine warmup in progress Slowly increased
Engine stopped after warmup Slowly decreased
During idling (ambient temperature
17 INT. AIR TEMP. . C 20 to 35C
25C)
Engine speed increased to 2000 to
ON
2900 rpm after warm
44 EGR SOLENOID ON/OFF
Others than above OFF
[Actuator test] A2: EGR ADVANCE
When exhaust shutter is active ON
45 EXH BRAKE SOL ON/OFF When exhaust shutter is inactive OFF
[Actuator test] A4: EXH BRAKE SOL
Accelerator pedal dereleased ON
47 ACCEL SW ON/OFF
Accelerator pedal released OFF
Starter switch ON (engine not made to
ON
start)
49 W/LAMP (AMBER) ON/OFF No error generated after engine has
OFF
started
[Actuator test] A6: W/LAMP (AMBER)
Memory clear switch ON (OPEN) ON
4A MEM CLEAR SW ON/OFF
Memory clear switch OFF (SHORT) OFF

13E-18
 13E
No. Item Data Inspection condition Requirement
Transmission at neutral ON
4B NEUTRAL SW ON/OFF Transmission at any other position
OFF
than neutral
Diagnosis switch ON (OPEN) ON
4C DIAGNOSIS SW ON/OFF
Diagnosis switch OFF (SHORT) OFF
Starter switch ON ON
4D STARTER SW (M) ON/OFF
Starter switch LOCK, ACC OFF
Warming switch ON ON
53 COLD START SW ON/OFF
Warming switch OFF OFF
Exhaust brake switch ON ON
54 EXH MAIN SW ON/OFF
Exhaust brake switch OFF OFF
Exhaust brake switch ON (when ex-
ON
haust shutter is active)
55 EXH LAMP ON/OFF Exhaust brake switch OFF (when ex-
OFF
haust shutter is inactive)
[Actuator test] A8: EXH LAMP
Starter switch ON (engine not made to
ON
start)
57 W/LAMP (RED) ON/OFF No error generated after engine has
OFF
started
[Actuator test] AA: W/LAMP (RED)
Clutch pedal pressed ON
59 CLUTCH SW ON/OFF
Clutch pedal released OFF
When fuel injection is shut off ON
5D SHUT OFF ON/OFF
When engine is running OFF

5. Actuator Tests Performed Using Multi-Use Tester

No. Item Explanation Confirmation method

ON/OFF sound of magnet-
ic valve
A2 EGR ADVANCE Exhaust gas recirculation 3-way magnetic valve drive signal
[Service data]
44:EGR SOLENOID
ON/OFF sound of magnet-
ic valve
A4 EXH BRAKE SOL Exhaust shutter 3-way magnetic valve drive signal
[Service data]
45:EXH BRAKE SOL
Operating state of warning
lamp Amber (Orange)
A6 W/LAMP (AMBER) Warning lamp (amber) drive signal
[Service data]
49:W/LAMP (AMBER)
Operating state of indicator
lamp
A8 EXH LAMP Indicator lamp drive signal
[Service data]
55:EXH LAMP
ON/OFF state of warning
lamp Amber (Red)
AA W/LAMP (RED) Warning lamp (red) drive signal
[Service data]
57:W/LAMP (RED)

13E-19
TROUBLESHOOTING
6. TDC Check Mode by Multi-Use Tester
With the Multi-Use Tester in the TDC check mode, a TDC pulse phase check, an injection timer operation check and
a fuel injection pump installed position check can be performed. When this mode is selected, fuel injection timing is
set in the maximum retarded condition and the timer position at that condition is indicated in crank angle. If the read-
ing is 2 2CA, everything is in order. If the reading deviates from it, check the installed condition of the fuel injec-
tion pump.

When checking, all of the following conditions must be met

Engine speed 800 rpm
Engine coolant temperature > 70C
Vehicle speed 0 km/h

The checks are to be ended if either of the following conditions below is met
Engine speed > 800 rpm
Engine coolant temperature < 70C
Vehicle speed > 0 km/h
60 seconds passed
End check sequence performed with Multi-Use Tester
Multi-Use Tester found abnormal in communication.

7. Inspections Performed on Electronic Control Unit Connectors

These inspections aid troubleshooting by enabling you to check whether electronic control unit signals are being
correctly transmitted via the vehicle harness and connectors.
The white-on-black numbers ( 01 , 02 , and so on) correspond to the similarly printed reference numbers in sec-
tion 3. Inspections based on diagnosis codes.

7.1 Electronic control unit connector terminal layout

7.2 Inspection instructions

Some inspections are performed with the connectors removed. Others are performed with the connectors fitted.
Observe the following caution.
CAUTION
Do not touch any terminal except those specified for the inspection. Be particularly careful not to cause
short circuits between terminals using the tester probes.

13E-20
 13E
Check item Measurement method
01 [Conditions]
Starter switch ON
Voltage of clutch switch Vehicle-side harness connected (Perform inspection on back of connec-
tor.)
[Requirements]
Terminals(+)-(): A26-A80, A26-A81
When clutch pedal is pressed: 12 V
When clutch pedal is released: 0 V
02 [Conditions]
Starter switch OFF
Resistance of engine speed sensor Disconnect connector. Perform inspection on vehicle-side connector.
[Requirements]
Terminals: B24-B32
2150 300
04 [Conditions]
Starter switch ON
Output voltage of accelerator pedal position sen- Vehicle-side harness connected (Perform inspection on back of connec-
sor tor.)
[Requirements]
Terminals(+)-(): A33-A44
With accelerator pedal not pressed: 0.815 0.1 V
With accelerator pedal pressed: 4.15 0.1 V
05 [Conditions]
Starter switch ON
Signal voltage of vehicle speed sensor Vehicle-side harness connected (Perform inspection on back of connec-
tor.)
Using chassis dynamometer or the like, slowly rotates wheels.
[Requirements]
Terminals (+)-(): A63-A81, A63-A80
High pulse voltage: Approx. 8 1 V
Low pulse voltage: 0.5 V or lower
06 [Conditions]
Starter switch ON
Voltage of transmission neutral switch Vehicle-side harness connected (Perform inspection on back of connec-
tor.)
[Requirements]
Terminals (+)-(): B35-A81, B35-A80
When transmission at neutral: 12 V
When transmission position other than neutral: 0 V
09 [Conditions]
Starter switch ON
Operating voltage of accelerator pedal switch Vehicle-side harness connected (Perform inspection on back of connec-
tor.)
[Requirements]
Terminals (+)-(): A64-A44
When accelerator pedal is pressed: 0 V
When accelerator pedal is released: 5 V
13 [Conditions]
Starter switch (S position)
Voltage of starter switch (Starter signal) Vehicle-side harness connected (Perform inspection on back of connec-
tor.)
[Requirements]
Terminals (+)-(): A27-A81, A27-A80
12 V

13E-21
INSPECTION OF ELECTRICAL EQUIPMENT
#001 Inspection of combination switch
AK14A connector connection table
Switch position Terminals with continuity
OFF
Exhaust brake switch
ON 8-9
If there is any abnormality, replace the switch.

#002 Inspection of starter switch

AP2A, AN6A connector connection table
Switch position Terminals with continuity
LOCK
ACC (2) - 3
ON (1) - (2) - 3 - 4
START (1) - (2) - 2 - 3 - 4
Terminal numbers within parentheses ( ) show terminals of
AP2A.
If there is any abnormality, replace the switch.

#031 Inspection of clutch switch

Switch position Terminals with continuity
A 1-4
B 2-3
If there is any abnormality, replace the switch.

#056 Inspection of transmission neutral switch

Switch position Terminals with continuity
OFF
ON 1-2
If there is any abnormality, replace the switch.

13E-22
 13E
#201 Inspection of relay (normally open type 5 pin)
Perform continuity check and operation check, and if any fault is
found, replace the relay.

#262 Inspection of water temperature sensor

Place the water temperature sensor in a container filled with en-
gine oil.
Heat the oil to each of the specified temperatures. Stir the oil
well while doing so.
Measure the resistance between terminals 1 and 2.
20C 2.45 0.14 k
Standard value 80C 0.32 k (reference value)
110C 147.1 2
If either measurement is out of specification, replace the sensor.

#263 Inspection of engine speed sensor

Measure the resistance between terminals 1 and 2.
Standard value (at 20C) 2150 300
If any measurement is out of specification, replace the sensor.

#265 Inspection of vehicle speed sensor

With the battery voltage applied to terminals 1 and 2, slowly turn
shaft of the sensor.
Measure the maximum voltage (high pulse voltage A) and mini-
mum voltage (low pulse voltage B) occurring at each specified
pair of terminals.
Terminals Inspection condition Standard value
25-pulse output: Low pulse voltage 0.5 V or less
terminals 1 and 4 High pulse voltage 81V
If any measurement is out of specification, replace the sensor.

#304 Inspection of intake air temperature sensor

Place the intake air temperature sensor in a container filled with
engine oil.
Heat the oil to each of the specified temperatures. Stir the oil
well while doing so.
Measure the resistance between terminals 1 and 2.
0C 5880 588
Standard value 20C 2450 245
80C 322 48
If any measurement is out of specification, replace the sensor.

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INSPECTION OF ELECTRICAL EQUIPMENT
#318 Inspection of boost pressure sensor
Apply 5 V DC to terminals 3 and 1.
Apply air pressure. Gradually increase it and, while doing so,
measure the output voltage occurring at terminals 2 and 1.
Air pressure
Voltage
(gauge pressure)
101.67 kPa
Standard value Approx. 3.2 V
{1.04 kgf/cm2}
165.67 kPa
Approx. 4.5 V
{1.69 kgf/cm2}
If any measurement is out of specification, replace the sensor.

#324 Inspection of accelerator pedal position sensor

[Inspection]
Apply 5 V DC to terminals 4 and 2 of the accelerator pedal posi-
tion sensor.
Measure the output voltage at terminals 2 and 5 with the accel-
erator lever in each specified position.
Accelerator lever position Output voltage
Idling position A 0.815 0.1 V
Standard
value Accelerator pedal switch operating
1.0 0.24 V
position B
Full load position C 4.15 0.1 V

A: Position in which accelerator lever is touching stopper

B: Position at which continuity between terminals 2 and 3 dis-
appears as accelerator pedal is pushed downward
C: Position in which accelerator lever is touching stopper bolt
If any output voltage is out of specification, make an adjustment.
If any output voltage is still out of specification when you have
made an adjustment, replace the sensor.

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 13E
[Adjustment]
To adjust the output voltage for the idling position A, loosen the
screws and move the accelerator pedal position sensor. Tighten
the screws after making the adjustment.
To adjust the output voltage for the full load position C, loosen
the nut and make the adjustment using the stopper bolt. After
making the adjustment, lock the stopper bolt in position with the
nut.

#565 Inspection of 3-way magnetic valve

<Type-1>
Perform the following checks. If there is any abnormality, replace
the 3-way magnetic valve.
(1) Checking operation
Gradually increase from zero the voltage applied to terminals 1
and 2.
Observe the voltage when the 3-way magnetic valve operates.
(Determine the magnet valves OFF-ON operation from the op-
erating sound.)
Standard value
11 V or less
(min. operating voltage)

(2) Checking continuity and airtightness

Vacuum pressure applied during check: -100 kPa {-750 mmHg}

<Type-2>
Perform the following checks. If there is any abnormality, replace
the 3-way magnetic valve.
(1) Checking operation
Gradually increase from zero the voltage applied to terminals 1
and 2.
Observe the voltage when the 3-way magnetic valve operates.
(Determine the magnet valves OFF-ON operation from the op-
erating sound.)
Standard value
12 V or less
(min. operating voltage)

(2) Checking continuity and airtightness

Vacuum pressure applied during check: -100 kPa {-750 mmHg}

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INSPECTION OF ELECTRICAL EQUIPMENT
#828 Inspection of fuel injection rate adjustment resistor
Measure the resistance of the resistor number marked on the
fuel injection rate adjustment resistor.
1 270 13.5
2 510 25.5
3 820 41
4 1300 65
5 2000 100
Standard value
Resistor No. 6 3300 165
(at 20C)
7 5600 280
8 15000 750
9 390 19.5
10 4300 215
11 9100 455

If the measurement is out of specification, replace the fuel injec-

tion rate adjustment resistor with one that has the same resistor
number and same specified resistance.
CAUTION
The fuel injection rate adjustment resistor is matched to the
engine. If you replace it, be sure to replace it with one that
has the same resistor number.

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 13E
M E M O

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INSTALLED LOCATIONS OF PARTS

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13E

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INSTALLED LOCATIONS OF PARTS

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 13E
M E M O

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ELECTRIC CIRCUIT DIAGRAM

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13E

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ELECTRIC CIRCUIT DIAGRAM

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13E

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ELECTRIC CIRCUIT DIAGRAM

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