Injection Pumps & Governors

Kobelco
Construction Machinery
America LLC.

Mitsubishi Engine
Injection Pumps & Governors

Kobelco Construction
Machinery America LLC.
MITSUBISHI TRAINING 09/01
Page 6-1
 Injection Pumps & Governors

Fuel Pump

Main Fuel
Pump Housing

Governor

Coupler

Feed Pump
Automatic
Timer

6D16 Fuel Pump Example - SK290~330

MITSUBISHI TRAINING 09/01

Page 6-2
 Injection Pumps & Governors

Governor Main Fuel

Pump Housing

Coupler

Feed Pump
Automatic
Timer

6D24 Fuel Pump Example - SK480

MITSUBISHI TRAINING 09/01

Page 6-3
 Injection Pumps & Governors

Fuel System Flow Chart:

1. Diesel fuel flows from the fuel tank Item #4
2. From the fuel tank to fuel flow to Feed pump Item #5
3. Fuel from feed pump # 5 is pumped thru Fuel Filter #2
4. From Fuel filter # 2 fuel flows to Fuel Rack # 8
5. The fuel is then pressurized in the Fuel Rack #8 and is sent to Fuel Injector #1
6. The pressurized fuel is then injected into the combustion chamber at the optimal moment for fuel
compression and proper combustion.
7. Excess fuel from Fuel injector #1 not used during the injection process and excess fuel from Fuel
Rack’s pressure relief valve returns to the Fuel Tank #4

MITSUBISHI TRAINING 09/01

Page 6-4
 Injection Pumps & Governors

6D16 Fuel Pump Example - SK290~330

MITSUBISHI TRAINING 09/01
Page 6-5
 Injection Pumps & Governors

1. Delivery Valve Holder

2. Delivery Valve spring
3. Delivery Valve
4. Plunger barrel
5. Control pinion
6. Plunger
7. Control Rack
8. Control Sleeve
9. Plunger Spring
10. Tappet
11. Camshaft

The injection pump feeds fuel to the injection nozzles under high pressure and incorporates
a mechanism for increasing the fuel.

MITSUBISHI TRAINING 09/01

Page 6-6
 Injection Pumps & Governors
Rack Explanation:

MITSUBISHI TRAINING 09/01

Page 6-7
 Injection Pumps & Governors

1. Spring
2. Needle Valve
3. Nozzle Tip
4. Return Passage
5. Injector Body
A. Return
B. Pressure Inlet

• When pressureized fuel fed from the injection pump over comes the spring # 1, it
pushes up needle valve #2 and sprays out of the orifice at the end of the nozzle.
• The injector pressure is adjusted by increasing or decreasing the thickness of the
washer

MITSUBISHI TRAINING 09/01

Page 6-8
 Injection Pumps & Governors

Example SK210~SK250 - 6D34

MITSUBISHI TRAINING 09/01
Page 6-9
 Injection Pumps & Governors

Example SK210~SK250 - 6D34

MITSUBISHI TRAINING 09/01
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 Injection Pumps & Governors

MITSUBISHI TRAINING 09/01

Page 6-11
 Injection Pumps & Governors

Governor:
1.Tension Lever 10. Stop Lever
2. Guide Lever 11. Full-Load Stopper Bolt
3. Supporting Lever Shaft 12. Ungleich Spring or idling Spring
4. Governor Housing 13. Idling Subspring
5. Control Rack 14. Governor Spring
6. Adjusting Lever 15. Control Lever
7. Swivel Lever 16. Shackle
8. Cam Shaft 17. Start Spring
9. Flyweight

The governor is an all speed type that utilizes the centrifugal force of the flyweight arrangement.
In additional to control to controlling the maximum and minimum speed, the governor automatically
controls the engine speed at any intermediate speed position

MITSUBISHI TRAINING 09/01

Page 6-12
 Injection Pumps & Governors

Feed Pump

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Page 6-14
 Injection Pumps & Governors

MITSUBISHI TRAINING 09/01

Page 6-15
 Injection Pumps & Governors

MITSUBISHI TRAINING 09/01

Page 6-16
 Kobelco
Construction Machinery
America LLC.

SK 480 - Fuel System

Kobelco Construction
Machinery America LLC.
MITSUBISHI TRAINING 09/01
Page 480-1
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

1. GENERAL
With the electronically controlled injection pumpsys- The electronic governor ECUoptimally controls the
tam, electronic control is applied to the governor and governor and timer in accordance with data signals
timer (the components of the injection pumpassam- from sensors mountedon the engine and other parts of
bly) to realize the optimum fuel injection timing and the vehicle.
fuel injection rate.
1.1 Principle of operation

,I

1 RED-4internal circuit 8 "13mer control valve 14 Plunger

2 Control rack position sensor 9 Injection nozzle 15 Camshaft
3 Control rack 10 Combustion chamber 16 Injection pump
4 Engine speed sensor2 11 Fuel tank 17 Linear DC motor
5 Electronic timer 12 Feed pump 18 Electronic governor actuator
6 Engine speed sensor1 13 Control sleeve 19 Fuel filter
7 Engine ECU ®43638

The extent ofoperation ofthe linear motor 17 and timer
control valve 8 are determined by signals from the
engine ECU7.
The linear motor 17 movesthe control rack 3, thereby
changing the fuel injection quantity,
The timer control valve 8 controls the hydraulic pres-
sure applied to the electronic timer 5, thus adjusting
the fuel injection timing,
The RED-4internal circuit 1 is incorporated into the
electronic governor actuator 18. It contains a control
rack position sensor processing circuit and a linear DC
motor drive circuit, which are conventionally incorpo-
rated into the engine ECU. This arrangement elimi-
nates noise in the harness and thus prevents erro-
neous ECUoperation. Moreaccurate electronic control
is possible as a result.
The engine speed is sensed by engine speed sensor 1 6
and engine speed sensor 2 4. Each of these sensors
acts as a backupif the other fails.

13E-2
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

1.2 Electronic Governor

1 Cover
2 RED-4internal circuit
3 Control rack position sensor
4 4 Housing
5 6 5 Sensing gear
6 Emergency engine stop lever
7 7 Link
8 8 Coil assembly
9 Linear DC motor

®38928

(2) Control rack position sensor

A 3 The control rack position sensor 3 senses whether the
control rack A is movedto the correct position by the
linear DC motor 9. In the event of a discrepancy
betweenthe actual control rack position and the target
control rack position (this is determined by the engine
6
ECUand RED-4 internal circuit 2), the engine ECU
causes the linear DCmotor 9 to perform a corrective
movement.

~~_~ i (3) Emergency engine stop lever

24952
(1) Linear DC motor
The linear DCmotor 9 movesthe coil assembly8 verti-
cally in accordance with signals from the engine ECU
and RED-4internal circuit. Via the link 7, this movement
is transmitted to the control rack A, which movesIongi-
tudinally to increase and decreasethe fuel quantity,
The emergencyengine stop lever 6 is connected to the
link 7. Via a wire, it enables the link to be movedfrom
the driver’s seat. In the event of a systemfault that pre-
vents the engine from being stopped normally, opera-
tion of the emergencyengine stop lever forces the con-
trol rack A to moveto the position at which fuel injec-
tion is terminated. This operation takes place irrespec-
tire of the position of the linear DCmotor 9.

13E-3
B ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

1.3 Electronic ]3mer

1 Cover
2 Engine speed sensor 2
2 3 -Iqming sensor
j~ 4 Cap
5 Disc
12 6 Disc
! 7 Flange
’ 8 Large eccentric cam
~"~1~
11 9 Small eccentric cam
L- 10 Plate
10 ~ 11 Spring seat
12 Timer spring
9 8 7 6 ~ 13 Pilot pin
14 Cylinder
4 15 Piston
24960

The electronic timer uses an eccentric cam arrange-

15~ ~
ment to adjust the injection timing. The eccentric cams
14 -,~/,~ 8, 9 in the electronic timer are movedby hydraulic pres-
sure supplied from the timer control valve assembly.
12 (1) The timer incorporates four pistons 15, which are
activated by hydraulic pressure A. The pistons are
arranged as two pairs, and each piston slides verti-
-’(~/
~~8~
@ cally in a cylinder 14.
15 14 02720 (2) Eachpair of pistons 15 is linked to a plate 10. The
two plates are pressed against each other by the
timer springs 12.
7 (3) Whenhydraulic pressure A acts upon the pistons
0
15, the pistons move toward the outside of the
timer flange 7.
(4) As the pistons 15 move outward, the plates
(thus far pressed together by the timer springs 12)
A
also move outward.
(5) The eccentric cams8, 9 move in conjunction with
the plates 10, thereby altering the fuel injection
timing.
10
8 9 02721

13E-4
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

1.4 Timer Control Valve

p 1 Seat
o
2 Valve
3 Plunger
,,=,,p~l 4 Spring
2 5 Coil
/:~"~ ,1~ 3 6 Pu m p-side solenoid valve
~ --f~~4 5
7 Release-side solenoid valve

A: Port A
P: Port P
R: Port R
7

24961

The timer control valve controls the hydraulic pressure (1) Advancementof fuel injection timing
(engine oil) that activates the electronic timer assem-
bly. A
Internal oil passages emergeat port P (where engine t~-~"~[
oil enters the assembly), port A (which supplies engine ii
oil to the timer), and port R (which returns engineoil
J~ p
the oil pan).
The oil passages are interrupted by two solenoid
valves 6, 7, one on the pumpside and the other on the
release side. The solenoid valves control the hydraulic 6
pressure reaching the timer. Eachsolenoid valve incor- 7 ~ -
porates a plunger 3 and coil 5. Whenthe solenoid valve
is activated, the coil 5 attracts the plunger 3, which 24963
movesthe valve 2 away from the seat 1, thereby open-
ing the oil passage. Openingand closing timing of the The pump-side solenoid valve 6 is activated.
solenoid valves is controlled by the electronic timer The release-side solenoid valve 7 is not activated.
control unit. With the solenoid valves in these conditions, ports P
and A are connected, allowing the supply of hydraulic
pressure to the timer. Thus, the fuel injection timing is
advanced.

13E-5
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

(2) Maintenance of advanced(or retarded) fuel injec- (3) Retardation of fuel injection timing
tion timing

-- ~6
7-
24964
The pump-side solenoid valve 6 is not activated.
The release-side solenoid valve 7 is not activated.
With the solenoid valves in these conditions, the ports
are isolated from each other. Thus, the hydraulicpres-
sure in the timer stays constant and the timer remains
in its current condition.
7-
R
24965
The pump-side solenoid valve 6 is not activated.
The release-side solenoid valve 7 is activated.
With the solenoid valves in these conditions, ports A
and R are connected, allowing oil in the timer to return
to the oil pan. Thus, the fuel injection timing is
retarded.

1.5 Electronic Control System

(1) System block diagram

Input signals Output signals

Control rack position signal 1 RED-4internal circuit ~ L~Linear DC motor drive 9
~
(incorporated into electronic
governor)

Engine ECU

Engine speed signal 2

Fuel injection qu~ro-I-= Timer control valve drive 10 I
Engine start signal 3
Coolant temperature signal 4 .... I
Fuel injection timing control ~>~ Warning lamp
Accelerator pedal position signal 5 I
Fault diagnosis signal 6
r --~ Heater relay
Fuel injection quantity signal 7 ~ .... p_reheat control
Boost pressure signal 8 ----~-~ Preheat lamp
J
Fault diagnosis function 1 ~ ~
Tachometer output ]

13E-6
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

Signal Part Main function/operation

1 Control rack position signal
2 Engine speed signal
3 Enginestart signal
.....
4 Coolant temperature signal
5 Accelerator pedal position signal
- .i. (ONWi-th-pe~dal.re-l-ea~sed!-
6 Fault diagnosis signal
7 Fuel injection quantity signal
8 Boost pressure signal
9 -
10 - Timer control valve
Control rack position sensor Sensing of control rack position
Engine speed sensors 1, 2 Sensing of engine speed
Use of two sensors allows for backup if one
sensorfails.
Starter switch Recognition of engine startup with starter
switch in STARTposition
[ ..............
/ Coolant temperature sensor Sensing of coolant temperature
i Accelerator pedal position sensor Sensing of extent of depression of accelerator
pedal
............
Accelerator pedal switch Detection of pedal depressed/released condi-
tion
_
Diagnosis switch Callup of diagnosis codes
Memoryclear switch Deletion of diagnosis codes; callup of past
diagnosis codes
Fuel injection quantity adjusting resis- Correction of fuel injection quantity
tor
Boost pressure sensor Detection of boost pressure
Linear DC motor Moving of control rack
Control of hydraulic pressure applied to elec-
tronic timer

Injection quantity adjusting resistor

No.
02734

The injection quantity adjusting resistor makesfine ad-

justments to achieve optimal commensuration of in-
jectied fuel quantity with fuel feed from the common
rail.
NOTE:
This resistor, selected as the best from amongseveral
types, determinesthe final injection quantity. DONOT
changeit for any other type.

13E-7
D ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

(2) Control of fuel injection quantity

r C°ntr°l rack p°siti°n sens°r ilt
!
JJ
[ Engine ECU < >[-R-ED-4inter-
I ~ !
- t nal circuit
-i [ [1
¯ Engine speed sensor l F
Engine speed sensor 2 Ta-rget rack position
l J L
¯ Coolant temperature sensor ~ LinearDC !
F q
¯ Accelerator pedal position Idling characteristics. motor
l 1 m

sensor
¯ Fuel injection quantity adjust- Running characteristics
ing resistor
Full rack characteristics

Starting characteristics

(a) Control affected by engine ECUand RED-4internal (b) Feedbackcontrol affected using control rack posi-
circuit tion sensor

The RED-4internal circuit processes control rack posi-
tion signals and transmits the results to the engine
ECU.
The engine ECUeffects control during engine opera-
tion using the stored idling characteristics or running
characteristics, and it determines the target control
rack position in accordance with signals issued by the
RED-4internal circuit,
The control rack position signal issued by the engine
ECUis returned to the RED-4internal circuit. Via the
servo circuit and drive circuit, it causesactivation of the
linear DCmotor such that the control rack is moved.
The control rack position sensor enables the RED-4
internalcircuittocalculatewhetherthelinearDCmotor
has movedthe control rack to the target position. This
arrangement enables the RED-4to ensure thatthe con-
trol rack position always correspondsto the target val-
ue.
The engine ECUreceives signals indicating the control
rack’s actual position from the RED-4internal circuit
and uses them to evaluate control rack position errors.

(3) Control of fuel injection timing

Control rack position sensor

nal circuit
| RED-4inter-
Engine ECU ~<~---~ I
¯ Engine speed sensor 1
¯ Engine speed sensor 2 ~ ...... ~ [ Load timer ]
characteristics ..... ~ -Iqmer control
¯ Coolant temperature sensor h J valve
¯ Accelerator pedal position
r~Cold idling characteristicsl
sensor

13E-8
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

(a) The engine ECUcontrols the fuel injection timing (4) Preheat control
by controlling the activation of the timer control Preheat control improves startability when the
valve, which applies hydraulic pressureto the elec- engine’s coolant temperature is low.
tronic timer.
(a) Operating modes
(b) The engine ECUcontrols the timer control valve
determining the target and actual advanceangles, 1) Engine coolant temperature higher than 0°C
comparing them with each other and with charac-
teristics stored in its memory,and issuing drive
START
signals to the timer control valve in accordance ..[ i
ON -
Starter switch OFF I
with the results.
1) Target advance angle: calculated by comparison of ON
Preheat lamp OFF
data signals from sensors with characteristics
stored in engine ECU’s memory Running
Engine Not running [
2) Actual advance angle: determined in accordance
with signals from engine speed sensor 1 and ON
Heater relay OFF
engine speed sensor 2.
(C) Whenthe engine is cold, startability and post-start
warmup are optimized by the use of cold idling ®43717
characteristics in determination of the fuel injec-
tion timing.
No preheating is necessary at the time of engine
startup, so the heater relay is kept OFE
2) Engine coolant temperature 0°C or lower

START
ON r---I
Starter switch jOFF

ON
Preheat lamp OFF-] I

Running
Engine Not running I

ON
Heaterrelay /OFF 7 L
h -I
Preheat Afterheat

043718

"ts" seconds after the starter switch is turned ON, the

heater relay is turned ON,causing preheating to begin.
The preheat lamp illuminates simultaneously.
Whenpreheating finishes, the preheat lamp goes offto
indicate that the engine can be started. The heater relay
remains ONuntil the engine is started.
Whenthe engine is started, the engine ECUdetermines
whether afterheating is necessary in accordance with
the engine coolant temperature. If the engine ECU
determines that afterheating is not necessary, preheat
control is terminated. If it deemsthat afterheating is
necessary, the heater relay remains ONfor a certain
period after engine startup to cause afterheating.
13E-9
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

ECUTerminal Configuration

A: CW32A

11 10 9 8 7 6 5 4 2
24 23 22 21 20 19 18 17 16
32 31/ 301 I 29] 28 27I 26I

B: CW25A

6 5 4 3 2
16 15 14 13 12 10 9
1251241 123 22 211201 19J

C: CW31A

10 9 8 7 6 5 4
22 21 20 19 18 17 16 15 14
A / 31l 301 29/ 1 28 27 26 I 25j 24123j

D: CW16A

4 3 2
11 10 9 8 7
116115S14J

®43639

A: CW32A
Terminal No. Item(s) to which terminal is connected Terminal No. Item(s) to which terminal is connected
1 - 17 -
2 - 18 Boost pressure sensor (SIG)
3 RED-4 ECU (PULL DOWN) 19 Engine speed sensor 2 (GND), RED-4 ECU(SIGNAL
GND-2)
4 - 20 -
5 - 21 Engine speed sensor 1 (GND)
6 Boost pressure sensor (+5V) 22 -
7 Engine speed sensor 2 (SIG) 23
8 Engine speed sensor 1 (SIG) 24 -
9 - 25 -
10 - 26 -
11 Heater relay 27 -
12 - 28 -
13 - 29 Boost pressure sensor (GND)
14 RED-4 ECU (LIMP HOME) 30 Coolant temperature sensor (GND)
15 - 31 Timer control valve (ADV)
16 - 32 ~mer control valve (RTD)

13E-10
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

B: CW25A
Terminal No. Item(s) to which terminal is connected Terminal No. Item(s) to which terminal is connected
1 Warning lamp (orange) 14 RED-4 ECU(+5 VCC-2)
2 Accelerator pedal switch 15 RED-4 ECU (PWM SOL-2)
3 - 16 RED-4 ECU(V-IST)
4 Injection quantity adjusting resistor (SIG) - i7 " -Framegr0und (M/V POWERGND)
5 RED-4 ECU(+5 VCC-1) 18 -
6 RED-4 ECU(PWM SOL-l) 19 -
7 RED-4 ECU(VB2) 20 MUT-II connector (K-LINE)
8 RED-4 ECU(VB1) 21 -
9 Accelerator pedal position sensor 2 (SIG) 22 Shield (SHIELD) of VB-1, VB-2, GND-1, and GND-2
10 - 23 RED-4 ECU(SIGNAL GND-1)
11 - 24 RED-4 ECU(GND-2)
12 - 25 RED-4 ECU(GND-1)
13 Injection quantity adjusting resistor (GND) ~--~ ....

C: CW31A
Terminal No. Item(s) to which terminal is connected Terminal No. Item(s) to which terminal is connected
1 - 17 Accelerator pedal position sensor 1 (SIG)

2 Engine speed output signal (NE OUTSIG) 18

3 Starter switch S terminal (STARTER
SWS) 19 Diagnosis switch
4 - 20 -
5 - 21 -
6 - 22 -
7 Battery relay (STARTERSWM~2i -- 23 -
8 Battery relay (STARTERSWM-l) 24 Battery ground (CASE GND)
9 - 25 -
10 MUT-II connector (DCT) 26 Preheat lamp (PREHEATLAMP)
11 - 27 Accelerator pedal position sensor 2 (GND)
12 Control rack position output signal (RAC OUT 28 Accelerator pedal position sensor 1 (GND)
SIG)
13 - 29 Memoryclear switch
14 - 30 -
15 Coolant temperature sensor (SIG) 31 -
16 ............. - I

D: CWl 6A
Terminal No. Item(s) to which terminal is connected Terminal No. Item(s) to which terminal is connected
1 Engine ECUmain power relay (+VB-2) 9
2 Engine ECUmain power relay (+VB-1) 10

3 Warning lamp (red) 11 -

4 - 12 -
5 DDS-3 connector (DDS3) 13 Engine ECUmain power relay (MAIN RELAY-2)

6 Battery ground (GND-2) 14 -

7 Battery ground (GND-1) 15 -
8 Engine ECUmain power relay (MAIN RELAY-1 16

13E-11
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

Starter switch

~,~.-r~,,,OFF
~OB
ACC
MB1B~I1
ACC T!~
ON
STAR

STARTERSW(S C3
STARTERSW(M)1!
°-’°EngineT ECU main power relay
~ STARTERSW(M)2 C7
f, ’ MAINRELAY1 D8
I ~ ,, ~ MA[NRELAY2D13
’, ECUPOWER(+VB) 1
o~! ’
~ ECU POWER(+VB)2D2

_1 GND1 D7
Battery GND2 D6
relay -~
GND(CASEGND) C24
GND(M/VPWRGND)B17

SIG A8
= Engine speed sensor1 ~: Oa GNDsIG
A21
Battery ~ []] 0

I
- =
Engine speed sensor 2
(TIMING)
[:

,
~Lu(1

~TI
,, (/ - -GNDIA719

V ISTIB16
Battery Frame I 411 PWMSOL lib
6 SOL
PWM 2 B15
ground ground 411----
JIl~- P~
LIMP ~3A1,
.ONE
I 411--- va-~Bs
qll ~
RED-4-III/I I / vB2B7
RED-4 ECU internal
4111 I II GND ~ B2S
I circuitqll U ~J GND-2 B24
III ~ +5v(vcc) l B22
SH~E’D
-II1~

~USlGNALGN~ 2

Timer control valve (ADV) ~ A31

Timer control valve (RTD) ~ A32
SIG B4
Injection quantity adjusting resistor [1] GNDB13

Coolant temperature sensor s’G A30

GND :~s
[]]
+SV
SIG A18
Boost pressure sensor GNDA29

Warning lamp (red) ~ [:)3

Warning lamp (orange) [JJ[w~ B1
Memory clear switch ~ c29
Diagnosis switch - (]]-~H]] =19

DATAD5
DDS-3 connector ~ E}
K Line B20
MUT-II connector DCTC10

Rack position output signal < ~12

Engine speed output signal "~ c2

®45865-1

13E-12
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - GENERAL

Engine ECU

c2s ~ = Preheat lamp

All :X
’~- ol
’, ¯ Heater relay

Heater relay

: ...... 7 Air heater

I V~ 1 _L

SIG
C17 GND ’ Accelerator pedal
c28 ~ position sensor 1
89 SIG ; Accelerator pedal
c27 GND ~ position sensor 2

82 Accelerator pedal
Depressed: OPEN, o~
/ _ switch
Released: GND

..L
CASE GND ®45865-2

13E-13
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - SPECIFICATIONS

2. SPECIFICATIONS

Item i Specification

Injection pump assembly Manufacturer I BOSCH AUTOMOTIVE SYSTEMS

Model | Electronically controlled in-line pump

Injection pumpmodel F NP-PE6P120
Governor model RED-4(RED-4with internal circuit)
]]mer model SPGH
Feed pump model KD
-Iqmer control valve Manufacturer .......... BOSCH AUTOMO]-iVE SYSTEMS
Rated voltage V 24
2}
Pressure range kPa {kgf/cm 49 to 980 {0.5 to 10}
ECU Manufacturer BOSCH AUTOMOTIVE SYSTEMS
__
Rated voltage V 24

13E-14
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

3. TROUBLESHOOTING ¯ Do not forget to clear the diagnostic trouble code by

3.1 Inspection Procedures
3,1.1 Diagnostic function
Wheneverthe starting switch is placed at ON,the diag-
nostic function is activated to checkall the sensors,etc.
If any of them is found faulty, the warning lamp in the
meter cluster is lit to alert the driver. At the sametime,
the fault location is stored in memory,and the system
enters the backup mode.
¯ The resistance value of each componentis affected
The stored fault location can be read as a diagnostic
trouble code bythe Multi-Use Tester II orthe diagnostic
switch,
Warning lamp indications
the Multi-Use Tester II or memoryclear switch after
a fault has beenrectified.
¯ As a rule, inspection operations should be per-
formed with the starting switch at the LOCKposi-
tion. Somechecks, however, may have to be made
with the starting switch at the ONposition. In such
a case, use care to makesure that no short circuit
develops between pins of the connectors or with
the body.
by the temperature and the accuracy of the tester.
The reading, therefore, does not always fall within
the standard limits. Note that the check values
shownin the text are the values obtained at normal
temperature (10 to 35°C).

Safety-critical errorI .....

Warning lamp
Red
¯ Whether or not the system automatically returns to
normal from the backup modeafter a fault has been
(Vehiclemustnot bedriven) removed depends on the diagnostic trouble code
Non-safety-critical
error Orange (fault location).
(Vehiclecanbe drivendespitepoor
controlfeeling) ¯ Even when the fault has been removed and the sys-
tem has been automatically returned to the normal
NOTE: mode, the diagnostic trouble code of the fault
¯ Check to ensure that the battery voltage is within remains stored in the engine control unit.
the specified range. ¯ Whena fault occurs at a point where the system is
¯ Check all the harness and device connectors for not automatically reset, perform the memoryclear
looseness. Always remove a connector at least 20 procedure to let the system exit from the backup
seconds after placing the starting switch at the mode. l~ P13E-19
LOCKposition.

13E-15
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

3.1.2 Inspection flowchart

The system inspection can be performed effectively by
use of the Multi-Use Tester II. The types of system
inspections maybe broadly divided as shownbelow in
accordance with the trouble symptomsand diagnostic
trouble code outputs.
(1) Inspections based on diagnostic trouble codes
stored in the engine control unit
(2) Inspections of transient troubles

Vehicle brought into workshop

,L
Readdiagnostic trouble codes [~ P13E-19 J
[
Normal code No communications
Trouble code output output can be made with
Multi-Use Tester II.

Normal code output

after erasure
Check for
Identify cause for diagnostic transient troubles
trouble code issue and rec- ~ P13E-31
tify ~ P13E-21

If no communications can be madewith all the other systems,

it is highly likely that the diagnostic circuit is faulty.
If no communicationscan be madewith this system only, an open
Driving test
circuit in the diagnostic output circuit or power supply circuit

J/
(including the ground circuit) of this system is suspected.

¯ If the samediagnostic trouble code is issued during test driving, reexamine the cause for the
diagnostic trouble code issue and rectify. ~ P13E-21
¯ If none of the diagnostic trouble codes stored in the engine control unit before the test driving is
issued, perform the checks on transient troubles in addition to the checks based on the
diagnostic trouble codes.

Erace the dianostic trouble codes.

~j~,, P13E-19

13E-16
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

3.2 Connectionof Multi-Use Tester II

3.2.1 Special tools
Unit: mm Unit: mm
Tool name Shape Tool name Shape
Multi-Use Tester II Multi-Use Tester II harness
MB991496 MB991499
Inspection of system To use Multi-Use Tester II as
a circuit tester

19492 2O536
Multi-Use Tester II harness Battery clamp harness
(for communications) MK320193
MC887252 Power supply to Multi-Use
To supply power to Multi-Use Tester II in vehicle without
Tester II proper and commu- cigarette lighter; detection of
nicate with vehicle side elec- ’/~,~,~"~-~ start signal in vehicle without
trical devices ,/i/ i!,,%~ -~ cigarette lighter ~,
~I. ,~..~:

19141 20537
Read-only memory pack
(MRI-E1)
MK369392
Data for inspection and con-
trol of engine control unit

19493
Memorycard (set in Multi-
UseTester II proper)
MB991500
To write data

20538

13E-17
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

The Multi-Use Tester II typically draws power from the (2) Powersupplied to Multi-Use Tester II from battery
cigarette lighter. In a vehicle without a cigarette lighter,
the powerconnection ofthe Multi-Use Tester II is differ-
ent dependingon the type of the starter switch as fol- ~~
lows:
A--...~
Multi-Use With cigarette lighter socket Without ciga-
Tester II T............... rette lighter
power supply Starter switch [ Starter switch socket
connection
........... typeA*b
typ~A*a E H~ ,
Cigarette
lighter socket
Battery O O D
--- - /
*a With starter switch type A, power supply to cigarette lighter
continues while engine is being cranked.
*b With starter switch type B, powersupply to cigarette lighter is
suspendedwhile engine is being cranked.
/
/
(1) Power supplied to Multi-Use Tester II from ciga-
rette lighter
1

c A
L I

®35849

(a) Place the starter switch in the LOCKposition.

(b) Connect the ~ Multi-Use Tester II harness (for
communication) to the ~ Multi-Use Tester II, then
insert the ~ ROMpack.
®41163
(c) Connect the ¯ clamp D (red) of the ~ battery
clamp harness to the (~ terminal E of the battery
(a) Place the starting switch at the LOCKposition.
and the O clamp F (black) to the O terminal G of the
(b) Connect the ~ Multi-Use Tester II harness
battery.
Multi-Use Tester II and insert the ~ read-only
(d) Fit the connector Aintothe socket H of the ~ bat-
memoryin the tester.
tory clamp harness.
(c) ConnecttheconnectorAtothecigarlightersocket.
(e) Fit together the Multi-Use Tester II connector B (16
(d) Connect the Multi-Use Tester II connector C (16
pins) and connector C (16 pins).
pins) to the data link connector B (16 pins).
NOTE:
NOTE:
Connectthe ¯ clamp D (red) of the ~ battery clamp
For the operating proceduresfor the Multi-Use Tester
harness before connectingthe O clampF (black).
II, refer to the instruction manualfor the Multi-UseTes-
terII.

13E-18
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

3.3 Reading and Erasing Diagnostic Trouble (b) Reading diagnostictroublecode

Codes
Twotypes of methodsare available for reading or eras- 10sdigit Units digit
ing a diagnostic trouble code; one using the Multi-Use -~x~-~"
r F-J~- ~
Tester II and one using the vehicle side diagnostic func-
ON
tions. I
(1) Methodusing Multi-Use Tester
OFF I~ ] /
(a) Current diagnostic trouble code
1) Checktoseethatthememoryclearswitch 1 iscon- 1.2*"0
nected.
2) Set the starting switch to ON.
3) Operate the Multi-Use Tester II to read the current 0.4~-
i
~-=

diagnostic trouble code and determine the fault o.4 =

location. Diagnosticswitch
disconnected
(b) Past diagnostic trouble code | First diagnostic trouble codedisplayed
(Diagnostic troublecode12)
1)
2)
Set the starting switch to ON.
Disconnect the memoryclear switch 1. ON
! r
Second
~’1, rq
"-’1 ~ ~,I--.....,~
OF’F I...IM(, nn’~
I LJUl diagnostic
3) Operatethe Multi-Use Tester II to read the past reg-
istered diagnostictrouble codes and determine the
I I
2.4
1 I

2.4
r

2.4
J
~
| trouble
-- code
2.8 displayed
fault location.

(c) Erasing diagnostic trouble codes ®13705

1) Set the starting switch to ON. 1) Diagnostictroublecodesareindicatedbythenum-

2) Operate the Multi-Use Tester II to erase all of the
diagnostic trouble codes stored in the engine con-
trol unit.
(2) Method Not Using Multi-Use Tester II (Method
Using Diagnostic Switch and Memory Clear
Switch)
(a) Current diagnostic trouble code
1) Set the starting switch to ON.
2) Disconnect the diagnostic switch 2.
3) The diagnostictrouble code is displayed byflashes
of the warning lamp 3.
ber of times the warning lamp 3 flashes and their
duration.
¯ The flashing intervals also differ betweenthe 10s
digit and units digit.
¯ 10s digit: 1.2 secondinterval
¯ Units digit: 0.4 secondinterval
¯ Each diagnostic trouble code is displayed from the
10s digit followed by the units digit. As for a code
which has no 10s digit, units digit only is displayed.
2) Each diagnostic trouble code is displayed three
times in succession.
3) If there is no more code stored, the sequence is
then repeated from the beginning with each code
indicated three times.
4) Whenthe diagnostic switch 2 is connected, the
engine control unit will immediately stop display-
ing codes.

13E-19
B ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

(c) Past diagnostic trouble codes
1 ) After reading the current diagnostic trouble codes
(with the diagnostic switch 2 disconnected), dis-
connect the memoryclear switch 1. Then the ~
warning lamp 3 will restart flashing.
2) Thistime, thewarninglampdisplaysthepastdiag-
nostictrouble codes. Determine the fault locations
based on the indicated codes,
(d) Erasing diagnostic trouble codes
A second
or more 3 seconds
~- =~- = ¯ Wheneverthe engine control unit has been replaced
Connected
Disconnect the memoryclear switch 1 and the diag-
nostic switch 2 then reconnect them. Thenall the diag-
nostic trouble codes stored in the engine control unit
will be cleared.
NOTE:
¯ If the contents of memoryare not to be cleared after
display of the stored codes, set the starting switch
to OFF with the memory clear switch 1 discon-
nected. Thereafter, connect the memory clear
switch.
¯ Whenyou change the combination of the injection
pumpand engine control unit, you mustrewrite the
pumpdata stored in the engine control unit, For this
purpose, be sure to perform the diagnostic trouble
code erasing procedure.
with a new one, be sure to erase the diagnostic

Released
I I
I
~
~1
Memory cleared
at this point
trouble codes by disconnecting the memoryclear
switch I and diagnostic switch 2 after connecting all
the connectors. Upon completing the procedure,
confirm that no diagnostic trouble codes is stored.

®02739

13E-20
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

3.4 Causesof Diagnostic Trouble CodeIssue, and Inspection Items

3.4.1 Diagnostic trouble codes
Multi-Use Tester II display Page of Multi-Use Tester II display Page of
reference reference
Diagnostic Message Diagnostic Message
trouble code trouble code
07 OVERREV. v~ P13E-21 23 TCV P13E-24
11 GOV. SERVO 24 ACCEL. SNSR-1 ~ P13E-25
14 SUB NE SNSR i: P13E-22 32 BST PRES SNSR
15 NE SNSR 33 | ECU SYSTEM
16 ACCEL. SNSR-2 ~: P13E-23 34 l (3 RESlS-I’OR
17 TCV FEEDBACK 45 ENG_REVERSE J .. P13E-26
~
19 AIR PRES SNSR 65 | -- ACCEL SW..... i
21 WTR TEMP SNSR ~ P13E-24 78 ~ J HEATER RELAY
22 RACK SNSR

3.4.2 Diagnostictrouble codeissue conditions, and checkitems

Performservice operationswith referenceto the diagnostictrouble codeissue conditionsandprobablecauses
shownbelow.

07 OVERREV,
Code issue condition
IReset condition]
Action taken by ECU
Probable cause and check item
Diagnostic trouble code 07 indicates that the engine speedis too high.
]The code is reset whenthe engine speed returns to a specified range.]
Governor operation is stopped.
Injection pump assembly’s Inspection of injection pumpassembly
control sleeve faulty (Have inspection performed by Bosch Automotive Systems service
¯ Over-revving of engine (for station.)
example, on downhill road)
¯ ECUfaulty

11 GOV. SERVO
Code issue condition
]Reset condition]
Action taken by ECU
Probable cause and check item
Diagnostic trouble code 11 indicates that the difference between the target control rack position and
actual control rack position is too large.
[No reset condition]
Governor operation is stopped.
¯ Control rack position sensor ¯ Perform checks on basis of Multi-Use Tester II service data.
faulty [_~] P13E-27
¯ ECUfaulty No. 09: Measurementof target rack position
No. 0A: Measurementof actual rack position
¯ Inspection of control rack position sensor
(Have inspection performed by Bosch Automotive Systems ser-
vice station.)

13E-21
 ELECTRONICALLY CONTROLLEDFUEL SYSTEM - TROUBLESHOOTING
14 SUBNE SNSR(injection pump side)
Code issue condition
[Reset condition]
Action taken by ECU
Probable cause and check item
14 SUBNE SNSR(injection pumpside)
15 NE SNSR(flywheel housing side)
Code issue condition
[Reset condition]
Action taken by ECU
Probable cause and check item
15 NE SNSR(flywheel housing side)
Code issue condition
[Reset condition]
Action taken by ECU
Probable cause and check item
13E-22
Diagnostic trouble code 14 indicates that the numberof pulses from engine speedsensor 2 (on the injec-
tion pump) is smaller than the numberof pulses from engine speed sensor 1 (on the flywheel housing).
[The code is reset when engine speed sensor 1 is normal and the number of pulses from engine speed
sensor 2 returns to normal].
¯ Normal control is effected using only engine speed sensor 1.
¯ If engine speedsensor 1 is also faulty, governor operation is stopped.
¯ Opencircuit or short circuit in ¯ Perform checks on basis of Multi-Use Tester II service data.
harness between ECU and P13E-27
engine speed sensor 2 No. 02: Measurementof engine speed
¯ Engine speed sensor 2 faulty ¯ Inspection using ECUconnector P13E-29
¯ ECUfaulty ~ : Measurementof resistance of engine speed sensor 2
¯ Inspection of engine speed sensor 2
i P13E-32: Inspection of Electrical Equipment~
¯ Check of circuit between ECUand engine speed sensor 2
Diagnostic trouble codes 14 and 15 are both issued if engine speed sensor 1 (on the flywheel housing)
and engine speedsensor 2 (on the injection pump) fail at the sametime.
[The code is reset whenpulses are applied from engine speed sensor 1 or engine speedsensor 2 following
engine startup.]
Fuel injection timing control is stopped, and governor operation is stopped.
¯ Opencircuit or short circuit in ¯ Perform checks on basis of Multi-Use Tester II service data.
harness between ECU and :Ld P13E-27
engine speed sensors 1 and 2
No. 02: Measurementof engine speed
¯ Engine speed sensors l and 2 ¯lnspectionusingECUconnector .jP13E-29
fa u Ity
¯ ECUfaulty ~ : Measurement of resistance of engine speed sensor 2
: Measurementof resistance of engine speed sensor 1
¯ Inspection of engine speed sensors 1 and 2
~i P13E-32: Inspection of Electrical Equipment~
¯ Check of circuit between ECUand engine speed sensors 1 and 2
Diagnostic trouble code 15 indicates that the numberof pulses from engine speed sensor 1 (on the fly-
wheel housing) is smaller than the numberof pulses from engine speedsensor 2 (on the injection pump).
[The code is reset when engine speed sensor 2 is normal and the number of pulses from engine speed
sensor 1 returns to normal.]
¯ Normal control is effected using only engine speed sensor 2.
¯ If engine speedsensor 2 is also faulty, governor operation is stopped.
¯ Opencircuit or short circuit in ¯ Perform checks on basis of Multi-Use Tester II service data.
harness between ECUand _ P13E-27
engine speed sensor 1 No. 02: Measurementof engine speed
¯ Engine speed sensor l faulty ¯Inspection usingECUconnector._~ P13E-29
¯ ECUfaulty B : Measurementof resistance of engine speed sensor 1
¯ Inspection of engine speed sensor 1
L!!P13E-32 Inspection of Electrical Equipment
’ ¯ Check of circuit between ECUand engine speed sensor 1
 ELECTRONICALLY CONTROLLED FUEL SYSTEM -
16 ACCEL. SNSR-2
Code issue condition
[Reset condition]
Action taken by ECU
Probable cause and check item
17 TCV FEEDBACK
Code issue condition
[Reset condition]
Action taken by ECU
Probable cause and check item
19 AIR PRESSNSR
Code issue condition
[Reset condition]
Action taken by ECU
Probable cause and check item
TROUBLESHOOTING
Diagnostic trouble code 16 indicates short or open circuit in accelerator position sensor 2 harness and
faulty sensor proper. (If diagnostic trouble code 16 is issued, inspections for diagnostic trouble code 24
must also be performed.)
The code is issued whenaccelerator position sensor 2 voltage is out of specified limits.
[Whenaccelerator position sensor 2 voltage is back within specified limits, a reset is made.]
¯ Normalcontrol is effected using only non-faulty accelerator pedal position sensor 1.
¯ If accelerator pedal position 1 is also faulty, control is effected using assumptionsof 100%with the
pedal depressed and 0%with the pedal released.
¯ Openor short circuit in har- ¯ Perform checks on basis of Multi-UseTester II service data.
nessbetweenECUand . P13E-27
accelerator position sensor 2
No. 03, 04: Measurementof throttle opening indicated by
¯ Accelerator position sensor 2 accelerator pedal position sensor
faulty or poorly adjusted
No. 5: Measurementof accelerator pedal position sensor’s
¯ ECUfaulty output voltage
¯ Inspection of accelerator pedal position sensor
¯ Check of circuit between ECUand accelerator pedal position sen-
sor 2
Diagnostic trouble code 11 indicates that the difference betweenthe target and actual timer positions
exceedsa specified limit.
[After a return to a normal condition, the code is reset whenthe starter switch is turned from OFFto ON.]
Fuel injection timing control is stopped.
¯ Timer control valve faulty ¯ Perform checks on basis of Multi-Use Tester II service data.
LIj P13E-27
¯ Electronic timer faulty
¯ Engine hydraulic system faulty No. 12: Measurementof timer angle difference
¯ ECUfaulty ¯ Inspection of timer control valve main body
L-~i P13E-32: Inspection of Electrical Equipment E
¯ Inspection of engine hydraulic system i !i Gr 12
¯ Inspection of electronic timer
(Have inspection performed by Bosch Automotive Systems ser-
vice station.)
Diagnostic trouble code 19 indicates short or open circuit in air pressure sensor harness and faulty air
pressure sensor (built in ECU).
The code is issued whenair pressure sensor voltage is out of specified limits.
[Whenair pressure sensor voltage falls back within specified limits, a reset is made.]
Air pressure is defaulted to100 kPa {7(~0 mmHg}. - .........
¯ Air pressure sensor [built in ¯ Perform checks on the basis of Multi-Use Tester II service data.
ECU)faulty, i.’l P13E-27
¯ ECUfaulty No. 18: Air pressure measurement
13E-23
 ELECTRONICALLY CONTROLLED FUEL SYSTEM -
21 WTR TEMP SNSR
Code issue condition
[Reset condition]
Action taken by ECU
Probable cause and check item ¯ Open or short circuit in har-
22 RACK SNSR
Code issue condition
[Reset condition]
Action taken by ECU
Probable cause and check item
23 TCV
Codeissue condition
[Reset condition]
Action taken by ECU
Probable cause and check item
13E-24
TROUBLESHOOTING
Diagnostic trouble code 21 indicates open circuit in water temperature sensor harness and faulty sensor
proper.
The code is issued whenwater temperature sensor voltage is out of specified limits.
[Whenwater temperature sensor voltage falls back within specified limits, a reset is made.]
Controls are continued assuming that coolant temperature is -20°C when engine is started and 80;C
when engine is running.
¯ Perform checks on basis of Multi-Use Tester II service data.
ness between ECUand water ~! P13E-27
’ temperature sensor No. 16: Measurementof engine coolant temperature
¯ Water temperature sensor ¯ Inspection using ECUconnector: P13E-29
fa u Ity
~ : Measurementof resistance of coolant temperature sensor
¯ ECUfaulty
¯ Inspection of coolant temperature sensor
L-~; P13E-32:Inspection of Electrical Equipment
¯ Check of circuit between ECUand coolant temperature sensor
Diagnostic trouble code 22 indicates that the control rack position sensor’s output voltage is outside speci-
fled limits.
[No reset condition]
Governor is temporarily stopped. Feedbackcontrol is resumedafter the engine is restarted.)
¯ Control rack position sensor ¯ Perform checks on basis of Multi-Use Tester II service data.
faulty ~-~l P13E-27
¯ Control rack not moving No. 0A: Measurementof actual rack position
smoothly ¯ Inspection of control rack position sensor and control rack
¯ Governoractuator’s link faulty (Have inspection 3erformed by Bosch Automotive Systems ser-
e ECUfaulty vice station.)
Diagnostic trouble code 23 is issued in the following circumstances:
(1) The ECUissues a command to turn the timer control valve OFFfollowing a short circuit in the
timer control valve.
[The code is reset whenthe timer control valve returns to normal.]
(2) The ECUissues a command to turn the timer control valve ONfollowing an open circuit in the
timer control valve.
[After the opencircuit is rectified, the code is reset whenthe starter switch is turned from OFFto ON.]
Fuel injection timing control is sto ~ped.
¯ Opencircuit or short circuit in ¯ Perform checks on basis of Multi-Use Tester II service data.
harness between ECU and ’~1 P13E-27
timer control valve No. 12: Measurementof timer angle difference
¯ Timer control valve faulty ¯ Inspection of timer control valve
¯ ECUfaulty
ill P13E-32:Inspection of Electrical Equipment!~-~!
¯ Check of circuit betweenECUand timer control valve
 ELECTRONICALLY CONTROLLED FUEL SYSTEM -
24 ACCEL. SNSR-1
Code issue condition " Diagnostic trouble code 24 indicates short or open circuit in accelerator position sensor 1 harness and
]Reset condition]
Action taken by ECU
Probable cause and check item
32 BST PRES SNSR
Code issue condition
[Reset condition]
Action taken by ECU
Probable cause and check item
33 ECU SYSTEM
Code issue condition
]Reset condition]
Action taken by ECU
Probable cause and check item ECUfaulty
34 Q RESISTOR
Codeissue condition
[Reset condition]
Action taken by ECU
Probable cause and check item
TROUBLESHOOTING
/ must
faultyalso
sensor proper. (If diagnostic trouble code 24 is issued, inspections for diagnostic trouble code 16
be performed.)
i Thecode is issued whenaccelerator position sensor 1 voltage is out of specified limits.
i [Whenaccelerator position sensor 1 voltage falls back within specified limits, a reset is made.]
¯ Normalcontrol is effected using only non-faulty accelerator pedal position sensor 2.
¯ If accelerator pedal position 2 is also faulty, control is effected using assumptionsof 100 %with the
pedal depressed and 0 % with the pedal released.
¯ Openor short circuit in har- ¯ Perform checks on basis of Multi-Use Tester II service du1~J
nessbetweenECUandaccel- I. P13E-27
erator position sensor 1
No. 03, 04: Measurement of throttle opening indi(;al~.’d by
¯ Accelerator position sensor 1 accelerator pedal position sensor
faulty or poorly adjusted
No. 5: Measurementof accelerator pedal position
¯ ECUfaulty sensor’s output voltage
¯ Inspection of accelerator pedal position sensor
¯ Check of circuit betweenECUand accelerator pedal position sen
sor 1
Diagnostic trouble code 32 indicates short or open circuit in boost pressure sensor harness and faulty sen-
sor proper.
The code is issued whenboost pressure sensor voltage is out of specified limits.
[Whenboost pressure sensor voltage falls back within specified limits, a reset is made.]
Control is effected with the boost ;ressure assumedto be fixed at 0 kPa {0 mmHg}.
¯ Openor short circuit in har- ¯ Perform checks on basis of Multi-Use Tester II service data.
ness between ECUand boost ~ P13E-27
pressure sensor No. 2D: Measurementof boost pressure
¯ Boost pressure sensor faulty ¯ Inspection of boost pressure sensor main body
¯ ECUfaulty
IJ, P13E-32:Inspection of Electrical Equipment
¯ Check of circuit between ECUand boost pressure sensor
’ Diagnostic trouble code 33 indicates a processing error or memoryerror in the ECU.
[No reset condition]
Governor operation is stopped.
iJ -
Diagnostic trouble code 34 indicates short or open circuit in injection quantity adjusting resistor harness
and faulty adjusting resistor,
Thecode is issued wheninjection quantity adjusting resistor voltage is out of specified limits.
[Wheninjection quantity adjusting resistor voltage falls back within specified limits, a reset is made.]
Injection quantity correction value is fixed at No. 1 value.
¯ Openor short circuit in har- ¯ Perform checks on basis of Multi-Use Tester II service data.
ness between ECUand injec- L.~! P13E-27
tion quantity adjusting resistor No. 14: Check of resistor numberof fuel injection quantity
¯ Injection quantity adjusting re- adjusting resistor
sistor faulty ¯ Inspection using ECUconnector P13E-29
¯ ECUfaulty ~ : Measurementof resistance of fuel injection quantity
adjusting resistor
¯ Inspection of fuel injection quantity adjusting resistor
i’~ P13E-32:Inspection of Electrical Equipmenti~P~I
¯ Check of circuit betweenECUand fuel injection quantity adjusting
resistor
13E-25
i~ ELECTRONICALLY
45 ENG. REVERSE
Codeissue condition
[Reset condition]
Action taken by ECU
Probable cause and check item
65 ACCEL SW
Codeissue condition
]Reset condition]
Action taken by ECU
Probable cause and check item
78 HEATERRELAY
Codeissue condition
[Reset condition]
Action taken by ECU
Probable cause and check item
13E-26
CONTROLLED FUEL SYSTEM - TROUBLESHOOTING
Diagnostic trouble code 45 indicates that an extremely low engine speed(a speed lower than that result-
ing from cranking with the starter) has been detected with the starter switch in the OFFposition.
[The code is reset whenthe engine speedis no longer detected with the starter switch in the OFFposition
or whenthe starter switch is turned to the ONposition.]
Governor operation is stopped
¯ Operating error at time of en-
gine startup
¯ Poor matching of connected
devices
¯ ECUfaulty
Diagnostic trouble code 65 indicates short or open circuit in accelerator pedal switch harness and faulty
accelerator switch.
The code is issued whenaccelerator pedal is released (accelerator switch ON) and accelerator pedal open-
ing signal is input.
[Whenaccelerator pedal opening signal returns to normal, a reset is made.]
Normalcontrol is effected.
¯ Openor short circuit in bar- ¯ Perform checks on basis of Multi-Use Tester II service data.
ness between ECUand accel- iv J P13E-27
erator pedal switch No. 03, 04: Measurementof throttle opening indicated by
¯ Accelerator pedal switch faulty accelerator pedal position sensor
¯ ECUfaulty No. 69: Checkof operation of accelerator pedal switch
¯ Inspection using ECUconnector P13E-29
: Checkof continuity of accelerator pedal switch
¯ Inspection of accelerator pedal switch
¯ Check of circuit between ECUand accelerator pedal switch
Diagnostic trouble code 78 is issued in the following circumstances:
(1) The ECUissues a command to turn the heater relay OFFfollowing a short circuit in the heater
relay.
[The code is reset whenthe heater relay returns to normal.]
(2) The ECUissues a command to turn the heater relay ONfollowing an open circuit in the heater
relay.
[No reset condition]
Preheat control is stopped.
¯ Opencircuit or short circuit in ¯ Perform checks on basis of Multi-Use Tester II service data.
harness between ECUand -~] P13E-27
heater relay No. 92: Checkof operation of heater relay
¯ Heater relay faulty ¯ Actuator test using Multi-Use Testerlll. P13E-28
¯ ECUfaulty No. BC: Check of operation of heater relay
¯ Inspection of heater relayi~i Gr 16
¯ Check of circuit between ECUand heater relay
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING D

3.5 Multi-Use Tester II Service Data

Multi-Use Tester II display Condition at time of Normal condition

inspection

01 BATT VOLTAGE I ¯ ¯. ¯ ¯ V Idling 20 to 30 V

02 ENGINE SPEED ¯ ¯ ¯ ¯. rpm Racing Sameas tachometer indication
(with engine running)
03 ACCEL (%) ¯ ¯ ¯. ¯ % Accelerator pedal released 0 %
Accelerator pedal gradually depressed Gradually increases
Accelerator pedal fully depressed 100 %
04 ACCEL (%) REAL ¯ ¯ am. ¯ % Accelerator pedal released 0 %
! Accelerator pedal gradually depressed Gradually increases
i ........ ’
I Accelerator pedal fully depressed 100 %
05 ACCEL(V) i.¯ ¯ ¯V Accelerator pedal gradually depressed Depends on vehicle specifica-
! from released position tions
O9 TARGET RACK i| ¯ ¯" ¯ ¯ mm Starter switch ON 3 mm
0A REAL RACK ¯ ¯. ¯ ¯ mm Starter switch ON 3 mm
12 TCVANG. DIFF. ¯ m. ¯ ¯ °CA Dependson vehicle specifications
¯ m. ¯ ¯ deg
14 Q RESISTOR m. ¯ ¯ ¯ - Sameas number marked on fuel
injection quantity adjusting
resistor
16 WATER TEMP ¯ ¯ I1. ¯ °C Engine cold Approximately same as ambient
temperature
¯ ¯ i. ¯ °F
During engine warmup Gradually increases
Engine stopped after warmup Gradually decreases
18 AIR PRESS ¯ ¯ ¯ i. kPa Altitude 0 m 101 kPa
¯ ¯ ¯ ¯. mmHg Altitude 600 m 95 kPa
Altitude 1,200 m 88 kPa
2D BOOST PRESS ¯ ¯ ¯ ¯. kPa Running at high idle speed Depends on vehicle specifica-
tions
¯ ¯ ¯ ¯. mmHg
4F DIAGNOSIS SW ON/OFF Diagnosis switch ON ON
(connected to connector)
Diagnosis switch OFF OFF
(disconnected from connector)
51 DIAG LAMP(U) ON/OFF Starter switch in ONposition ON
(engine not started)
Starter switch in OFFposition OFF
52 DIAG LAMP(R) ON/OFF Starter switch in ONposition ON
(engine not started)
Starter switch in OFFposition OFF
56 KEY SW ! ON/OFF Starter switch in ON position ON
Starter switch in any position except OFF
ON
----62 ....... DIAG RESET SW ¯ ON/OFF Memoryclear switch ON ON
(connected to connector)
Memoryclear switch OFF OFF
(disconnected from connector)
67 PULL DOWN ON/OFF Normal condition OFF
Abnormal condition ON
(during pulldown control)

13E-27
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

Multi-Use Tester display Condition at time of Normal condition

inspection
No. Item Data
69 ACCEL SW ON/OFF Accelerator pedal depressed ON
Accelerator pedal released OFF
73 START SW ON/OFF Engine cranked with starter switch in ON
STARTposition
Starter switch in any position except OFF
START
91 PRE-HEAT LAMP ON/OFF Starter Coolant temperature ON
switch ON low

Coolant temPerature OFF

high
92 HEATER RELAY ON/OFF Starter Coolant temperature ON
switch ON low
Coolant temperature OFF
high

3.6 Actuator Tests Using Multi-Use Tester II

Multi-Use Tester II display Method of checking operation

No. Item
AC DIAG LAMP (U) ¯ Create warning lamp illumination conditions.
¯ Perform test with engine speed of zero and vehicle speed of zero.
¯ Causewarning lamp five times to be on for one secondthen off for
one second.
AD DIAG LAMP(R) ¯ Create warning lamp illumination conditions.
¯ Perform test with engine speedof zero and vehicle speed of zero.
¯ Causewarning lamp five times to be on for one second then off for
one second.
BB PRE-HEAT LAMP ¯ Create indicator lamp illumination conditions.
¯ Perform test with engine speedof zero and vehicle speed of zero.
¯ Causeindicator lamp five times to be on for one secondthen off for
one second.
BC HEATER RELAY ¯ Create air heater operating conditions.
¯ Perform test with engine speedof zero and vehicle speed of zero.
¯ Causeair heater five times to be on for one secondthen off for one
second.

13E-28
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

3.7 Inspection Using ECU Connector

Thesechecks allow correct transmission of ECUsignals via vehicle harnesses and connectors to be verified. They
are intended to assist in troubleshooting. The numbers((~]i, ~, etc.) in the tables correspond to reference num-
bers in section 3.4, "Causes of Diagnostic Trouble CodeIssue, and Inspection Items".
3.7.1 ECUterminal configuration

A: CW32A

,i,0 ,16/ 1,1, ,13121,

:4 23 22 21 20 19 18 15 14 13
-- L_3231/30 2912~ 26J 27212~ 2~

B: CW25A

8 6 5 4 t
18 16 "15 14 13 12 9
25~4~ I 23 22 21J 20I 19|

C: CW31A

tl7-0 9 8 7 6 5 4 3 I
122 2120 191817 16 151413 11
A 31 30 29 26 5

D: CW16A

i TTihl
4 3 2
11 10 9 8 7
1161151141 1
®4363g

No. Item Page of reference

Resistance of engine speed sensor 2
[o I."
92 Resistance of engine speed sensor 1

Resistance of coolant temperature sensor , I P13E-30

Resistance of fuel injection quantity adjusting resistor

Continuity of accelerator pedal switch

3.7.2 Inspection instructions

NOTE:
Someinspections are performed with the connector
removed, and others are performed with the connec-
tor fitted. Notethe following instructions:
¯ Do not touch any terminal other than the ones spe-
cified for the inspections.Beparticularly careful not
to causeshort circuits betweenterminals using the
tester probes.
¯ Terminal numbersshownin the tables are the num-
bers of terminals on the ECU.Be careful not to select
the wrongterminals for inspections.

13E-29
 ELECTRONICALLY CONTROLLED FUEL SYSTEM - TROUBLESHOOTING

Check item Method

Q Resistance of engine [Check conditions]

speed sensor 2 ¯ Starter switch OFF
¯ Connector removed. Check performed on vehicle-side harness.
[Normal condition]
Betweenterminals A 7 and A 19:2.1 to 2.5 ~2
Resistance of engine [Check conditions]
speed sensor 1 ¯ Starter switch OFF
¯ Connector removed. Check performed on vehicle-side harness.
[Normal condition]
Betweenterminals A 8 and A 2~: 2.1 to 2.5 k~
Resistance of coolant [Check conditions]
temperature sensor ¯ Starter switch OFF
¯ Connector removed. Check performed on vehicle-side harness.
[Normal conditions]
Betweenterminals C 15 and A 30: 2.3to 2.6 k~ (at 20°C)
0.3 to 0.34 k~.~ (at 80°C)
Resistance of fuelinjec- [Check conditions]
[04~ tion quantity adjusting ¯ Starter switch OFF
resistor ¯ Connector removed. Check performed on vehicle-side harness.
[Normal conditions]
Betweenterminals B 4 and B 13:

,
1 I 270 ~ / 4 !
,o0o,, ,,000,,
1300~Z / 7 l 5600 ~

~ Continuity of accelera- [Check conditionsl

tor pedal switch ¯ Starter switch OFF
¯ Connector removed. Check performed on vehicle-side harness.
[Normal conditionsl
Between terminals (@ and O) B 2 and D ¯ Accelerator pedal depressed: Continuity does not exist.
¯ Accelerator pedal released: Continuity exists.

13E-30
i~~ELECTRONICALLY CONTROLLEDFUEL SYSTEM - INSPECTION OF ELECTRICAL EQUIPMENT

4. INSPECTIONOF ELECTRICALEQUIP-
Standard value i 2.3 ± 0.2 k~2
MENT (at 20°C) !

Checking Water Temperature Sensor (2) If the reading is out of the standardvalue range, re-
place the engine speed sensor, i; Gr11

1 NOTE:

C~ 2
If the sensoris not tightened sufficiently, it maynot
issue signals. Make sure the sensor’s tightening
torqueis correct.

<Engine speed sensor 2>

~ r~ --J [Inspection]

®34629

(1) Put the water temperature sensor in a container

filled with engine oil.
(2) Heat the engine oil to various specified tempera-
tures while stirring the engine oil.
(3) Measurethe resistance value between pins 1 and 2
(body).
24984
Standard value 20°C 2.3 to 2.6 kD
80°C 0.30to 0.34kD (1) Measure the resistance between terminals 1 and
Referance value in parentheses 3.
(4) If the reading is out of the standard value, replace
the water temperature sensor, l-~i Gr 14 Standardvalue 2.1to 2.5~

(2) Check for continuity between terminals 1 and ;

Checking Engine Speed Sensor
between terminals 2 and 3.
<Engine speed sensor 1>
Standard value i Continuity exists

(3) If either result is out of specification, replace the

sensor.

[Installation]

05049

(1) Measure the resistance value between pins 1 and

2.

24985
laE-a2
 ELECTRONICALLY
CONTROLLED
FUEL SYSTEM- INSPECTION OF ELECTRICALEQUIPMENT

(1) Screwin engine speed sensor 2 A until it touches Unit: mm

the protrusion on the timer flange Bo Tool name Shape
(2) Back off engine speedsensor 2 A by 0.8 to 1,0 turn InspectionHarness
MC854336
tO create a clearance C (1.2 to 1,5 mm)betweenthe
sensor and the protrusion B.
(3) -lighten the lock nut D on engine speedsensor 2

Checking Boost Pressure Sensor

<Checking by use of Multi-Use Tester I1> ~] P13E-27
~~>~
NOTE:
The boost pressure checking conditions differ be-
02806
tween when the boost pressure is checked by use of
the Multi-Use Tester II and whenit is checkedwithout (2) Mount pressure gauge A for measurement of the
use of the Multi-Use Tester II. So the standardvalues boost pressure.
alsodiffer. C: To inlet manifold
<Checking without use of Multi-UseTester I1> (3) Set the starting switch to ON.
(4) Measurethe output voltage of the boost pressure
sensor B according to the following table.
A
Item Connector Pin

C 1 Power(+) 2 GND(-) 3 Output (+)

Power voltage O----- O
*Output voltage
(Refer to the out-
put characteris- O -O
~ [~_
tics shown at
left.)

*: Start the engine before measurement.

°
®42415

(1) Disconnect the chassis side harness D and connect

the ~ inspection harness between them.

13E-33
i~~ ELECTRONICALLYCONTROLLEDFUEL SYSTEM - INSPECTION OF ELECTRICAL EQUIPMENT

Output Characteristics (1) Removethe connector from the timer control valve
then connect a 24V DCpower supply A and selector
switch B.
Temperature
25°C (2) Slightly loosen the eyebolt D on port
4.9 ~ (3) Run the engine at idling speed.
4.5 (4) Turn the selector switch B to the port E setting and
3.22 check that oil leaks from the eyebolt D of port C.
1.86 (5) Turn the selector switch B to the port F setting and
0.5 - checkthat oil stops leaking.
~ 1 (6) After confirming that oil stops leaking, tighten the
0 -34.3 33.7 98.7 163.7
{-255} {250} {740} {1230} eyebolt D to the specified torque.
I i i t

Boost pressure (kPa {mmHg}) Tightening torque 20 to 25 Nm(2 to 2.5 kgfm)

0278:
C: Engine oil outlet
(hydraulic pressure supply to electronic timer)
Standard Value 2-3 5V E: Engine oil inlet
1--2....... 0.5V/-34.3 kPa {-255 mmHg} F: Engine oil return outlet
1.86V/33.7 kPa {250 mmHg}
3.22V/98.7kPa{740mmHg} (7) If this inspection reveals any abnormality, replace
4.5V/163.7 kPa {1230 mmHg} the timer control valve. Gr 13A

(5) If the results of the above mentioned checks show <Checking valve resistances>
any deviation from the standard values, replace (1) Take resistance measurementsbetween terminals
the boost pressure sensor B. 1 and 3 and between terminals 2 and 4. Deter-
mine whether the measurements comply with the
Inspection of timer control valve
standard value.
<Checking valve operation>
Standard value 21.9 to 24.1 ~2

(2) Makesure that there is not continuity betweenter-

(~) minals 3 and 4; between terminal 3 andthe body;
and between terminal 4 and the body.
B A
(3) If these checks reveal any abnormality, replace the
timer control vaIve. Li Gr13A

(DC24V) I[~ Inspection of fuel injection quantity adjusting re-

sistor

No.

(~24981

~
/’//D/ C

AL2A No.

--E
O
02786
i"
24982

13E-34
 ELECTRONICALLY
CONTROLLED
FUEL SYSTEM- INSPECTION OF ELECTRICALEQUIPMENT

(1) Measurethe resistance of the fuel injection quan-

tity adjusting resistor. The standard value corre-
sponds to the resistor numbermarkedon the case.

Standard value Resistor No. 1 270 ~2

(at 20°C)
2 510 ~2
3 820 ~2
4 1300 ~2
5 2000 ~2
6 3300 ~-~
7 5600
8 i 15000 ~2

(2) If the measurement is out of specification, replace

the fuel injection quantity adjusting resistor.
NOTE:
The fuel injection quantity adjusting resistor is
matchedto the injection pump. Replace it only with
one that has the sameresistor number.

13E-35