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WORKSHOP MANUAL
C&E SERIES
ENGINE CONTROL SYSTEM

(6WF1-TC, 6WG1-TC (Common Rail) models)
SECTION 1A
NOTICE
Before using this Workshop Manual to assist you in performing

vehicle service and maintenance operations, it is recommended that
you carefully read and thoroughly understand the information
contained in Section-0 under the headings “GENERAL REPAIR
INSTRUCTIONS”.
All material contained in this Manual is based on latest product

information available at the time of publication.
All rights are reserved to make changes at any time without prior
notice.
Applicable Model:
C&E Series
This Manual is applicable to 2006 year model vehicles.

THIS MANUAL INCLUDES THE FOLLOWING SECTIONS:
SECTION No. CONTENTS

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

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

on
ABS Anti-lock Brake System A device to prevent brakes from locking
A/D Analog/Digital Analog/Digital
APP Accelerator Pedal Position The extent to which the accelerator pedal has
been depressed.
ASR Anti Slip Regulator A device to restrict slipping of the driven wheels.
CAN Anti Slip Regulator Communications between control devices
CKP Crankshaft Position Indicates the position of the crankshaft (flywheel).
Abbreviati Name Meaning, notes

on
DLC Data Link Connector A connector for connecting the scan tool.
DTC Diagnostic Trouble Code Self-diagnostic codes, trouble codes, diagnostic
codes
EBS Electronic Brake System An electronically-controlled brake system.
ECM Engine Control Module A computer for controlling the engine.
ECT Engine Coolant Temperature Temperature of the engine coolant.
ECU Electronic Control Unit Computers for various control functions.
EGR Exhaust Gas Recirculation Recirculation of exhaust gas.
EMI Electronic Magnetic Interference Electromagnetic Interference.
Exh Exhaust Exhaust gas.
FT Fuel Temperature The temperature of the fuel.
GND Ground Connection to ground/earth
GVW Gross Vehicle Weight The gross weight of the vehicle.
IAT Intake Air Temperature Temperature of air taken in (outside air
temperature).
MIL Malfunction Indicator Lamp Warning lamp MIL (check engine lamp)
OBD On Board Diagnostic Diagnostic system on the vehicle (or vehicle-
mounted malfunction diagnostic system)
PCV Pump Control Valve A valve that controls the volume of fuel flowing to
the fuel rail.
P/T Power Tilt Cab tilting mechanism.
PTO Power Take Off System for taking motive power.
PWM Pulse Width Modulation Modulation of wave pulse width
QOS Quick On Start Engine warming system.
RP Rail Pressure Pressure in the rail.
SBF Slow Blow Fuse Slow blow fuse.
SIG Signal Signal
TWV Two Way Valve Valve within an injector.
VGS Variable Geometry Turbo System Variable turbocharge system.
VSS Vehicle Speed Sensor Vehicle speed sensor
Wiring colors
The wiring in all harnesses can be distinguished by the
insulation colors. The harness that is the main circuit
within a given electrical system is identified by single-
colored wires, while sub-circuits of that system are
identified by striped colors. In wiring diagrams, sizes
and colors are indicated by the following method:
LNW38ASH015101
Symbols Colors Symbols Colors

B Black BR Brown
W White LG Light Green
R Red GR Gray
G Green P Peach
Y Yellow SB Sky blue
L Blue V Violet
O Orange
Explanation of Functions and Operations Electronic Control Fuel Injection System

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

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

Voltage (built in ECU)
load
circuit
APP sensor
Accelerator switch
PTO Remote
throttle sensor
Injector
Pressure limiter
Fuel leak pipe
Starter motor Fuel rail

Fuel pressure sensor
Flow damper
Supply pump
Air
cleaner
ECT sensor
Fuel filter
Fuel tank
CMP sensor
CKP sensor
Flywheel Feed pump Pre-fuel filter
HCW61ALF000201
System Control Schematic Diagram
Engine Control Module
Accelerator pedal position sensor input
Boost pressure sensor input

Basic fuel
injection rate
Crankshaft sensor
Camshaft sensor
Compensation Engine coolant temperature sensor input,

Common rail accelerator pedal position sensor input,
pressure sensor start switch input
Compensation
Vehicle speed sensor input,
clutch switch input
PCV opening/closing
timing decision Injector (TWV) power supply time,
timing decision
Common rail pressure sensor
Common rail
(normally high pressure)
TWV(Two Way Valve)
PCV
Supply
pump
Injector
Fuel tank
HCW4ADXF000201
Exhaust Gas Recirculation (EGR)
The EGR (Exhaust Gas Recirculation) system
recirculates part of the exhaust gas within the intake
manifold, mixing inert gases with intake air. This lowers
the combustion temperature, reducing the generation
of NOx. The EGR volume is controlled by the action
(opening and closing) of the EGR valve, which is
situated between the exhaust manifold and the intake
manifold. The EGR volume is determined according to
the engine speed and engine load rate (fuel injection
volume). A vehicle equipped with an intercooler turbo
has a cooler built into the EGR gas channel, so that hot
EGR gas is cooled by the cooler and mixed with fresh
air. This achieves a greater reduction in combustion
temperature than normal EGR, further reducing NOx
generation (cooled EGR). Furthermore, the EGR
system uses a one-way valve to restrict the backward
flow of EGR gas. As one-way flow is ensured, the EGR
volume can be increased.
System Control Schematic
5
6
7
8
4
9
3
10
17
2
11
1 12
16
15 14 13
HCW4ADMF001501
Legend
1. EGR gas cooling device 9. Engine load
2. EGR valve 10. Accelerator pedal sensor
3. Air line 11. EGR valve
4. EGR magnetic valve 12. EGR gas cooling device
5. Air tank 13. Non return valve
6. Engine control module (ECM) 14. Intake air
7. Crankshaft position (CKP) sensor 15. Non return valve
8. Engine speed 16. Engine
17. Exhaust gas
Variable Geometry Turbo System (VGS)

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

Engine Speed of the Compensation
VGS steps
B
Various Switch
Signals Input A
Magnetic Valve control Circuit

Engine Control Module
Air
Cylinder
Nozzle Vane
HCW61AMF001101
Pneumatic Cylinder
9
Port 3 Port 2 Port 1
12
15
18
21 (Full Stroke)
HCW61ASF000901
Pressurizes Air Atmospheric Open

Stroke
Port
0 3 6 9 12 15 18 21
Port1
Port2
Port3
HCW61ASF001001
Idling Control AUTO … Auto mode

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

If, and only if, an external accelerator is connected, the
fuel injection characteristics can be switched by the
status of the PTO switch, which is input to the engine
control. However, as before, fuel injection characteristic
switching is only possible when the vehicle is at rest.
The switching conditions are as follows:
Conditions in which it is possible to switch from driving
characteristics to working characteristics (conditions in
which working characteristics can be used).
All the following conditions must be satisfied (these are
AND conditions)
• PTO switch is turned on (PTO switch: ON)
HCW5ADSH000301 • Vehicle is at rest.
• Parking brake is engaged (parking brake switch:
Idling control switch On)
The idling control switch can be used to adjust the • External accelerator input is normal (PTO remote
idling speed. The maximum speed varies according to throttle sensor voltage 0.1-4.8V)
the engine type, vehicle specification and engine
• External accelerator is in idling position (PTO
temperature.
remote throttle sensor <5%)
Up • Drive accelerator is in idling position (accelerator
While the switch is pressed to the Up side, the engine sensor <5%)
speed increases and the idling speed can be
• PTO accelerator switch is not switched on (PTO
increased.
accelerator switch: Off)
Down
While the switch is pressed to the Down side, the NOTE:
engine speed decreases and the idling speed can be These are added setting (modified) switches for
decreased. However, it cannot be reduced below the concrete pump vehicles.
minimum idling speed.
• No DTC has been issued to stop PTO control
(refer to DTCs)
Conditions in which it is possible to switch from working
characteristics to driving characteristics (conditions in
which driving characteristics can be used).
UP All the following conditions must be satisfied (these are
AND conditions)
DOWN • PTO switch is not turned on (PTO switch: OFF)
• Vehicle is at rest.
• Parking brake is engaged (parking brake switch:
High Low On)
UP UP • External accelerator input is normal (PTO remote
throttle sensor voltage 0.1-4.8V)
• External accelerator is in idling position (PTO
remote throttle sensor <5%)
DOWN DOWN
• Drive accelerator is in idling position (accelerator
HCW61ASH000101
sensor <5%)
• No DTC has been issued to stop PTO control
PTO Control (fuel injection characteristic (refer to DTCs)
switching)
PTO control under the engine control system is called
“fuel injection characteristic switching”.
Accelerator Switching Conditions “switching • Parking brake is engaged (parking brake switch:
between driving accelerator and external On)
accelerator” • External accelerator is in idling position (PTO
Conditions in which the external accelerator can be remote throttle sensor <5%)
used (driving accelerator and external accelerator can Conditions in which the external accelerator is disabled
both be used) (only the driving accelerator can be used)
All the following conditions must be satisfied (these are When any of the conditions below is satisfied
AND conditions) • The parking brake has been released.
• Vehicle is at rest. • The vehicle is in motion (vehicle speed has been
detected).
1 4
2
HCW4ADMF001801
Legend
1. PTO switch 5. PTO accelerator switch “ON” when using
2. Governor characteristic switching conditions operation characteristics
3. Accelerator open 0% 6. Operation characteristics
4. Drive characteristics
Speed Restriction Control
Speed restriction control is a function by which the
engine control module (ECM) controls the fuel injection
volume on the basis of the vehicle speed signal and the
engine speed, so that vehicle speed cannot exceed the
set value (90km/h).
The vehicle speed signal is received by the speed
sensor control unit from the vehicle speed sensor. The
speed sensor control unit corrects the vehicle speed
signal according to the type of vehicle and forwards it to
the ECM, meters and elsewhere. The ECM recognizes
the engine speed from the signal provided by the CKP
signal.
Equipment with speed restriction control (device) is
mandatory under the Road Trucking Vehicle Law for
vehicles with GVW of 8t or more, or with cargo load of
5t or more.
Meter
Other C/U
Engine ECM VSS C/U
Fuel Injection Control
Crank Position (CKP) Ve h i c l e S p e e d S e n s o r

Sensor (VSS)
LFW36ESF000401
Cruise Control Set Coast function (lower the cruise control set
This function can maintain speed at a set level (within speed)
the range 40-80km/h) without depression of the If the Cruise Set switch is pressed during the cruise
accelerator pedal. When the cruise main switch is control, speed reduces for as long as the switch is
turned On (the Cruise Main lamp lights) and the target pressed. Release the Cruise Set switch when speed
speed is reached, the Cruise Set switch can be has fallen to the desired level to change the set speed
operated (push - release) to put the vehicle into auto to the vehicle speed at that time.
cruise mode (the Cruise Set lamp lights). Then, the
target speed is maintained even if the accelerator pedal Tip Down function
is released. This function lowers the set speed during the cruise
control. It is used for fine tuning of the set speed. If the
Temporary Acceleration Function Set switch is briefly pressed and released during the
During the cruise control, the accelerator pedal can be cruise control, the set speed is reduced by 1km/h for
depressed for temporary acceleration. When the each time it is pressed. Fine adjustment of up to 10km/
accelerator pedal is released, the vehicle decelerates h (press 10 times) is possible. However, It is not
and returns to cruise control mode. possible to adjust the set speed below the minimum
cruise control set speed (40km/h).
NOTE: Resume function (revert to cruise control mode).
If tip down operation is used repeatedly in a short If the cruise control function has been cancelled, the
period, the gap between set speed and actual speed Cruise Resume switch can be operated (press -
increased, so that the auxiliary brake linkage cruise release) to revert to the cruise control state that applied
control function may act to use auxiliary braking before the cancellation (the Cruise Set lamp lights).
(exhaust brake and retarder). However, if the cruise control was cancelled under any
of the following conditions, it is not possible to revert to
Set Acceleration function (raise the cruise control
the cruise control state that applied before the
set speed)
cancellation.
During the cruise control, the Cruise Resume switch The cruise control state must be set again.
can be pressed to raise the speed for as long as it is • The Cruise Main switch was turned Off (Cruise
pressed. Release the Cruise Resume switch when Main switch: Off).
speed has increased to the desired level to change the
set speed to the vehicle speed at that time. • The Cruise Set switch and the Cruise Resume
switch are pressed at the same time (Cruise Set
Tip Up function switch: On AND Cruise Resume switch: On).
This function raises the set speed during the cruise • A malfunction occurs in the engine control system
control. It is used for fine tuning of the set speed. If the (refer to DTCs).
Cruise Resume switch is briefly pressed and released • The engine stops.
during the cruise control, the set speed is raised by
1km/h for each time it is pressed. Fine adjustment of up NOTE:
to 10km/h (press 10 times) is possible. However, It is The Resume function is operable when vehicle speed
not possible to adjust the set speed above the is 40km/h or more.
maximum cruise control set speed (80km/h).
Cruise control cancel

The cruise control function is cancelled under any of
the following conditions:
• The Cruise Main switch is turned Off (Cruise Main
switch: Off)
• Vehicle speed falls down to 30km/h or less.
• The Cruise Set switch and the Cruise Resume
switch are pressed at the same time (Cruise Set
switch: On AND Cruise Resume switch: On).
• A malfunction occurs in the engine control system
(refer to DTCs).
• The engine stops.
• The clutch pedal is depressed (Clutch switch: Off).
• The foot brake is depressed (Brake switch-1: On
OR Brake switch-2: On).
• The Exhaust Brake lever is operated (Exhaust
Brake switch: On).
• The Retarder lever is operated (Retarder switch:
On).
• The Cruise Cancel switch is pressed (Cruise
Cancel switch: Off).
• The Shift lever is moved to neutral (Neutral switch:
On).
Auxiliary Brake Linkage cruise control
During the cruise control, auxiliary braking (exhaust
braking and retarder) are automatically linked, so that
this function restricts acceleration on gentle downward
slopes. The aim is to reduce driving strain on the driver
(by reducing foot brake operations required to counter
speed increases).
When a vehicle driving under the cruise control enters
a downhill slope and the vehicle speed exceeds the
cruise set speed, the exhaust brake acts first to restrict
any increase in speed. If the vehicle speed increases
while the exhaust brake is operating, the retarder acts
in addition to the exhaust brake to restrict any increase
in speed. (The stop lamps light during auxiliary
braking).
When vehicle speed has fallen to the cruise set speed,
auxiliary braking ceases (the retarder is released first,
followed by the exhaust brake).
Downward slope Downward slope Flat way
Exhaust brake and retarder Exhaust brake operates.
operates.
HCW61ASF000301
Auxiliary braking (exhaust brake and retarder) during
the cruise control is performed through the exhaust
brake and retarder control unit. The Engine Control
Module (ECM) sends an action signal to the exhaust
brake and retarder control unit. In response to the
signal, the exhaust brake and retarder control unit
engages and releases auxiliary braking (exhaust brake
and retarder).
Exhaust
brake operate signal
Engine control Exhaust brake and

Retarder
unit retarder control unit
operate signal
Vehicle speed signal (25pulse)
Retarder Exhaust
Speed sensor control unit
M/V brake M/V
Vehicle speed sensor
HCW61ASF000401
ECM Communications
The various control units are in communication and
signals necessary for control functions (accelerator
opening, vehicle speed, various switch signals, etc.)
are sent and received.
The communications methods are Pulse Width
Modulation (PWM) and Controller Area Network (CAN).
CAN (Controller Area Network) Communications
ABS/ASR EBS Meter MIMAMORI

ECU (for Truck) ECU (for Tractor) ECU ECU
Resistor Resistor
Air
Smoother-G
Suspension ECM TCM
ECU ECU
HCW61AMF001201
Communications Methods • EBS control unit: Tractor

• PWM (Pulse Width Modulation)
Functions for communications with ABS/ASR, EBS
One type of pulse modulation method, in which the
control units
frequency and amplitude are constant and the
pulse width is varied according to the signal. The Engine Control Module (ECM) uses CAN
The proportion of On time in one cycle is varied to communications with the ABS/ASR and EBS control
create the signal. units.
• CAN (Controller Area Network) • ECM → ABS/ASR and EBS control units (normal
CAN communication is implemented with two transmission) The ECM sends the current
wires (communication lines) to connect control accelerator pedal depression distance, as the ASR
units to each other for communication. accelerator opening signal, to the ABS/ASR and
Each control unit is able to exchange multiple data EBS control units.
items simultaneously at different transfer rates • ABS/ASR and EBS control units → ECM
(high/ medium/ low speed) and with the number of (transmission during ASR control only) The ABS/
signals. Furthermore, signals are shared by each ASR and EBS control units send the restricted
control unit to use for various types of control. accelerator pedal depression distance, as the fuel
reduction volume signal, to the ECM.
Functions for communications with ABS/ASR, EBS
control units and fuel reduction volume control
NOTE:
• ABS/ASR control unit: Truck
Fuel Reduction volume control
If the ABS/ASR and EBS control units detect slippage
of driven wheels, they send the fuel reduction volume
signal, calculated from the ABS/ASR and EBS
accelerator opening signal, to the ECM. The ECM uses
this fuel volume reduction signal to choke the fuel
injection volume, limiting the output of the engine to
restrict slippage of driven wheels.
Engine Control Module (ECM)
Fuel injection
Detection
Accelerator Pedal APP Control
of the
Position (APP) Sensor injection
quantity
APP Fuel Cut Signal
Signal
ABS/ASR, EBS
ECU
HCW61ASF001101
Engine speed control and communications with the
Smoother-G control unit
When ASR operates, or when there is a gear change
request, in order to synchronize the transmission
revolutions a signal is sent to the engine control module
(ECM) (request to increase or decrease the fuel
injection) to control the engine speed.
Also, the following communications functions are used
with the Smoother-G control unit.
CAN Communications
Accelerator Pedal
APP
Position (APP) Sensor Engine
Switch Signals
Control Smoother-G
Signals Vehicle Speed
Module Control Unit
State of Cruise Control
(ECM)
Fuel Cut Signal
ABS/ASR
EBS
ECU
Accelerator Pedal
Engine Control
Engine
HCW61AMF001301
Accelerator Pedal
Engine Smoother-G
Position (APP) Sensor
Control Control Unit
Module
21 (ECM)
CAN-H
18
CAN-H
95
Clutch Switch
CAN-L
25
52
CAN-L
Stop Lamp Switch 1 96
53
Stop Lamp Switch 2
80
Cruise Main Switch
60
Cruise Operation Signal
Cruise Set Switch
79
Retarder Operation Signal
Cruise Release Switch 1 45
93
Exhaust Brake
Cruise Resume Switch Operation Signal
92 42
Cruise Release Switch 2
94
27
Exhaust Brake
Speed Sensor
and Retarder
Control Unit
Control Unit
Vehicle Speed Sensor Exhaust Retarder

Brake M/V M/V
HCW61ALF000801
Communications control with the meter ECU
The meter ECU uses the Engine Control Module
(ECM) CAN communications to send engine coolant
temperature data, overheat signal and overheat
warning buzzer action request signal to operate the
engine coolant temperature meter, overheat warning
lamp and overheat warning buzzer.
The ECM receives the parking switch signal from the
meter ECU using CAN communications.
Thermo Meter
Engine Coolant Signal CAN

Temperature Meter
Engine Control
(ECT) Sensor ECT Signal ECU
Module (ECM) Over Heat
Parking Brake
Warning Lamp
Switch Signal
Over Heat
Warning Buzzer
Parking Brake
Switch
HCW61ASF001201
Engine Speed Output to the Tachometer

The Engine Control Module (ECM) outputs engine
speed signal (4 pulses for one rotation of the engine) to
the tachometer as tachometer output. The tachometer
uses the engine speed signal received from the ECM to
display the engine speed.
1 2 3 4 5
HCW46ESF000401
Legend
1. Crankshaft Position (CKP) Sensor 4. Tachometer output
2. Engine Speed 5. Tachometer
3. Engine Control Module (ECM)
Idle position signal output to the exhaust brake and

retarder control unit
The Engine Control Module (ECM) outputs the
“accelerator pedal depression state (depressed/ not
depressed)” to the brake central control unit as an idle
position signal output.
The exhaust brake and retarder control unit uses the
“accelerator pedal depression state”, together with the
directly detected control operation states (exhaust
brake lever, retarder lever, clutch pedal etc.) to engage
and disengage the exhaust brake and retarder.
Accelerator Pedal
APP Engine Control
Position (APP)
Module (ECM)
Sensor
Idle Position
Signal Output
Exhaust Brake Switch
Exhaust Brake M/V
Retarder Switch
Exhaust Brake and
Retarder Control Unit Retarder M/V
Clutch Switch
HCW61ASF001301
Q Adjustment Data
When the vehicle is shipped, it has a label on the body
to notify of Q adjustment data. Use it to compare
against the content displayed on the scan tool (Tech2).
Label Positions
Q-ADJ T
HCW61ASF001401
Content of the label The ECM is installed under the center cluster inside the
cab. The ECM constantly monitors data sent from
various sensors, and controls the systems of the power
train. It performs diagnostic functions on systems,
detects problems in their operation and uses the MIL
1 2
(Check Engine lamp) to warn the driver, as well as
storing the DTC (diagnostic trouble code). The DTC
identifies the area affected by the problem and assists
the service engineer in making the repair.
ECM Functions
4 The ECM outputs 5V and other voltages to supply
power to the sensors and switches. This power supply
3 passes through the resistance of the ECM, so the
resistance is extremely high and even if a test light is
connected to the circuit, it will not light. In special
cases, the resistance of a normal multi meter may be
too low, so to obtain an accurate reading, it is
HCW46ESH003301 necessary to use a digital multi meter with an input
impedance of more than 10MΩ. Special tool 5-8840-
Legend
2691-0 is suitable. In the ECM, the ground or power
1. Q adjustment data numbers (Q1, Q2, Q3, from
supply circuits are controlled through transistors or
the left)
another device to control the output circuits.
2. Timing correction resistance value (not used)
3. Vehicle model
ECM and Component Parts
4. Factory management number (the number is
different for each vehicle) The ECM is designed to maintain gas emissions at
regulated levels while delivering superior driveability
and fuel efficiency. The ECM monitors the functions of
Engine Control Module (ECM) the engine and the vehicle through sensors such as the
The ECM Crank Position (CKP) sensor and the Vehicle Speed
(VS) sensor.
Explanation of ECM Voltage

The ECM applies standard voltage to various switches
and sensors. The ECM is able to apply voltages in this
way because its own resistance is very high, so that the
voltage actually applied to the circuit is low. In some
cases a test light connected to the circuit will not light.
The input impedance of the multi meter generally used
in servicing workshops is tool low, so they may not give
accurate readings in some cases. Use a digital multi
meter with input impedance of 10MΩ (For example, 5-
8840-2691-0) to obtain accurate readings.
ECM input/ output devices include analog/ digital
converters, signal buffers, counters and special drivers.
The ECM uses electronic switches to control most
components.
HCW4ADSH000301
Electrically Erasable Programmable ROM
(EEPROM)
The EEPROM is a permanent memory chip that is
soldered to the circuit board inside the ECM. It contains
the programs and calibration information the ECM
needs to control the actions of the power train.
The EEPROM cannot be replaced. Replace the ECM if
any malfunction is found in the EEPROM.
Precautions on ECM Servicing The PCV (Pump Control Valve) is attached to the
The ECM is designed to withstand normal current supply pump and controls the supply of fuel (output
consumption associated with driving. The circuits must volume) to the fuel rail. The Engine Control Module
not be overloaded. When testing for broken wires and (ECM) controls the time of communication to the PCV
short circuits, do not connect the ECM circuitry to a and so controls the fuel output volume.
ground connect or apply voltage to it, unless
specifically instructed to do so. Always use a digital
multi meter 5-8840-2691-0 to perform such circuit tests.
Supply Pump
HCW46ESH003601
The supply pump uses the rotary force of the ending to

highly pressurize fuel and pump it into the fuel rail. The
Pump Control Valve (PCV), Camshaft Position (CMP)
Sensor and feed pump are attached to the supply
pump.
PCV (Pump Control Valve)
MFW31ASH005001
Fuel Rail
HCW46DMF000101
Legend
1. Flow damper 3. Fuel pressure sensor
2. Pressure limiter
The fuel rail receives fuel from the supply pump, Flow Damper
maintains fuel rail (fuel) pressure and distributes fuel to
each cylinder. The fuel pressure sensor, flow damper
and pressure limiter are attached to the fuel rail.
HCW46ESH000101
The flow damper restricts pressure pulsation inside the Engine Coolant Temperature (ECT) Sensor
fuel rail and prevents injection of excess fuel through
the injectors. When the flow damper acts, fuel supply to
the injectors is stopped.
Pressure Limiter
3
2 1
HCW46ESH001201
Legend
1. Signal
2. Meter output
3. GND
HCW46ESH000201
The pressure limiter acts when pressure inside the fuel The engine coolant temperature (ECT) sensor is
rail becomes abnormally high, releasing the excess attached to the engine block thermostat housing. The
pressure. resistance of its thermistor changes with temperature.
The resistance value falls as the engine coolant
Fuel pressure sensor temperature rises, and vice versa. The Engine Control
Module (ECM) applies 5V to the ECT sensor through
the pull-up resistance and calculates the engine
coolant temperature from the change in that voltage.
The result is used in fuel injection control and other
control functions. The voltage is low when the
resistance is low (i.e. when the temperature is high),
and rises when the resistance is higher (when the
temperature is lower).
HCW46ESH000301
The fuel pressure sensor is attached to the fuel rail and

detects the fuel pressure inside it. The pressure is
converted into a voltage signal and sent to the Engine
Control Module (ECM). The voltage is higher with
higher pressure, and vice versa. The ECM calculates
the actual pressure in the fuel rail (the fuel pressure)
from the voltage signal sent by the sensor, and uses it
for fuel injection control and other purposes.
Cam Shaft Position (CMP) sensor Crankshaft position (CKP) sensor
1
1 2
HCW46ESH001101 HCW46ESH001301
Legend Legend
1. Signal 1. Signal (High)
2. GND 2. Signal (Low)
3. Power supply
The crank position (CKP) sensor is attached to the
The cam shaft position (CMP) sensor is attached to the flywheel housing. A CKP signal is generated when the
supply pump. A CMP signal is generated when the cam hole in the flywheel passes the sensor. The Engine
shaft inside the supply pump passes through the Control Module (ECM) identifies the cylinder from the
sensor. The Engine Control Module (ECM) identifies CKP signal and the CMP signal input from the cam
the cylinder from the crank shaft position (CKP) signal shaft position (CMP) sensor, determines the crank
and the CKP signal input from the CKP sensor, angle and uses it to calculate fuel injection control and
determines the crank angle and uses it to calculate fuel engine speed. These control functions are usually
injection control and engine speed. These control based on the CKP signal, but if the CKP sensor
functions are usually based on the CKP signal, but if malfunctions, they are based on the CMP signal.
the CKP sensor malfunctions, they are based on the
CMP signal.
Atmospheric Temperature Sensor Accelerator Pedal Position (APP) Sensor
2
3 2 1
1
HCW46ESH001401 HCW46ESH001501
Legend Legend
1. Signal 1. GND
2. GND 2. Signal
3. Temperature sensor 3. Power supply
The atmospheric temperature sensor is attached to the The Accelerator Pedal Position (APP) sensor is
inside of the front lid. The resistance of its thermistor attached to the top of the accelerator pedal and sends
changes with temperature. The resistance value falls a voltage signal to the Engine Control Module (ECM)
as the intake air (external air) temperature rises, and that corresponds to the angle of the accelerator pedal.
vice versa. The Engine Control Module (ECM) applies The ECM calculates the accelerator position from the
5V to the atmospheric temperature sensor through the voltage signal and uses it for fuel injection control and
pull-up resistance and calculates the intake air many other control functions.
temperature from the change in that voltage. The result
is used in fuel injection control and other control Vehicle Speed Sensor (VSS)
functions. The voltage is low when the resistance is low
(i.e. when the temperature is high), and rises when the
resistance is higher (when the temperature is lower).
MFW31ASH001401
The Vehicle Speed sensor (VSS) is attached to the Atmospheric Pressure Sensor
transmission, and the Hall effect circuit is attached to it.
The magnet attached to the output shaft of the
transmission rotates with the shaft and interacts with
the magnetic field generated to send a signal to the
speed sensor control unit. The Engine Control Module
(ECM) receives the vehicle speed signal from the
speed sensor control unit.
Boost Sensor
HCW4ADSH000301
The atmospheric pressure sensor is mounted inside

3 2 1
the Engine Control Module (ECM) and converts
atmospheric pressure into a voltage signal. The ECM
calculates the atmospheric pressure from the voltage
signal and carries out compensation etc. according to
that pressure.
MFW4ADSH000901 Accelerator Pedal Position (APP) Switch

Legend
1. GND
2. Signal
3. Power supply
The boost sensor is connected to the intake duct of the

engine. It detects the boost (intake pressure) inside the
intake manifold, converts the pressure to a voltage
signal and sends it to the Engine Control Module
(ECM). The voltage is higher with higher pressure, and
vice versa. The ECM calculates the boost (the intake
pressure) from the voltage signal sent by the sensor,
and uses it for fuel injection control and other purposes.
MFW31ASH001201
The Accelerator Pedal Position (APP) switch is

attached to the top of the accelerator pedal and
supplies a switch signal to the Engine Control Module
(ECM) that corresponds to the position of the
accelerator pedal. The ECM calculates the accelerator
pedal position from the voltage signal and uses it for
fuel injection control and many other control functions.
PTO Remote Throttle Sensor The injectors are mounted on the cylinder head and
inject fuel under the control of the Engine Control
Module (ECM). The ECM raises the injector drive
voltage internally and applies it to the injectors. By
controlling the duration of power supply to the injectors,
it controls the volume, timing and other aspects of fuel
injection.
3 2 1
HCW46ESH001601
Legend
1. GND
2. Signal
3. Power supply
The PTO remote throttle sensor is attached outside the

cab as an external accelerator voltage signal to the
Engine Control Module (ECM) that changes according
to the angle of the accelerator pedal. The ECM
calculates the PTO accelerator opening from the
voltage signal and uses it for fuel injection control and
many other control functions.
Injectors
5A52 701E
35DD 2157
001F 5A00
0000 BD
HVW4ADSH000101
Legend
1. Injector ID code plate
2. Injectors
MIL (Check Engine Lamp) Display
The MIL (check engine lamp) lights inside the meter. It
lights to warn the driver of a malfunction in the engine
or a related system. When the Engine Control Module
(ECM) detects a malfunction using its self-diagnostic
functions (vehicle-mounted malfunction diagnostic
system), it lights the MIL (check engine lamp). If the
diagnostics switch (the connection with the diagnostics
connector and the diagnostics common connector) is
switched On, the MIL (check engine lamp) flashes, and
the DTC detection status can be checked.
(Reference) The meter for the 6WF1
HCW51AMF000201
Diagnostics Connector, Data Link Connector (DLC)

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

The DLC (data link connector) is attached to the inside
of the inspection cover. It is the connector for
communications and connections with external
diagnostic devices (scan tools) and controllers.
Parts layout diagram
Instrument Panel
Lower Harness
1
3 4
2
5
HCW61ASH004501
Legend
1. Diagnostics connector (brown)
2. Memory clear connector (white)
3. Diagnostics common connector (green)
4. Data link connector (DLC), 20 terminals
Engine Component Layout Diagram
2 3 4 5
1 6
9 8
10
HCW61AMF003101
Legend
1. Boost Sensor 6. EGR valve
2. EGR valve 7. Crankshaft position (CKP) sensor
3. Engine coolant temperature (ECT) sensor 8. Fuel pressure sensor
4. EGR gas temperature sensor 9. PCV
5. EGR gas temperature sensor 10. CMP sensor
Cab Interior Switch Layout Diagram
2
3
HCW61ALF000901
Legend
1. PTO Switch 4. Idling Control AUTO/MANU Switch
2. ASR Cut Switch 5. Idling Control UP/DOWN Switch
3. Cruise Main Switch
Cab Interior Control Unit Layout Diagram
2
9
6
7
8
Back of the Radio
<Bracket Section> <Lower Section> <Upper Section>

10 Without Digital Tachograph Without Digital Tachograph
12
11
13 17
18
<Lower Section>
With Digital Tachograph
14
16 15
HCW61AXF001001
Legend
1. ECM Main Relay 10. Glow Relay
2. Exhaust Brake and Retarder Control Unit 11. QOS Control Unit
3. Tachograph 12. Flasher Unit
4. Speed Sensor Control Unit 13. MIMAMORI Control Unit
5. SRS Control Unit 14. Flasher Unit
6. Digital Tachograph 15. EBS Control Unit
7. ABS/ASR Control Unit 16. Cab Suspension Control Unit
8. Engine Control Module (ECM) 17. EBS Control Unit
9. Retractable Mirror Control Unit 18. Cab Suspension Control Unit
Chassis Component Layout Diagram

Chassis Section
3
1 2
5
6
HCW4ADMF001701
Legend
1. Atmospheric temperature sensor (inside open lit) 4. Transmission section (vehicle speed sensor,
2. Brake valve section neutral switch, reverse switch)
3. Cab rear member section (magnetic valve, PTO 5. Battery
remote throttle sensor) 6. Air tank section
Cab Rear Member Magnetic Valve
2 3 4 5
7 6
HCW4ADMF001201
Legend
1. Cab back member 5. VGS magnetic valve 3
2. Exhaust brake magnetic valve 6. VGS turbocharger pneumatic cylinder
3. VGS magnetic valve 1 7. Exhaust brake air cylinder
4. VGS magnetic valve 2
Circuit Diagram
ECM System Wiring Diagram
New Zealand
Starter Switch Engine Control Module (ECM)

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

APP Sensor 65 A N.C
21
55
( ) 47
CKP Sensor
40 ( )111 M/V;VGS 1
41 ( )112 M/V;VGS 2
39 ( )113
( )114 M/V;VGS 3
133
CMP Sensor 120 ( )115 Injector Power Supply 1
131 106
123 107
Fuel Pressure 121
Sensor 132 103 Injector Signal 1 (Cyl.1)
136
Atmospheric Injector Signal 3 (Cyl.3)
Temperature 104
154
Sensor 135 Injector Signal 5 (Cyl.2)
105
ECT Sensor 155
Injector Power Supply 2
142
143
EGR Gas Temperature 54 Injector Signal 2 (Cyl.5)
Sensor 1 33 137
Injector Signal 4 (Cyl.6)
138
EGR Gas Temperature Injector Signal 6 (Cyl.4)
Sensor 2 30 139
PTO Control Resistance
34 95 CAN H Other
126 96 CAN L ECU
Boost Sensor 128
134
Vehicle
PTO Remote 27 Speed TCM
Throttle Sensor 23 Sensor
Other ECU
1 : 6WF1 Engine
2 : 6WG1 Engine
HCW61AXF001101
153
PCV 1
152
151 A
PCV 2
Diagnostics Switch 150
68
M/V;Exh.Brake
Parking Brake Switch
97 M/V;Exh.Brake Operation Signal
( 2)91
Accelerator Switch Signal Output

Low Air Pressure Switch ( 2)10
87( 1)
Exh.Brake Drive Signal M/V;Retarder
42
Retarder Drive Signal Exhaust Brake
Stop Lamp Switch 1
53 45 and Retarder
Control Unit
9 Tachometer
Stop Lamp Switch 2
80
Data Link
Neutral Switch 19
61
Connector
N.C Starter Relay
Back Lamp switch

A 77 Starter Switch
44 A
Clutch Switch
52 Starter Cut Relay
Accelerator Switch
58
Cruise Resume Switch

92
Cruise Set Switch

79
Exhaust Brake Switch EGR Fail Safe Relay

49( 1)
B N.C
Cruise Main Switch
60
110
Cruise Release Switch 1 M/V;EGR 1
93 108
M/V;EGR 2
Retarder Switch 109
59
Idling MANU/AUTO Switch

88
Idling Up Switch
81
Idling Down Switch

99 72
73
PTO Switch
89
102

94( 2)
(Exhaust Brake Switch) 141
1 : 6WF1 Engine
2 : 6WG1 Engine
HCW61AXF001201
G. Exp
Starter Switch Engine Control Module (ECM)

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

APP Sensor 65 A N.C
21
55
( ) 47
CKP Sensor
40 ( )111 M/V;VGS 1
41 ( )112 M/V;VGS 2
39 ( )113
( )114 M/V;VGS 3
133
CMP Sensor 120 ( )115 Injector Power Supply 1
131 106
123 107
Fuel Pressure 121
Sensor 132 103 Injector Signal 1 (Cyl.1)
136
Atmospheric Injector Signal 3 (Cyl.3)
Temperature 104
154
Sensor 135 Injector Signal 5 (Cyl.2)
105
ECT Sensor 155
Injector Power Supply 2
142
143
EGR Gas Temperature 54 Injector Signal 2 (Cyl.5)
Sensor 1 33 137
Injector Signal 4 (Cyl.6)
138
EGR Gas Temperature Injector Signal 6 (Cyl.4)
Sensor 2 30 139
PTO Control Resistance
34 95 CAN H Other
126 96 CAN L ECU
Boost Sensor 128
134
Vehicle
PTO Remote 27 Speed TCM
Throttle Sensor 23 Sensor
Other ECU
1 : 6WF1 Engine
2 : 6WG1 Engine
HCW61AXF001101
153
PCV 1
152
151 A
PCV 2
Diagnostics Switch 150
68
M/V;Exh.Brake
Parking Brake Switch
97 M/V;Exh.Brake Operation Signal
( 2)91
Accelerator Switch Signal Output

Low Air Pressure Switch ( 2)10
87( 1)
Exh.Brake Drive Signal M/V;Retarder
42
Retarder Drive Signal Exhaust Brake
Stop Lamp Switch 1
53 45 and Retarder
Control Unit
9 Tachometer
Stop Lamp Switch 2
80
Data Link
Neutral Switch 19
61
Connector
N.C Starter Relay
Back Lamp switch

A 77 Starter Switch
44 A
Clutch Switch
52 Starter Cut Relay
Accelerator Switch
58
Cruise Resume Switch

92
Cruise Set Switch

79
Exhaust Brake Switch EGR Fail Safe Relay

49( 1)
B N.C
Cruise Main Switch
60
110
Cruise Release Switch 1 M/V;EGR 1
93 108
M/V;EGR 2
Retarder Switch 109
59
Idling MANU/AUTO Switch

88
Idling Up Switch
81
Idling Down Switch

99 72
73
PTO Switch
89
102

94( 2)
(Exhaust Brake Switch) 141
1 : 6WF1 Engine
2 : 6WG1 Engine
HCW61AXF001201
ECM Pin Layout
NOTE:
Use the right control unit for the vehicle, as stated in the
“Comment text” and “Applicable engine identifier name”
stated in the labels.
Use of the wrong control unit for the vehicle will cause
breakdowns.
167 162 136 129 101 97 69 62 34 28

161 154 128 118 96 87 61 54 27 18
153 144 117 108 86 77 53 42 17 8
143 137 107 102 76 70 41 35 7 1
HCS4Z0LF002101
New Zealand
Terminal Terminal
Signal name Signal name
No. No.
1 – 85 –
2 – 86 –
3 – 87 Low air pressure switch signal [6WF1]
4 – 88 Idling MANU/AUTO switch signal
5 Power supply (Main relay) 89 PTO switch signal
6 Power supply (Main relay) 90 –
Terminal Terminal
No. No.
7 Power supply (Main relay) 91 Exhaust brake magnetic valve (M/V) action
signal input [6WG1]
8 – 92 Cruise resume switch signal
9 Tachometer 93 Cruise release switch 1 signal
10 Accelerator switch signal output [6WG1] 94 Cruise release switch 2 (Exhaust Brake
Switch) signal [6WG1]
11 Overheat lamp [6WF1] 95 CAN-HIGH
12 Overheat buzzer [6WF1] 96 CAN-LOW
13 – 97 Parking brake switch signal
14 – 98 –
15 – 99 Idling Down switch signal
16 – 100 –
17 – 101 –
18 – 102 GND
19 Data link connector (DLC) 103 Injector 1 (No. 1 cylinder)
20 – 104 Injector 3 (No. 3 cylinder)
21 Accelerator pedal position (APP) sensor 105 Injector 5 (No. 2 cylinder)
signal
22 – 106 Injector power supply (injector 1, 3, 5)
23 PTO remote throttle sensor signal 107 Injector power supply (injector 1, 3, 5)
24 – 108 EGR M/V 1
25 – 109 EGR M/V 2
26 – 110 EGR fail safe relay
27 Vehicle speed sensor signal 111 VGS M/V 1 [6WG1]
28 – 112 VGS M/V 2 [6WG1]
29 – 113 VGS M/V 2 [6WG1]
30 EGR gas temperature sensor 2 signal 114 VGS M/V 3 [6WG1]
31 – 115 VGS M/V 3 [6WG1]
32 – 116 –
33 EGR gas temperature sensor 1 signal 117 –
34 PTO control resistance 118 –
35 – 119 –
36 – 120 Camshaft position (CMP) sensor signal
37 – 121 Fuel pressure sensor signal
38 – 122 –
39 Crankshaft position (CKP) sensor shield 123 Fuel pressure sensor power supply
40 CKP sensor (+) 124 –
41 CKP sensor (-) 125 –
Terminal Terminal
No. No.
42 Exhaust brake drive signal output 126 Boost and PTO remote throttle sensors
power supply
43 – 127 –
44 Starter cut relay 128 Boost sensor signal
45 Retarder drive signal output 129 –
46 Starter switch “ON” signal (Battery relay) 130 –
47 VGS fail safe relay [6WG1] 131 CMP sensor GND
48 Starter switch “START” signal 132 Fuel pressure sensor signal
49 Exhaust brake switch signal [6WF1] 133 CMP sensor power supply
50 Engine stop switch signal 134 Boost, PTO remote throttle sensors GND
51 – 135 Engine coolant temperature (ECT) and
atmospheric temperature sensors GND
52 Clutch switch signal 136 Fuel pressure sensor GND
53 Stop lamp switch 1 signal 137 Injector 2 (No. 5 cylinder)
54 EGR gas temperature sensors and PTO 138 Injector 4 (No. 6 cylinder)
control resistance GND
55 APP sensor GND 139 Injector 6 (No. 4 cylinder)
56 Starter switch “ON” signal (Battery relay) 140 GND
57 – 141 GND
58 Accelerator switch signal 142 Injector power supply (injector 2, 4, 6)
59 Retarder switch signal 143 Injector power supply (injector 2, 4, 6)
60 Cruise main switch signal 144 –
61 Neutral switch signal 145 –
62 – 146 –
63 – 147 –
64 – 148 –
65 APP sensor power supply 149 –
66 – 150 Pomp control valve (PCV) 2
67 – 151 PCV 2
68 Diagnostics switch 152 PCV 1
69 – 153 PCV 1
70 – 154 Atmospheric temperature sensor signal
71 – 155 ECT sensor signal
72 ECM GND 156 –
73 ECM GND 157 –
74 ECM main relay 158 –
76 – 160 –
Terminal Terminal
No. No.
77 Back lamp switch signal 161 –
78 – 162 –
79 Cruise Set switch signal 163 –
80 Stop lamp switch 2 signal 164 –
81 Idling Up switch signal 165 –
82 Check engine lamp 166 –
83 Cruise set lamp 167 –
84 Cruise main lamp – –
G. Exp
Terminal Terminal
No. No.
1 – 85 PTO control indicator lamp
2 – 86 –
3 – 87 Low air pressure switch signal
4 – 88 Idling MANU/AUTO switch signal
5 Power supply (Main relay) 89 PTO switch signal
8 – 92 Cruise resume switch signal
9 Tachometer 93 Cruise release switch 1 signal
10 – 94 Cruise release switch 2 signal
11 Overheat lamp 95 –
12 Overheat buzzer 96 –
13 – 97 Parking brake switch signal
14 – 98 –
15 – 99 Idling Down switch signal
16 – 100 –
17 – 101 –
18 – 102 GND
19 Data link connector (DLC) 103 Injector 1 (No. 1 cylinder)
20 – 104 Injector 3 (No. 3 cylinder)
21 Accelerator pedal position (APP) sensor 105 Injector 5 (No. 2 cylinder)
signal
22 – 106 Injector power supply (injector 1, 3, 5)
23 PTO remote throttle sensor signal 107 Injector power supply (injector 1, 3, 5)
24 – 108 EGR M/V 1
25 – 109 EGR M/V 2
Terminal Terminal
No. No.
26 – 110 EGR fail safe relay
27 Vehicle speed sensor signal 111 –
28 – 112 –
29 – 113 –
31 – 115 –
32 – 116 –
34 PTO control resistance 118 –
35 – 119 –
36 – 120 Camshaft position (CMP) sensor signal
37 – 121 Fuel pressure sensor signal
38 – 122 –
39 Crankshaft position (CKP) sensor shield 123 Fuel pressure sensor power supply
40 CKP sensor (+) 124 –
41 CKP sensor (-) 125 –
42 Exhaust brake drive signal output 126 Boost and PTO remote throttle sensors
power supply
43 – 127 –
44 Starter cut relay 128 Boost sensor signal
45 Retarder drive signal output 129 –
46 Starter switch “ON” signal (Battery relay) 130 –
47 – 131 CMP sensor GND
48 Starter switch “START” signal 132 Fuel pressure sensor signal
49 Exhaust brake switch signal 133 CMP sensor power supply
50 Engine stop switch signal 134 Boost, PTO remote throttle sensors GND
51 – 135 Engine coolant temperature (ECT) and
atmospheric temperature sensors GND
52 Clutch switch signal 136 Fuel pressure sensor GND
53 Stop lamp switch 1 signal 137 Injector 2 (No. 5 cylinder)
54 EGR gas temperature sensors and PTO 138 Injector 4 (No. 6 cylinder)
control resistance GND
55 APP sensor GND 139 Injector 6 (No. 4 cylinder)
56 Starter switch “ON” signal (Battery relay) 140 GND
57 – 141 GND
58 Accelerator switch signal 142 Injector power supply (injector 2, 4, 6)
59 Retarder switch signal 143 Injector power supply (injector 2, 4, 6)
60 Cruise main switch signal 144 –
Terminal Terminal
No. No.
61 Neutral switch signal 145 –
62 – 146 –
63 – 147 –
64 – 148 –
65 APP sensor power supply 149 –
66 – 150 Pomp control valve (PCV) 2
67 – 151 PCV 2
68 Diagnostics switch 152 PCV 1
69 – 153 PCV 1
70 – 154 Atmospheric temperature sensor signal
71 – 155 ECT sensor signal
72 ECM GND 156 –
73 ECM GND 157 –
76 – 160 –
77 Back lamp switch signal 161 –
78 – 162 –
79 Cruise Set switch signal 163 –
80 Stop lamp switch 2 signal 164 –
81 Idling Up switch signal 165 –
82 Check engine lamp 166 –
83 Cruise set lamp 167 –
84 Cruise main lamp – –
ECM Circuit Diagram
New Zealand
1/6
FUSE10 FU55 0.5B/R

J/T:ILLUMINATION
1.25R/G
H7
79
0.5B/R
33 FL68
J/C:4 22
29 FL659
0.85R/G
FUSE17 0.5V/W 20 J/C:5
0.3B/R
FL658 H48
J/C:FUSE17 22 12 H48
0.5V/W
0.85R/G
0.85B/R 18 A IDLING SPEED CONTROL 13
FL1(2) SWITCH(AUTO/MANUAL)
0.3B/R
STARTER 19 CLOSE;MANUAL , OPEN;AUTO
SWITCH 20
21 0.85R/G G53 G53 1 0.3B/R G60
G59 4 J/T:ILLUMINATION
0.5V/W H48 0.5V/W J/T:TAIL
14 5 G53 G53 3
33
IDLING SPEED CONTROL
0.5V/W
FL658
SWITCH (UP/DOWN)
0.5P/W
0.5V/W
J/C:STARTER 31
0.5V/W
SWITCH UP FL134
2 1 4
FL4 FL2 5 FL134
EXCEPT FL134 2
ACCEL CLUTCH DOWN
Smoother-G.AND
SWITCH SWITCH A/T MODEL
DOWN 0.5P/G
H48
0.5P/B
FL4 FL2 7
1 2
0.5P/W
KEY ON 0.5V/W
KEY ON 0.5V/W
0.5B/R
0.5V
EXCEPT A/T MODEL

0.5V/R
UP
2 0.5V/R H282 0.5V/R F70(16)
FL560 Smoother-G
J/C:CLUTCH 2 8 CONTROL
4 UNIT
0.5V/R
48 46 56 58 52 99 81 88
FL558 FL558 FL558 FL558 FL558 FL559 FL559 FL559
ENGINE CONTROL MODULE (ECM)
FL656 FL559 FL559 FL559 FL557 FL558 FL559 FL557 FL558 FL558 FL559
J/C:EXHAUST BRAKE MAGNETIC VALVE 2 91 2 94 97 27 53 80 10 49 59 87
FL522(20) EXHAUST&RETARDER 0.5L/Y 0.5L/Y
0.3H/B
CONTROL UNIT 22 20 FL656 2 1

0.3P/L
J/C:EXHAUST BRAKE SWITCH

FL9(18) COMBINATION SWITCH 0.5L/Y 0.5L/Y
14 12
0.3Y/G
0.5L/W
0.5L/Y
16
FB145(1) PARKING BRAKE SWITCH 0.5L/B H301 0.5L/B H10 0.3L/B FL560
9 49 22 J/C:PARKING 6
FL11(3) SPEED SENSOR 0.5P/L FL659
CONTROL UNIT 11 J/C:5
AUTO CRUISE CONTROL ONLY FL658
J/C:STOP LIGHT SWITCH 1
FL21(1) STOPLIGHT SWITCH 0.3G/B 0.3G/B 6 FL560
28 26 J/C:LOW AIR
PRESSURE
FL658 11
J/C:STOP LIGHT SWITCH 2
0.3Y/G
FL20(1) STOPLIGHT SWITCH 0.3G 0.3G

25 23
FL522(1) EXHAUST&RETARDER 0.3V/W
CONTROL UNIT H6
FL9(18) COMBINATION SWITCH 0.5L/Y 38
FL655
0.5Y/G
FL9(20)COMBINATION SWITCH 0.5L/W J/C:RETARDER

32 30
0.5Y/G
H299 3
J77 FB263
J12(1) LOW AIR PRESSURE SWITCH 0.5Y/G J/T LOW AIR PRESSURE J/T:
(SECONDARY) AIR SUSPENSION
CYJ5 ,EXY5 MODEL
J24(1) LOW AIR PRESSURE SWITCH 0.5Y/G ONLY
(PRIMARY)
J43(1) LOW AIR PRESSURE SWITCH 0.5Y/G
(MAIN)
(ACCESSORY) 1 6WF1 MODEL ONLY
2 6WG1 MODEL ONLY
(WHEEL PARK)
HCW58DXF032801
2/6
AUTO CRUISE CONTROL ONLY

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

FL400(4) STARTER CUT RELAY 0.3W/B

0.5LG 0.5LG FL658
F11(2) PTO SWITCH H12 14 4 J/C:PTO
2
FL531(3) CAN L 0.5L
FL531(6) CAN H 0.5L/W
FL661(3) ENGINE STOP

CONNECTOR
0.5LG
0.5L/Y
ENGINE STOP ONLY
TACHO OUT (4P)

ENG STOP
EXH.(REQ)
RET.(REQ)
CAN-L
CAN-H
50 95 96 89 44 9 45 42
E72 E71 E72 FL558 FL557 FL558 FL557

155 135 154 65 21 55 19
GND
0.5GY/L GND
VCC
SIG
SIG
SIG
0.3BR
0.3Y/R
0.3V/R
0.3Y
29 FL511
30 J/C:DATA LINK
0.5GY
H162 H162 H162 CONNECTOR
5 6 7
FU9(7) METER
0.5BR
0.3V/R
0.3Y/G
1
H7
FL537 FL536
SRS CONNECTOR
4 (B)
0.3V/R SRS CONNECTOR
(A)
0.3Y/G
0.3Y/R
1
0.3Y
H20 H20
H10 H10 H10 1 5
0.85BR
49 50 51
0.5Y/G
0.5Y/R
0.5L/W
0.5L/R
0.5V/R
0.5Y/R
0.5Y
0.5L
FL535(15)
2 1 3 SRS CONTROL
UNIT
FB155 FB155 FB155
1 2 3 2 1
I4 I4 FL133 FL133 FL133
COOLANT OUTSIDE ACCELERATION

TEMPERATURE SENSOR TEMPERATURE SENSOR SENSOR
HCW58DXF032901
3/6
FUSE10 1.25R/G
A 0.5V/W
0.3B/R FU35(8)METER
FL657 AUTO CRUISE CONTROL ONLY
J/C:
FUSE11 0.85Y 22 FUSE11
21 FU55
0.85Y J/T:ILLMINATION
0.5B/R
H7
42 0.5Y H7
0.85Y
0.5Y 79
FU58 0.5Y
0.5B/R
J/T: 10
FUSE11 33 22
FU18
FL68 FL659
INDICATOR LIGHT
23 J/C:4 12 J/C:5
0.5Y
0.5V/W
OVER HEAT
9 16 9
AUTO CRUISE MAIN

16
AUTO CRUISE SET

FU8
FU33
FU8
INDICATOR LIGHT
INDICATOR LIGHT
INDICATOR LIGHT
FU18
0.5R/G
0.3B/R
FL9
3 AUTO CRUISE CONTROL
MAIN SWITCH 16
0.3G
RELEASE SWITCH
6
RESUME SWITCH
6 FL532 5 6 FL532 2
AUTO CRUISE
AUTO CRUISE
AUTO CRUISE
FU62
SET SWITCH
0.3O/B FU5
0.3V/R FU33
FU33
5 J/C:
IE
6 OVER HEAT 15 14 0.5V/W

FL511(4) 3 FL532 1 2 FL532 1
0.3G
DIAGNOSIS JOINT
CONNECTOR 0.3Y
15 11 26
H7 H7 H7 H7
FL559 0.5L/R FL9
FL559 0.5V/R FL9
FL559 0.5V/G FL10

3 2 61 62
15 11 7
FL558 0.3B/W
FL559 0.3O/B
FL559 0.3V/R
0.3G
0.3Y
FL558 0.5V
68 82 11 84 83 60 79 92 93
FL557
FL559

0.3B/G FL558
FL559
FL558
FL558
FL558
G-VCC E71
G-SIG E71
0.5GY G-GND E71
E71
E71
E71
E71
61 77 40 41 39 133 120 131 121 132 123 136
0.5R/L
0.5Y NE (+)
SIG-1
SIG-2
0.5BR NE (-)
GND
VCC
7 29
FL658 FL560
0.5GY/W
0.5GY
J/C:NUETRAL 11 33 J/C:BACK
0.85R/L
0.3B/G
9 28
H10 H10
1 2
0.5GY/W H162 0.5GY/W
3
0.85R/L
0.5B/G
0.5Y H162
0.5BR H162
0.5W/L
0.5O/L
0.5W
0.5B
0.5W
0.5O
0.5R
H158 3 FB274
FULLER T/M J/T:BACK
M40(2) 0.5B/G H158 2
NEUTRAL SWITCH MJX16 MANUAL
H175 0.5GY/W
H177 0.5GY
H177 0.5GY
H387 36 1 2 3 4 3 2 1 12 11 10 9 5
0.85R/L
Smoother-G
H177
H177
H177
H177
H177
H177
H177
H175
H175
0.5B/G H215
2
Smoother-G
0.5B
0.5B
0.5B
H158 1
0.5W
0.5O
FULLER T/M
M5(2) 0.85R/L H158 4
BACK LIGHT SWITCH MJX16 MANUAL
0.5BR
E42 0.5W/L
0.5W
0.5B
E42 0.5O/L
0.5R
0.5Y
E42 0.5W
H387 41
Smoother-G 2 1 3 1 2 2 3 1
E45
E45
E46
E46
E46
H215 4
Smoother-G
NE SENSOR G-SENSOR FUEL PRESSURE
(CRANKSHAFT SENSOR
SPEED)
HCW58DXF033001
4/6
DIODE
(WATER BUZZER)
0.3Y/V 0.3G/Y 0.3G/Y 0.3G/Y FU28(14)
9 3 FL385 FL385 4 15 H7 METER(WATER LEVEL)
FL650
J/C:BUZZER
AUTO CLUTCH & FL657

AIR SUSPENSION BUZZER J/C:FUSE11
0.3Y/V 0.85Y 0.85Y FUSE11
10 2 FL397 FL397 1 20 22
DIODE(BUZZER)
F56 1 0.3W/O 0.3W/O
24 H290
0.3W/O H10 0.5W/O H304 0.5W/O H42
1 16 1 J67(3)
AIR SUSPENSION
0.3Y/V 0.3Y/V F56 BUZZER
11 2 H280 2
8 0.3W/L
F56 3 F70(21)
Smoother-G CONTROL UNIT
0.3Y/V
12
FL557
ENGINE CONTROL MODULE(ECM)
FL557
FL557
FL558
FL557
FL557
E71
E71
E71
33 54 30 34 128 126 134 23

G-GND
G-VCC
G-SIG
GND
SIG
SIG
H162 0.5L/W SIG

0.5G/B
FL655 15
J/C:EGR
21 GRAND
0.5GY/B
0.5GY
20
22
0.5G/W
0.5G/B
0.5G/B
0.5G/O
0.5G/Y
0.5GY
12 13 14
0.5W
0.5B
0.5R
2 1
H162
H162
H162
FL552
FL552
0.5L/W
0.5L/R
0.5L
0.5G/W
0.5G/B
0.5G/Y
PTO MODE
H176 0.5GY
0.5GY H357 0.5GY
CONNECTOR
13 14 15 16 3 4 2 8
H176
H176
H176
H357
H357
H357
1 2 3
H176
H176
H176
0.5B
0.5L/W
0.5L/R
0.5L
0.5W
0.5B
0.5R
0.5G/W
0.5G/B
0.5G/B
0.5G/Y
2 1 2 1 2 3 1 2 3 1
E75
E75
E76
E76
E36
E36
E36
SIG B14
+5V B14
GND B14
EGR EGR BOOST PRESSURE ALL SPEED

TEMPERATURE TEMPERATURE SENSOR ACCELERATION
SENSOR 1 SENSOR 2 SENSOR HCW58DXF033101
5/6
3W
SLOW BLOW FUSE 1
FL519 FL520
3L/W
SLOW BLOW FUSE 3
J/T: SBF1 J/T: SBF3
3L/W
3L/W
3W
(7.5A)
FUSE49
FUSE16
FUSE48
(15A)
(15A)
1.25W/L
0.5V/W
1.25O
IE MAIN RELAY
FL398
0.5V/W
5
FL398
0.5V/W
1
1.25R/B
1.250
FL398 FL398 EGR RELAY
2 4
FL555 FL555
0.5V/W
1 4
VGS RELAY
FL555
3
FL554 FL554
0.5V/W
FL555 1 4
5
FL554
0.3BR/G
3
FL554
1.25R/B
1.25R/B
1.25R/B
5
0.3R/L
0.3R/L
4
H162
0.3SB
0.3BR/G
75 74 7 6 5 110 47
FL559 FL559 FL557 FL557 FL557 E71 FL558
E72 E72 E72 E72 E71 E71 E71 E71 E71 E71 E71
153 152 151 150 108 109 111 112 113 114 115
0.5Y/BR
0.5Y/BR
0.5Y/V
0.5Y/V
1.25WL
1.25WL
0.5W/R
0.5P/W
0.5R/W
0.5R/W
0.5R/B
0.5R/B
5 2
E73
4 J/C; (1) 1 1 3 19 20
0.5Y/G
0.5Y/R
0.5Y/B
0.5Y/BR
6 3
0.5Y/V
9 8 11 6 H162 H162 H162 H162
H176 H177 H176 H177
10 9 7 6 5
H357 H357 H357 H357 H357

0.5R/W
0.5R/W
0.5Y/BR
0.5R/B
0.5R/B
0.5Y/G
0.5Y/R
0.5Y/B
0.5Y/V
1 1 1 1 1
M/V:VGS 3
M/V:EGR 2
M/V:EGR 1
M/V:VGS 1
M/V:VGS 2
B54 B55 B43 B44 B45

0.5R/W
B54 B55 B43 B44 B45

0.5R/B
PRESSURE CONTROL
PRESSURE CONTROL
2 2 2 2 2
2 2
VALVE 1
VALVE 2
E43 E44
0.5W/R
0.5W/R
0.5P/W
0.5P/W
0.5P/W
1.25W/L
1.25W/L
0.5W/R
0.5P/W
E43 E44
1 1
0.5P/W
1.25W/L
1.25W/L
H357
12
0.5W/R
H357
11
1.25W/L
H176
10
1.25W/L
H177
7
HCW58DXF033201
6/6
E71 E71 E71 E71 E71 E72 E72 E72 E72 E72 E71 E72 E72 FL559 FL559
106 103 105 107 104 142 139 137 143 138 102 140 141 72 73
POWER.GND
POWER.GND
POWER.GND
ECU.GND
ECU.GND
1.25B/P
1.25B/P
0.5B
0.5B
5B
* *
0.5GY 0.5GY FL65 29
E59
CASE J/C:1 30
1 3 2
EARTH 33
E74
1.25B
1.25B
1.25B
J/C:1
0.85W
0.85W
0.85G
0.85G
0.85R
0.85R
0.85Y
0.85B
0.85Y
0.85B
0.85L
0.85L
0.85B/O
0.5GY 0.5GY
1.25B
H175 H175 H175 H176 H176 H176

4 5 7 8 6 12
1.25B
H176 H176 H176 H175 H175 H357

4 7 5 8 6 1
1.25B
E78
J/T:
FRAME EARTH
H39
13
1.25B
CYH,CYJ CYZ,EXZ H6
MODEL MODEL
0.85W
83
0.85G
0.85R
0.85Y
0.85B
0.85L
0.85W
0.85L
0.85G
0.85Y
0.85R
FB376 FB267
J/T: J/T:
EARTH EARTH
5B
5B
(CAB GND) (GVNR GND)
0.85B/O
FB39 FB40
* *
CAB EARTH
3 2 7 4 6 3 2 7 4 6
5B
H179 H179 H179 H179 H179 H180 H180 H180 H180 H180 FB82
H179 H179 H179 H179 H179 H180 H180 H180 H180 H180
FRAME
7 6 3 8 2 7 6 3 8 2 EARTH(3)
0.75BR
0.75W
0.75W
0.75G
0.75R
0.75R
0.75Y
0.75B
0.75V
0.75L
E77
0.75R 0.75R 0.75W 0.75W
FRAME EARTH
1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 (ENGINE)
E53 E53 E53 E57 E57 E57 E55 E55 E55 E58 E58 E58 E54 E54 E54 E56 E56 E56
INJECTOR.1 INJECTOR.2 INJECTOR.3 INJECTOR.4 INJECTOR.5 INJECTOR.6
CYLINDER NO.1 CYLINDER NO.5 CYLINDER NO.3 CYLINDER NO.6 CYLINDER NO.2 CYLINDER NO.4
INSIDE CYLINDER HEAD COVER
* : END OF CABLE OPEN
HCW58DXF033301
G. Exp
1/5
0.5V/W
FUSE17 A 0.5V/W
B
FUSE9
IDLE SWITCH (AUTO/MANUAL)

CLOSE;MANUAL,OPEN;AUTO
0.5B/W
0.5V/W
0.5V/W
FL585 FL585
1 1
0.5V/W
0.5V/W
0.5V/W
IDLING SPEED CONTROL
SWITCH (UP/DOWN)
UP
FL134
2 1 4
FL134
FL4 FL182 5
FL134
2
0.5V/W
DOWN
ACCEL CLUTCH
SWITCH SWITCH
0.5P/W
0.5P/G
0.5P/B
FL4 FL182
1 2
0.5V/R
0.5V
H256 H400 H400 H256 H256 H256 H256 H256
9 9 8 17 16 12 13 11
0.5B/W
0.5V/W
0.5V/W
0.5P/W
0.5P/G
0.5V/R
0.5P/B
0.5V
START SW
KEY ON
KEY ON
DOWN
UP
48 46 56 58 52 99 81 88
FL559 FL557 FL558 FL559 FL558 FL559 FL558 FL558 FL559
97 27 53 80 61 77 49 59 87
0.3L/B
0.3P/L
0.5L/ 0.5L/ 0.5L/B 0.3L/B

FB145(1) PARKING BRAKE SWITCH H390 H10 H257
0.5L/W
0.3B/G
49 0.5R/L
0.5L/Y
2 10
0.3Y/G
0.5P/L
FL11(3) SPEED SENSOR H257
9
H257
0.5G/B 0.3G/B 0.3G/B 11

FL21(1) STOPLIGHT SWITCH H257
7
0.5G 0.3G 0.3G 0.3Y/G

FL20(1) STOPLIGHT SWITCH H257
8
MJT
0.5B/G 0.5B/G 0.5B/G 0.3B/G
MAL6 M40(2) NEUTRAL SWITCH H158 H10 H400
0.5Y/G
2 9 17
MJX16-MANUAL
0.5R/L
H10 H400
28 18
H10
0.5L/Y 23
FL9(18) COMBINATION SWITCH H257
16
0.5Y/G
H257
5
0.5Y/G
H299
3
J77
J12(1) LOW AIR PRESSURE SWITCH 0.5Y/G J/T:LOW AIR PRESSURE
(SECONDARY)
J24(1)LOW AIR PRESSURE SWITCH 0.5Y/G

(PRIMARY)

(MAIN)

(ACCESSORY)

(WHEEL PARK)
HCW58DXF033401
2/5
FL128(4) 0.3L/P
EXHAUST BRAKE RELAY
0.3W/R 0.3W/R
FU72(23) TACHO METER H7
1

0.3W/B
FL400(4) STARTER CUT RELAY

FU14(1) PTO SWITCH 0.5LG 0.5LG
H7 82
0.5LG
H257 H256 H257 H257 H257
1 15 6 4 3
H256
10
TACHO OUT (4P) 0.3W/R

0.5LG
0.3W/B
0.3L/W
0.3L/P
0.5L/Y
ENGINE STOP ONLY

ENG STOP
EXH.(REQ)
RET.(REQ)
50 89 44 9 45 42
FL558 FL559 FL558 FL557 FL558 FL558
E72 E71 E72 FL558 FL557 FL558 FL557

155 135 154 65 21 55 19
GND
0.5GY/L GND
0.5L/R VCC
SIG
SIG
0.5L/W SIG
0.3Y/R
0.3V/R
0.3Y
0.3BR
0.5GY
H316 H316 H316
12 13 14
FU8(12) METER
0.5L
0.5Y/V
0.3Y/R
0.3V/R
0.3Y
0.5GY
H256
H7 H400 H400 H257 14
4 3 2 12 H256 H256 H256 H256
21 22 20 19
0.5GY
0.3Y/R
0.5Y/V
0.3Y
0.5BR
H10 H10 H10

64 81 80
0.3V/R
0.3Y/R
0.5Y/G
0.5Y/R
0.5L/W
0.5L/R
0.5GL
0.5Y
2 1 3
FB155 FB155 FB155
1 2 3 2 1
FL466 FL466 FL133 FL133 FL133
1
FL223
COOLANT OUTSIDE ACCELERATION DATA LINK

TEMPERATURE SENSOR TEMPERATURE SENSOR SENSOR CONNECTOR
HCW58DXF033501
3/5
B
0.5Y 0.5Y 0.5Y NE (+)
E45 H175 FL558
1
H316
2
1
0.5BR 0.5BR 0.5BR NE (-) FUSE11
E45 H175 FL558
2
H316
1
2
40 41
SPEED)
AUTO CRUISE MAIN
NE SENSOR
0.5B 0.5GY/W 0.5GY/W 0.5GY/W 0.5GY/W INDICATOR LIGHT
(CRANKSHAFT
H175 H316 FL558
3
3
39
0.3V/R 0.3V/R 0.3B 0.3V/R
FL559 H400 H7 FU18 FU18 H7
4
4
5
56
45
84
0.85Y
0.5R 0.5R G-VCC AUTO CRUISE SET
J/C:
E46 H177 E71
3
4
0.5Y
0.5W 0.5W G-SIG INDICATOR LIGHT FU7
FUSE11
E46 H177 E71
1
3
AUTO CRUISE CONTROL ONLY
0.5B 0.5B 0.5GY G-GND 0.3Y 0.3Y 0.3Y 0.5Y 0.85Y

E46 H177 E71 FL559 H400 H7 FU18 FU18 H7
2
7
8
6
G-SENSOR
57
19
42
133 120 131

83
0.5B 0.5GY
12
22 18
H177
1
0.5W 0.5O 0.5O SIG-1
E42 H177 E71
2
0.5W 0.5W SIG-2 0.5R/G
H177 E71
0.5O/L 0.5O/L VCC
E42 H177 E71
3
0.5V/W
0.5W/L 0.5GY GND
SENSOR
0.5W/L
E42 H177 E71
1
12 11 10 9
0.5R/G
3
6
121 132 123 136

1.25R/G
A
FUEL PRESSURE
0.5B 0.5GY
H177
5
FL532
FL532
1
5
0.5G/W 0.5G/W 0.5G/W SIG

E75 H176 H316 FL557
1
4
2
RELAY
33
FL49(1)
EGR
1
0.5G/B 0.5G/B 0.5G/B 0.5G/B GND
TAIL LIGHT
E75 H176 H316 FL558
SENSOR 1
2
1
2
5
54
3
MAIN SWITCH
FL716
J/C:(2)
0.5G/Y 0.5G/Y 0.5G/Y SIG
E76 H176 H316 FL557
2
3
6
30
AUTO CRUISE CONTROL
2 FL532
6 FL532
0.5G/B
EGR
E76
1
1
2
SENSOR 2
0.5G/O 0.5G/O
FL552 H257 FL557 0.3B
2
0.5V 0.5V
TEMPERATURE TEMPERATURE
FL558 H400
17
34
6
0.5G/B 0.5G/B 60

FL552 H257
1
18
PTO MODE
CONNECTOR
AUTO CRUISE
SET SWITCH
0.5W 0.5W G-SIG
E36 H176 E71 0.5L/R
2
15
FL559 H400 FL9

5
0.5R 0.5R 0.5GY/B G-VCC

79
15
E36 H176 E71 AUTO CRUISE
3
0.5B 0.5B 0.5GY G-GND RESUME SWITCH
E36 H176 E71
SENSOR
0.5V/R
13 14 15
128 126 134
11
FL559 H257 FL569

1
0.5B 0.5GY 0.5GY

92
15
H176 AUTO CRUISE
BOOST PRESSURE
16
RELEASE SWITCH
0.5V/G
26
16
FL559 H400 FL569 FL9

2
93
16
16
0.5L/W 0.5L/W 0.5L/W 0.5L/W 0.5L/W SIG

SIG B14 H357 H316 FL557
2
6
7
FL514(1)DIAGNOSIS
5
0.3B/W 0.5B/W
23
0.5L/R 0.5L/R 0.5L/R FL558 H256

+5V B14
5
H357 CONNECTOR
3
4
68
0.5L 0.5L 0.5GY

0.5Y
GND B14 H357
1
2
E74
SENSOR
J/C:(1)
ALL SPEED
0.5GY
ACCELERATION
IE INDICATOR LIGHT
0.5Y
H357
8
0.3O/B 0.3O/B 0.3O/B
FL559 H256 H7 FU5 FU5
3
6
7
52
82
BUZZER
OVERRUN
FL494(2)
OVERHEAT INDICATOR LIGHT
0.3G/Y 0.3G/Y 0.3G/Y

FL557 H400 H7 FU8 FU9
7
1
20
15
11
DIODE(OVERRUN)
0.3G 0.5G
FL557 H400 FL475 FL475
1
2
21
12
FU8(6) METER
FL475
3
Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
5B/L 2FB/L 2B
H10
FB82
40
0.5BR 0.5BR
H7
31
FRAME EARTH(3)
FB253
CENTER
J/T:EARTH
HCW58DXF033601
1A-55
4/5
3W 3W/L 5W/L
H10 H187 SLOW BLOW FUSE1
45 1
FL519 FL520
3L/W 3Y
FB283 H10 H186 SLOW BLOW FUSE3
J/T: SBF1 J/T: SBF3 37 2
J/T: SBF1
3R
H10 H186 SLOW BLOW FUSE2
46 1
3L/W
3W
3R
FUSE34
FUSE16
FUSE45
(7.5A)
(15A)
(15A)
1.25W/L
0.5V/W
1.25O
0.85R/B FL196(1)
ABS RELAY
IE MAIN RELAY
1.25O
FL398
5
FL398
1
EGR RELAY
1.25O
1.25R/B
FL398 FL398 FL731 FL731
4
0.5V/W
2 3
5
FL731
2
0.3BR/G
FL731
4
1.25R/B
1.25R/B
1.25R/B
0.3R/L
0.3R/L
H257
0.3BR/G
H256 H256 H256 H256 H256
11
18 6 2 7 8
H316
1.25R/B
1.25R/B
1.25R/B
1.25WL
1.25WL
0.5W/R
0.3R/L
0.3R/L
0.3BR/G
75 74 7 6 5 110
FL559 FL559 FL557 FL557 FL557 E71
E72 E72 E72 E72 E71 E71
153 152 151 150 108 109

0.5R/W
0.5R/W
0.5R/B
0.5R/B
0.5Y/R
0.5Y/B
9 8 11 6 14 1 15
H177 H177
H176 H176 H400 H256 H400
10 9
H357 H357
0.5R/W
0.5R/W
0.5R/B
0.5R/B
0.5Y/R
0.5Y/B
1 1
M/V;EGR 2
M/V;EGR 1
1.25W/L
1.25W/L
B54 B55
0.5W/R
B54 B55
2 2
0.5R/W
0.5R/B
PRESSURE CONTROL
PRESSURE CONTROL
2 2
VALVE 1
VALVE 2
E43 E44
0.5W/R
0.5W/R
E43 E44
1 1
1.25W/L
1.25W/L
0.5W/R
H357 H316
11 8
1.25W/L 1.25W/L
H176 H316
10 9
1.25W/L 1.25W/L
H177 H316
7 10
HCW58DXF033701
5/5
E71 E71 E71 E71 E71 E72 E72 E72 E72 E72 E71 E72 E72 FL559 FL559
106 103 105 107 104 142 139 137 143 138 102 140 141 72 73
POWER.GND
POWER.GND
POWER.GND
1.25B ECU.GND
1.25B ECU.GND
H257 H257
0.5B 13 14
1.25B
1.25B
0.5B
* *
5B
0.5GY 0.5GY 15
E59
1 3 2 FL65 20
J/C 22
CASE
1.25B/O
E74 EARTH
0.85W
0.85W
0.85G
0.85G
0.85R
0.85R
0.85Y
0.85B
0.85Y
0.85B
J/C:1
1.25B
1.25B
1.25B
0.85L
0.85L
9
FL65
J/C 11
0.5GY 0.5GY
1.25B/O
1.25B
H175 H175 H175 H176 H176 1 H357
1.25B
4 5 7 8 6
1.25B
H176 H176 H176 H175 H175

4 7 5 8 6
H176 H39 E78
12 J/T:FRAME EARTH
13 FB376
1.25B
J/T:EARTH H10
(CAB GND) 42
0.85W
1.25B/L
5B
5B
0.85G
0.85R
0.85Y
0.85B
0.85L
0.85W
0.85L
0.85G
0.85Y
0.85R
FB39 FB40
5B
CAB EARTH
* *
3 2 7 4 6 3 2 7 4 6
H179 H179 H179 H179 H179 H180 H180 H180 H180 H180 E77 FB11 2B/L FB10
H179 H179 H179 H179 H179 H180 H180 H180 H180 H180
7 6 3 8 2 7 6 3 8 2 FRAME EARTH BATTERY FRAME
(ENGINE) EARTH EARTH(1)
0.75BR
0.75W
0.75W
0.75G
0.75R
0.75R
0.75Y
0.75B
0.75V
0.75L
0.75R 0.75R 0.75W 0.75W

1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3
E53 E53 E53 E57 E57 E57 E55 E55 E55 E58 E58 E58 E54 E54 E54 E56 E56 E56
INJECTOR 1 INJECTOR 2 INJECTOR 3 INJECTOR 4 INJECTOR 5 INJECTOR 6
CYLINDER NO.1 CYLINDER NO.5 CYLINDER NO.3 CYLINDER NO.6 CYLINDER NO.2 CYLINDER NO.4
INSIDE CYLINDER HEAD COVER
*:END OF CABLE OPEN
HCW58DXF033801
Connector List
No. Connector Face No. Connector Face
B-14 1 2 3 E-42 1 2 3
003-030 003-067
B-41 1 2 E-43 1 2
002-006 002-068
B-43 1 2 E-44 1 2
002-108 002-068
B-44 1 2 E-45 1 2
002-108 002-031
B-45 1 2 E-46 1 2
002-108 002-031
3 2 1
B-54 1 2 E-53
002-108 003-125
3 2 1
B-55 1 2 E-54
002-108 003-125
3 2 1
E-36 1 2 3 E-55
003-067 003-125
3 2 1
E-56 E-74 1 2 3 4 5 6
003-125 006-070
3 2 1
E-57 E-74 6 5 4 3 2 1
003-125 006-071
3 2 1
E-58 E-75 1 2
003-125 002-006
E-59 E-76 1 2
000-012 002-006
107 106 105 104 103 102
117 116 115 114 113 112 111 110 109 108
E-71 128 127 126 125 124 123 122 121 120 119 118
E-77
136 135 134 133 132 131 130 129
035-003 000-012
143 142 141 140 139 138 137
153 152 151 150 149 148 147 146 145 144
E-72 161 160 159 158 157 156 155 154

E-92
167 166 165 164 163 162
031-004 000-012
E-73 1 2 3 4 5 6 F-11 1 2
006-070 002-067
E-73 6 5 4 3 2 1
F-56 1 2 3
006-071 003-023
9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10
F-70 25 24 23 22 21 20 19 FL-1 1
5
2
6
3
7
4
8
32 31 30 29 28 27 26
032-017 008-007
FB-10 FL-2 1 2
000-012 002-067
FB-11 FL-4 1 2
000-012 002-067
1 2 3 4 5 6 7 8 9 10
FB-39 FL-9 11 1213 141516 17 1819 202122
000-012 022-001
1 2 3 4
FB-40 FL-10 5 6 7 8 9
000-012 009-006
FB-82 FL-11 1 2 3 4
5 6 7 8
000-012 008-016
FB-145 1 2 FL-11 1 2 3 4
5 6 7 8 9 10 1112
002-006 012-038
FB-155 1 2 3 FL-20 2 1
003-105 002-005
FL-21 2 1
FL-182 1 2
002-005 002-067
1 1
2 3 4 2 3 4
FL-49 5
FL-196 5
005-012 005-012
2 3 4
FL-54 5
FL-223 1 2 3
005-012 003-015
1 2 3 4 5 6 7 8 9 10 11
FL-65 12 13 14 15 16 17 18 19 20 21 22
FL-385 1 2 3 4
23 24 25 26 27 28 29 30 31 32 33
033-001 004-021
1 2 3 4 5 6 7 8 9 10 11
1
FL-68 12 13 14 15 16 17 18 19 20 21 22
FL-397
23 24 25 26 27 28 29 30 31 32 33
2
033-001 002-012
1 1
2 3 4 2 3 4
FL-128 5
FL-398 5
005-012 005-012
2 3 4
FL-133 1 2 3
FL-400 5
003-015 005-012
FL-134 1 2 3 FL-466 1 2
4 5 6
006-004 002-101
1 2 3 4
FL-475 1 2 3
FL-536 5 6 7 8 9 10
003-023 010-002
4 3 2 1
1
FL-494 FL-537 10 9 8 7 6 5
2
002-012 010-003
1 2 3 4 5 6 7 8 9 10 11
1
FL-511 FL-552
12 13 14 15 16 17 18 19 20 21 22 2
022-005 002-012
1 2
FL-514 FL-554
2
3 4 5
002-012 005-023
2
FL-522 1 2 3 4 5 6 7 8 9 10 FL-555
11 12 13 14 15 16 17 18 19 20 3 4 5
020-008 005-023
7 6 5 4 3 2 1
17 16 15 14 13 12 11 10 9 8
FL-531 1 2 3 4 5 6
FL-557 27 26 25 24 23 22 21 20 19 18
34 33 32 31 30 29 28
006-056 034-004
41 40 39 38 37 36 35
53 52 51 50 49 48 47 46 45 44 43 42
1 2 3
FL-532 4 5 6 FL-558 61 60 59 58 57 56 55 54
69 68 67 66 65 64 63 62
006-002 035-002
76 75 74 73 72 71 70
1 2 3 4 5 6 7 8 9 1011121314 86 85 84 83 82 81 80 79 78 77
FL-535 FL-559 96 95 94 93 92 91 90 89 88 87
151617 1819 2021
101 100 99 98 97
021-001 032-025
1 2 3 4 5 6 7 8 9 10 11
FL-560 12 13 14 15 16 17 18 19 20 21 22
FL-716 1 2 3 4
23 24 25 26 27 28 29 30 31 32 33
033-001 004-008
2 3 4
FL-569 1 2 3 4 FL-731 5
004-021 005-012
2
FL-605 FU-5 1 2 3 4 5 6 7 8 9 10
3 4 5
005-023 010-027
1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11
FL-655 12 13 14 15 16 17 18 19 20 21 22
FU-7 12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33 23 24 25 26 27 28 29 30 31 32 33
033-001 033-001
1 2 3 4 5 6 7 8 9 10 11
FL-656 12 13 14 15 16 17 18 19 20 21 22
FU-8 1 2 3 4 5 6 7 8 9 10 11 12
23 24 25 26 27 28 29 30 31 32 33
033-001 012-018
1 2 3 4 5 6 7 8 9 10 11
FL-657 12 13 14 15 16 17 18 19 20 21 22
FU-9 1 2 3 4 5 6 7 8 9 10 11 12 13 14
23 24 25 26 27 28 29 30 31 32 33
033-001 014-007
1 2 3 4 5 6 7 8 9 10 11
FL-658 12 13 14 15 16 17 18 19 20 21 22
FU-14 1 2 3
4 5 6
23 24 25 26 27 28 29 30 31 32 33
033-001 006-024
FL-716 4 3 2 1
FU-18 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
004-007 016-031
1 2 3 4 5 6 7 8 9 1 2 3 4
FU-28 H-20 5 6 7 8
10111213141516171819202122
022-022 008-009
4 3 2 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
FU-33 H-20 8 7 6 5
016-030 008-010
1 2 3 4
1 2 3 5 6 7 8
FU-35 4 5 6 7 8 H-39 9 10 11 12
13 14 15 16
008-030 016-019
4 3 2 1
8 7 6 5
FU-62 1 2 3 4 5 6
H-39 12 11 10 9
16 15 14 13
006-056 016-020
1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4
FU-72 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
H-42 5 6 7 8
030-002 008-005
4 3 2 1
1 2 3
G-53 4 5 6 H-42 8 7 6 5
006-002 008-006
1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6
H-12 11 1213 141516 17 1819 202122 H-48 7 8 9 10 11 12 13 14
022-001 014-003
10 9 8 7 6 5 4 3 2 1 6 5 4 3 2 1
H-12 2221201918 17 16 1514131211 H-48 1413 12 11 10 9 8 7
022-002 014-004
1 2 3 4
5 6 7 8 1 2 3 4
H-158 9 10 11 12 H-177 5 6
9 10 11 12
7 8
13 14 15 16
016-019 012-013
4 3 2 1
4 3 2 1
8 7 6 5
8 7 6 5
H-158 12 11 10 9
H-177 12 11 10 9
16 15 14 13
016-020 012-014
10 9 8 7 6 5 4 3 2 1
1 2 3 4
H-162 2221201918 17 16 1514131211 H-179
5 6 7 8
022-002 008-046
1 2 3 4 5 6 7 8 9 10
4 3 2 1
H-162 11 1213 141516 17 1819 202122 H-179
8 7 6 5
022-001 008-047
1 2 3 4
1 2 3 4
H-175 5 6
9 10 11 12
7 8
H-180
5 6 7 8
012-013 008-046
4 3 2 1
8 7 6 5 4 3 2 1
H-175 12 11 10 9
H-180
8 7 6 5
012-014 008-047
1 2 3 4
5 6 7 8
H-176 9 10 11 12 H-186 1 2
13 14 15 16 3 4
016-019 004-015
4 3 2 1
8 7 6 5
2 1
H-176 12 11 10 9
H-186 4 3
16 15 14 13
016-020 004-035
1 1 2 3 4 5 6 7 8 9 10
H-187 2
H-280 11 1213 141516 17 1819 202122
002-010 022-001
10 9 8 7 6 5 4 3 2 1
H-187 1
5
2
6
3
7
4
8
H-280 2221201918 17 16 1514131211
008-017 022-002
1 2 3 4 1 2 3 4 5 6 7 8 9
5 6 7 8
H-215 9 10 11 12 H-282 10 11 12 13 14 15 16 17 18 19 20 21
13 14 15 16
22 23 24 25 26 27 28 29 30 31 32
016-019 032-014
4 3 2 1
9 8 7 6 5 4 3 2 1
8 7 6 5
H-215 12 11 10 9
H-282 21 20 19 18 17 16 15 14 13 12 11 10
16 15 14 13
32 31 30 29 28 27 26 25 24 23 22
016-020 032-015
1 2 3 4 5 6 7 8 9
1 2 3 4 5 6 7 8 9 10
H-256 11 1213 141516 17 1819 202122 H-290 10 11 12 13 14 15 16 17 18 19 20 21
22 23 24 25 26 27 28 29 30 31 32
022-001 032-014
9 8 7 6 5 4 3 2 1
10 9 8 7 6 5 4 3 2 1
H-256 2221201918 17 16 1514131211 H-290 21 20 19 18 17 16 15 14 13 12 11 10
32 31 30 29 28 27 26 25 24 23 22
022-002 032-015
8 7 6 5 4 3 2 1
1 2 3 4
H-257 18 17 16 15 14 13 12 11 10 9 H-299 5 6 7 8
018-001 008-005
1 2 3 4 5 6 7 8 4 3 2 1
H-257 9 10 11 12 13 14 15 16 17 18
H-299 8 7 6 5
018-002 008-006
1 2 3 4
5 6 7 8
1 2 3 4
H-301 9 10 11 12 H-390 5 6 7 8
13 14 15 16
016-019 008-005
4 3 2 1
8 7 6 5
4 3 2 1
H-301 12 11 10 9
H-390 8 7 6 5
16 15 14 13
016-020 008-006
1 2 3 4
5 6 7 8
H-304 9 10 11 12 I-4 1 2
13 14 15 16
016-019 002-006
4 3 2 1
8 7 6 5
H-304 12 11 10 9
J-12 1 2
16 15 14 13
016-020 002-006
1 2 3 4 5 6
H-316 7 8 9 10 11 12 13 14
J-24 1 2
014-003 002-006
6 5 4 3 2 1
H-316 1413 12 11 10 9 8 7 J-43 1 2
014-004 002-006
1 2 3 4
H-357 5 6
9 10 11 12
7 8
J-44 1 2
012-013 002-006
4 3 2 1
H-357 J-46
8 7 6 5
12 11 10 9 1 2
012-014 002-006
No. Connector Face H-7
J-67 1 2
002-006
1 2 3 4 5 6 7 8 9 10 11 12 12 11 10 9 8 7 6 5 4 3 2 1
13 14 15 16 17 18 19 20 21 22 23 24 24 23 22 21 20 19 18 17 16 15 14 13
25 26 27 28 29 30 31 32 33 34 35 36 36 35 34 33 32 31 30 29 28 27 26 25
37 38 39 40
40 39 38 37
41 42 43 44 44 43 42 41
M-5 1 2 45 46 47 48 48 47 46 45
49 50 51 52 53 54 55 56 57 58 59 60 60 59 58 57 56 55 54 53 52 51 50 49
61 62 63 64 65 66 67 68 69 70 71 72 72 71 70 69 68 67 66 65 64 63 62 61
002-006
73 74 75 76 77 78 79 80 81 82 83 84 84 83 82 81 80 79 78 77 76 75 74 73
M-40 1 2 HCW39CSH014301
H-10
002-006
H-6
1 2 3 4 5 6 7 8 9 10 11 12 12 11 10 9 8 7 6 5 4 3 2 1
13 14 15 16 17 18 19 20 21 22 23 24 24 23 22 21 20 19 18 17 16 15 14 13
25 26 27 28 29 30 31 32 33 34 35 36 36 35 34 33 32 31 30 29 28 27 26 25
37 38 39 40
40 39 38 37
1 2 3 4 5 6 7 7 6 5 4 3 2 1
41 42 43 44 44 43 42 41
8 9 10 11 12 13 14 14 13 12 11 10 9 8
15 16 17 18 19 20 20 19 18 17 16 15 45 46 47 48 48 47 46 45
21 22 23 24 24 23 22 21
49 50 51 52 53 54 55 56 57 58 59 60 60 59 58 57 56 55 54 53 52 51 50 49
25 26 27 28 28 27 26 25
61 62 63 64 65 66 67 68 69 70 71 72 72 71 70 69 68 67 66 65 64 63 62 61
73 74 75 76 77 78 79 80 81 82 83 84 84 83 82 81 80 79 78 77 76 75 74 73
29 30 31 32 32 31 30 29
33 34 35 36 36 35 34 33
37 38 39 40 41 42 42 41 40 39 38 37
43 44 45 46 47 48 49 49 48 47 46 45 44 43
50 51 52 53 54 55 56 56 55 54 53 52 51 50
HCW39CSH014301
HCW39CSH014401
H-387
1 2 3 4 5 6 7 8 9 10 11
11 10 9 8 7 6 5 4 3 2 1
12 13 14 15 16 17 18 19 20 21 22
22 21 20 19 18 17 16 15 14 13 12
23 24 25 26 27 28 29 30 31 32 33
33 32 31 30 29 28 27 26 25 24 23
34 35 36 37 38 39 40 41
41 40 39 38 37 36 35 34
42 43 44 45 46 47
47 46 45 44 43 42
48 49 50 51 52 53 54
54 53 52 51 50 49 48
LNW48ASF000201
Fault diagnosis process The diagnostic procedure is always used to solve E/E
system problems, and forms the starting point for any
System Diagnosis Method
repairs that may be required. The progress of diagnosis
The system diagnosis method is a uniform procedure will be described in the following steps:
for the repair of all electrical/ electronic (E/E) systems.
1. Confirm customer complaint.
E/E system breakdowns differ from general vehicle
breakdowns and often involve the following steps: • To confirm the content of the customer’s
complaint, the vehicle diagnosis engineer must
1. Initial stage of the breakdown;
know the normal operating state of the system.
• Breakdown occurrence is a single incident of
2. Perform preliminary inspection.
short duration, which is often overlooked by the
customer. Customer complaints at that stage • Overall visual inspection
are vague and the problem cannot be • Review service history.
reproduced. However, there many be a record • Detect abnormal noises, odors etc.
of the breakdown in the Engine Control Module
• Use a scan tool (Tech2) to gather DTCs, data
(ECM) memory.
etc.
= Past fault
3. Inspect the service information.
2. Intermediate stage of the breakdown;
4. Refer to “Diagnosis by symptoms” in the manual.
• Breakdown occurrence is a single incident of
short duration, but repeats at intervals, and will • “Diagnosis by Symptoms” includes information
always occur under certain conditions. about systems that is not displayed under the
Customer complaint (nature of the breakdown) DTCs (Diagnostic Trouble Codes). Therefore
is clear and the area of uncertainty is in the “Diagnosis by Symptoms” can be used to
conditions under which the breakdown occurs. confirm proper operation of the system and
Therefore, the vehicle diagnosis engineer can learn the appropriate diagnostic method.
reproduce the breakdown by identifying the 5. Refer to content related to engine mechanics etc.
conditions.
= Intermittent fault If there is a DTC (Diagnostic Trouble Code) in
3. Fault manifestation stage; memory
• The breakdown occurrence is constant and Follow the specified DTC chart precisely to carry out
fixed, with clear and concrete customer the repair.
complaints.
Therefore the diagnosis engineer can If there is no DTC.
reproduce the breakdown. However, a single Select the symptoms from Diagnosis by Symptom.
breakdown incident may have multiple causes. Follow the diagnostic procedure to complete the repair.
= Current fault Inspections can be made with reference to functional
diagnosis.
If there are no applicable symptoms. 1. Re-investigate the complaint
1. Investigate the complaint in detail. If it is not possible to adequately detect or identify
the problem, the diagnosis must be begun again.
2. Draw up a diagnosis plan.
Recheck the complaint. As described in “If the fault
3. Use wiring diagrams and operating principles. is intermittent” above, the complaint could refer to
Ask for technical assistance with cases resembling an intermittent fault, or the vehicle could actually
repair histories that you can obtain. Make effective use be normal.
of technical knowledge and usable service information.
2. Repair and check.
Carry out the repair after identifying the cause.
If the fault is intermittent
Check whether the vehicle operates normally, and
A fault is said to be intermittent if it does not always check that the symptoms have been corrected. In
appear. Take the following steps to solve an intermittent the situations below, this check will include road
problem. driving tests and other methods to confirm solution
1. Check DTC information and engine data. of the problem.
2. Evaluate signs and conditions described by the • Test in the state described by the customer to
customer. check.
3. Use a check sheet or other method to check the • If a DTC has been diagnosed, check the scan
circuits and electrical system components. tool data while reproducing the state that
applied when the DTC was set, to confirm
If the trouble cannot be detected whether the fault has been repaired.
This state refers to cases where the vehicle is judged to
Verify repair
be operating normally. The state described by the
customer may actually be normal. Compare the If an electrical control system has been repaired, it is
customer’s complaint against a different vehicle that is necessary to check after repairing the vehicle whether
functioning normally. The vehicle state may also the repair was correct. If this check is not performed
involve and intermittent problem. Before returning the thoroughly, the MIL (check engine lamp) could relight
vehicle, check the content of the complaint in the state when the vehicle is being returned to the customer, or
described by the customer. problems in drive performance could recur. With
intermittent faults it is particularly important to
reproduce the conditions of the customer’s complaint
and Verify repair
Item Item Purpose Method

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

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

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

Current and past trouble codes (DTCs) recorded in the
ECM can be displayed, and the MIL (check engine
lamp) made to flash by connecting a diagnostics
switch.
If the DTC is stored
The stored trouble code is shown three times. If
multiple trouble codes are stored, each is displayed
three times, starting from the one with the smallest
number. After all the codes have been shown, the
display starts repeating again from code 23. This
display continues for as long as the diagnostics
connector is connected.
Check engine lamp (in case of code "23")
t4 t3 t2 t3 t2 t1 t2 t1 t2 t1 t4 t1 = About 0.3 sec
ON t2 = About 0.6 sec

t3 = About 1.2 sec
t4 = About 2.4 sec
OFF
Tens digit Units digit
Check engine lamp (in case of code "413")
t4 t1 t2 t1 t2 t1 t2 t1 t2 t3 t2 t1 t2 t1 t2 t1 t4
ON
OFF Tens
Hundreds digit digit Units digit
HCW4ADSF000101
DTCs from the MIL (check engine lamp) flashing 5. Push the accelerator pedal to the WOT position for
display more than 1 second and less than 3 seconds.
While the engine is stopped, both the current DTCs and 6. Release the accelerator pedal for more than 1
past DTCs are displayed. second and less than 3 seconds.
While the engine is running, only currently-occurring 7. After that, turn the starter switch Off again and
DTCs are displayed. back to On.
(Alternatively, disconnect the connector and then
How to delete DTCs using accelerator pedal reconnect).
operation If the deletion process was carried out correctly, the
* Use of this operation deletes all electrical system normal code is displayed.
DTCs, other than those for some electrical systems
(ABS, Smoother-G, SRS, etc.), so proceed with
caution.
• The starter switch is On with the engine stopped.
• Connect the diagnostics connector and the
diagnostics common connector.
Under these conditions, perform the operations below
to delete the trouble codes.
1. After the connector is connected, push the
accelerator pedal to the wide open throttle (WOT)
position for more than 1 second and less than 3
seconds.
2. Release the accelerator pedal for more than 1
second and less than 3 seconds.
3. Push the accelerator pedal to the WOT position for
more than 1 second and less than 3 seconds.
4. Release the accelerator pedal for more than 1
second and less than 3 seconds.
Breakdown diagnosis using the scan tool.
The Scan Tool (Tech2) and the Tech2 Adapter
This is an effective tool for diagnosing electrical
breakdowns in the electronic control systems and
carrying out system checks. If the Tech2 adapter is
used to connect to the DLC on the vehicle, various
diagnoses and tests can be run on the ECM and
communications on the vehicle.
HCW35ALF001301
Legend
1. PCMCIA card (specialized) 3. DLC cable
2. Tech2 (main unit)
TE
CH
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AP
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HCW35AMF001501
Legend
1. Tech2 adapter 3. Adapter cable (for connection to the Tech2 DLC)
2. Adapter cable (for connection to the vehicle
DLC)
Characteristics and precautions concerning the • To delete the diagnostic trouble code (DTC), open
Tech2/ Tech2 adapter the Application menu and select “Clear DTC Info”
• Tech2 is a 12V power supply system. Do not of DTC deletion.
connect it directly to a 24V power supply. The • The Tech2 adapter has a built-in DC-DC converter
Tech2 power supply is supplied via the Tech2 (to transform 24V to 12V). Refer to the instruction
adapter. (The Tech2 adapter has a built-in function manual for details.
to convert from 24V power supply to 12V). • The Tech2 adapter has a selector to switch
Therefore do not power the Tech2 directly from the between signals (electronic control unit (ECU)
battery or cigarette lighter. signals).
• Turn off the power supply before inserting or Select “3” for engine control.
removing the PCMCIA card. • Set the PCMCIA card into the Tech2 and
• Tech2 has 3 (the older version had 2). Attach the DLC cable to the VCI (Vehicle
snapshots of capacity. Communication Interface) on the Tech2 body,
• The PCMCIA card is vulnerable to magnetism and Next, attach the adapter cable to the Tech2
static electricity, so it should be handled with care. adapter. The Tech2 and Tech2 adapter are linked,
and the adapter cable is linked to the vehicle DLC.
• Tech2 can draw a graph of a snapshot.
• When selecting a menu item, used the selection or
function keys to select an item, then press the
Enter key.
• Press the Exit key to go back to the Main Menu at
any time.
Parts of the Tech2
2
3
13
4
8
14
3
5 6
15
16
7 12
11
9
10
HCW35ALF001401
Legend
1. Soft keypad 10. VCI module fastening bar
2. Selection keys (arrow keys) 11. DLC cable connector
3. Action keys (Yes, No, Enter, Exit) 12. AC adapter connector
4. Function keys (F0 - F9) 13. PCMCIA card slot (with cover)
5. Help key (?) 14. PCMCIA card release button
6. Control key (PWR/ Shift) 15. External communications connector (RS485
7. Wide stand port)
8. Display (LCD screen) 16. External communications connector (RS232
9. Vehicle Communications Interface (VCI) module port)
1. Soft keypad 2. Selection keys (arrow keys)

When Tech2 is operated, the selection instruction These are used for menu selections and display
box appears in the top of the screen. The soft keys switching on the Tech2 screen. The highlighted
correspond to the selection box. If there is no portion of the screen display content is the
selection box on the screen, the instrument cannot selection.
be used.
3. Action keys (Yes, No, Enter, Exit)
These are used to confirm Tech2 operations,
answer on-screen instructions and questions and
switch/ move between menu screens.
4. Function keys (F0 - F9)
These confirm menu functions within the screen
display. If the screen menu contains elements such
as “F0”, the key corresponds to that display.
5. Help key (?)
When this key is pressed, a screen appears,
explaining the Tech2 function currently in use.
6. Control key (PWR/ Shift)
The PWR key turns the Tech2 power on and off.
The shift key is used to adjust screen contrast. An
LED lights (orange) when the shift key is enabled.
At that time, all keys and functions other than the
selection keys are locked. An LED (green) lights
when the power supply is turned on.
7. Wide stand
This is used as a stand for the instrument. The
stand can be moved through angles of 0-180?.
8. Display (LCD screen)
This is an LCD display with a contrast adjustment
function. It displays ECM information, instruction
screens etc.
9. Vehicle Communications Interface (VCI) module
The module that allows communications between
the vehicle and Tech2.
10. VCI module fastening bar
Operate this bar to mount and fasten the VCI or
remove it.
11. DLC cable connector
This is the connector for using (connecting) Tech2
on a vehicle. Connect the DLC cable.
12. AC adapter connector
This is the connector for connecting the accessory
AC adaptor. This is for using Tech2 outside a
vehicle.
13. PCMCIA card slot (with cover)
Open the cover to insert a PCMCIA card into
Tech2. Insert the PCMCIA card with the cover
open. Never insert or remove the PCMCIA card
while Tech2 is switched on.
14. PCMCIA card release button
Use this button to remove the PCMCIA card from
Tech2. Press the button to take the PCMCIA card
out. Never remove the PCMCIA card while Tech2
is switched On.
15. External communications connector (RS485 port)
This is a telephone line connector, but it is not
currently used on Tech2. Do not connect this
connector to a telephone line etc.
16. External communications connector (RS232 port)
This is the connector to connect Tech2 to another
computer.
Parts of the Tech2 adapter
TE
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2
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9
2
3
HCW35AMF001601
Legend
1. Selector 4. Adapter cable (for connection to the vehicle
2. Select switch (signal switching) DLC) connector
3. Adapter cable (for connection to the Tech2 DLC) 5. Vehicle DLC connector
connector
1. Selector 3. Adapter cable (for connection to the Tech2 DLC)

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

HCW46ELH000101
6WF1-TC/6WG1-TC (Common Rail)

F0: Fault diagnosis code (DTC)
Select one of the following F0: DTC display
Vehicle Type (s) F1: Fault history
F2: DTC deletion
(N*) ELF, NPR, NQR, VFR F1: Data display
(off-Road) Industrial Engine F2: Snapshot
(C*,E*,L*,F*) Heavy, Medium Duty F3: Actuator test
F0: Common rail system
F0: Rail pressure control
(C*,E*,L*,F* ENTER)
F1: Stop injection from each injector
F1: Device control
System Selection Menu F0: Turbocharger control
(C*,E*,L*,F*) Heavy, Medium Duty F1: EGR control
F2: Exhaust brake relay
F0 : Engine F3: Retarder relay
F1 : Transmission F4: Programming
F2 : Chassis
F0: Q adjustment compensation
F0: Q adjustment compensation data
F3 : Body
upload (Tech2)
F1: Q adjustment compensation data
(F0 ENTER)
download (ECM)
F2: Service mode
Vehicle Identification F1: Injector ID code
Select one of the following
F0: Injector ID code
F1: ID code registration
Engine
F2: ID code upload (Tech2)
6WF1-TC (Common Rail)
F3: ID code download (ECM)
F4: History information
6WG1-TC (Common Rail)
6UZ1 (Common Rail) Menu Items

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

The table below indicates which functions are
implemented and displayed in the current Tech2
software.
Fault diagnosis code (DTC) Data display
Read, check and delete DTCs The states recognized and controlled by the ECM are
Put the Tech2 adapter select switch in the “1” position displayed in various items.
to read DTCs. Put the Tech2 adapter select switch in the “1” position
Put the Tech2 adapter select switch in the “2” position to read data.
to delete DTCs. The displayed numerical items are stated under
representative values for the Tech2 data list.
Content of the display items is stated under data.
TE
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Data Display
AP
TE
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2
System Voltage V
6
1
Engine Speed RPM

PS
8
W
1
Desired Idle Speed RPM

APP(Accelerator Pedal) V
Accelerator Opening %
Accelerator Pedal ON/OFF
APP(Accelerator Pedal) %
Accelerator Position Le V
1
2 Select DTC Quick More

Items Snapshot
HCW61ASH000401
DTCs are the language for the diagnosis engineer to HCW460SH000201

communicate with the vehicle ECM.
DTCs can be broadly divided into past and current This menu can be used to display current data.
DTCs. The display is synchronized with the state of the vehicle
• Current DTCs: Indicate faults (breakdowns) in the and any devices.
current ignition cycle. • If the menu for data display cannot be displayed:
• Past DTCs: Indicate faults (breakdowns) in the last A breakdown has occurred in the wiring between
or earlier ignition cycles. the ECM and the DLC.
The select switch on the Tech2 adapter is in the
• Multiple DTCs: Several DTCs may be displayed at
wrong position.
once. These are called multiple DTCs. This occurs
when multiple faults (breakdowns) happen at once. • If the display shows an abnormal fixed value:
In other cases, when multiple sensors or switches E.g. If the data display values for engine speed
share the same GND or power supply, a broken and various sensors are fixed and differ from the
connection or short in that ground or power actual status. Move the connector or harness by
connection can cause the display of multiple DTCs hand and see if the display stops being fixed. If so,
for all related sensors and switches. If multiple the cause is a poorly fitting terminal, misaligned
DTCs are displayed, refer to the chart for DTCs pins, a broken or shorted harness wire at the
that require inspection of broken connections and position moved by hand, etc., requiring repair.
shorts in common power supply or GND • If the numerical display is marked with “*”:
connections, and delete the vehicle DTC This is a Tech2 software problem.
information. If even one item has an asterisk mark during data
display, the PCMCIA card requires a version
upgrade.
Snapshot
A snapshot is taken so that data can be reviewed and
used in identifying the cause of a breakdown.
• The snapshot can be stored in the data list menu
and displayed graphically.
• Using this mode, the conditions of a customer
complaint can be reproduced and recorded to
identify data faults.
• If the method of determining the trigger type is Actuator test
used, the data for the moment at which the DTC Perform all applicable tests, operate components,
was displayed can be recorded. inspect functions and confirm that they are either faulty
• Recorded data can be played back on a domestic or normal.
power supply. When performing instructions (commands) for the ECM
from the test screen, place the select switch of the
Programming Tech2 adapter in its second position.
When replacing the ECM, confirm history information
prior to replacing. (Data confirmation), in addition CAUTION:
upload data to Tech2. After replacing the ECM, If conditions concerning the vehicle, operating
download data to the new ECM. conditions, coolant temperature, vehicle speed,
switches, gear position are not satisfied or if a DTC is
detected, there are cases where not all tests are
performed.
Item Description Method of use

M a g n e t i c Exhaust brake valve Confirm operation of the If the magnetic valve does not operate
v a l v e magnetic valve when on/off when turned on, there may be an
system commands are given. abnormality with the exhaust magnetic
valve, harness, or ECM.
VGS valve Confirm operation of the If the magnetic valve does not operate
magnetic valve when on/off when turned on, it means there is an
commands are given. abnormality with the VGS magnetic valve,
harness, or ECM.
EGR valve Confirm operation of the If the magnetic valve does not operate
magnetic valve when on/off when turned on, it means there is an
commands are given. abnormality with the EGR valve, harness,
or ECM.
E n g i n e Rail pressure control Perform a rail pressure increase If the increase in rail pressure does not
control command to check the condition operate when performed, it means there is
of the rail pressure control. an abnormality with the PCV, PCV control
harness or ECM etc.
Stoppage of When a command for stopping If there are no changes to engine rpm or in
injection on a per injection is performed for the the way the engine vibrates when an
injector basis injector for each cylinder, confirm injector stop command is performed, this
the status for each cylinder. indicates that the injector was stopped
prior to the command being performed.
This means that there is an abnormality in
this injector, the harness, or ECM etc.
Method for selecting trigger type and creating a 6. The screen will change and when [continue] is
graph displayed at the bottom of the screen, select
1. Select [data display] in the application menu. [continue].
2. Make the selection when items are displayed on 7. When [plot] is displayed at the bottom of the
the screen. screen, select [plot].
3. When the snapshot option is displayed on the 8. If the item selection screen is displayed, click on
screen, choose the trigger method, and select the desired item and push the enter key, select up
[record snapshot] at the bottom of the screen. to 3 and select the “approval” button at the bottom
of the screen.
4. If (standby) at the bottom of the screen flashes,
select [trigger] at the bottom of the screen. 9. A graph is displayed on the screen.
5. Confirm the trigger type.
Method for playing back a graph of the recorded 2. Make the selection when items are displayed on
data the screen.
1. Select [snapshot data] from the screen after 3. When the snapshot option is displayed on the
turning the Tech2 power on. screen, choose the trigger method, and select
2. Confirm that the snapshot data title is displayed. [record snapshot] at the bottom of the screen.
3. Select the snapshot data title. 4. If (standby) at the bottom of the screen flashes,
select [trigger] at the bottom of the screen.
4. Data is displayed on the screen. If you would like
to see a graph of the data, select on [plot] at the 5. Confirm the trigger type.
bottom of the screen. 6. The screen will change and when [continue] is
5. If the item selection screen is displayed, click on displayed at the bottom of the screen, select
the desired item and push the enter key, select up [continue].
to 3 and select the [approval] button at the bottom 7. When [plot] is displayed at the bottom of the
of the screen. screen, select [plot].
6. A graph is displayed on the screen. 8. If the item selection screen is displayed, click on
the desired item and push the enter key, select up
Graph creation to 3 and select the [approval] button at the bottom
of the screen.
This enables creation of a graph of the snapshot data.
Reviewing this graph enables investigation of the 9. A graph is displayed on the screen.
cause of a failure occurrence.
Method for playing back a graph of the recorded
Method for creating a graph after displaying data data
1. After selecting [data display] in the application 1. Select [snapshot data] from the screen after
menu and vehicle data is displayed, select turning the Tech2 power on.
[snapshot] from the bottom of the screen. 2. Confirm that the snapshot data title is displayed.
2. After a certain amount of time passes, push the 3. Select the snapshot data title.
[Exit] button. 4. Data is displayed on the screen. If you would like
3. The screen will change and when [continue] is to see a graph of the data, select on [plot] at the
displayed at the bottom of the screen, select bottom of the screen.
[continue]. 5. If the item selection screen is displayed, click on
4. When [plot] is displayed at the bottom of the the desired item and push the enter key, select up
screen, select [plot]. to 3 and select the [approval] button at the bottom
5. If the item selection screen is displayed, click on of the screen.
the desired item and push the enter key, select up 6. A graph is displayed on the screen.
to 3 and select the [approval] button at the bottom
of the screen. Tech2 data reference values
6. A graph is displayed on the screen. Data lists are for confirming the status of the vehicle
and each piece of equipment.
Method for selecting trigger type and creating a Compares data from each vehicle to basic values and
graph finds temporary deviations from reference values and
1. Select [data display] in the application menu. cases where deviation is continuous. This is used for
diagnostics. (This Tech2 display menu may be changed
without notification.)
Data display items Units Idle reference values (changes

caused by vehicle conditions)
System voltage V more than 24
Engine RPM RPM With respect to goals ±25
Target idle speed RPM 475-525
Acceleration sensor V 0.25-0.75
Accelerator amount open % 0
Accelerator pedal switch ON/OFF ON

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

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

Diagnostics switch On/Off OFF
Final amount injected after mm3/st
correction
Injection amount control mode – –
Injection control mode – –
High pressure pump control mode – –
Final injection amount mm3/st
ISC corrected injection amount mm3/st
Function Inspection List
Oral consultation Point sequence based on customer’s complaint for the

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

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

At the time the vehicle is received at the service
workshop from the customer, it is necessary to confirm
the “fault symptoms” and “fault occurrence data” based
on the engine control system questionnaire with the
customer.
HCW01ASH011801
Legend
1. Fault symptoms
2. Fault frequency / fault conditions
Because:
ENGINE CONTROL SYSTEM CHECK SHEET Inspectors Name

Customers Name Model & Model Year
Drivers Name Chassis No.
Date Vehicle Brought In Engine No.
License No. Odometer Reading km/miles
Engine Does Engine does not crank No initial combustion No complete combustion
Not Run
Hard Start Engine cranks slowly Other ( )
Abnormal idling speed High idling speed ( RPM) Low idling speed ( RPM)
Problem Symptoms
Incorrect Idle Rough idling

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

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

Highway Suburbs City area Uphill
Place
Downhill Rough road Other ( )
Load Condition Over (approx. tons) No load
Other (approx. tons)
Engine Cold Warming up After warming up Any temperature
Temperature Other ( )
Starting Just after starting ( Min.) Idling
Engine Operation Racing Driving Constant speed Acceleration
Deceleration A/C switch On/Off
Other ( )
Fuel Amount Full Above 1/2 Below 1/2 Near empty
Fuel Bland
Condition of Check Engine Lamp Remains On Intermittently turns On Does not turn On
Present Code Nothing P Code & Symptom Code

No. ( )
Diagnostic Trouble
Code (DTC) or Flash
Code P Code & Symptom Code
History Code Nothing No. ( )
Other Additional
Condition
HCW46EXF002401
On-Board Diagnosis (OBD) System Check
Description Test Description
The on-board diagnosis (OBD) system check is the The following numbers show the step numbers of the
starting point for all vehicle driving condition diagnoses. diagnostic chart:
Before using this procedure, carefully do a visual
inspection to ensure there is no dirt or loose fittings in
2. The MIL (check engine lamp) is continually on
engine control module (ECM), connectors, and power
while the starter switch is on but engine is not
supply and grounding.
running and afterwards turns off. If it does not
In addition, this is a method for confirming by each
turn on, use a diagnostic chart to inspect
function the problems arising from imperfect
functions in order to check the MIL circuit and
functioning of engine control system. repair it.
3. Make sure the ECM has the capability to control
Diagnostic Aids
the MIL and that the MIL drive circuit is
Intermittent fault (intermittent) may occur due to poor connected to ground. If there is an abnormality,
connection or harness damage. Check for the following use a diagnostic chart to inspect functions in
conditions, and repair or replace if fault is detected. order to check the MIL flash circuit and repair it.
• Poor connection at ECM: At the harness 4. Inspect the data communication circuit, and
connector, inspect to ensure there is no projecting confirm the ability of ECM to transmit serial data.
terminal end portion, inappropriate fit, lock 6. If the specified DTC is detected, the engine may
damage, inappropriate shape or damage to not start. In addition, inspect and repair since the
terminal, or poor connection of terminal and wire. engine control may not be functioning normally.
• Damage to harness: Inspect to ensure there is no 11. Reference an inspection method for each DTC
abrasion of wire insulation, broken wire inside the and perform an inspection
insulation, and the like. 14. If the scan tool data differs from the
representative value, this will be useful in
checking the areas where an abnormality has
occurred.
Step Action Value(s) Yes No

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

Connect the scan tool.
1. Turn the starter switch OFF.
2. Connect scan tool to data link connector
(DLC:3 pole).
4 —
4. Turn ON the scan tool.
5. Communicate with the engine control
module (ECM) using a scan tool.
Go to “Checking
Was power supplied to scan tool, and was the scan tool
connection with the ECM confirmed? Go to Step 5 circuit system”
DTC is read and recorded using scan tool.
1. Turn the starter switch ON. (At this time,
engine does not start up)
5 2. Turn ON the scan tool. —
3. Read the DTC using scan tool.
Is the action complete? Go to Step 6 —

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

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

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

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

Inspect/repair fault portions according to the
phenomena considered to be faults by
14 referring to oral consultation (user data) and —
engine data. Go to applicable
symptom
Is the action complete? Go to Step 15 diagnostic table
Erase DTCs from the ECM and restore the
15 vehicle to its initial state. —
Is the action complete? Verify repair —
Checking the MIL (check engine lamp) lighting circuit system (MIL does not turn ON)
Fuse 11
(7.5A)
0.5Y
KEY ON
A30 Meter
ECM
A14 C8
GND
0.3 O/B
0.5B
5B/L
8B
82 Engine
Control
Module
(ECM)
HCW61AMF001401
Circuit Description Also check for abnormality such as of other ECM

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

Make sure the other lights (parking brake light,
charge light, etc.) in the display turn on.
1. Turn the starter switch on.
1 2. Make sure the lights in the display turn —
on.
Did the other lights turn on? Go to Step 5 Go to Step 2

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

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

on again.
1. Connect all the harnesses.
5 —
After staying lit for 15s, the lamp flashes 3
times on a 1s cycle, then lights again. Verify repair and
return to the OBD
Did the MIL (check engine lamp) turn on? system check Go to Step 6
Check the MIL (check engine lamp) drive
circuit.
2. Disconnect the harness from the ECM.
6 3. Turn on the starter switch and confirm —
that the MIL (check engine lamp) turns on
when a jumper is used between the ECM
harness connector and ground.
Did the MIL (check engine lamp) turn on? Go to Step 8 Go to Step 7
Repair or replace the MIL (check engine lamp)
7 drive circuit. —

on again.
8 —
After staying lit for 15s, the lamp flashes 3
times on a 1s cycle, then lights again. Verify repair and
return to the OBD
Did the MIL (check engine lamp) turn on? system check Go to Step 9
1. Replace the ECM.
IMPORTANT:
9 items of programming. —
• Injector ID code Verify repair and
return to the OBD
Is the action complete? system check —
Checking the MIL (check engine lamp) flashing control system (MIL does not flashing)
Fuse 11
(7.5A)
0.5Y
KEY ON
A30 Meter
ECM
A14 C8
GND
0.3 O/B
0.5B
5B/L
8B
82 Engine
Control
Module
(ECM)
HCW61AMF001401
Circuit Description Test Description

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

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

Check the MIL (check engine lamp) drive
circuit.
2. Disconnect the harness from the display.
3 4. Check that there are no short circuits in —
the harness between the display and the
ECM.
necessary.

flashes correctly again.
4 —
3. Connect the diagnostic switch (diagnostic
connector and diagnostic common
connector).
Verify repair and
Did the MIL (check engine lamp) flash return to the OBD
correctly? system check Go to Step 5

Check the display.
5 —
4. Make sure the MIL (check engine lamp)
turns on.
Did the MIL (check engine lamp) turn off
correctly? Go to Step 8 Go to Step 6
Replace the meter.
6 —
7 (At this time, engine does not start up) —
3. Connect the diagnostic switch
(connector).
Verify repair and
circuit of the ECM.

9 (At this time, engine does not start up) —
3. Connect the diagnostic switch
(connector).
Verify repair and
1. Replace the ECM.
IMPORTANT:
return to the OBD
Checking the Scan Tool Circuit System
Fuse 22
(7.5A)
0.5V 3
Data Link 2 0.5B/P 1.25B/O

Connector
(DLC)
0.5B/P
1
2B/L
Diagnostics Common
Connector (Green)
Diagnostics Connector
(Brown)
0.3Br
0.5B/W
19 68 Engine
Control
Module
(ECM)
HCW61AMF001501
Circuit Description • Damage to harness: Inspect to ensure there is no

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

Check the power circuit of scan tool.
2. Connect scan tool to data link connector
1 (DLC). —
4. Turn ON the scan tool.
Was the scan tool turned ON? Go to Step 3 Go to Step 2


Check to ensure that there is no broken wire
or short circuit in the power supply and GND
circuit of the DLC.
2 If fault is detected, repair or replace as —
necessary.
Check the communication circuit of scan tool.
3. Check to ensure that there is no broken
3 —
wire or short circuit in the communication
circuit of the DLC.
necessary.

Connect the scan tool again.
2. Connect the scan tool to the DLC.
5. Communicate with the ECM using a scan
tool.
Verify repair and
Was power supplied to scan tool, and was return to the OBD
connection with the ECM confirmed? system check Go to Step 5
Inspect the scan tool.
1. Reference the users manual and perform
a auto diagnostics of the main unit.
• Cable for connecting DLC
5 • PCMCIA card —
• Scan tool main unit
necessary.
tool.
Verify repair and
circuit of the ECM.


tool.
Verify repair and
1. Replace the ECM.
IMPORTANT:
return to the OBD
Checking the starting system
SBF.4 Fuse 16 Fuse 28

(80A) (7.5A) (15A) Smoother-G
B1 S G M1 M2 B2 P2 P1
OFF
ACC Smoother-G
ON A/T Smoother-G Control unit
HEAT
START
0.85B/R
0.5V/W
Starter
Cut Relay
Neutral
Emergency
Relay
Starter
Relay
0.3W/B
8W
Starter
Relay
Battery
B
+
C
3B/L
44 Engine
61
- Control
Module
(ECM)
HCW61AMF001601

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

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

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

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

Restore the vehicle and Verify repair
9 —
Checking the fuel system
3
4
12
2
11
10
7 5
8 6
HCW3C0MF001401
Legend
1. Fuel filter 7. PCV
2. Flow damper 8. Supply pump
3. Injector 9. Field pump
4. Fuel pipe 10. Pressure limiter
5. Overflow valve 11. Fuel pressure sensor
6. Fuel tank 12. Fuel rail
Circuit Description • Supply pump internal failure (internal seal ability

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

• Air getting into the fuel piping The following numbers show the step numbers of the
• Pressure limiter, flow damper (operation, internal diagnostic chart:
seal ability deterioration etc.)
• Injector internal malfunction
4. Remove air from the fuel system (high pressure

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

Inspect the amount of fuel.
1 — Filling with fuel,
Is there sufficient fuel? Go to Step 2 and go to Step 2
Inspect the quality of the fuel.
1. Discharge some fuel from the fuel tank.
2. Fill with fuel to the designated amount.
2 —
3. Remove air from the fuel piping.
4. Start the engine.
Did the engine start? Go to Step 7 Go to Step 3

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

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

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


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

Restore the vehicle to its initial state, remove
7 air from the fuel lines again and Verify repair —
Air removal method Fuel filter

1. Turn the supply pump priming pump cap until it
flips up.
2. Loosen the air removal plug on the fuel filter.
3. Operate the priming pump to discharge air bubbles
from the air removal plug. 1
4. In addition, operate the priming pump and when air
bubbles are no longer discharged from the air
removal plug, tighten the air removal plug.
5. Tighten the supply pump air removal plug.
6. Operate the priming pump to discharge air bubbles
from the air removal plug.
7. In addition, operate the priming pump and when air
bubbles are no longer discharged from the air
removal plug, tighten the air removal plug.
8. After tightening all of the plugs, push the priming
pump over 150 times. HCW5ADSH001001
9. Return the priming pump cap to its original position Legend
and securely tighten the cap. 1. Air removal plug
10. Wipe up spilled fuel, start the engine and make
sure there are not any fuel leaks. Here, if the
engine does not start, repeat starting from step 8.
Supply Pump
2 1
HCW5ADSH001101
Legend
1. Priming pump
2. Air removal plug
3. Supply Pump
Checking the intake air system
Fuse 16
(7.5A)
0.5V/W
0.5V/W
0.5V/W
3 1
3 1
VGS
EGR
Fail Safe
Fail Safe
Relay
Relay
0.5/P/W
5
0.35B
5 4
0.3Br/G
0.5W/R
0.5P/W
0.5P/W
0.5P/W
0.5W/R
0.5W/R
2 2 2
2 2 VGS VGS
VGS
M/V2 M/V3
M/V1
EGR EGR
M/V1 M/V2
1
0.5Y/Br
1 1
0.5Y/V
0.5Y/G
1 1
0.5Y/R
0.5Y/B
0.5Y/Br
0.5Y/V
0.5Y/Br
0.5Y/V
Engine
110 108 109 47 111 112 113 114 115
Control
Module
(ECM)
HCW61AMF001701

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

Check the condition of the air cleaner.
(Inspect the indicator and whether or not the
1 filter is dirty) —
Is the air cleaner status normal? Go to Step 3 Go to Step 2

Clean or replace the air cleaner.
2 —
Inspect inside the air cleaner case to make
3 sure there is not any water or filth. —
Is the inside of the case clean? Go to Step 5 Go to Step 4
Clean inside the air cleaner case or inspect
the water removal valve.
If there is an abnormality such as being
4 plugged, perform any necessary repair and/or —
replacements.
Inspect the intake air duct for crushing,
5 looseness, or damage. —
Is the air intake duct normal? Go to Step 7 Go to Step 6
Repair or replace the crushed or damaged
6 areas of the intake air duct. —
Inspect the intake cooler duct for being
crushed, looseness, damage, and mounting
7 failure. —
Is the intercooler duct normal? Go to Step 9 Go to Step 8

Repair or replace the crushed for damaged
8 areas of the intercooler duct. —
Inspect the VGS turbo.
1. Connect the scan tool (Tech2), inspect
the VGS valve operating condition using
the VGS M/V test.
9 —
2. If an issue is found, inspect the valve for
deposits, air cylinder return, and for air
leakage and perform repairs as needed.
Was an issue found? Go to Step 10 —
Restore the vehicle and Verify repair
10 —
Checking the exhaust system
Fuse 13
(7.5A)
0.5SB
Exhaust
Brake
switch
0.5L/Y
0.5L/Y
0.5L/Y
0.5L/Y
0.85L/Y
A12 A20
1
Exhaust Brake and Retarder Control unit Exhaust
Brake
0.5L/Y
0.5L/Y
A17 A1 M/V
2
0.3V/W
0.3L/P
2B
10 91 Engine
42 49
Control
Module
(ECM)
HCW61AMF001801
Circuit Description Assumed factors

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

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

operate? Go to Step 10 Go to Step 2

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

of switch? Go to Step 4 Go to Step 3
Check conduction at exhaust brake switch
circuit, and repair or replace places with
errors.
1. Combination switch body
2. Fuse No. 13 to connection switch
3. Connection switch to base harness
connector
4. Base harness connector to engine control
module (ECR)
5. Combination switch to floor (left) harness
3 —
connector
6. Instrument (lower) harness connector to
seat harness connector
7. Floor (left) harness connector to brake
intensive control unit connector (A)
8. After repairing or replacing, use the
connector (PA 1-terminal, green) inside
the inspection cover again to check
exhaust brake operation.
Does the exhaust brake operate? Go to Step 10 Go to Step 4

1. Measure resistance of exhaust brake
magnetic valve with a digital multi meter
(DMM).
4 • Between multimedia terminals: 34 - —
40 Ω
• Between terminal and body: ∞Ω
Are the resistance values normal? Go to Step 6 Go to Step 5

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


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

Inspect the functioning of the exhaust brake
magnetic valve.
1. Connect scan tool.
7 5. Confirm on scan tool data display —
whether exhaust brake switch (ON, OFF)
changes by disconnecting/connecting
inspection cover.
Did the display change by disconnecting/

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

Restore the vehicle and check repair.
10 — Inspection
Is the measure complete? complete —
Magnetic valve appearance, connector name and Magnetic valve connector name
resistance
Connector Signal name
Magnetic valve appearance number
1 Magnetic valve (coil)
2 Magnetic valve (coil)
2 1
HCW31ASH008101
<Magnetic valve resistance>

Check area Resistance Comments
Z-type 1↔2 34-40Ω Between magnetic valve coils
connector
1↔body ∞Ω Between magnetic valve coil and body
(gray) 2-
terminal 2↔body ∞Ω Between magnetic valve coil and body
NOTE:
Resistance values vary depending on the magnetic
valve temperature.
Checking the EGR
Fuse 16
(7.5A)
0.5V/W
0.5V/W
0.5V/W
3 1
3 1
VGS
EGR
Fail Safe
Fail Safe
Relay
Relay
0.5/P/W
5
0.35B
5 4
0.3Br/G
0.5W/R
0.5P/W
0.5P/W
0.5P/W
0.5W/R
0.5W/R
2 2 2
2 2 VGS VGS
VGS
M/V2 M/V3
M/V1
EGR EGR
M/V1 M/V2
1
0.5Y/Br
1 1
0.5Y/V
0.5Y/G
1 1
0.5Y/R
0.5Y/B
0.5Y/Br
0.5Y/V
0.5Y/Br
0.5Y/V
Engine
110 108 109 47 111 112 113 114 115
Control
Module
(ECM)
HCW61AMF001701
Description of circuit • ECM malfunction

EGR magnetic valves 1 and 2 are used as valves to
supply air to EGR valve air cylinder. EGR valves are Assumed factors
controlled appropriately by controlling air supply. EGR • EGR valve air cylinder abnormalities
magnetic valve power is supplied through EGR • EGR pipe abnormality (loose, crushed, damaged,
magnetic valve fail safe relay, and connected to the gas leaking, etc.)
engine control module (ECM) through the EGR
• EGR valve, EGR magnetic valve (main body, air
magnetic valve. ECM controls individual EGR magnetic
pipe abnormality, etc.)
valves. If abnormalities are detected, it controls the
EGR magnetic valve fail safe relay to stop power • ECM abnormalities
supply to individual EGR magnetic valves and stop
controls.
Diagnostic aids
Check the connector for poor connection, and check to
make sure that there are no abnormalities such as a
frayed or broken harness, frayed wiring in the harness,
or a short to another circuit. Furthermore, perform
functional diagnostics to check things like operation
and control of each component. Resolve any
abnormality.
• EGR valve air cylinder abnormalities
• EGR pipe abnormality (loose, crushed, damaged,
gas leaking, etc.)
• EGR valve, EGR magnetic valve (main body, air
pipe abnormality, etc.)

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

Inspect for incorrect assembly of air pipe and
harness to EGR magnetic valve. If there are
2 any abnormalities, reassemble to specified —
condition.
Magnetic valve (EGR-related system) DTC:
Check whether P0424, P0441, P0442, P0446,
3 P0447, P0448, and P0449 are detected. —
Go to applicable
Was the DTC detected? DTC Go to Step 4
Use scan tool to inspect EGR magnetic valve
operation.
2. Turn the starter switch ON. At this time,
engine does not start up
3. Remove air pipe from EGR valve air
cylinder.
4. Use scan tool to check magnetic valve
4 —
operation.
5. At the same time, use the scan tool to
operate the magnetic valve, and inspect
for air being sent to EGR valve and air
cylinder. (Refer to “Scan Tool” in the scan
tool for fault diagnosis actuator test and
magnetic valve operation check.)
Did the magnetic valve function normally? Go to Step 6 Go to Step 5

Repair or replace magnetic valve with
5 abnormality. —
Check the functioning of EGR valve.
1. Disconnect EGR valve from the engine.
2. Attach air piping to EGR valve.
3. Use scan tool to operate magnetic valve
as in Step 4.
(With the EGR valve removed from the
engine, attach air piping and inspect
6 —
valve function.)
CAUTION:
EGR system disassembly and assembly in
ways other than the repair manual procedures
for each engine may result in gas leaks, etc.
Did the EGR valve function? Go to Step 8 Go to Step 7


Repair or replace EGR valve.
7 —
8 — Inspection
Is the measure complete? complete —
Magnetic valve arrangement

Cab rear member
3
4
5
1 6
HCW61ASH004701
Legend
1. EGR magnetic valve 2
6. Midway connectors
Checking the engine control module (ECM) power supply and ground circuit
Fuse 49 Fuse 17
(15A) (7.5A)
1.25 O
0.5V/W
1.25 O
1.25 O
2 5
Main
Relay POWER GND 5B
Accelerator
4 1
switch
0.3R/L
.25R/B
ECM GND
1.25B/O
KEY ON
1.25R/B
KEY ON
1.25R/B
1.25B/P
1.25B/P
1.25R/B
0.3R/L
0.3R/L
1.25B
1.25B
1.25B
75 74 5 6 7 58 46 56 102 140 141 72 73 Engine

Control
Module
(ECM)
HCW61AMF001901
Circuit Description • Damage to harness: Inspect to ensure there is no

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

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


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

Check engine control module (ECM) power
supply harness for disconnection or shorts.
1. Turn the starter switch Off.
3. Attach a digital multi meter (DMM)
between the ECM connector terminals
and ground.
4. Measure the voltage of the switch circuit.
• At starter switch ON position:
Between pin 46 and GND: Battery
3 voltage —
• At starter switch ON position:
Between pin 56 and GND: Battery
voltage
• At other than starter switch ON or
START position:
Between pin 46 and GND: 0V
• At other than starter switch ON or
START position:
Between pin 56 and GND: 0V
Is the applied voltage normal? Go to Step 7 Go to Step 4

Check starter switch.
2. Disconnect the harness from the starter
switch.
4 —
3. Attach digital multimedia (DMM) to starter
switch, operate the switch, and inspect
switch function.
Is the starter switch normal? Go to Step 5 Go to Step 6

Check starter switch circuit.
broken wires in the harness between the
ECM and starter switch.
power supply and starter switch.
3. If a fault is detected, repair or replace if
necessary.

Replace starter switch.
6 —

Check ground circuit.
ECM and ground.
necessary.

8 —
Is the measure complete? Verify repair —
Checking the PTO
Fuse 13
(7.5A) Smoother-G/A/T
0.85SB 0.5SB
0.85SB
0.85SB
Smoother-G
PTO PTO
PTO Switch Switch
PTO
Switch (Dump 0.5LG
Switch
(Dump Lever) Lever)
Fire Car
0.5LG
A/T (Neutral) PTO

Relay M/V
0.5LG
PTO
Lamp
0.5SB
A/T
0.5LG
A/T PTO
Relay Relay
(PTO)
1
PTO PTO
M/V Lamp
Parking
0.5LG
Brake
2
Switch
Parking
Brake
switch
97 87 Engine V22 V13 32
82 69
Control Transmition
Module
Control Module Smoother-G
(TCM)
(ECM) Control Unit
HCW61AMF002001

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

Inspect whether PTO operation is normal.
1. ON operation:
Operate the PTO switch when all the
following conditions are met:
• Parking lever is pulled.
• Gear position is in neutral.
• It is in idling state.
1 • Depress the clutch pedal. (Manual —
transmission vehicle)
2. OFF operation: Operate the PTO switch
when all the following conditions are met
• Leave in idling state.
• Set the gear position to neutral.
• Release (lower) the parking lever.
Are the operations normal? Go to Step 3 Go to Step 2

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

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

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


Inspect the PTO switch circuit.
5. Operate the PTO switch.
6 6. Confirm whether the PTO switch (ON, —
OFF) in the data display on the scan tool
screen changes according to operation of
switch.
If the switch input display (ON/OFF) does
not change at this time, inspect/repair the
PTO switch, circuit and the like.

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

Inspect the parking switch circuit.
5. Operate the parking switch.
8 6. Confirm whether the parking switch (ON, —
OFF) in the data display on the scan tool
screen changes according to operation of
the switch.
If the switch input display (ON/OFF) does
not change at this time, inspect/repair the
parking switch, circuit and the like.

Conduct PTO operation, and check if
accelerator switch state switch is (drive
accelerator and external accelerator) is
9 performed normally. —
Does engine speed change normally if using
drive accelerator or external accelerator when
using PTO? Go to Step 11 Go to Step 10

1. Replace the ECM.
IMPORTANT:

11 —
Is the measure complete? Verify repair —
Table of diagnostics codes
DTC Item Failure details Judgment

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

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

time
P0242 Accelerator switch ON malfunction Accelerator sensor output is in access of 3.06 Continue
Store. V and accelerator switch=ON for 0.5
seconds
P0245 Fuel pressure sensor malfunction PC sensor output value is more than 4.7 V or Continue
Store. less than 0.7 V. for 0.1
seconds
P0247 PCV1 system broken wire or short When PCV1=OFF: PCV1 drive voltage value Continue
Store. circuit (ground circuit) malfunction malfunction for one
second
P0248 PCV2 system broken wire or short When PCV2=OFF: PCV2 drive voltage value Continue
Store. circuit (ground circuit) malfunction malfunction for one
second
P0271 1st cylinder injector drive system Injector (TWV) 1 coil or harness disconnection
–
Store. malfunction
P0272 2nd cylinder injector drive system Injector (TWV) 5 coil or harness disconnection
–
Store. malfunction
P0273 3rd cylinder injector drive system Injector (TWV) 3 coil or harness disconnection
–
Store. malfunction
P0274 4th cylinder injector drive system Injector (TWV) 6 coil or harness disconnection
–
Store. malfunction
–
Store. malfunction
–
Store. malfunction
P0277 Injector circuit disconnection (Common Disconnection of injectors (TWV) 1, 3, and 5
–
Store. 1 injector 1, 3, 5 system) or disconnection of Common 1 harness
P0278 Injector circuit disconnection (Common Disconnection of injectors (TWV) 2, 4 and 6 or
–
Store. 2 injector 2, 4, 6 system) disconnection of Common 2 harness
P0411 VGS magnetic valve 1 drive system When VGS M/V1=ON: Drive voltage Continue
Store. malfunction malfunction for 1.2
seconds
seconds
seconds
P0416 Main relay system malfunction Main relay=OFF output Continue 7
Store. (When starter switch is OFF and ECM power seconds
source cannot be shut down from
starter
switch=OF
F
P0418 VGS magnetic valve relay malfunction When VGS fail safe relay=ON: Relay drive Continue
Store. voltage malfunction for one
second

time
P0421 Both PCV 1 and 2 systems malfunction When PVC=OFF: PCV drive voltage value
Continue
Store. malfunction or
for one
When PCV=ON: PCV drive voltage value
second
malfunction
P0424 EGR magnetic valve relay malfunction When EGR fail safe relay=ON: Relay drive Continue
Store. voltage malfunction for one
second
P0441 EGR magnetic valve 1 drive error When EGR M/V1=ON: Drive voltage Continue
Store. malfunction for 1.2
seconds
P0442 EGR magnetic valve 2 drive error When EGR M/V2=ON: Drive voltage Continue
Store. malfunction for 1.2
seconds
P0446 Abnormalities in fixation when closing EGR temperature 1 is higher than 210°C Continue
Store. EGR valve1 when EGR is not functioning. for three
minutes
P0447 Abnormalities in fixation when opening EGR temperature 1 is lower than 40°C when Continue
Store. EGR valve1 EGR is functioning. for three
minutes
P0448 Abnormalities in fixation when closing EGR temperature 2 is higher than 210°C Continue
Store. EGR valve 2 when EGR is not functioning. for three
minutes
P0449 Abnormalities in fixation when opening EGR temperature 2 is lower than 40°C when Continue
Store. EGR valve 2 EGR is functioning. for three
minutes
P0518 ROM error Checksum mismatch in target domain for
–
Store. inspection
P0543 Overrun error 6WF1: Engine speed is 2450 rpm or more.
–
Store. 6WG1: Engine speed is 2700 rpm or more.
*1: Reference
Engine speed 500 rpm: approx. 10 sec.
Engine speed 1000 rpm: approx. 5 sec.
Engine speed 1500 rpm: approx. 3.5 sec.
Engine speed 2000 rpm: approx. 2.5 sec.
Backup contents
DTC
DATA Control Cruise VGS EGR
P0014 Only perform control with Reset Regular Regular
–
Store. CMP sensor completely control control
P0015 Only perform control with Reset Regular Regular
–
Store. CKP sensor completely control control
P0022 Control atmospheric Control with backup value Regular Regular
–
Store. temperature -25°C control control
P0023 When starting: engine coolant Control with backup value
Store. temperature= -25°C Regular Regular
–
Other: engine coolant control control
temperature= 50È
Backup contents
DTC
P0024 Accelerator opening ratio regulation when judging malfunction
Store. (0% fixed). When depressing the accelerator, quickly increase
accelerator opening ratio to 10%, then gradually increase to
Reset Regular Control
50% (max. 50%). Decrease accelerator opening ratio to 0%
completely control stopped
when not depressing the accelerator. Afterwards, control
accelerator opening ratio by accelerator switch through a
certain amount of acceleration and deceleration. (max. 50%)
P0025 Stop speed limiter, and Reset Regular Regular
–
Store. control engine speed completely control control
P0032 (1) Boost pressure = 53 kPa (1) Control with backup value Reset Regular Control
Store. (2) Make backup full Q map (2) - completely control stopped
P0033 Fuel consumption regulation Control with backup value Reset Regular Regular
Store. (Max. 110 mm 3/st) completely control control
P0035 Fuel pressure regulation
Store. (Max. 60 MPa) Reset Regular Regular
–
Fuel consumption regulation completely control control
(Max. 110 mm 3/st)
P0042 Make backup full Q map Control Control
Reset
Store. – stopped stopped
completely
Relay drive Relay drive
P0051 Engine stop {injector (TWV) / Regular Regular
– -
Store. PVC power supply stop} control control
P0071 Control atmospheric pressure Control with backup value Reset Regular Control
Store. = 100 kPa completely control stopped
P0072 Engine stop {injector (TWV) /
Reset Regular Regular
Do not – PVC power supply stop}
completely control control
store.
P0115 Fuel pressure regulation Expected control
Store. (Max. 60 MPa) Reset Regular Control
Fuel consumption regulation completely control stopped
(Max. 110 mm 3/st)
P0118 (1st level) (2nd level)
Store. Fuel pressure regulation Engine stop {injector (TWV) /
(Max. 60 MPa) PVC power supply stop}
Fuel consumption regulation
(Max. 110 mm 3/st)
–
(Max. 110 mm 3/st)
Store. (Max. 60 MPa)
Fuel consumption regulation –
6WF1: (Max. 165mm 3/st)
6WG1: (Max. 200mm 3/st)
Backup contents
DTC
6WF1: (Max. 165mm 3/st)
6WG1: (Max. 200mm 3/st)
P0211 When starting: Control fuel Control with backup value
Store. temperature= -25°C Regular Regular
–
(6WG1) Other: Control fuel control control
temperature=40°C
P0217 Fuel pressure regulation Reset Regular Control
–
Store. (Max. 60 MPa) completely control stopped
–
–
(Max. 110 mm 3/st)
P0227 Fuel pressure regulation Stop engine one minute after
Store. (Max. 60 MPa) fault conditions are met Reset Regular Control
Fuel consumption regulation {injector (TWV) / PVC power completely control stopped
(Max. 110 mm 3/st) supply stop}
P0241 Control accelerator opening
Store. ratio regulation –
(max. 80%)
P0242 Control accelerator opening
Store. ratio regulation –
(20% fixed)
P0245 Fuel pressure regulation Expected control
Store. (Max. 60 MPa) (PCV open control) Reset Regular Control
(Max. 110 mm 3/st)
–
–
P0271 Fuel consumption regulation
Store. 6WF1: (Max. 165mm 3/st) –
6WG1: (Max. 200mm 3/st)
Store. 6WF1: (Max. 165 mm 3/st) –
6WG1: (Max. 200 mm 3/st)
6WG1: (Max. 200 mm 3/st)
6WG1: (Max. 200 mm 3/st)
Backup contents
DTC
6WG1: (Max. 200 mm 3/st)
6WG1: (Max. 200 mm 3/st)
6WF1: (Max. 165 mm 3/st)
6WG1: (Max. 200 mm 3/st)
6WF1: (Max. 165 mm 3/st)
6WG1: (Max. 200 mm 3/st)
P0411 VGS M/V 1, 2, 3 Control Control Control
Reset
Store. – stopped stopped stopped
completely
P0412 VGS M/V 1, 2, 3 Control Control Control
Reset
completely
P0413 VGS M/V 1, 2, 3 control Control Control
Reset
completely
P0416 Regular Regular
– – –
Store. control control
P0418 VGS, EGR M/V control Control
Store. stopped stopped
Reset Control
– Relay drive
completely stopped
(At ground
short)
P0421 Reset Regular Control
– –
Store. completely control stopped
P0424 EGR M/V 1, 2 control stopped Control
Store. stopped
Reset Regular
– Relay drive
completely control
(At ground
short)
Reset Regular
Store. – stopped
completely control
Relay drive
Reset Regular
Store. – stopped
completely control
Relay drive
P0446 Reset Control Control
– –
Store. completely stopped stopped
Backup contents
DTC
P0447 Reset Regular Regular
– –
Store. completely control control
P0448 Reset Control Control
– –
Store. completely stopped stopped
– –
– –
P0543 Engine stop {injector (TWV) /
Store. – PVC power supply stop}
Exhaust brake drive
Check engine lamp

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

display
Control restore
conditions
P0051 CPU normal Do not light
5•1 { { {
Store. up
P0071 Atmospheric pressure
Store. sensor output is 0.85 V Lights up 7•1 { { {
or more, or 4.9 V or less.
P0072 When there is CKP pulse
Do not or CMP pulse input Lights up 7•2 { { {
store.
P0015 When PC sensor output
Lights up 1•1•5 { { {
Store. value changes
P0118 Actual fuel pressure is
Store. less than 130 MPa.
If control is stopped,
Lights up 1•1•8 { { {
engine stall or actual fuel
pressure is 10 MPa or
less.
Lights up 1•5•1 { { {
Store. again after stalling
Lights up 1•5•8 { { {
Store. again after stalling.
Lights up 1•5•9 { { {
P0211 Fuel temperature sensor
Store. output value is 0.85 V or
Lights up 2•1•1 { – –
(6WG1 more, or 4.9 V or less.
)
P0217 PCV 1 drive voltage
Lights up 2•1•7 { { {
Store. normal
P0218 PCV 2 drive voltage
Lights up 2•1•8 { { {
Store. normal
Lights up 2•2•6 { { {
Lights up 2•2•7 { { {
Lights up 2•4•1 { { {
Store. supply is turned OFF.
Lights up 2•4•2 { { {
P0245 PC sensor output value
Store. is 4.7 V or more, or 0.7 V Lights up 2•4•5 { { {
or less.
Check engine lamp

display
Control restore
conditions
P0247 Held until ECM power Check engine
Lights up 2•4•7 { { {
Store. source is turned OFF. lamp lights
even when
Lights up 2•4•8 storing as { { {
past failure.
Store. again when current value Lights up 2•7•1 { { {
is normal or after stalling.
Lights up 2•7•7 { { {
Lights up 2•7•8 { { {
Lights up 4•1•1 { – –
Lights up 4•1•2 { – –
Lights up 4•1•3 { – –
P0416 Held until ECM power Do not light
4•1•6 { { {
Store. source is turned OFF. up
P0418 When fail safe relay=ON:
Store. Relay drive voltage Lights up 4•1•8 { – –
normal
P0421 –
Lights up 4•2•1 { { {
Store.
P0424 When fail safe relay=ON:
Store. Relay drive voltage Lights up 4•2•4 { – {
normal
Check engine lamp

display
Control restore
conditions
Lights up 4•4•1 { { {
Lights up 4•4•2 { { {
P0446 EGR temperature 1 is
Lights up 4•4•6 { – –
Store. 200°C or less.
Lights up 4•4•7 { – –
Lights up 4•4•8 { – –
Lights up 4•4•9 { – –
P0518 When power ON is reset
Lights up 5•1•8 { { {
Store.
P0543 6WF1: Engine speed is
Store. 2250 rpm or less. Does not
5•4•3 { { {
6WG1: Engine speed is light up
2600 rpm or less.
DTC P0014 (Flash code 14)
Camshaft position (CMP) sensor system
malfunction
Engine
Control
Module
(ECM)
40 41 39 133 120 131
GND
VCC
SIG
(+)
(-)
0.5B/R
0.5Y
0.5W
0.5R
0.5B
2 1 3 1 2
Crankshaft Position Camshaft Position

(CKP) Sensor (CMP) Sensor
HCW61AMF002101
Description of circuit Set conditions of DTC

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

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

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

Recheck the DTC.
1. Connect all harnesses.
2. Clear the DTC.
3. Turn the starter switch OFF, wait for more
4 —
than 15 seconds, then turn the switch ON
and start the engine.
4. Check the DTC.
Was DTC P0014 detected? Go to Step 5 Go to Step 11

Remove the CMP sensor, and inspect the
5 sensor tip for scratches or damage. —
Is the CMP sensor normal? Go to Step 6 Go to Step 9

Check the CMP sensor circuit harness.
2. Remove the ECM and CMP sensor
harness.
3. Connect jumper wires to each terminal of
the CMP sensor harness connector side.
4. Measure the resistance value between
ECM harness connector terminals with
and without jumper wires.
• With jumper wires
6 - Between pins 120 and 131/133: —
less than 0.5Ω
- Between pins 131 and 133: less
than 0.5Ω
• Without jumper wires
- Between pins 120 and 131/133:
∞Ω
- Between pins 131 and 133: ∞Ω
Was an abnormality detected? Go to Step 11 Go to Step 7

Check the CMP sensor circuit for GND shorts.
2. Remove the harness from the ECM and
CMP sensors.
Between pins
7 120/133 and
the ECM harness connector terminals
GND: ∞Ω
and GND.
Check the CMP sensor circuit for a short to
the power supply.
CMP sensors. Between
each
terminals and
the voltage between the CMP sensor
GND: 0V
harness connector terminal and GND.
Replace the CMP sensor.
9 —

1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
11 —
4. Check the DTC.

Use the scan tool to check if other DTCs are
12 detected. — Go to applicable
Are other DTCs detected? DTC Verify repair
CMP sensor
HCW46ESH001101
Legend
1. Signal
2. GND
3. Power supply
Crankshaft position (CKP) sensor system
malfunction
Engine
Control
Module
(ECM)
40 41 39 133 120 131
GND
VCC
SIG
(+)
(-)
0.5B/R
0.5Y
0.5W
0.5R
0.5B
2 1 3 1 2

HCW61AMF002101

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

crankshaft position (CKP) sensor.
slackness in the sensor installation
2 condition. —
corrected.

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


Inspect the CKP sensor harness.
broken wires between the ECM-CKP
5 sensors. —

Use a scan tool and check the engine data
display.
1. Attach the harness.
6 475-525rpm
4. Display the engine data and check
[Engine speed].
Are the engine speed normal? Go to Step 7 Go to Step 8

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

1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
10 than 15 seconds, then turn the switch ON —
4. Check the DTC.

Use the scan tool to check if other DTC are
CKP sensor
HCW51ASH000201
2 1
HCW01ASH011901
Legend
1. Sensor signal (-)
2. Sensor signal (+)
Item Specifications Condition

Resistance 110-140 Ω 20°C
CKP sensor
between
terminals
Insulation ∞Ω DC500V Mega-
resistance (not less than ohm meter
10MΩ) Between terminal
and other
conductors
Atmospheric temperature sensor system
malfunction
Engine
Control
6WG1
Module
155 135 154 162 (ECM)
GND
SIG
SIG
SIG
0.5Y/R
0.3Y
0.5Y/G
0.3Y/R
0.3V/R
0.5Y/R
0.3Y
0.5Y/R
0.5Y
1 3 1 2 1 2
Atmospheric Fuel Temperature

Temperature Sensor
Sensor
Engine Coolant
Temperature (ECT)
Sensor
HCW61AMF002201
Description of circuit Actions when DTC is set

The atmospheric temperature sensor detects the • MIL (Check engine lamp) lights.
atmospheric temperature (temperature outside the • When the atmospheric temperature sensor is
vehicle). The engine control module (ECM) applies malfunctioning, the ECM controls using the backup
voltage to the atmospheric temperature sensor value (-25°C at startup).
installed inside the front lid, reads the changes in
applied voltage as signals, and optimizes the fuel Clear conditions of MIL/DTC
injection control based on those signals. Also, the
When trouble occurs in the system and that DTC is
sensor’s GND circuit is shared by each temperature
memorized by ECM, since the fault region is not
related sensor.
Main trouble phenomena
• White smoke (while cooling) clear the DTCs before performing inspection.
• Black smoke (at engine start) DTC deletion method
• Deleting DTC by operating the accelerator pedal
Set conditions of DTC (Refer to “How to delete DTCs by operating the
If the voltage value applied to the atmospheric accelerator pedal” in “Fault diagnosis process”)
temperature sensor exceeds 4.9V, or remains lower • Use the scan tool (Tech2) to clear DTC.
than 0.085V for 0.5 seconds or more, “Atmospheric
temperature sensor system malfunction” is diagnosed, Diagnostic Aids
and [DTC P0022] is displayed. • Connector section bad connection
• Atmospheric temperature sensor (SIG) circuit • Check the connector for poor connection, and
broken wire or short circuit check to make sure that there are no abnormalities
• Atmospheric temperature sensor (GND) circuit such as a frayed or broken harness, frayed wiring
broken wire or short circuit in the harness, or a short to another circuit.
• Atmospheric temperature sensor malfunction
• ECM internal malfunction

atmospheric temperature sensor connector.
slackness in the connector installation
2 condition. —
corrected.

Inspect the atmospheric temperature sensor
harness.
atmospheric temperature sensor - ECM.

Inspect the atmospheric temperature sensor
circuit.
Between
2. Disconnect the harness from the connector
atmospheric temperature sensor. power supply
4
3. Turn the starter switch ON, and measure terminal and
the voltage between the sensor harness GND: 4.75-
connector power supply terminal and 5.25V
GND.
Are the voltage values normal ? Go to Step 5 Go to Step 6


Inspect the atmospheric temperature sensor.
1. Disconnect the harness from the
atmospheric temperature sensor.
connector terminals.
necessary.
• Between terminals: 3kΩ (20°C)
• Between each terminal- GND: ∞Ω (at
normal temperatures)

1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
4. Check the DTC.

Atmospheric temperature sensor
HCW46ESH001401
Legend
1. Signal
2. GND
3. Temperature sensor
Sensor resistance value properties (reference)

100
10
k
Resistance value
1
0.1
-40 -30 -20 -10 0 10 20 30 40
Temperature °C
HCW61ASH002101
Resistance values between each terminal

Resistance Comments
value
B e t w e e n Approx. 3.0kΩ 25°C
terminals
Between each ∞Ω
terminal and –
body
Engine coolant temperature sensor system
malfunction
Engine
Control
6WG1
Module
155 135 154 162 (ECM)
GND
SIG
SIG
SIG
0.5Y/R
0.3Y
0.5Y/G
0.3Y/R
0.3V/R
0.5Y/R
0.3Y
0.5Y/R
0.5Y
1 3 1 2 1 2

Temperature Sensor
Sensor
Engine Coolant
Temperature (ECT)
Sensor
HCW61AMF002201

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

Check the installation condition of the engine
coolant temperature (ECT) sensor connector.
2 condition. —
corrected.

Inspect the ECT sensor harness.
ECT sensor - ECM.
necessary.

Inspect the ECT sensor circuit.
2. Disconnect the harness from the ECT Between
sensor. connector
power supply
terminal and
the voltage between the sensor harness
GND: 4.75-
connector power supply terminal and
5.25V
GND.


Inspect the ECT sensor.
1. Disconnect the harness from the ECT
sensor.
connector terminals while adding
temperature changes.
necessary.
• Between terminals: Refer to the
graph
• Between each terminal - GND: ∞Ω
(Excluding terminals for meters)

1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
4. Check the DTC.

Have been other DTCs detected? DTC Verify repair
Water Temperature (ECT) Sensor
4
5
3
2
1
MFW31ASH004201
Legend
1. Sensor signal (for SIG, engine control)
2. Sensor signal (for SIG, meter)
3. Sensor (GND)
4. Temperature sensor for engine control
5. Temperature sensor for meter
ECT sensor properties

100
k
10
Resistance value
1
0.1
-50 0 50 100
Temperature °C
HCW61ASH002201
Accelerator pedal position sensor system
malfunction
Engine
Control
Module
65 21 55 (ECM)
GND
VCC
SIG
0.3L/W
0.3L/R
0.3L
3 2 1
Accelerator Pedal
Position (APP) Sensor
HCW61AMF002301

The accelerator pedal position (APP) sensor detects • MIL (Check engine lamp) lights.
the opening ratio of the accelerator pedal. Voltage is • The ECM is linked with the accelerator position
applied to the APP sensor installed in the accelerator (APP) switch, and changes the accelerator pedal
pedal link, and the voltage value that returns to the opening ratio to the backup value to control it.
engine control module (ECM) becomes a signal. The
ECM reads changes in the voltage from the APP Clear conditions of MIL/DTC
sensor, then optimizes the fuel injection control and
accelerator opening ratio based on those signals.
• Lack of output require that you check DTCs, so be sure to note and
• Accelerator pedal reaction (response) malfunction clear the DTCs before performing inspection.
DTC deletion method
• PTO stop
accelerator pedal” in “Fault diagnosis process”)
If the APP sensor signal voltage value exceeds 4.85V,
or remains lower than 0.1V for 1 second or more, • Use the scan tool (Tech2) to clear DTC.
“Accelerator pedal position sensor system malfunction”
is diagnosed, and [DTC P0024] is displayed. Diagnostic Aids
• Connector section bad connection
• APP sensor (power source) circuit broken wire or • Accelerator pedal failure
short circuit (Poor adjustment, looseness, link malfunction,
• APP sensor (SIG) circuit broken wire or short spring malfunction)
circuit • Accelerator switch failure (poor adjustment,
• APP sensor (GND) circuit broken wire or short looseness)
circuit • Check the connector for poor connection, and
• APP sensor malfunction check to make sure that there are no abnormalities
(Sensor internal or detection section malfunction) such as a frayed or broken harness, frayed wiring
• APP sensor installation failure (poor adjustment, check things like operation and control of each
looseness) component. Resolve any abnormality.

Accelerator pedal position (APP) sensor
connector attachment
Check the condition.
2 slackness in the connector installation —
condition.
corrected.

Inspect the APP sensor harness.
APP sensor - ECM.
necessary.

Inspect the APP sensor circuit.
2. Disconnect the harness from the APP Between
sensor. connector
power supply
terminal and
GND: 4.75-
5.25V
GND.


display.
2. Attach the harness.
5 4. Turn the starter switch ON. 0.25-0.75V
5. Display the engine data, and while
operating the accelerator pedal, check for
smooth data motion and check the idling
accelerator voltage value.
Go to diagnostic
Are the voltage values normal ? aids Go to Step 6
1. Replace the APP sensor.
2. Use a scan tool to check the APP sensor
6 output voltage in the idling position. 0.25-0.75V
Are the voltage values normal? Go to Step 9 Go to Step 7

Adjust the APP sensor installation.
7 —
1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
4. Check the DTC.

Accelerator Pedal Position (APP) Sensor
3 2 1
MFW31ASH002601
Legend
1. Sensor (GND)
2. Sensor (SIG)
3. Sensor (power supply)
Accelerator position sensor properties (reference)
4
Output voltage (V)
0.5
IDLE FULL
Accelerator pedal position
HCW4ADSH000201
Vehicle speed sensor system malfunction
Fuse 17
(7.5A)
4(8)
KEY ON
Speed Sensor
Control Unit
SPEED SPEED SPEED
VB SIG GND DATA 25P 8P
3(7) 10(2) 12(5) 9
0.3P
0.3P/L
0.3G
0.3B/P
0.3W
0.3R
Tachograph
Smoother-
} Control Unit
Other ECU
1.25B/O
0.3B/P
2B/L
1(3) 3(2) 2(1)
27 Engine
Control
Module
(ECM)
Vehicle Speed Sensor

Note:
Number with "( )" is for A/T
HCW61AMF002401
Description of circuit Main trouble phenomena

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

Check the installation condition of the vehicle
speed sensor connector.
2 condition. —
corrected.

Inspect the vehicle speed sensor circuit.
2. Remove the harness from the ECM,
speed sensor control unit, and vehicle
speed sensor.
3. Check the circuits between the ECM-
3 speed sensor control unit, and between —
the speed sensor control unit - vehicle
speed sensor for broken wires and short
circuits.
necessary.

Inspect the vehicle speed signal for
malfunctions.
1. Start the engine and drive the vehicle.
4 —
2. Check that the vehicle speed display in
the scan tool is correct.
Whether the numerical value is normal? Go to Step 12 Go to Step 5


Inspect the vehicle speed sensor.
2. Remove the vehicle speed sensor.
3. Check the vehicle speed sensor shaft,
gears etc. for malfunctions. Voltage
At this time, inspect the transmission gear changes
5 section if necessary and repair any between 1.0-
malfunctions. 3.0V and
4. Attach the harness to the vehicle speed 12.0-15.0V
sensor, and turn the starter switch ON.
5. Slowly rotate the vehicle speed sensor
shaft and check the changes in voltage.
Is the vehicle speed sensor normal? Go to Step 7 Go to Step 6

Replace the vehicle speed sensor.
6 —
Inspect the speed sensor control unit for
malfunctions.
2. Connect to the vehicle speed sensor and
7 harness. —
3. Start the engine and drive the vehicle.
4. Check that the vehicle speed display in
the scan tool is correct.

Replace the speed sensor control unit.
8 —
1. Using a scan tool, operate the following
switches and inspect whether the inputs
are correct.
• Neutral switch
9 —
• Clutch switch
• Parking switch
Are the inputs for each switch normal? Go to Step 11 Go to Step 10

Repair or replace the switch system in which
10 the fault was detected. —
1. Replace the ECM.
IMPORTANT:


Recheck the DTC.
2. Clear the DTC.
12 —
4. Check the DTC.

Vehicle speed sensor 4. Slowly rotate the vehicle speed sensor shaft
section and measure the output voltage.
When the vehicle speed sensor shaft is revolving
Output voltage: Voltage changes between 0.5.0-
1.5V and 12.0-15.0V
MFW31ASH002201
1
Legend
1. Sensor (power supply)
2. Sensor (SIG) MFW31ASH003001
3. Sensor (GND)
Legend
1. Shaft
Vehicle sensor signal checking procedure
5. Turn the starter switch OFF, and remove the
The output voltage from the vehicle speed sensor
harness from the vehicle speed sensor.
changes according to the shaft revolution angle.
Slowly rotate the shaft section by hand and measure 6. Attach the vehicle speed sensor.
the output voltage. Tightening torque = 25-34N.m {2.5-3.5kgf.m}
1. Remove the vehicle speed sensor.
2. Connect the harness to the vehicle speed sensor.
Speed sensor control unit
Connecto Connecto Signal name
r number r number
(12 pin) (8 pin)
1 1 8 pulse signal output (SIG)
2 4 25 pulse signal output (SIG)
3 7 Power supply to vehicle
speed sensor
4 8 Speed sensor control unit
power supply
10 2 Pulse signal input (SIG)
12 5 Ground
1 2 3 4
1 2 3 4 5 6 7 8
5 6 7 8 9 10 1112
MFW31ASH005301
Vehicle sensor
Parts checked Output voltage Remarks
shaft condition
12 pins 4 ↔ 12
– Battery voltage (28V)
8 pins 5↔8
12 pins 3 ↔ 12
– Battery voltage (28V)
8 pins 5↔7
Not rotating 1.0 - 3.0V or 10 pin:

(vehicle stop) 12.0 - 15.0V Measurement of
12 pins 10 ↔ 12
25 pulse input
8 pins 2↔5 Rotating Pulse signal which changes signal from
(vehicle between vehicle speed
Speed sensor
traveling) 1.0 - 3.0V and 12.0 - 15.0V sensor
control unit
connector (12 Not rotating
pins or 8 pins) 1.0 - 3.0V 2 pin:
12 pins 2 ↔ 12 (vehicle stop)
Measurement of
8 pins 4↔5 Rotating Pulse signal which changes 25-pulse output
(vehicle between signal
traveling) 1.0 - 3.0V and 12.0 - 15.0V
Not rotating
0 - 1.5V
12 pins 1 ↔ 12 (vehicle stop) Measurement of
8-pulse output
8 pins 1↔5 Rotating Pulse signal which changes
signal
(vehicle between 0 - 1.5V and meter power
traveling) source (8.0V) - 0.5V
Boost sensor system malfunction/ height
boost malfunction
Engine
Control
Module
(ECM)
128 126 134 128
GND
VCC
SIG
0.5G/B
0.5W
0.5Gy
0.5R
0.5B
0.5L/W
0.5L/R
0.5L
2 3 1 2 3 1
Boost Sensor PTO Remote Throttle Sensor

HCW61AMF002501
Description of circuit • Boost sensor system malfunction

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

Check the installation condition of the boost
sensor connector.
condition.
2 2. Perform a visual inspection of the boost —
sensor for cracks or blockages.
corrected.

Inspect the boost sensor harness.
2. Disconnect the harness from the ECM
and boost sensor.
3 —
boost sensor - ECM.
necessary.

Inspect the boost sensor circuit.
2. Disconnect the harness from the boost Between
sensor. connector
power supply
terminal and
GND: 4.75-
5.25V
GND.
Are the voltage values normal? Go to Step 5 Go to Step 8


display.
Boost
2. Attach the oil cooler hose.
pressure
5 3. Connect scan tool. (relative
4. Start the engine. pressure): -2-
5. Display the engine data and check [Boost 2kPa
(relative pressure)] during idling.

1. Check the boost (relative pressure) while
operating the accelerator pedal.
• Depress the pedal: Change to the
plus side
6 • Release the pedal: change to the —
minus side
Do the numeric changes follow the pedal

operation? Go to Step 8 Go to Step 7
Replace the boost sensor.
7 —
1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
4. Check the DTC.

Boost sensor
3 2 1
MFW4ADSH000901
Legend
1. GND
2. Signal
3. Power supply
Boost sensor properties (reference)
4.5
Output voltage
2.5
0.5
66.7 200 333.3(kPa)
500 1500 2500(mmHg)
Boost pressure
(absolute voltage)
HCW61ASH002301
Malfunction of IC for monitoring CPU Clear conditions of MIL/DTC
Description memorized by ECM, since the fault region is not
The engine control module (ECM) is equipped with eliminated as it is by DTC, it should be deleted in the
internal processing unit (CPU), memory (RAM), IC for following ways. Furthermore, inspection and repair may
monitoring CPU etc. require that you check DTCs, so be sure to note and
The IC for monitoring CPU monitors whether the CPU clear the DTCs before performing inspection.
is operating (calculations and various controls)
correctly. DTC deletion method
If there is a malfunction in the IC for monitoring CPU, it • Deleting DTC by operating the accelerator pedal
is unknown whether the CPU inside the ECM is (Refer to “How to delete DTCs by operating the
operating normally (calculations and various controls), accelerator pedal” in “Fault diagnosis process”)
and incorrect operations of various controls may occur. • Use the scan tool (Tech2) to clear DTC.
Main trouble phenomena Diagnostic Aids

• Lack of output • Connector section bad connection
Set conditions of DTC
If a malfunction is detected in the IC for monitoring check to make sure that there are no abnormalities
CPU, “Malfunction in IC for monitoring CPU” is such as a frayed or broken harness, frayed wiring
diagnosed, and [DTC P0033] is displayed. in the harness, or a short to another circuit.
Actions when DTC is set check things like operation and control of each
• MIL (Check engine lamp) lights. component. Resolve any abnormality.
• ECM limits fuel consumption.

Check the power supply and GND circuit for Go to “Checking
the engine control module (ECM). the engine control
2 — module (ECM)
Is the process complete? power supply and
Go to Step 3 ground circuit”
Check the installation condition of the ECM
connector.
3 condition. —
corrected.

1. Replace the ECM.
IMPORTANT:


Recheck the DTC.
2. Clear the DTC.
5 —
4. Check the DTC.

Low charge malfunction/ over charge • ECM limits fuel consumption.
malfunction
Clear conditions of MIL/DTC
Description When trouble occurs in the system and that DTC is
The engine control module (ECM) converts the signals memorized by ECM, since the fault region is not
from various switches and sensors (analog signals) to eliminated as it is by DTC, it should be in the following
digital signals, and uses them in various calculations ways. Furthermore, inspection and repair may require
and controls. that you check DTCs, so be sure to note and clear the
If this conversion (A/D conversion) is not performed DTCs before performing inspection.
correctly, (calculations and various controls) performed
DTC deletion method
by the CPU malfunction, and various controls may not
operate correctly. Also, a power source booster circuit • Deleting DTC by operating the accelerator pedal
for injectors is installed inside the ECM that operates (Refer to “How to delete DTCs by operating the
the injectors. accelerator pedal” in “Fault diagnosis process”)
• Use the scan tool (Tech2) to clear DTC.
• Charge circuit malfunction Diagnostic Aids
• Engine stall • Connector section bad connection
• White smoke • ECM internal malfunction
Set conditions of DTC check to make sure that there are no abnormalities
If a malfunction is detected in the charge circuit, “Low such as a frayed or broken harness, frayed wiring
charge malfunction/over charge malfunction” is in the harness, or a short to another circuit.
diagnosed, and [DTC P0035] is displayed. Furthermore, perform functional diagnostics to
Actions when DTC is set component. Resolve any abnormality.

connector.
2 condition. —
corrected.
3 — module (ECM)

Inspect the injector.
each injector terminal.
2. When fault is detected, replace if
necessary.
4 —
IMPORTANT:
If an injector is replaced, you need to program
the injector ID code.

1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
6 —
4. Check the DTC.

High boost malfunction
Engine
Control
Module
(ECM)
128 126 134 128
GND
VCC
SIG
0.5G/B
0.5W
0.5Gy
0.5R
0.5B
0.5L/W
0.5L/R
0.5L
2 3 1 2 3 1
Boost Sensor PTO Remote Throttle Sensor

HCW61AMF002501

The boost sensor detects pressure inside the intake During engine rotations the boost pressure normally
manifold. When the pressure inside the intake manifold changes. However, if the actual boost pressure
changes due to the condition of the engine remains high for not less than 0.5 seconds when
(turbocharger), the output voltage of the boost sensor compared to the boost pressure being used as
changes (output voltage is low when the intake standard by the ECM, [High boost malfunction] is
manifold interior pressure is low, and the output voltage diagnosed, and [DTC P0042] is displayed.
increases when the pressure increases).
The engine control module (ECM) reads this change in Actions when DTC is set
output voltage, converts it to boost pressure and uses it • MIL (Check engine lamp) lights.
for control.
The boost sensor shares use of the sensor power Clear conditions of MIL/DTC
supply (5V), and GND circuit with the PTO remote
throttle sensor. When trouble occurs in the system and that DTC is
Main trouble phenomena eliminated as it is by DTC, it should be deleted in the
• Lack of output require that you check DTCs, so be sure to note and
• Black smoke clear the DTCs before performing inspection.
DTC deletion method

Diagnostic Aids • Suction system malfunction
• Turbocharger, air cylinder malfunction (intercooler, intake pipe etc.)
• Connector section bad connection • Boost sensor detection hole blocked
• Boost sensor (power source) circuit short circuit • Check the connector for poor connection, and
• Boost sensor (SIG) circuit short circuit
such as a frayed or broken harness, frayed wiring
• Boost sensor (GND) circuit broken wire or short in the harness, or a short to another circuit.
circuit Furthermore, perform functional diagnostics to
• Boost sensor failure check things like operation and control of each
(Sensor internal or detection section malfunction) component. Resolve any abnormality.

Check the installation condition of the boost
sensor connector.
condition.
2 2. Perform a visual inspection of the boost —
sensor for blockages.
corrected.

Inspect the boost sensor harness.
and boost sensor.
3 —
boost sensor - ECM.
necessary.

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

Replace the boost sensor.
5 —

1. Inspect the turbo charger.
6 necessary. —

1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
8 —
4. Check the DTC.

Boost sensor Boost sensor properties (reference)
4.5
Output voltage
2.5
0.5
66.7 200 333.3(kPa)
500 1500 2500(mmHg)

3 2 1
Boost pressure
(absolute voltage)
HCW61ASH002301
MFW4ADSH000901
Legend
1. GND
2. Signal
3. Power supply
CPU malfunction DTC deletion method
Description (Refer to “How to delete DTCs by operating the
The engine control module (ECM) is equipped with accelerator pedal” in “Fault diagnosis process”)
internal processing unit (CPU), memory (RAM), IC for • Use the scan tool (Tech2) to clear DTC.
monitoring CPU etc.
The CPU performs calculations based on information Diagnostic Aids
collected by the ECM and performs various controls. If intermittent problem is suspected, the causes cited
next are considered.
• Harness connector connection failure
• Lack of output
DTC set conditions • Check the connector for poor connection, and
If the ECM detects a malfunction in the CPU, “CPU
Malfunction” is diagnosed, and [DTC P0051] is
displayed.
The ECM stops the power supply to injectors and pump • Damage to harness
control valve (PCV).
- Inspect to ensure no damage to the external
Clear conditions of MIL/DTC appearance of harness
- While moving the harness or connector related
to sensor, check the display of related items in
scan tool’s engine data. The display changes
show the fault region.

2 — module (ECM)
connector.
3 condition. —
corrected.


1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
5 —
4. Check the DTC.

Atmospheric pressure sensor malfunction • When the atmospheric pressure sensor is
malfunctioning, the ECM uses the backup value for
Description control.
The atmospheric pressure sensor detects atmospheric
pressure. The atmospheric air pressure sensor is
installed inside the engine control module (ECM). When trouble occurs in the system and that DTC is
When atmospheric pressure changes due to altitude or memorized by ECM, since the fault region is not
weather conditions, the output voltage of the eliminated as it is by DTC, it should be deleted in the
atmospheric pressure sensor changes (output voltage following ways. Furthermore, inspection and repair may
is low when the atmospheric pressure is low, and require that you check DTCs, so be sure to note and
output voltage increases when the atmospheric clear the DTCs before performing inspection.
pressure increases). The ECM reads the output voltage
changes and converts them to air pressure, then uses DTC deletion method
those signals to optimize the fuel injection control or to • Deleting DTC by operating the accelerator pedal
calculate the boost pressure relative pressure. (Refer to “How to delete DTCs by operating the
Main trouble phenomena • Use the scan tool (Tech2) to clear DTC.
• When driving on high-ground
• Lack of output Diagnostic Aids
• White smoke • Connector section bad connection
Set conditions of DTC • Perform a test run where possible driving from low
If the atmospheric pressure sensor signal voltage value ground to high ground, and check if any failures
exceeds 4.9V, or remains lower than 0.085V for not are detected.
less than 1 second, “Atmospheric pressure sensor • Check the connector for poor connection, and
system malfunction” is diagnosed, and [DTC P0071] is check to make sure that there are no abnormalities
displayed. such as a frayed or broken harness, frayed wiring
Actions when DTC is set Furthermore, perform functional diagnostics to
• MIL (Check engine lamp) lights. check things like operation and control of each

Recheck the DTC.
2. Clear the DTC.
4. Check the DTC.


1. Replace the ECM.
IMPORTANT:

CKP &CMP both sensor malfunction
Engine
Control
Module
(ECM)
40 41 39 133 120 131
GND
VCC
SIG
(+)
(-)
0.5B/R
0.5Y
0.5W
0.5R
0.5B
2 1 3 1 2

HCW61AMF002101

The camshaft position sensor (CMP) detects the cam • MIL (Check engine lamp) lights.
shaft revolutions and discriminates between the • The ECM stops the power supply to injectors and
cylinders. When the pulsar installed in the camshaft pump control valve (PCV).
passes the CMP sensor tip section, voltage is
generated that becomes a pulse signal. The engine Clear conditions of MIL/DTC
control module (ECM) reads this pulse signal, then
discriminates between the cylinders based on the
signal.
The crankshaft position (CKP) sensor detects the
engine speed. When the sensing ball installed in the
flywheel housing passes the CKP sensor tip section,
voltage is generated that becomes a pulse signal. The
ECM reads this pulse signal, and calculates the engine DTC deletion method
speed and fuel injection timing based on this signal.
Main trouble phenomena (Refer to “How to delete DTCs by operating the
• Engine stall
• Engine does not start
Diagnostic Aids
DTC set conditions
If intermittent problem is suspected, the causes cited
• When both CMP and CKP pulses cannot be next are considered.
detected for 5 seconds or more during cranking,
“CKP & CMP both sensor malfunction” is • Poor connection of harness connector
diagnosed, and [DTC P0072] is displayed. • Poor harness wiring plan
• Wearing out of harness covering - Damage to connector lock
• Broken wire inside the harness covering - Poor connection between terminal and wire
For the detection of these causes, the following kinds of • Damage to harness
inspections are required:
- Inspect to ensure no damage to the external
• Harness connector and ECM connector poor appearance of harness
connection
- While moving the harness or connector related
- Terminal breaks loose from connector to sensor, check the display of related items in
- Inappropriate fit of terminals scan tool’s engine data. The display changes
show the fault region.

Check the DTC.
2 1. Use the scan tool and check the DTC. —
Go to applicable
Is DTC P0014 or DTC P0015 being detected? DTC Go to Step 3
1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
than 15 seconds, then turn the switch
4 ON. —
4. Crank the engine for more than 5
seconds.
5. Check the DTC.

Fuel pressure sensor output fixed
Engine
Control
Module
(ECM)
121 132 123 136
SIG 1
SIG 2
GND
VCC
0.5W/L
0.5O/L
0.5W
0.5O
0.5W
2 3 1
Fuel Pressure Sensor

HCW61AMF002601

The fuel pressure sensor detects the pressure inside If the fuel pressure is above 10Mpa and the fuel
the fuel rail. The fuel pressure sensor is attached to the pressure sensor output value remains unchanged for
fuel rail. When the fuel pressure inside the fuel rail approx. 8 seconds or longer, “fuel pressure sensor
changes due to the condition of the engine, the output output fixed” is diagnosed, and [DTC P0115] is
voltage of the fuel pressure sensor changes (output displayed.
voltage is low when the fuel rail internal fuel pressure is
low, and the output voltage increases when the Actions when DTC is set
pressure increases). The engine control module (ECM) • MIL (Check engine lamp) lights.
reads this change in output voltage, converts it to fuel
rail internal fuel pressure and uses it for control. The
sensor power supply (5V), SIG, GND for fuel pressure
sensor are specialized circuits connected to the ECM.
Also, the sensor circuits are shielded to prevent the When trouble occurs in the system and that DTC is
intrusion of electrical noise etc. memorized by ECM, since the fault region is not
Main trouble phenomena following ways. Furthermore, inspection and repair may
• White smoke/black smoke
• Lack of output
• Fluctuation of revolutions (hunting) DTC deletion method
• Rough idling • Deleting DTC by operating the accelerator pedal
• Start up deterioration (Refer to “How to delete DTCs by operating the
• PTO stop
Diagnostic Aids • To check the operation of the fuel pressure sensor
• Connector section bad connection at high fuel pressure (not less than 60Mpa), apply
load on the engine with a specified loading, and
• Fuel pressure sensor (GND) circuit broken wire or
check the fuel pressure changes with a scan too.
short circuit
• Fuel pressure sensor (SIG) circuit broken wire or
short circuit
• Fuel pressure sensor (electrical power) circuit in the harness, or a short to another circuit.
broken wire or short circuit Furthermore, perform functional diagnostics to
• Fuel pressure sensor failure check things like operation and control of each

Perform air bleeding, and check the DTC
again.
1. Clear the DTC.
3. Check the DTC.

Check the installation condition of the fuel
pressure sensor connector.
3 condition. —
corrected.

Inspect the fuel pressure sensor harness.
fuel pressure sensor.
4 —
fuel pressure sensor - ECM.
necessary.


display.
2. Attach the oil cooler hose. Fuel
3. Connect scan tool. pressure:
5
Approx.
0MPa
5. Display the engine data and check [Fuel
pressure].

1. Check the fuel pressure while operating
the accelerator pedal.
plus side
minus side

Remove the fuel pressure sensor and check
that there is no dirt etc. adhering to the fuel
7 pressure sensor, and clean it if it is dirty. —

again.
2. Clear the DTC.
8 3. Turn the starter switch OFF, wait for more —
4. Check the DTC.

Replace the fuel pressure sensor.
9 —
1. Replace the ECM.
IMPORTANT:


Recheck the DTC.
2. Clear the DTC.
11 —
4. Check the DTC.

Fuel pressure sensor Fuel pressure sensor properties
0.84
Output voltage
0.6
(Vout / Vc)
0.2
MPa
0 100 160
2
kgf/cm
0 1019 1631
Pressure
3 2 1
At Vc=5V, actual reading ON 4.2V(160MPa)
OFF 1.0V( 0MPa)
HCW61ASH002401
HCW01ASH013301
Legend
1. Sensor (power supply +5V)
2. Sensor (SIG)
3. Sensor (GND)
Fuel pressure malfunction
Engine
Control
Module
(ECM)
121 132 123 136
SIG 1
SIG 2
GND
VCC
0.5W/L
0.5O/L
0.5W
0.5O
0.5W
2 3 1

HCW61AMF002601

The fuel pressure sensor detects the pressure inside There are 2 levels of DTC set conditions, 1st level and
the fuel rail. The fuel pressure sensor is attached to the 2nd level.
fuel rail. When the fuel pressure inside the fuel rail 1st level
changes due to the condition of the engine, the output • If the actual fuel pressure exceeds 165Mpa for 0.1
voltage of the fuel pressure sensor changes (output or more seconds, “Fuel pressure malfunction” is
voltage is low when the fuel rail internal fuel pressure is diagnosed, and [DTC P0118] is displayed.
low, and the output voltage increases when the 2nd level
pressure increases). The engine control module (ECM)
• If the actual fuel pressure exceeds 170Mpa for 0.1
or more seconds, “Fuel pressure malfunction” is
rail internal fuel pressure and uses it for control. The
diagnosed, and [DTC P0118] is displayed.
Also, the sensor circuits are shielded to prevent the
intrusion of electrical noise etc. • MIL (Check engine lamp) lights.
• ECM limits fuel consumption. (1st level)
Main trouble phenomena • Limits the fuel pressure. (1st level)
• White smoke/black smoke • The ECM stops the power supply to injectors and
• Lack of output pump control valve (PCV). (2nd level)
• Rough idling
• Start up deterioration/Engine stop
• PTO stop
Clear conditions of MIL/DTC • Injector internal malfunction
When trouble occurs in the system and that DTC is • Supply pump internal malfunction
memorized by ECM, since the fault region is not • Flow damper operation
eliminated as it is by DTC, it should be deleted in the • Pressure limiter not operating
require that you check DTCs, so be sure to note and • Fuel system (leak side) malfunction (blockage,
clear the DTCs before performing inspection. crushed etc.)
DTC deletion method • To check the operation of the fuel pressure sensor
• Deleting DTC by operating the accelerator pedal. at high fuel pressure (not less than 60Mpa), apply
(Refer to “How to delete DTCs by operating the load on the engine with a specified loading, and
accelerator pedal” in “Fault diagnosis process”) check the fuel pressure changes with a scan too.
• Use the scan tool (Tech2) to clear DTC. • Check the connector for poor connection, and
Diagnostic aids such as a frayed or broken harness, frayed wiring
• Connector section bad connection in the harness, or a short to another circuit.
• Fuel pressure sensor failure check things like operation and control of each
• Fuel pressure sensor installation malfunction,
looseness

again.
1. Clear the DTC.
3. Check the DTC.
3 condition. —
corrected.

1. Check the installation condition of the
supply pump.
4 2. When fault is detected, repair if —
necessary.


Inspect the fuel pipe.
1. Stop the engine.
2. Check all fuel pipes for crushing,
blockages and other such malfunctions.
5 Also check the fuel filters etc. for —
malfunctions.
necessary.

Use a scan tool and check the injector’s fuel
injection condition.
6 3. Clear the DTC. ±4
4. Check the cylinder compensation
injection amount.
Is the compensation amount within the normal

range? Go to Step 8 Go to Step 7
1. Perform inspection cleaning of the
problem cylinder injector, and replace if
required.
7 IMPORTANT: —

8 —
necessary.

Use a scan tool and check the fuel pressure
condition.
1. Turn the starter switch ON. Approx.
9
2. Display the engine data and check [Fuel 0MPa
pressure].
Is the fuel pressure value normal? Go to Step 10 Go to Step 12


display.
10
Approx.
0MPa
pressure].

plus side
minus side

12 pressure sensor. —
Is the fuel pressure sensor normal? Go to Step 14 Go to Step 13

13 —
1. Turn the starter switch ON, and run the
engine.
2. Depress the accelerator pedal until the
engine speed reaches 2100rpm.
Be careful not to overrun the engine.
3. Turn the starter switch OFF and stop the
14 engine, and check the operating sounds —
of the flow damper within approx. 120
seconds of stopping the engine.
If the flow damper is working correctly,
you can hear the operating sounds after
the engine stopped.
Can you hear operating sounds? Go to Step 16 Go to Step 15

Replace the flow damper.
15 —

Again, check the condition of the fuel
pressure.
1. Perform air bleeding, and start the
engine.
2. Using a scan tool, check the [Fuel
pressure] while operating the accelerator
16 pedal. —
plus side
• Release the pedal: change to the
minus side

Replace the supply pump.
17 —
again.
2. Clear the DTC.
4. Check the DTC.

Replace the pressure limiter.
19 —
1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
4. Check the DTC.

3 2 1
HCW01ASH013301
Legend
1. Sensor (GND)
2. Sensor (SIG)
Fuel pressure sensor properties

0.84
Output voltage
0.6
(Vout / Vc)
0.2
MPa
0 100 160
2
kgf/cm
0 1019 1631
Pressure

OFF 1.0V( 0MPa)
HCW61ASH002401
Fuel pressure malfunction (pump
overpressure transmission)
Engine
Control
Module
(ECM)
121 132 123 136
SIG 1
SIG 2
GND
VCC
0.5W/L
0.5O/L
0.5W
0.5O
0.5W
2 3 1

HCW61AMF002601

The fuel pressure sensor detects the pressure inside If the difference between the fuel rail fuel pressure
the fuel rail. The fuel pressure sensor is attached to the value recognized in the ECM during engine start and
fuel rail. When the fuel pressure inside the fuel rail target fuel pressure set by the ECM remains more than
changes due to the condition of the engine, the output 10Mpa for approx. 8 seconds, or if the PCV closed
voltage of the fuel pressure sensor changes (output valve time becomes more than 180°CA for approx. 8
voltage is low when the fuel rail internal fuel pressure is seconds, “Fuel pressure malfunction (pump
low, and the output voltage increases when the overpressure transmission)” is diagnosed, and [DTC
pressure increases). The engine control module (ECM) P0151] is displayed.
rail internal fuel pressure and uses it for control. The Actions when DTC is set
sensor power supply (5V), SIG, GND for fuel pressure • MIL (Check engine lamp) lights.
Also, the sensor circuits are shielded to prevent the
intrusion of electrical noise etc. • Limits the fuel pressure.
Main trouble phenomena Clear conditions of MIL/DTC

• White smoke/black smoke When trouble occurs in the system and that DTC is
• Lack of output
• Fluctuation of revolutions (hunting) following ways. Furthermore, inspection and repair may
• Rough idling require that you check DTCs, so be sure to note and
DTC deletion method • Pressure limiter not operating
• Deleting DTC by operating the accelerator pedal • Fuel system (leak side) malfunction (blockage,
(Refer to “How to delete DTCs by operating the crushed etc.)
accelerator pedal” in “Fault diagnosis process”) • ECM internal malfunction
• Use the scan tool (Tech2) to clear DTC. • To check the operation of the fuel pressure sensor
at high fuel pressure (60Mpa or more), apply load
Diagnostic aids on the engine with a specified loading, and check
• Connector section bad connection the fuel pressure changes with a scan too.
• Fuel pressure sensor failure • Check the connector for poor connection, and
(Sensor internal or detection section malfunction) check to make sure that there are no abnormalities
looseness
• Injector internal malfunction check things like operation and control of each
• Supply pump internal malfunction component. Resolve any abnormality.
• Flow damper operation

again.
2. Clear the DTC.
4. Check the DTC.

3 condition. —
corrected.

1. Check the installation condition of the
supply pump.
4 2. When fault is detected, repair if —
necessary.


Inspect the fuel pipe.
1. Stop the engine.
2. Check all fuel pipes for crushing,
blockages and other such malfunctions.
malfunctions.
necessary.

6 3. Clear the DTC. ±4
injection amount.
Is the compensation amount within the normal

range? Go to Step 8 Go to Step 7
required.
7 IMPORTANT: —

8 —
necessary.

display.
9
Approx.
0MPa
pressure] when idling.


plus side
minus side

11 pressure sensor. —

12 —
1. Turn the starter switch ON, and run the
engine.
2. Depress the accelerator pedal until the
engine speed reaches 2100rpm.
Be careful not to overrun the engine.
3. Turn the starter switch OFF and stop the
13 engine, and check the operating sounds —
of the flow damper within approx. 120
seconds of stopping the engine.
If the flow damper is working correctly,
you can hear the operating sounds after
the engine stopped.
Can you hear operating sounds? Go to Step 15 Go to Step 14

Replace the flow damper.
14 —
the accelerator pedal again.
plus side
minus side

16 —

again.
2. Clear the DTC.
4. Check the DTC.

18 —
1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
20 —
4. Check the DTC.

3 2 1
HCW01ASH013301
Legend
1. Sensor (GND)
2. Sensor (SIG)
Fuel pressure sensor properties

0.84
Output voltage
0.6
(Vout / Vc)
0.2
MPa
0 100 160
2
kgf/cm
0 1019 1631
Pressure

OFF 1.0V( 0MPa)
HCW61ASH002401
Injector power supply system malfunction
(Common 1 “indicator 1, 3, 5 system”)
Engine
Control
Module
(ECM)
103 104 105 106 107 137 138 139 142 143
0.85W
0.85L
0.85Y
0.85G
0.85R
0.85W
0.85G
0.85R
0.85L
0.85Y
0.5B
1.25B
(Cylinder No.3)
(Cylinder No.2)
(Cylinder No.5)
(Cylinder No.6)
(Cylinder No.6)
(Cylinder No.1)
INJ INJ INJ INJ INJ INJ

1 3 5 2 4 6
5B
HCW61AMF002701

The injectors perform fuel injection. The injectors are If there is a short circuit in the battery etc. voltage or
installed in the engine head. The Engine Control GND system for the injector internal two-way valve
Module (ECM) controls the amount of fuel consumption (TWV) drive circuit, or if there is a short circuit in the
and timing by controlling the power supply time to the battery etc. voltage or GND for each injector, “Injector
injectors. Also, the ECM generates voltage for power supply system malfunction (Common 1 “Injector
operating the injectors (over 100V) internally, then 1, 3, 5 system”)” is diagnosed, and “DTC P0158” is
applies the stored voltage (over 100V) to the injectors. displayed.
When the injector operates, the voltage applied to the
injector returns to the ECM through the injector as an Actions when DTC is set
ECM signal, and the ECM performs controls using this • MIL (Check engine lamp) lights.
signal.
Main trouble phenomena • Limits the fuel pressure.
• Engine stall
• PTO stop
• Rough idling memorized by ECM, since the fault region is not
• White smoke eliminated as it is by DTC, it is eliminated in the
• Starting difficulties following ways. Furthermore, inspection and repair may
• Reduced output require that you check DTCs, so be sure to note and
DTC deletion method • Injector number and cylinder number
• Deleting DTC by operating the accelerator pedal Injector 1 1st cylinder
(Refer to “How to delete DTCs by operating the Injector 2 5th cylinder
accelerator pedal” in “Fault diagnosis process”) Injector 3 3rd cylinder
Injector 4 6th cylinder
Injector 5 2nd cylinder
Diagnosis help
Common1: Power supply for 1st - 3rd cylinder
• Connector section bad connection injector
• Failure of injector unit (internal malfunction) Common2: Power supply for 4th - 6th cylinder
• Injector (power source side) circuit short circuit injector
• Injector (drive side) circuit short circuit • Precautions to observe on injector inspection
As the injector drive voltage is over 100V, always
• Check the connector for poor connection, and perform inspection and repair work with the starter
check to make sure that there are no abnormalities switch in the OFF position to prevent electric
such as a frayed or broken harness, frayed wiring shocks.

Inspect the injector power supply circuit for
broken wires or short circuits.
injectors (1st cylinder, 2nd cylinder, 3rd
cylinder).
ECM connector terminals.
• Between pins 106 and 107: 0.5Ωor
less
2 —
• Between pins 106 and 103/104/105:
∞Ω
∞Ω
• Between pins 106/107 and GND: ∞Ω
necessary.


Inspect the circuit between ECM - injector for
broken wires.
1. Connect jumper wires between the
injector terminals.
3 • Between pins 106 and 103/104/105: —
0.5Ω or less
0.5Ωor less
corrected.

short circuits.
2. Measure the voltage between ECM Between pins
4 connector terminals. 106/107 and
GND: 0V
necessary.

Inspect the injector unit.
1. Remove the harness from the injectors
(1st cylinder, 3rd cylinder, 5th cylinder).
injector terminals.
• Between injector terminals: 0.3 -
1.3Ω
5 • Between terminals - body: ∞Ω —
necessary.
IMPORTANT:

1. Replace the ECM.
IMPORTANT:


Recheck the DTC.
2. Clear the DTC.
7 —
4. Check the DTC.

Injectors
00 0 0
00 0 0
00 0 0
00
3
00 0 0
00 0 0
00 0 0
00 0 0
1 2
HCW51ASH000301
Legend
1. Injector signal
2. Injector power supply
3. ID code plate
4. Injectors
Injector power supply system malfunction
(Common 2 “indicator 2, 4, 6 system”)
Engine
Control
Module
(ECM)
103 104 105 106 107 137 138 139 142 143
0.85W
0.85L
0.85Y
0.85G
0.85R
0.85W
0.85G
0.85R
0.85L
0.85Y
0.5B
1.25B
(Cylinder No.3)
(Cylinder No.2)
(Cylinder No.5)
(Cylinder No.6)
(Cylinder No.6)
(Cylinder No.1)

1 3 5 2 4 6
5B
HCW61AMF002701

The injectors perform fuel injection. The injectors are If there is a short circuit in the battery etc. voltage or
installed in the engine head. The Engine Control GND system in the injector internal two-way valve
Module (ECM) controls the amount of fuel consumption (TWV) drive circuit, or if there is a short circuit in the
and timing by controlling the power supply time to the battery etc. voltage or GND for each injector, “Injector
injectors. Also, the ECM generates voltage for power supply system malfunction (Common 2 “Injector
operating the injectors (over 100V) internally, then 2, 4, 6 system”)” is diagnosed, and “DTC P0159” is
applies the stored voltage (over 100V) to the injectors. displayed.
injector returns to the ECM through the injector as an Actions when DTC is set
ECM signal, and the ECM performs controls using this • MIL (Check engine lamp) lights.
signal.
Main trouble phenomena • Limits the fuel pressure.
• Engine stall
• PTO stop
• Rough idling memorized by ECM, since the fault region is not
• White smoke eliminated as it is by DTC, it is eliminated in the
• Starting difficulties following ways. Furthermore, inspection and repair may
• Reduced output require that you check DTCs, so be sure to note and
DTC deletion method • Injector number and cylinder number
• Deleting DTC by operating the accelerator pedal Injector 1 1st cylinder
(Refer to “How to delete DTCs by operating the Injector 2 5th cylinder
accelerator pedal” in “Fault diagnosis process”) Injector 3 3rd cylinder
Injector 5 2nd cylinder
Diagnostic help
• Connector section bad connection injector
• Failure of injector unit (internal malfunction) Common2: Power supply for 4th - 6th cylinder
• Injector (power source side) circuit short circuit injector
• Injector (drive side) circuit short circuit • Precautions to observe on injector inspection
• Check the connector for poor connection, and perform inspection and repair work with the starter
check to make sure that there are no abnormalities switch in the OFF position to prevent electric
such as a frayed or broken harness, frayed wiring shocks.

broken wires or short circuits.
injectors (1st cylinder, 2nd cylinder, 3rd
cylinder).
• Between pins 142 and 143:0.5Ω or
less
2 —
∞Ω
∞Ω
necessary.


Inspect the circuit between ECM - injector for
broken wires.
1. Connect jumper wires between the
injector terminals.
3 • Between pins 142 and 137/138/139: —
0.5Ωor less
0.5Ωor less
corrected.

short circuits.
2. Measure the voltage between ECM Between pins
4 connector terminals. 142/143 and
GND: 0V
necessary.

1. Remove the harness from the injectors
(2nd cylinder, 4th cylinder, 6th cylinder).
injector terminals.
• Between injector terminals: 0.3 -
1.3Ω
5 • Between terminals - body: ∞Ω —
necessary.
IMPORTANT:

1. Replace the ECM.
IMPORTANT:


Recheck the DTC.
2. Clear the DTC.
7 —
4. Check the DTC.

Injectors
00 0 0
00 0 0
00 0 0
00
3
00 0 0
00 0 0
00 0 0
00 0 0
1 2
HCW51ASH000301
Legend
1. Injector signal
3. ID code plate
4. Injectors
Fuel temperature sensor malfunction
Engine
Control
6WG1
Module
155 135 154 162 (ECM)
GND
SIG
SIG
SIG
0.5Y/R
0.3Y
0.5Y/G
0.3Y/R
0.3V/R
0.5Y/R
0.3Y
0.5Y/R
0.5Y
1 3 1 2 1 2

Temperature Sensor
Sensor
Engine Coolant
Temperature (ECT)
Sensor
HCW61AMF002201
Description of circuit Clear conditions of MIL/DTC

The fuel temperature (FT) sensor detects the fuel When trouble occurs in the system and that DTC is
temperature. The engine control module (ECM) applies memorized by ECM, since the fault region is not
voltage to the FT sensor installed in the fuel filter, reads eliminated as it is by DTC, it is eliminated in the
the changes in applied voltage as signals, and following ways. Furthermore, inspection and repair may
optimizes the fuel injection control based on those require that you check DTCs, so be sure to note and
signals. Also, the sensor’s GND circuit is shared by clear the DTCs before performing inspection.
each temperature related sensor.
DTC deletion method
Main trouble phenomena • Deleting DTC by operating the accelerator pedal
• Lack of output (Refer to “How to delete DTCs by operating the
Set conditions of DTC • Use the scan tool (Tech2) to clear DTC.
If the voltage value applied to the FT sensor exceeds
4.9V, or remains lower than 0.085V, “Fuel temperature Diagnostic Aids
sensor malfunction” is diagnosed, and “DTC P0211” is If an intermittent problem is suspected, consider the
displayed. following causes.
• Poor connection of harness connector
• Poor harness wiring plan
• Wearing out of harness covering
• The ECM uses the backup value to control.
• Broken wire inside the harness covering
For the detection of these causes, the following kinds of
• Harness connector and ECM connector poor • Damage to harness
connection - Inspect for damage to the exterior of harness.
- Terminal breaking loose from connector - While moving the harness and connector
- Inappropriate fit of terminals related to the sensor, check the display of
- Damage to connector lock related items in the scan tool’s engine data. The
display changes show the fault region.
- Poor connection of terminal and wire

Is the action complete? Go to Step 2 system check”
temperature sensor connector.
2 condition. —
2. Correct any detected malfunction if
necessary.

Inspect the fuel temperature sensor harness.
1. Turn the starter switch off.
fuel temperature sensor - ECM.
necessary.

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

Repair or replace the fuel temperature sensor.
5 —
Inspect the fuel temperature sensor.
temperature sensor.
Between
2. Measure the resistance values of sensor terminals:
6 connector terminals while adding between
temperature changes. each terminal
3. When fault is detected, replace if and GND: ∞Ω
necessary.


Recheck the DTC.
2. Clear the DTC.
7 —
4. Check the DTC.

1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
9 —
4. Check the DTC.

Fuel temperature (FT) sensor 3. Sensor signal
2 3
HCW51ASH000501
Legend
1. Fuel filter
2. Sensor GND
PCV1 system short (battery, power supply
system circuit) malfunction
Fuse 48
(15A)
1.25W/L
1.25W/L
1.25W/L
1.25W
1.25W
1 1
Pressure Pressure
Control Control
Valve 1 Valve 2
(PCV1) (PCV2)
2 2
0.5R/W
0.5R/B
0.5R/W
0.5R/B
0.5R/W
152 153 150 0.5R/B

151 Engine
Control
Module
(ECM)
HCW61AMF002801

The pump control valve (PCV) controls the amount of When the starter switch is ON, and the supply pump is
fuel pressure fed to the fuel rail. When a signal normal, if the signal voltage from PCV1 is continually
(voltage) is sent to the PCV of the supply pump, the high for more than 1 second, “PCV1 System short
PCV closes and fuel is pressure fed from the supply (battery, power supply system circuit) malfunction” is
pump to the fuel rail. The Engine Control Module diagnosed, and [DTC P0217] is displayed.
(ECM) operates the PCV by controlling the valve
opening time. An earlier PCV valve opening time Actions when DTC is set
results in a larger amount of fuel being pressure fed to • MIL (Check engine lamp) lights.
the common relay, as well as a rise in the internal
• ECM limits the fuel pressure.
pressure of the fuel rail.
There are 2 PCVs attached to the supply pump so that
the engine can operate with only one PCV if the other
one fails. However, the engine will stop without a DTC When trouble occurs in the system and that DTC is
being detected if the harness is connected in he memorized by ECM, since the fault region is not
opposite way because PCV support is for each fuel eliminated as it is by DTC, it is eliminated in the
injection cylinder. following ways. Furthermore, inspection and repair may
Main trouble phenomena clear the DTCs before performing inspection.
• White smoke/black smoke DTC deletion method
• Rough idling
• Lack of output accelerator pedal” in “Fault diagnosis process”)
• PTO stop • Use the scan tool (Tech2) to clear DTC.
• PCV circuit short
• PCV unit malfunction (internal short circuit Furthermore, perform functional diagnostics to
malfunction) check things like operation and control of each
• ECM internal malfunction component. Resolve any abnormality.

Inspect the PCV1 unit.
2. Disconnect the harness from the PCV1. Approx. 3.2Ω
3. Measure the resistance values between (at normal
2
PCV1 terminals. temperatures
4. If fault is detected, repair or replace the )
PCV (supply pump) as necessary.

Inspect the PCV1 circuit for short circuits in
the power supply (B+).
3. Measure the voltage between ECM
harness connector terminals.
3 • Between pins 152 and 72/73: 1V or —
less
• Between pins 153 and 72/73: 1V or
less
necessary.

Inspect the PCV1 circuit for broken wires or
short circuits.
and PCV1.
4 • Between pins 152 and 153: 0.5 Ω or —
less
4. Check that there are no power supply
shorts between PCV-ECM.
necessary.


1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
6 —
4. Check the DTC.

Pump control valve (PCV) PCV arrangement
2 1
MFW31ASH006101
MFW31ASH005001
Legend
1. PCV1
2. PCV2
PCV2 system short (battery, power supply
system circuit) malfunction
Fuse 48
(15A)
1.25W/L
1.25W/L
1.25W/L
1.25W
1.25W
1 1
Pressure Pressure
Control Control
Valve 1 Valve 2
(PCV1) (PCV2)
2 2
0.5R/W
0.5R/B
0.5R/W
0.5R/B
0.5R/W
0.5R/B
152 153 150 151 Engine
Control
Module
(ECM)
HCW61AMF002801

(voltage) is sent to the PCV of the supply pump, the high for more than 1 second, “PCV2 System short
PCV closes and fuel is pressure fed from the supply (battery, power supply system circuit) malfunction” is
pump to the fuel rail. The Engine Control Module diagnosed, and “DTC P0218” is displayed.
opening time. An earlier PCV valve opening time Actions when DTC is set
results in a larger amount of fuel being pressure fed to • MIL (Check engine lamp) lights.
pressure of the fuel rail. There are 2 PCVs attached to
the supply pump so that the engine can operate with
only one PCV if the other one fails. However, the
engine will stop without a DTC being detected if the When trouble occurs in the system and that DTC is
harness is connected in he opposite way because PCV memorized by ECM, since the fault region is not
support is for each fuel injection cylinder. eliminated as it is by DTC, it is eliminated in the
Main trouble phenomena require that you check DTCs, so be sure to note and
• White smoke/black smoke
• Rough idling DTC deletion method
• Start up deterioration • Deleting DTC by operating the accelerator pedal
• PTO stop accelerator pedal” in “Fault diagnosis process”)
• PCV circuit short
• PCV unit malfunction (internal short circuit Furthermore, perform functional diagnostics to
malfunction) check things like operation and control of each

2. Disconnect the harness from the PCV2. Approx. 3.2Ω
3. Measure the resistance values between (at normal
2
PCV2 terminals. temperatures
4. If fault is detected, repair or replace the )

Inspect the PCV1 circuit for short circuits in
the power supply (B+).
3 • Between pins 150 and 72/73: 1V or —
less
• Between pins 151 and 72/73: 1V or
less
necessary.

Inspect the PCV2 circuit for broken wires or
short circuits.
and PCV2.
4 • Between pins 150 and 151:0.5Ω or —
less
4. Check that there are no power supply
shorts between PCV - ECM.
necessary.


1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
6 —
4. Check the DTC.

2 1
MFW31ASH006101
MFW31ASH005001
Legend
1. PCV1
2. PCV2
Fuel pressure malfunction (pump no pressure
transmission)
3
4
12
2
11
10
7 5
8 6
HCW3C0MF001401
Legend
2. Flow damper 8. Supply pump
Description of circuit Main trouble phenomena

The engine control module (ECM) monitors the fuel rail • Lack of output
internal pressure based on signals from the fuel
pressure sensor, if the pressure is low, the ECM Set conditions of DTC
operates and adjusts the pump control valve (PCV) for DTC P0217, P0218, P0245, P0247, P0248 are not
the supply pump, and raises the fuel rail’s internal detected, and the condition in which PCV closing time
pressure. is +1 °CA or less of the PCV closing time limit value, or
If the supply of fuel to the supply pump fails, or a supply the fuel rail internal fuel pressure F/B control value is -
pump malfunction occurs, the fuel rail internal pressure 60°CA or less lasts for longer than 1 second, “Fuel
cannot raise. pressure malfunction (pump no pressure transmission)”
If the fuel rail pressure raises above the regular is diagnosed, and “DTC P0226” is displayed.
pressure, the pressure limiter installed in the fuel rail (When the actual fuel pressure is lower by a greater
operates reducing the fuel pressure, therefore amount than the fixed value than the engine control
preventing a mechanical failure in the engine. module’s target fuel pressure)
Actions when DTC is set • Pressure limiter operation
• MIL (Check engine lamp) lights. (Operates below the specified value, internal seal
deterioration etc.)
• Supply pump internal fault, installation malfunction
Clear conditions of MIL/DTC • PCV connection failure
When trouble occurs in the system and that DTC is • Fuel system pipe malfunction (fuel leak, blockage,
memorized by ECM, since the fault region is not crushed pipe etc.)
eliminated as it is by DTC, it is eliminated in the • Fuel filter malfunction
following ways. Furthermore, inspection and repair may (Blockage, overflow valve malfunction etc.)
require that you check DTCs, so be sure to note and • Fuel tank malfunction (blockage, amount of fuel,
clear the DTCs before performing inspection. additional tank etc.)
DTC deletion method
• Use the scan tool (Tech2) to clear DTC. Furthermore, perform functional diagnostics to
Diagnostic Aids component. Resolve any abnormality.
• Air mixed in the high-pressure fuel piping

Check the quantity of fuel. If there is not
2 enough, refill it. —
Bleed air from the fuel.
3 (Refer to fuel system checks) —
Recheck the DTC.
2. Clear the DTC.
4 —
4. Check the DTC.

Inspect the fuel pipe and filters.
1. Stop the engine.
2. Check all of the fuel pipes for fuel
leakage, crushed pipes, blockages, and
other malfunctions.
malfunctions.
necessary.


Using a scan tool, check the installation
condition of the supply pump.
2. Connect the scan tool, and switch the
6 starter switch to the ON position. -8-8
3. Display the engine data and check [CMP
sensor installation variability correction].

Check the fuel high-pressure piping for fuel
leakage.
7 2. Press the accelerator pedal. —
3. Inspect the fuel high-pressure piping for
fuel leakage.
Was a malfunction detected? Go to Step 8 Go to Step 9

Repair or replace the section with the fuel
8 leak. —
3. Select [Actuator test] - [Fuel system] -
9 —
[Stop injection from each injector] to stop
the injection of fuel from each injector.
4. Check the change in engine sound when
the fuel injection is stopped.
Does the engine sound change? Go to Step 11 Go to Step 10

1. Replace the injector from the cylinder that
did not cause a change in engine sound.
IMPORTANT:
10 —

Inspect the PCV.
2. While idling, disconnect the harness from
the PCV1.
3. Check the condition of the engine.
11 —
CAUTION:
Since DTC [P0247] is detected when the
harness is disconnected from the PCV1, clear
the DTC after the inspection.
Did the engine stall? Go to Step 13 Go to Step 12


Inspect the PCV.
1. Attach the harness to the PCV1.
the PCV2.
12 —
CAUTION:

13 —
Inspect the pressure limiter.
2. Disconnect the fuel pipe from the
pressure limiter.
14 —
3. Connect the fuel pipe to a hose etc. and
prepare for the fuel runoff check.
4. Start the engine and perform a test drive.
Does fuel flow out of the pressure limiter? Go to Step 15 Go to Step 16

15 —
1. Clear the DTC.
16 2. Bleed air from the fuel. —
Recheck the DTC.
2. Clear the DTC.
17 —
4. Check the DTC.

1. Replace the ECM.
IMPORTANT:


Recheck the DTC.
2. Clear the DTC.
19 —
4. Check the DTC.

Fuel pressure malfunction (fuel outflow)
3
4
12
2
11
10
7 5
8 6
HCW3C0MF001401
Legend
2. Flow damper 8. Supply Pump
Description of circuit • Lack of output

The engine control module (ECM) monitors the fuel rail
internal pressure based on signals from the fuel Set conditions of DTC
pressure sensor, if the pressure is low, the ECM When DTC P0226 is detected, but at the same time
operates and adjusts the pump control valve (PCV) for DTC P0217, P0218, P0245, P0247, P0248 are not
the supply pump, and raises the fuel rail’s internal detected, and the actual fuel pressure is the target fuel
pressure. pressure +5Mpa or less, if the condition in which the
If the supply of fuel to the supply pump fails, or a supply PCV closed time is +1°CA or less of the PCV closing
pump malfunction occurs, the fuel rail internal pressure time limit value, or the fuel pressure F/B control value is
cannot raise. -50°CA or less for more than 8 seconds, “Pump no
If the fuel pressure raises above the regular pressure, pressure transmission (fuel loss)” is diagnosed and
the pressure limiter installed in the fuel rail operates “DTC P0227” is displayed.
reducing the fuel pressure, therefore preventing a (When the actual fuel pressure is lower by a greater
mechanical failure in the engine. amount than the fixed value than the engine control
module’s target fuel pressure)
• The engine stops.
Actions when DTC is set • Pressure limiter operation
• MIL (Check engine lamp) lights. (Operates below the specified value, internal seal
deterioration etc.)
• Supply pump internal fault, installation malfunction
Clear conditions of MIL/DTC • PCV connection failure
When trouble occurs in the system and that DTC is • Fuel system pipe malfunction (fuel leak, blockage,
memorized by ECM, since the fault region is not crushed pipe etc.)
eliminated as it is by DTC, it is eliminated in the • Fuel filter malfunction
following ways. Furthermore, inspection and repair may (Blockage, overflow valve malfunction etc.)
require that you check DTCs, so be sure to note and • Fuel tank malfunction (blockage, amount of fuel,
clear the DTCs before performing inspection. additional tank etc.)
DTC deletion method • ECM internal malfunction
• Use the scan tool (Tech2) to clear DTC. Furthermore, perform functional diagnostics to
Diagnostic Aids component. Resolve any abnormality.
• Air mixed in the high-pressure fuel piping

Check the quantity of fuel. If there is not
2 enough, refill it. —
Bleed air from the fuel.
3 —
Recheck the DTC.
2. Clear the DTC.
4 —
4. Check the DTC.
After DTC P0226 occurs, is P0227 detected? Go to Step 5 Go to Step 20

Inspect the fuel pipe and filters.
1. Stop the engine.
2. Check all of the fuel pipes for fuel
leakage, crushed pipes, blockages, and
5 other malfunctions. Also check the fuel —
filters etc. for malfunctions.
necessary.


Using a scan tool, check the installation
condition of the supply pump.
2. Connect the scan tool, and switch the
6 starter switch to the ON position. -8-8
3. Display the engine data and check [CMP
sensor installation variability correction].

Check the fuel high-pressure piping for fuel
leakage.
2. Use a scan tool, and gently press on the
7 accelerator pedal. —
3. Inspect the fuel high-pressure piping for
fuel leakage.
Was a malfunction detected? Go to Step 8 Go to Step 9

Repair or replace the section with the fuel
8 leak. —
9 ±4
injection amount.
4. Check the changes in compensation
amount.
Do the compensation values fall within the

specified range? Go to Step 11 Go to Step 10
required.
10 IMPORTANT: —

Inspect the PCV.
the PCV1.
11 —
CAUTION:


Inspect the PCV.
1. Attach the harness to the PCV1.
the PCV2.
12 —
CAUTION:

13 —
Inspect the pressure limiter.
2. Disconnect the fuel pipe from the
pressure limiter.
14 —
3. Connect the fuel pipe to a hose etc. and
prepare for the fuel runoff check.
4. Start the engine and perform a test drive.
Does fuel flow out of the pressure limiter? Go to Step 15 Go to Step 16

15 —
1. Clear the DTC.
16 2. Bleed air from the fuel. —
Recheck the DTC.
2. Clear the DTC.
17 —
4. Check the DTC.
After DTC P0226 occurs, is P0227 detected? Go to Step 18 Go to Step 20

1. Replace the ECM.
IMPORTANT:


Recheck the DTC.
2. Clear the DTC.
19 —
4. Check the DTC.

Accelerator switch ON malfunction
Fuse 49 Fuse 17
(15A) (7.5A)
1.25 O
0.5V/W
1.25 O
1.25 O
2 5
Main
Relay POWER GND 5B
Accelerator
4 1
switch
0.3R/L
.25R/B
ECM GND
1.25B/O
KEY ON
1.25R/B
KEY ON
1.25R/B
1.25B/P
1.25B/P
1.25R/B
0.3R/L
0.3R/L
1.25B
1.25B
1.25B
75 74 5 6 7 58 46 56 102 140 141 72 73 Engine

Control
Module
(ECM)
HCW61AMF001901

The accelerator switch detects depression of the When the accelerator pedal position (APP) sensor is
accelerator pedal. When voltage is applied to the normal, if the condition in which the APP sensor signal
accelerator switch installed in the accelerator pedal link voltage is more than 3.06V and voltage from the
and the switch is ON (accelerator pedal is in the idle accelerator switch is applied continues for over 0.5
position), voltage is applied to the engine control seconds, “Accelerator switch ON malfunction” is
module (ECM) that becomes a signal. The ECM reads diagnosed, and “DTC P0242” is displayed.
changes in the voltage from the accelerator switch,
then judges the accelerator pedal position based on Actions when DTC is set
those signals. (When the switch is OFF and the • MIL (Check engine lamp) lights.
accelerator pedal is recognized in a position other than
• The ECM fixes the accelerator pedal opening radio
idle.) When the accelerator switch malfunctions, the
condition.
ECM controls using the APP sensor signals and the
backup value.
Main trouble phenomena When trouble occurs in the system and that DTC is
• Lack of output
• Accelerator pedal reaction (response) malfunction following ways. Furthermore, inspection and repair may
• PTO stop require that you check DTCs, so be sure to note and
DTC deletion method

• Use the scan tool (Tech2) to clear DTC. • Accelerator pedal failure
(Poor adjustment, looseness, link malfunction,
Diagnostic Aids spring malfunction)
• Connector section bad connection • APP sensor failure
• Short in the accelerator switch circuit • ECM internal malfunction
• accelerator switch installation failure (poor • Check the connector for poor connection, and
adjustment, looseness) check to make sure that there are no abnormalities
• Accelerator switch unit malfunction such as a frayed or broken harness, frayed wiring
(Switch internal, rod section malfunction) in the harness, or a short to another circuit.

Inspect the accelerator switch.
accelerator switch.
3. Check the conduction between the
2 accelerator switch connector terminals. —
• Idling position:0.5Ω or less
• Positions other than idling position:
∞Ω
Is the switch normal? Go to Step 4 Go to Step 3

Replace the accelerator switch.
3 —
Inspect the accelerator switch circuit.
accelerator switch.
2. Turn the starter switch ON. Battery
4
3. Measure the voltage between the voltage
accelerator switch harness connector
power supply terminals - GND.
Repair or replace the harness between the
5 fuse (power supply) - accelerator switch. —

Inspect the accelerator switch circuit.
2. Attach the harness to the accelerator
switch.
4. Turn the starter switch ON, and measure
6 the voltage between the ECM harness
connector and GND.
• Between pin 58 and GND
- Starter switch ON: Battery voltage
- Starter switch OFF: 0V

7 fuse - accelerator switch- ECM. —
display.
8 0.25-0.75V
5. Display the engine data and check
[Accelerator sensor] output voltage while
operating the accelerator pedal.

Use a digital multi-meter (DMM) and check
the accelerator pedal position SW output
voltage while depressing the accelerator
9 pedal. (ECM58 pin: 0V when pedal released, —
battery voltage when pedal depressed)
Are results of the test normal? Go to Step 11 Go to Step 10

Adjust the accelerator switch installation.
10 —
1. Replace the ECM.
IMPORTANT:


Recheck the DTC.
2. Clear the DTC.
12 —
4. Check the DTC.
Was P0242 detected? Go to Step 2 Go to Step 13

Accelerator Pedal Position (APP) Switch Accelerator switch operating condition
1
2
1 2
MFW31ASH003401
MFW31ASH003901
Legend
Legend 1. Idling state
1. Accelerator switch unit 2. Depressed state
2. Connector section
3. Rod section
Fuel pressure sensor malfunction
Engine
Control
Module
(ECM)
121 132 123 136
SIG 1
SIG 2
GND
VCC
0.5W/L
0.5O/L
0.5W
0.5O
0.5W
2 3 1

HCW61AMF002601

The fuel pressure sensor detects the pressure inside If the fuel pressure sensor signal voltage value exceeds
the fuel rail. The fuel pressure sensor is attached to the 4.7V, or remains lower than 0.7V for more than 0.1
fuel rail. When the fuel pressure inside the fuel rail seconds, “Fuel pressure sensor system malfunction” is
changes due to the condition of the engine, the output diagnosed, and “DTC P0245” is displayed.
voltage of the fuel pressure sensor changes (output
voltage is low when the fuel rail internal fuel pressure is Actions when DTC is set
low, and the output voltage increases when the • MIL (Check engine lamp) lights.
pressure increases). The engine control module (ECM)
rail internal fuel pressure and uses it for control. The • ECM limits the fuel pressure.
sensor are specialized circuits connected to the ECM. Clear conditions of MIL/DTC
Also, the sensor circuits are shielded to prevent the When trouble occurs in the system and that DTC is
intrusion of electrical noise etc. memorized by ECM, since the fault region is not
Main trouble phenomena following ways. Furthermore, inspection and repair may
• White smoke/black smoke require that you check DTCs, so be sure to note and
• Lack of output
• Fluctuation of revolutions (hunting) DTC deletion method
• Rough idling • Deleting DTC by operating the accelerator pedal
• PTO stop accelerator pedal” in “Fault diagnosis process”)
Diagnostic Aids • ECM internal malfunction
• Connector section bad connection • Check the connector for poor connection, and
• Fuel pressure sensor failure check to make sure that there are no abnormalities
(Sensor internal or detection section malfunction) such as a frayed or broken harness, frayed wiring
looseness
• Fuel pressure sensor circuit broken wire or short component. Resolve any abnormality.
circuit

2 —
necessary.
Inspect the fuel pressure sensor circuit.
pressure sensor. Between
2. Connect the harness to the ECM. connector
power supply
3 3. Turn the starter switch ON.
terminal -
4. Measure the voltage between the fuel GND: 4.75 -
pressure sensor harness connector - 5.25V
GND.

again.
2. Clear the DTC.
4. Check the DTC.

Use the scan tool to check the fuel pressure.
Approx.
5 3. Turn the starter switch ON.
0MPa
pressure].


Inspect the fuel pressure sensor.
1. Remove the fuel pressure sensor and
check that there is no dirt etc. adhering to
the fuel pressure sensor. ∞Ω (10MΩ or
6
2. Check the resistance value between the more)
fuel pressure sensor connector terminal
and sensor body.

7 —
Perform air-bleeding work.
8 —
Recheck the DTC.
2. Clear the DTC.
9 —
4. Check the DTC.

Again, check the condition of the fuel
pressure.
1. Perform air bleeding, and start the
engine.
2. Using a scan tool, check the [Fuel
pressure] while gently depressing and
10 operating the accelerator pedal. —
plus side
• Release the pedal: change to the
minus side
Did the pressure change? Go to Step 12 Go to Step 11

1. Replace the ECM.
IMPORTANT:


Recheck the DTC.
2. Clear the DTC.
12 —
4. Check the DTC.

Fuel pressure sensor Fuel pressure sensor properties
0.84
Output voltage
0.6
(Vout / Vc)
0.2
MPa
0 100 160
2
kgf/cm
0 1019 1631
Pressure
3 2 1
OFF 1.0V( 0MPa)
HCW61ASH002401
HCW01ASH013301
Legend
2. Sensor (SIG)
3. Sensor (GND)
PCV1 system broken wire or short circuit
(ground circuit) malfunction
Fuse 48
(15A)
1.25W/L
1.25W/L
1.25W/L
1.25W
1.25W
1 1
Pressure Pressure
Control Control
Valve 1 Valve 2
(PCV1) (PCV2)
2 2
0.5R/W
0.5R/B
0.5R/W
0.5R/B
0.5R/W
152 153 150 0.5R/B

151 Engine
Control
Module
(ECM)
HCW61AMF002801

(voltage) is sent to the PCV of the supply pump, the low for more than 1 second, “PCV1 System broken wire
PCV closes and fuel is pressure fed from the supply or short circuit (ground circuit) malfunction” is
pump to the fuel rail. diagnosed, and “DTC P0247” is displayed.
The Engine Control Module (ECM) operates the PCV
by controlling the power supply time. A longer PCV Actions when DTC is set
valve operating time results in a larger amount of fuel • MIL (Check engine lamp) lights.
being pressure fed to the common relay, as well as a
rise in the internal pressure of the fuel rail.
• Lack of output
• PTO stop (Refer to “How to delete DTCs by operating the
• Disconnection or short of the PCV circuit
• PCV unit malfunction (internal broken wire, GND Furthermore, perform functional diagnostics to
short circuit malfunction) check things like operation and control of each

2. Disconnect the harness from the PCV1.
3. Measure the resistance values of the
PCV1 connector terminals.
2 • Between terminals: approx. 3.2Ω —
• Between each terminal - PCV1 body:
∞Ω (at normal temperatures)
4. If fault is detected, repair or replace the

Inspect the PCV1 circuit for broken wires.
and PCV1.
3. Connect jumper wires between the PCV1
harness connector terminals, and
3 measure the voltage on the ECM harness —
connector side.
• Between pin 152 and GND: Battery
voltage
voltage

Inspect the PCV1 circuit for a short.
1. Remove the jumper wires from between
the PCV1 harness connector terminals.
the voltage on the ECM harness
4 connector side. —
• Between pin 152 and GND: 0V
• Between pins 152 - 153: 0V
Is the voltage value normal? Go to Step 6 ToStep 5

Inspect the PCV1 harness, and repair or
5 replace if required. —

1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
7 —
4. Check the DTC.

2 1
MFW31ASH006101
MFW31ASH005001
Legend
1. PCV1
2. PCV2
PCV2 system broken wire or short circuit
(ground circuit) malfunction
Fuse 48
(15A)
1.25W/L
1.25W/L
1.25W/L
1.25W
1.25W
1 1
Pressure Pressure
Control Control
Valve 1 Valve 2
(PCV1) (PCV2)
2 2
0.5R/W
0.5R/B
0.5R/W
0.5R/B
0.5R/W
0.5R/B
152 153 150 151 Engine
Control
Module
(ECM)
HCW61AMF002801

(voltage) is sent to the PCV of the supply pump, the low for more than 1 second, “PCV2 System broken wire
PCV closes and fuel is pressure fed from the supply or short circuit (ground circuit) malfunction” is
pump to the fuel rail. The Engine Control Module diagnosed, and “DTC P0248” is displayed.
(ECM) operates the PCV by controlling the power
supply time. A longer PCV valve operating time results Actions when DTC is set
in a larger amount of fuel being pressure fed to the • MIL (Check engine lamp) lights.
common relay, as well as a rise in the internal pressure
of the fuel rail.
• Lack of output
• PTO stop (Refer to “How to delete DTCs by operating the
• Disconnection or short of the PCV circuit
• PCV unit malfunction (internal broken wire, GND Furthermore, perform functional diagnostics to
short circuit malfunction) check things like operation and control of each

2. Disconnect the harness from the PCV2.
3. Measure the resistance values of the
PCV2 connector terminals.
2 • Between terminals: approx. 3.2Ω —
• Between each terminal - PCV2 body:
∞Ω (at normal temperatures)
4. If fault is detected, repair or replace the

Inspect the PCV2 circuit for broken wires.
and PCV2.
3. Connect jumper wires between the PCV2
harness connector terminals, and
3 measure the voltage on the ECM harness —
connector side.
voltage
voltage

Inspect the PCV2 circuit for a short.
1. Remove the jumper wires from between
the PCV2 harness connector terminals.
the voltage on the ECM harness
• Between pins 150 and 151: 0V

Inspect the PCV2 harness, and repair or
5 replace if required. —

1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
7 —
4. Check the DTC.

2 1
MFW31ASH006101
MFW31ASH005001
Legend
1. PCV1
2. PCV2
1st cylinder injector drive system malfunction
Engine
Control
Module
(ECM)
103 104 105 106 107 137 138 139 142 143
0.85W
0.85L
0.85Y
0.85G
0.85R
0.85W
0.85G
0.85R
0.85L
0.85Y
0.5B
1.25B
(Cylinder No.3)
(Cylinder No.2)
(Cylinder No.5)
(Cylinder No.6)
(Cylinder No.6)
(Cylinder No.1)

1 3 5 2 4 6
5B
HCW61AMF002701

The injectors perform fuel injection. The injectors are • MIL (Check engine lamp) lights.
installed in the engine head. The Engine Control • ECM limits fuel consumption.
Module (ECM) controls the amount of fuel consumption
and timing by controlling the power supply time to the Clear conditions of MIL/DTC
injectors. Also, the ECM generates voltage for
operating the injectors (over 100V) internally, then
applies the stored voltage (over 100V) to the injectors.
injector returns to the ECM through the injector as an
ECM signal, and the ECM performs controls using this
signal.
DTC deletion method
• Rough idling accelerator pedal” in “Fault diagnosis process”)
Diagnostic Aids
Set conditions of DTC • Connector section bad connection
If there is no signal (voltage) input to the injector • Failure of injector unit (internal malfunction)
internal two-way valve (TWV) drive circuit, a 1st • Injector (power source side) circuit disconnection
cylinder injector drive system malfunction is diagnosed,
and “DTC P0271” is displayed. • Injector (drive side) circuit disconnection
• Check the connector for poor connection, and • Injector number and cylinder number
check to make sure that there are no abnormalities Injector 1 1st cylinder
such as a frayed or broken harness, frayed wiring Injector 2 5th cylinder
in the harness, or a short to another circuit. Injector 3 3rd cylinder
Furthermore, perform functional diagnostics to Injector 4 6th cylinder
check things like operation and control of each Injector 5 2nd cylinder
component. Resolve any abnormality. Injector 6 4th cylinder
injector
Common2: Power supply for 4th-6th cylinder
injector
CAUTION:
Precautions to observe on injector inspection:
perform inspection and repair work with the starter
switch in the OFF position to prevent electric shocks.

Check whether there is a harness
disconnection or short
between the connector terminals.
4. Measure the resistance of the injector
circuit.
• Between pins 106 and 107: 0.5Ω or
2 less —
• Between pins 103 and 106: 0.3 to
1.3Ω
• Between pins 103 and 107: 0.3 to
1.3Ω
• Between each connector and body
(ground): ∞Ω
• Between the injector body and each
connector: ∞Ω(at normal
temperature)
Is the resistance value normal? Go to Step 5 Go to Step 3


1. Disconnect the harness from the injector
(1st cylinder).
2. Measure the resistance between injector
terminals.
3 • Between connectors: 0.3 to 1.3Ω —
• Between each connector and body:
∞Ω
3. Check the harness in the block.

1. Replace the injector.
IMPORTANT:
4 If an injector is replaced, you need to program —

disconnection or short.
3. Disconnect the harness from the injector.
4. Use a jumper wire between the injector
side connector, and measure resistance
at the ECM side connector.
less
5 • Between pins 103 and 106: 0.5Ωor —
less (with jumper)
• Between pins 103 and 107: 0.5 Ω or
less (with jumper)
(ground): ∞Ω
connector: ∞Ω
5. If a malfunction is detected, repair or
replace the malfunctioning circuit.
Was the malfunction detected? Go to Step 7 Go to Step 6

1. Replace the ECM.
IMPORTANT:


Recheck the DTC.
2. Clear the DTC.
7 —
4. Check the DTC.

Injectors
00 0 0
00 0 0
00 0 0
00
3
00 0 0
00 0 0
00 0 0
00 0 0
1 2
HCW51ASH000301
Legend
1. Injector signal
3. ID code plate
4. Injector
2nd cylinder injector drive system malfunction
Engine
Control
Module
(ECM)
103 104 105 106 107 137 138 139 142 143
0.85W
0.85L
0.85Y
0.85G
0.85R
0.85W
0.85G
0.85R
0.85L
0.85Y
0.5B
1.25B
(Cylinder No.3)
(Cylinder No.2)
(Cylinder No.5)
(Cylinder No.6)
(Cylinder No.6)
(Cylinder No.1)

1 3 5 2 4 6
5B
HCW61AMF002701

signal.
DTC deletion method
Diagnostic Aids
internal two-way valve (TWV) drive circuit, “2nd • Injector (power source side) circuit disconnection
cylinder injector drive system malfunction” is
diagnosed, and “DTC P0272” is displayed. • Injector (drive side) circuit disconnection
injector
Common2: Power supply for 4th - 6th cylinder
injector
CAUTION:
Precautions to observe on injector inspection:

circuit.
2 • Between pins 106 and 107: 0.5Ω or —
less
• Between pins 105 and 106: 0.3-1.3Ω
(ground): ∞Ω
temperature)

(2nd cylinder).
terminals.
3 • Between connectors: 0.3-1.3Ω —
∞Ω

IMPORTANT:

less
less (with jumper)
less (with jumper)
(ground): ∞Ω
connector: ∞Ω

1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
4. Check the DTC.

Injectors
00 0 0
00 0 0
00 0 0
00
00 0 0 3
00 0 0
00 0 0
00 0 0
1 2
HCW51ASH000301
Legend
1. Injector signal
3. ID code plate
4. Injector
3rd cylinder injector drive system malfunction
Engine
Control
Module
(ECM)
103 104 105 106 107 137 138 139 142 143
0.85W
0.85L
0.85Y
0.85G
0.85R
0.85W
0.85G
0.85R
0.85L
0.85Y
0.5B
1.25B
(Cylinder No.3)
(Cylinder No.2)
(Cylinder No.5)
(Cylinder No.6)
(Cylinder No.6)
(Cylinder No.1)

1 3 5 2 4 6
5B
HCW61AMF002701

When trouble occurs in the system and DTC is stored
in ECM, the DTC does not disappear unless the
malfunction is fixed. To clear the DTC, follow the
procedure below. Furthermore, inspection and repair
may require that you check DTCs, so be sure to note
and clear the DTCs before performing inspection.
signal.
Method of clearing DTC
• Clearing DTC by operating the accelerator pedal
Diagnostic aids
internal two-way valve (TWV) drive circuit, a 3rd • Injector (power source side) circuit disconnection
and DTC P0273 is displayed. • Injector (drive side) circuit disconnection
Common1: Power supply for 1st to 3rd cylinder
injector
Common2: Power supply for 4th to 6th cylinder
injector
CAUTION:
Precautions to observe on the injector inspection:

circuit.
2 • Between pins 106 and 107: 05Ω or —
less
(ground): ∞Ω
temperature)

(3rd cylinder).
terminals.
3 • Between connectors: 0.3-1.3Ω
∞Ω

IMPORTANT:

less
less (with jumper)
less (with jumper)
(ground): ∞Ω
connector: ∞Ω

1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
4. Check the DTC.

Injectors
00 0 0
00 0 0
00 0 0
00
00 0 0 3
00 0 0
00 0 0
00 0 0
1 2
HCW51ASH000301
Legend
1. Injector signal
3. ID code plate
4. Injector
4th cylinder injector drive system malfunction
Engine
Control
Module
(ECM)
103 104 105 106 107 137 138 139 142 143
0.85W
0.85L
0.85Y
0.85G
0.85R
0.85W
0.85G
0.85R
0.85L
0.85Y
0.5B
1.25B
(Cylinder No.3)
(Cylinder No.2)
(Cylinder No.5)
(Cylinder No.6)
(Cylinder No.6)
(Cylinder No.1)

1 3 5 2 4 6
5B
HCW61AMF002701

signal.
Diagnostic aids
internal two-way valve (TWV) drive circuit, a 4th • Injector (power source side) circuit disconnection
injector
injector
CAUTION:

circuit.
less
(ground): ∞Ω
temperature)

(4th cylinder).
terminals.
∞Ω

IMPORTANT:

less
less (with jumper)
less (with jumper)
(ground): ∞Ω
connector: ∞Ω

1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
4. Check the DTC.
Was P0274 detected? Go to Step 2 Go to Step 8

Injectors
00 0 0
00 0 0
00 0 0
00
00 0 0 3
00 0 0
00 0 0
00 0 0
1 2
HCW51ASH000301
Legend
1. Injector signal
3. ID code plate
4. Injector
Engine
Control
Module
(ECM)
103 104 105 106 107 137 138 139 142 143
0.85W
0.85L
0.85Y
0.85G
0.85R
0.85W
0.85G
0.85R
0.85L
0.85Y
0.5B
1.25B
(Cylinder No.3)
(Cylinder No.2)
(Cylinder No.5)
(Cylinder No.6)
(Cylinder No.6)
(Cylinder No.1)

1 3 5 2 4 6
5B
HCW61AMF002701

signal.
Diagnostic aids
check things like operation and control of each Injector 5 2th cylinder
injector
injector
CAUTION:

circuit.
less
(ground): ∞Ω
temperature)

(5th cylinder).
terminals.
∞Ω

IMPORTANT:

less
less (with jumper)
less (with jumper)
(ground): ∞Ω
connector: ∞Ω

1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
4. Check the DTC.

Injectors
00 0 0
00 0 0
00 0 0
00
00 0 0 3
00 0 0
00 0 0
00 0 0
1 2
HCW51ASH000301
Legend
1. Injector signal
3. ID code plate
4. Injector
Engine
Control
Module
(ECM)
103 104 105 106 107 137 138 139 142 143
0.85W
0.85L
0.85Y
0.85G
0.85R
0.85W
0.85G
0.85R
0.85L
0.85Y
0.5B
1.25B
(Cylinder No.3)
(Cylinder No.2)
(Cylinder No.5)
(Cylinder No.6)
(Cylinder No.6)
(Cylinder No.1)

1 3 5 2 4 6
5B
HCW61AMF002701

signal.
Diagnostic aids
injector
injector
CAUTION:

circuit.
less
(ground): ∞Ω
temperature)

(6th cylinder).
terminals.
∞Ω

IMPORTANT:

less
less (with jumper)
less (with jumper)
(ground): ∞Ω
connector: ∞Ω

1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
4. Check the DTC.

Injectors
00 0 0
00 0 0
00 0 0
00
00 0 0 3
00 0 0
00 0 0
00 0 0
1 2
HCW51ASH000301
Legend
1. Injector signal
3. ID code plate
4. Injector
Injector circuit disconnection (Common 1
injector 1, 3, 5 system)
Engine
Control
Module
(ECM)
103 104 105 106 107 137 138 139 142 143
0.85W
0.85L
0.85Y
0.85G
0.85R
0.85W
0.85G
0.85R
0.85L
0.85Y
0.5B
1.25B
(Cylinder No.3)
(Cylinder No.2)
(Cylinder No.5)
(Cylinder No.6)
(Cylinder No.6)
(Cylinder No.1)

1 3 5 2 4 6
5B
HCW61AMF002701
Description of circuit DTC set conditions

The injectors perform fuel injection. The injectors are Disconnection of all harnesses of injectors 1, 3, and 5
installed in the engine head. The Engine Control in the injector circuit. Furthermore, when Common 1
Module (ECM) controls the amount of fuel consumption harness is disconnected, a injector circuit
and timing by controlling the power supply time to the disconnection (Common 1 injector 1, 3, 5 system) is
injectors. Also, the ECM generates voltage for diagnosed, and DTC P0277 is displayed.
applies the stored voltage (over 100V) to the injectors. Actions when DTC is set
The injector operates as the ECM performs controls • MIL (Check engine lamp) lights.
using this signal, and the voltage applied to the injector
returns to the ECM through the injector as an ECM
signal.
Main trouble phenomena When trouble occurs in the system and DTC is stored
• Engine stall
• Starting difficulties procedure below. Furthermore, inspection and repair
• Reduced output may require that you check DTCs, so be sure to note
• Rough idling and clear the DTCs before performing inspection.

Diagnostic aids • Injector number and cylinder number
If an intermittent problem is suspected, consider the - Injector 1: 1st cylinder
following causes. - Injector 2: 5th cylinder
• Connector section bad connection - Injector 3: 3rd cylinder
• Injector unit failure (internal malfunction) - Injector 4: 6th cylinder
• Injector circuit disconnection - Injector 5: 2nd cylinder
For the detection of these causes, the following kinds of - Injector 6: 4th cylinder
- Common1: Power supply for 1st to 3rd cylinder
• Poor connection of the harness connector and injector
ECM connector
- Common1: Power supply for 4th to 6th cylinder
- Terminal breaking loose from connector injector
- Inappropriate fit of terminals
- Damage to connector lock CAUTION:
• Damage to harness perform inspection and repair work with the starter
- Inspect for damage to the exterior of harness. switch in the OFF position to prevent electric shocks.
- While moving the harness and connector
related to the sensor, check the display of
related items in the scan tool’s engine data. The

Check the DTC.
1. Use the scan tool to check the DTC.
2
Was DTC P0271 to P0273 or DTC P0158 Go to applicable
detected? DTC Go to Step 3
Inspect for a disconnection to the injector
power supply circuit (Common1).
injectors (1st cylinder, 2nd cylinder, 3rd Between pins
3 cylinder). 106 and 107:
0.5 Ω or less
3. Measure the resistance between ECM
Do the resistance values fall within the

Repair or replace the injector power supply
4 circuit. —

Inspect for a short between the injector body
terminals and ground.
2. Disconnect the connector of the injector. Between pins
5 (1st cylinder, 2nd cylinder, 3rd cylinder) 1/2/3 and
3. Measure the resistance between the GND: ∞Ω
each injector connector terminal and
ground.

1. Replace any malfunctioning injector.
IMPORTANT:

1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
8 —
4. Check the DTC.

Injector circuit disconnection (Common 2
injector 2, 4, 6 system)
Engine
Control
Module
(ECM)
103 104 105 106 107 137 138 139 142 143
0.85W
0.85L
0.85Y
0.85G
0.85R
0.85W
0.85G
0.85R
0.85L
0.85Y
0.5B
1.25B
(Cylinder No.3)
(Cylinder No.2)
(Cylinder No.5)
(Cylinder No.6)
(Cylinder No.6)
(Cylinder No.1)

1 3 5 2 4 6
5B
HCW61AMF002701

The injectors perform fuel injection. The injectors are Disconnection of all harnesses of injectors 1, 3, and 5
installed in the engine head. The Engine Control in the injector circuit. Furthermore, when Common 1
Module (ECM) controls the amount of fuel consumption harness is disconnected, a injector circuit
and timing by controlling the power supply time to the disconnection (Common 2 injector 2, 4, 6 system) is
injectors. Also, the ECM generates voltage for diagnosed, and DTC P0278 is displayed.
applies the stored voltage (over 100V) to the injectors. Actions when DTC is set
The injector operates as the ECM performs controls • MIL (Check engine lamp) lights.
using this signal, and the voltage applied to the injector
returns to the ECM through the injector as an ECM
signal.
Main trouble phenomena When trouble occurs in the system and DTC is stored
• Engine stall
• Starting difficulties procedure below. Furthermore, inspection and repair
• Reduced output may require that you check DTCs, so be sure to note
• Rough idling and clear the DTCs before performing inspection.

• Use the scan tool (Tech2) to clear DTC. - While moving the harness and connector
Diagnostic aids related items in the scan tool’s engine data. The
If an intermittent problem is suspected, consider the display changes show the fault region.
following causes. • Injector number and cylinder number
• Connector section bad connection - Injector 1 1st cylinder
• Injector unit failure (internal malfunction) - Injector 2: 5th cylinder
• Injector circuit disconnection - Injector 3: 3rd cylinder
For the detection of these causes, the following kinds of - Injector 4: 6th cylinder
inspections are required: - Injector 5: 2nd cylinder
• Poor connection of the harness connector and - Injector 6: 4th cylinder
ECM connector
- Common1: Power supply for 1st to 3rd cylinder
- Terminal breaking loose from connector injector
- Inappropriate fit of terminals - Common1: Power supply for 4th to 6th cylinder
- Damage to connector lock injector
CAUTION:
• Damage to harness
- Inspect for damage to the exterior of harness. As the injector drive voltage is over 100V, always

Check the DTC.
1. Use the scan tool to check the DTC.
2
Was DTC P0274 to P0276 or DTC P0159 Go to applicable
detected? DTC Go to Step 3
Inspect for a disconnection to the injector
power supply circuit (Common2).
injectors (4th cylinder, 5th cylinder, 6th Between pins
3 cylinder). 142 and 143:
0.5 Ω or less
3. Measure the resistance between ECM

Repair or replace the injector power supply
4 circuit. —

Inspect for a short between the injector body
terminals and ground.
2. Disconnect the connector of the injector. Between pins
5 (4th cylinder, 5th cylinder, 6th cylinder) 1/2/3 and
3. Measure the resistance between the GND: ∞Ω
each injector connector terminal and
ground.

1. Replace any malfunctioning injector.
IMPORTANT:

1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
8 —
4. Check the DTC.

VGS magnetic valve 1 drive system
malfunction
Fuse 16
(7.5A)
0.5V/W
0.5V/W
0.5V/W
3 1
3 1
VGS
EGR
Fail Safe
Fail Safe
Relay
Relay
0.5/P/W
5
0.35B
5 4
0.3Br/G
0.5W/R
0.5P/W
0.5P/W
0.5P/W
0.5W/R
0.5W/R
2 2 2
2 2 VGS VGS
VGS
M/V2 M/V3
M/V1
EGR EGR
M/V1 M/V2
1
0.5Y/Br
1 1
0.5Y/V
0.5Y/G
1 1
0.5Y/R
0.5Y/B
0.5Y/Br
0.5Y/V
0.5Y/Br
0.5Y/V Engine
110 108 109 47 111 112 113 114 115
Control
Module
(ECM)
HCW61AMF001701
Description of circuit • The ECM stops the control of VGS magnetic valve
The VGS magnetic valve is used to supply air to the air 1, 2, and 3.
cylinder. Controlling the air supply to the air cylinder
enables the air cylinder for the VGS to be appropriately Clear conditions of MIL/DTC
controlled. When trouble occurs in the system and DTC is stored
The power of the magnetic valve is supplied via the in ECM, the DTC does not disappear unless the
VGS fail safe relay, and is then connected via the VGS malfunction is fixed. To clear the DTC, follow the
magnetic valve to the Engine Control Module (ECM). procedure below. Furthermore, inspection and repair
The ECM controls each magnetic valve, and when a may require that you check DTCs, so be sure to note
malfunction is detected, controls the VGS fail safe relay and clear the DTCs before performing inspection.
to stop power supply to the VGS and thus stop each
control. Method of clearing DTC
DTC set conditions
• If the operating voltage of VGS magnetic valve 1 Diagnostic aids
continues in an abnormal state for 1.2 seconds, a If an intermittent problem is suspected, consider the
VGS magnetic valve 1 drive system malfunction is following causes.
diagnosed, and “DTC P0411” is displayed. • Poor connection of harness connector
• Broken wire inside the harness covering - Poor connection of terminal and wire
- Inspect for damage to the exterior of harness.
• Poor connection of the harness connector and
ECM connector
- Terminal breaking loose from connector related items in the scan tool’s engine data. The
- Inappropriate fit of terminals display changes show the fault region.
- Damage to connector lock

Check the DTC.
2 1. Use the scan tool to check the DTC.
Was DTC P0418 detected? Go to DTC P0418 Go to Step 3

Check the state of the attached VGS magnetic
valve 1 connector, ECM connector, and
midway connectors.
1. Inspect for play or looseness in the
3 attached connectors. —
necessary.

Inspect VGS magnetic valve 1.
2. Attach the VGS magnetic valve 1
connector.
4 34-40Ω
3. Measure the resistance of the VGS
magnetic valve 1.

Replace VGS magnetic valve 1.
5 —
Check the harness between the VGS
magnetic valve 1 and VGS fail safe relay.
1. Check for a short with the harnesses for
the power supply and signals or a
6 disconnection between the harnesses. —
necessary.


magnetic valve 1 and ECM.
1. Check for a short or disconnection of the
7 ground. —
necessary.

Use the scan tool to inspect VGS magnetic
valve 1 operation.
the engine does not start.
3. Operate the scan tool and clear the DTC.
8 4. Remove the air pipe from the VGS air —
cylinder.
5. Use the scan tool to perform an actuator
test to check magnetic valve operation.
(Refer to “Breakdown Diagnosis using the
scan tool”)
Is VGS magnetic valve 1 working normally? Go to Step 10 Go to Step 9

1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
4. Check the DTC.

External view and resistance of the magnetic valve Fail safe relay
1
2 1
2
5
4
3
HCW31ASH008101 HCW01ASH014601
Magnetic valve resistance values Circuit diagram of fail safe relay

Resistance values 34-40Ω
between terminals
Installation position for the magnetic valve
3 4
4
5 1 2
3 5
2
1 6
HCW01ASH014701
HCW61ASH004701
Legend
malfunction
Fuse 16
(7.5A)
0.5V/W
0.5V/W
0.5V/W
3 1
3 1
VGS
EGR
Fail Safe
Fail Safe
Relay
Relay
0.5/P/W
5
0.35B
5 4
0.3Br/G
0.5W/R
0.5P/W
0.5P/W
0.5P/W
0.5W/R
0.5W/R
2 2 2
2 2 VGS VGS
VGS
M/V2 M/V3
M/V1
EGR EGR
M/V1 M/V2
1
0.5Y/Br
1 1
0.5Y/V
0.5Y/G
1 1
0.5Y/R
0.5Y/B
0.5Y/Br
0.5Y/V
0.5Y/Br
0.5Y/V Engine
110 108 109 47 111 112 113 114 115
Control
Module
(ECM)
HCW61AMF001701
DTC set conditions
diagnosed, and “DTC P0412” is displayed. • Poor connection of harness connector
ECM connector

Check the DTC.
Go to DTC P0418
Was DTC P0418 detected? diagnosis Go to Step 3
midway connectors.
necessary.

connector.
4 34-40Ω
magnetic valve 2.

5 —
necessary.


7 ground. —
necessary.

valve 2 operation.
cylinder.
scan tool”)

1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
4. Check the DTC.

1
2 1
2
5
4
3

between terminals
3 4
4
5 1 2
3 5
2
1 6
HCW01ASH014701
HCW61ASH004701
Legend
malfunction
Fuse 16
(7.5A)
0.5V/W
0.5V/W
0.5V/W
3 1
3 1
VGS
EGR
Fail Safe
Fail Safe
Relay
Relay
0.5/P/W
5
0.35B
5 4
0.3Br/G
0.5W/R
0.5P/W
0.5P/W
0.5P/W
0.5W/R
0.5W/R
2 2 2
2 2 VGS VGS
VGS
M/V2 M/V3
M/V1
EGR EGR
M/V1 M/V2
1
0.5Y/Br
1 1
0.5Y/V
0.5Y/G
1 1
0.5Y/R
0.5Y/B
0.5Y/Br
0.5Y/V
0.5Y/Br
0.5Y/V Engine
110 108 109 47 111 112 113 114 115
Control
Module
(ECM)
HCW61AMF001701
DTC set conditions
diagnosed, and “DTC P0413” is displayed.
Actions when DTC is set • Poor harness wiring plan
• MIL (Check engine lamp) lights. • Wearing out of harness covering
ECM connector

Check the DTC.
Go to DTC P0418
midway connectors.
necessary.

connector.
4 34-40Ω
magnetic valve 3.

5 —
necessary.


7 ground. —
necessary.

valve 3 operation.
cylinder.
scan tool”)

1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
4. Check the DTC.

1
2 1
2
5
4
3

between terminals
3 4
4
5 1 2
3 5
2
1 6
HCW01ASH014701
HCW61ASH004701
Legend
Main relay system malfunction
Fuse 49 Fuse 17
(15A) (7.5A)
1.25 O
0.5V/W
1.25 O
1.25 O
2 5
Main
Relay POWER GND 5B
Accelerator
4 1
switch
0.3R/L
.25R/B
ECM GND
1.25B/O
KEY ON
1.25R/B
KEY ON
1.25R/B
1.25B/P
1.25B/P
1.25R/B
0.3R/L
0.3R/L
1.25B
1.25B
1.25B
75 74 5 6 7 58 46 56 102 140 141 72 73 Engine

Control
Module
(ECM)
HCW61AMF001901

The main relay supplies power to the Engine Control When trouble occurs in the system and DTC is stored
Module (ECM). When the starter switch is in the ON or in ECM, the DTC does not disappear unless the
S position, the ECM turns the main relay on and the malfunction is fixed. To clear the DTC, follow the
main relay supplies power to the ECM. procedure below. Furthermore, inspection and repair
Main trouble phenomena and clear the DTCs before performing inspection.
• High battery consumption when there is a relay
failure
If the state of a voltage being applied from the main
relay continues for more than 7 seconds after the • Use the scan tool (Tech2) to clear DTC.
starter switch is turned OFF, a main relay system
malfunction is diagnosed, and “DTC P0416” is Diagnostic aids
displayed. • Disconnection or short of the main relay circuit
• Main relay failure
MIL (Check engine lamp) does not light.

Inspect the main relay circuit for a short.
2. Remove the main relay.
3. Disconnect the connector from the ECM.
2 —
5. Measure the voltage between the ECM
harness connector terminals and ground.
• Between pins 5/6/7 and GND: 0 V
• Between pins 74/75 and GND: 0 V
3 main relay and ECM. —
Inspect the main relay.
1. Attach the main relay.
2. Measure the voltage when the starter
switch is operated at the ECM connector
side.
4 —
• Between pins 5/6/7 and GND:
- Starter switch ON: battery voltage

Repair or replace the main relay or main relay
5 power source side circuit. —
Is the action complete? Go to Step 7 -
1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
7 —
4. Check the DTC.


VGS magnetic valve relay malfunction
Fuse 16
(7.5A)
0.5V/W
0.5V/W
0.5V/W
3 1
3 1
VGS
EGR
Fail Safe
Fail Safe
Relay
Relay
0.5/P/W
5
0.35B
5 4
0.3Br/G
0.5W/R
0.5P/W
0.5P/W
0.5P/W
0.5W/R
0.5W/R
2 2 2
2 2 VGS VGS
VGS
M/V2 M/V3
M/V1
EGR EGR
M/V1 M/V2
1
0.5Y/Br
1 1
0.5Y/V
0.5Y/G
1 1
0.5Y/R
0.5Y/B
0.5Y/Br
0.5Y/V
0.5Y/Br
0.5Y/V
Engine
110 108 109 47 111 112 113 114 115
Control
Module
(ECM)
HCW61AMF001701

The power source of the VGS magnetic valve is When trouble occurs in the system and DTC is stored
supplied via the VGS fail safe relay. It is then connected in ECM, the DTC does not disappear unless the
via the VGS magnetic valve to the Engine Control malfunction is fixed. To clear the DTC, follow the
Module (ECM). procedure below. Furthermore, inspection and repair
DTC set conditions
• If the operating voltage of VGS fail safe relay Diagnostic aids
continues in an abnormal state for 1 second, a If an intermittent problem is suspected, consider the
VGS magnetic valve relay malfunction is following causes.
diagnosed, and “DTC P0418” is displayed.
Actions when DTC is set • Poor harness wiring plan
• MIL (Check engine lamp) lights. • Wearing out of harness covering
• The ECM stops the control of the VGS and EGR • Broken wire inside the harness covering
magnetic valves. For the detection of these causes, the following kinds of
• Poor connection of the harness connector and • Damage to harness
ECM connector - Inspect for damage to the exterior of harness.

Check the VGS fail safe relay circuit (coil side)
for a short.
2. Remove the VGS fail safe relay.
Between the
3. Disconnect the harness from the Engine pin 47 and
2 Control Module (ECM). body
4. Turn the starter switch ON. (ground): 0V

VGS fail safe relay (coil side) and ECM. Also
3 inspect the connector connection. —

Inspect the VGS fail safe relay.
2. Attach the VGS fail safe relay.
switch is operated at the ECM harness
• Between pin 47 and the body
(ground):

Repair or replace the VGS fail safe relay or
5 VGS fail safe relay power supply side circuit. —
1. Replace the ECM.
IMPORTANT:


Recheck the DTC.
2. Clear the DTC.
7 —
4. Check the DTC.

Fail safe relay
5
4
3
HCW01ASH014601
Circuit diagram of fail safe relay
1 2
3 5
HCW01ASH014701
PCV system malfunction
Fuse 48
(15A)
1.25W/L
1.25W/L
1.25W/L
1.25W
1.25W
1 1
Pressure Pressure
Control Control
Valve 1 Valve 2
(PCV1) (PCV2)
2 2
0.5R/W
0.5R/B
0.5R/W
0.5R/B
0.5R/W
0.5R/B
152 153 150 151 Engine
Control
Module
(ECM)
HCW61AMF002801

The pump control valve (PCV) controls the amount of • The ECM stores the DTC when there is a PCV
fuel pressure fed to the fuel rail. When a signal system malfunction. At that time, MIL (check
(voltage) is sent to the PCV of the supply pump, the engine lamp) lights.
PCV closes and fuel is pressure fed from the supply • Turn the main relay off when 10 seconds elapse
pump to the fuel rail. The Engine Control Module after the starter switch is turned off.
opening time. An earlier PCV valve opening time Clear conditions of MIL/DTC
results in a larger amount of fuel being pressure fed to
pressure of the fuel rail.
one fails. However, the engine will stop without a DTC
being detected if the harness is connected in he
opposite way because PCV support is for each fuel Method of clearing DTC
injection cylinder.
• Not possible to sense.
Set conditions of DTC
Diagnostic aids
If a voltage is applied from PCV1 or PCV2 after the
starter switch is turned OFF, a PCV system malfunction • Connector section bad connection
is diagnosed, and DTC421 is displayed. • PCV circuit short
• ECM internal malfunction • Check the connector for poor connection, and
• Starter switch internal malfunction check to make sure that there are no abnormalities

Inspect the PCV circuit for a short.
2. Disconnect the connector from the ECM.
3. Disconnect the harnesses from PCV1
and PCV2.
4. Measure the voltage between the PCV
2 —
side connector terminals.
• Between pin 1 and body (ground):
0V
• Between pin 2 and body (ground):
0V

Repair or replace the harness between power
3 supply and PCV or PCV and ECM. —
Inspect the power system harness.
switch is operated at the PCV connector
side.
4 —
• Starter switch OFF: 0V
• Starter switch ON: battery voltage

Repair or replace the power supply circuit.
5 —
Recheck the DTC.
2. Clear the DTC.
6 —
4. Check the DTC.

Replace the Engine Control Module (ECM).
(Accelerator learning needs to be performed
7 after replacing the ECM.) —
Is the action complete? Verify repair -

EGR magnetic valve relay malfunction
Fuse 16
(7.5A)
0.5V/W
0.5V/W
0.5V/W
3 1
3 1
VGS
EGR
Fail Safe
Fail Safe
Relay
Relay
0.5/P/W
5
0.35B
5 4
0.3Br/G
0.5W/R
0.5P/W
0.5P/W
0.5P/W
0.5W/R
0.5W/R
2 2 2
2 2 VGS VGS
VGS
M/V2 M/V3
M/V1
EGR EGR
M/V1 M/V2
1
0.5Y/Br
1 1
0.5Y/V
0.5Y/G
1 1
0.5Y/R
0.5Y/B
0.5Y/Br
0.5Y/V
0.5Y/Br
0.5Y/V
Engine
110 108 109 47 111 112 113 114 115
Control
Module
(ECM)
HCW61AMF001701

The power of the EGR magnetic valve is supplied via When trouble occurs in the system and DTC is stored
the EGR fail safe relay, and is then connected via the in ECM, the DTC does not disappear unless the
EGR magnetic valve to the Engine Control Module malfunction is fixed. To clear the DTC, follow the
(ECM). The ECM controls each magnetic valves. procedure below. Furthermore, inspection and repair
If an ECM malfunction is detected, the EGR fail safe may require that you check DTCs, so be sure to note
relay is controlled to stop power supply to the EGR and clear the DTCs before performing inspection.
magnetic valve and thus stop each control.
Main trouble phenomena • Clearing DTC by operating the accelerator pedal
DTC set conditions • Use the scan tool (Tech2) to clear DTC.
• If the operating voltage of EGR fail safe relay
continues in an abnormal state for 1 second, an Diagnostic aids
EGR magnetic valve relay malfunction is If an intermittent problem is suspected, consider the
diagnosed, and “DTC P0424” is displayed. following causes.
• The ECM stops the control of the EGR magnetic
valve. • Broken wire inside the harness covering
For the detection of these causes, the following kinds of
• Poor connection of the harness connector and • Damage to harness
ECM connector - Inspect for damage to the exterior of harness.

Check the EGRS fail safe relay circuit (coil
side) for a short.
2. Remove the EGR fail safe relay.
Between the
3. Disconnect the harness from the Engine pin 110 and
2 Control Module (ECM). body
4. Turn the starter switch ON. (ground): 0V

EGR fail safe relay (coil side) and ECM. Also
3 inspect the connector connection. —

Inspect the EGR fail safe relay.
2. Attach the EGR fail safe relay.
switch is operated at the ECM harness
• Between pin 110 and the body
(ground):

Repair or replace the EGR fail safe relay or
5 fail safe relay power source side circuit. —
1. Replace the ECM.
IMPORTANT:


Recheck the DTC.
2. Clear the DTC.
7 —
4. Check the DTC.

Fail safe relay
5
4
3
HCW01ASH014601
Circuit diagram of fail safe relay
1 2
3 5
HCW01ASH014701
EGR magnetic valve 1 drive error
Fuse 16
(7.5A)
0.5V/W
0.5V/W
0.5V/W
3 1
3 1
VGS
EGR
Fail Safe
Fail Safe
Relay
Relay
0.5/P/W
5
0.35B
5 4
0.3Br/G
0.5W/R
0.5P/W
0.5P/W
0.5P/W
0.5W/R
0.5W/R
2 2 2
2 2 VGS VGS
VGS
M/V2 M/V3
M/V1
EGR EGR
M/V1 M/V2
1
0.5Y/Br
1 1
0.5Y/V
0.5Y/G
1 1
0.5Y/R
0.5Y/B
0.5Y/Br
0.5Y/V
0.5Y/Br
0.5Y/V
Engine
110 108 109 47 111 112 113 114 115
Control
Module
(ECM)
HCW61AMF001701

The EGR magnetic valve is attached to the right side of • MIL (check engine lamp) lights.
the cab rear member. The EGR magnetic valve • The ECM stops the control of the EGR magnetic
controls the air supply to the EGR valve. The EGR valves 1 and 2.
magnetic valve is supplied power supply voltage via the
battery relay and EGR fail safe relay, and is turned on Clear conditions of MIL/DTC
by a drive signal from the ECM. The ECM turns the
EGR magnetic valve on when the temperature of the
engine coolant rises and the EGR operating conditions
are met. A monitor circuit inside the ECM monitors
magnetic valve operation.
The ECM sets a DTC when the drive voltage becomes
abnormal while the EGR magnetic valve is being
driven.
• Lack of output
• If the operating voltage of EGR magnetic valve 1
Diagnostic aids
continues in an abnormal state for 1.2 seconds, an
EGR magnetic valve 1 drive error is diagnosed, If an intermittent problem is suspected, consider the
and “DTC P0441” is displayed. following causes.
• Wearing out of harness covering - Damage to connector lock
ECM connector

Check the DTC.
Was DTC P0424 detected? Go to DTC P0424 Go to Step 3

Check the state of the attached EGR
magnetic valve 1 connector, ECM connector,
and midway connectors.
necessary.

Inspect EGR magnetic valve 1.
2. Attach the EGR magnetic valve 1
connector.
4 34-40Ω
3. Measure the resistance of the EGR
magnetic valve 1.

Replace EGR magnetic valve 1.
5 —
Check the harness between the EGR
magnetic valve 1 and EGR fail safe relay.
necessary.


7 ground. —
necessary.

Use the scan tool to inspect EGR magnetic
valve 1 operation.
8 4. Remove the air pipe from the EGR valve —
and air cylinder.
scan tool”)
Is EGR magnetic valve 1 working normally? Go to Step 10 Go to Step 9

1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
4. Check the DTC.

EGR magnetic valve
2 1
HCW31ASH008101
EGR magnetic valve 2 drive error
Fuse 16
(7.5A)
0.5V/W
0.5V/W
0.5V/W
3 1
3 1
VGS
EGR
Fail Safe
Fail Safe
Relay
Relay
0.5/P/W
5
0.35B
5 4
0.3Br/G
0.5W/R
0.5P/W
0.5P/W
0.5P/W
0.5W/R
0.5W/R
2 2 2
2 2 VGS VGS
VGS
M/V2 M/V3
M/V1
EGR EGR
M/V1 M/V2
1
0.5Y/Br
1 1
0.5Y/V
0.5Y/G
1 1
0.5Y/R
0.5Y/B
0.5Y/Br
0.5Y/V
0.5Y/Br
0.5Y/V
Engine
110 108 109 47 111 112 113 114 115
Control
Module
(ECM)
HCW61AMF001701

The EGR magnetic valve is attached to the right side of • MIL (check engine lamp) lights.
the cab rear member. The EGR magnetic valve • The ECM stops the control of the EGR magnetic
controls the air supply to the EGR valve. The EGR valves 1 and 2.
magnetic valve is supplied power supply voltage via the
battery relay and EGR fail safe relay, and is turned on Clear conditions of MIL/DTC
by a drive signal from the ECM. The ECM turns the
EGR magnetic valve on when the temperature of the
engine coolant rises and the EGR operating conditions
are met. A monitor circuit inside the ECM monitors
magnetic valve operation.
The ECM sets a DTC when the drive voltage becomes
abnormal while the EGR magnetic valve is being
driven. Method of clearing DTC
• If the operating voltage of EGR magnetic valve 2 Diagnostic aids

continues in an abnormal state for 1.2 seconds, an
EGR magnetic valve 2 drive error is diagnosed, If an intermittent problem is suspected, consider the
and “DTC P0442” is displayed. following causes.
• Switch unit malfunction
• Switch adjustment problem
• Poor connection of harness connector - Inappropriate fit of terminals
• Poor harness wiring plan - Damage to connector lock
• Wearing out of harness covering - Poor connection of terminal and wire
• Broken wire inside the harness covering • Damage to harness
For the detection of these causes, the following kinds of - Inspect for damage to the exterior of harness.
• Poor connection of the harness connector and related to the sensor, check the display of
ECM connector related items in the scan tool’s engine data. The
- Terminal breaking loose from connector display changes show the fault region.

Check the DTC.
2 1. Use the scan tool to check the DTC. —
Go to DTC P0424
Check the state of the attached EGR
magnetic valve 2 connector, ECM connector,
and midway connectors.
necessary.

Inspect EGR magnetic valve 2.
2. Attach the EGR magnetic valve 2
connector.
4 34-40Ω
3. Measure the resistance of the EGR
magnetic valve 2.
Replace EGR magnetic valve 2.
5 —
magnetic valve 2 and EGR fail safe relay.
necessary.

7 ground. —
necessary.

Use the scan tool to inspect EGR magnetic
valve 2 operation.
8 4. Remove the air pipe from the EGR valve —
and air cylinder.
scan tool”)
Is EGR magnetic valve 2 working normally? Go to Step 10 Go to Step 9

1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
4. Check the DTC.

EGR magnetic valve
2 1
HCW31ASH008101
Abnormality in fixation when closing EGR
valve1
Engine
Control
Module
(ECM)
33 54 30 34
GND
SIG
SIG
0.5G/W
0.5G/O
0.5G/B
0.5G/Y
0.5G/B
0.5G/B
0.5G/B
0.5G/B
2 1 2 1 2 1
EGR Gas EGR Gas PTO Control Resister

Temperature Sensor 1 Temperature Sensor 2
HCW61AMF002901

EGR valve is opened and closed by switching air If EGR temperature 1 remains higher than 210°C for
supply on and off through the magnetic valve. EGR more than 3 minutes when EGR is not operating, “High
valve is normally closed, magnetic valve is switched boost malfunction” is diagnosed, and “DTC P0446” is
“ON” when a signal is input from ECM to the magnetic displayed.
valve, and valve will open through the effect of air in the
ECR valve. ECM switches “ON” the EGR valve based Measures taken during DTC setting
on conditions such as number of rotations of the • MIL (Check engine lamp) lights.
engine, temperature of the engine coolant, etc.
Moreover, there is a EGR gas temperature sensor on Elimination conditions of MIL/DTC
the lower side of EGR valve, and EGR gas temperature
is detected. When trouble occurs in the system and DTC is stored
In ECM, the EGR valve would remain open even in ECM, the DTC does not disappear unless the
though a command to close EGR valve has been malfunction is fixed. To clear the DTC, follow the
given, and DTC is set when EGR gas temperature procedure below. Further, as DTC can be checked at
becomes abnormally high. the time of inspection or repair, recording and
elimination of DTC is done before checking.
• Lack of output
• Black smoke (Refer to “How to delete DTCs by operating the
Diagnostic help - Terminal breaking loose from connector
If an intermittent problem is suspected, consider the - Inappropriate fit of terminals
following causes. - Damage to connector lock
• Poor connection of harness connector - Poor connection of terminal and wire
• Poor harness wiring plan • Damage to harness
• Wearing out of harness covering - Inspect for damage to the exterior of harness.
• Broken wire inside the harness covering - While moving the harness and connector
For the detection of these causes, the following kinds of related to the sensor, check the display of
inspections are required: related items in the scan tool’s engine data. The
• Poor connection of the harness connector and display changes show the fault region.
ECM connector

On-Board Diagnostic (OBD) system check is
1 done. — Go to “OBD
Check the DTC.
2 1. Use the scan tool to check the DTC. —
Go to applicable
Was DTC P0441 detected? DTC Go to Step 3
1. Inspect the EGR valve for deformation,
cracks, and damage.
3 2. If fault is detected, repair or replace as —
necessary.

Check the installation condition of the EGR
gas temperature sensor1, EGR magnetic
valve 1, ECM and midway connectors.
1. Check whether there is any play or
4 slackness in the condition of connector —
installed.
necessary.

Check that there are no short circuits or
broken wires between the EGR temperature
sensor1 - ECM.
2. Disconnect the ECM connector. Between pins
5 3. Turn the starter switch ON, and measure 33/54 - GND:
the voltage between the ECM sensor 0V
harness connector (33/54 pin) - GND.
necessary.


sensor1 - ECM.
2. Disconnect the ECM and sensor.
6 the ECM harness connector terminals —
and ECM harness connectors, and GND.
• Between pins 33 and 54: ∞Ω
necessary.

Inspect 5V power of EGR gas temperature
sensor1.
2. Disconnect the connector of the sensor.
3. Turn the starter switch ON/OFF, and
7 measure the voltage between each —
sensor harness connector signal terminal
and GND.
• Starter switch ON: 5V

Inspect the air spring beam.
1. Remove air pipe from EGR valve1.
2. Use scan tool to operate magnetic valve.
(Refer to “Scan Tool” in the scan tool for
fault diagnosis test mode magnetic valve
operation check.)
Check whether air comes from the
8 —
external air pipe.
• Magnetic valve ON: air emission
• Magnetic valve OFF: no air emission
necessary.

Check the functioning of EGR valve1.
1. Disconnect EGR valve1.
2. Send the default compression pressure
637.4-
to the air port, and check that the valve
882.6kPa
9 opens. Then check that the valve closes
(4781 -
when the compression pressure is
6620mmHg)
stopped.
Whether the operation of EGR valve1 is
normal? Go to Step 11 Go to Step 10
Replace EGR valve1.
10 —

Check the operation of EGR gas temperature
sensor1.
1. Attach all the harnesses.
2. Turn the starter switch ON, and operate
the engine.
3. Warm-up till the engine coolant
temperature becomes 80 ℃ .
4. Use scan tool to switch ON the EGR
magnetic valve.
11 —
5. Increase the engine rotations gradually,
and using scan tool, check that the EGR
gas temperature increases.
CAUTION:
There is no EGR control when exhaust brake
is being operated.
Whether the operation of EGR gas

temperature sensor1 is normal ? Go to Step 14 Go to Step 12
Replace EGR gas temperature sensor1.
12 —
Recheck the DTC.
2. Clear the DTC.
13 —
4. Check the DTC.

1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
4. Check the DTC.

About EGR gas temperature sensor
LNW31ASH005601
Legend
1. GND
2. Signal
EGR gas temperature sensor resistance value

Conditional temperature Resistance characteristic
(°C) (kΩ)
50 64.1-96.2
100 11.2-15.3
150 2.7-3.8
Abnormalities in fixation when opening EGR
valve1
Engine
Control
Module
(ECM)
33 54 30 34
GND
SIG
SIG
0.5G/W
0.5G/O
0.5G/B
0.5G/Y
0.5G/B
0.5G/B
0.5G/B
0.5G/B
2 1 2 1 2 1

HCW61AMF002901

EGR valve is opened and closed by switching air If EGR temperature remains lower than 40°C for more
supply on and off through the magnetic valve. EGR than 3 minutes when EGR is not operating, “error of
valve is normally closed, magnetic valve is switched fixation when opening EGR valve1” is diagnosed, and
“ON” when a signal is input from ECM to the magnetic “DTC P0447” is displayed.
In ECM, the EGR valve would remain closed even in ECM, the DTC does not disappear unless the
though a command to open EGR valve has been given, malfunction is fixed. To clear the DTC, follow the
and DTC is set when EGR gas temperature becomes procedure below. Further, as DTC can be checked at
higher than normal. the time of inspection or repair, recording and
• Lack of output
Diagnostic Aids - Terminal breaking loose from connector
ECM connector

Check the DTC.
Go to applicable
cracks, and damage.
necessary.

necessary.

sensor 1 - ECM.
5 3. Turn the starter switch ON, and measure 33/54 and
the voltage between the ECM harness GND: 0V
connector terminal and GND.
necessary.


sensor1 - ECM.
necessary.

sensor1
and GND.

operation check.)
8 —
external air pipe.
necessary.

637.4-
882.6kPa
9 to the air port, and check that the valve
(4781-
opens.
6620mmHg)
Replace EGR valve1.
10 —

Check the operation of EGR gas temperature
sensor1.
1. Attach all the harnesses.
2. Turn the starter switch ON, and start the
engine.
3. Warm-up till the engine coolant
temperature becomes 80 ℃ .
4. Use scan tool to switch ON the EGR
magnetic valve.
11 —
5. Increase the engine rotations gradually,
and using scan tool, check that the EGR
gas temperature increases.
CAUTION:
There is no EGR control when exhaust brake
is being operated.
Whether the operation of EGR gas

temperature sensor is normal? Go to Step 14 Go to Step 12
Replace EGR gas temperature sensor1.
12 —
Recheck the DTC.
2. Clear the DTC.
13 —
4. Check the DTC.

1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
4. Check the DTC.

About EGR gas temperature sensor
LNW31ASH005601
Legend
1. GND
2. Signal
EGR gas temperature sensor resistance value

Conditional temperature Resistance characteristic
(°C) (kΩ)
50 64.1-96.2
100 11.2-15.3
150 2.7-3.8
Abnormalities in fixation when closing EGR
valve2.
Engine
Control
Module
(ECM)
33 54 30 34
GND
SIG
SIG
0.5G/W
0.5G/O
0.5G/B
0.5G/Y
0.5G/B
0.5G/B
0.5G/B
0.5G/B
2 1 2 1 2 1

HCW61AMF002901

EGR valve is opened and closed by switching air If EGR temperature 2 remains higher than 210°C for
supply on and off through the magnetic valve. EGR more than 3 minutes when EGR is not operating,
valve is normally closed, magnetic valve is switched “Abnormality of fixation when closing bulb2” is
“ON” when a signal is input from ECM to the magnetic diagnosed, and “DTC P0448” is displayed.
In ECM, the EGR valve would remain open even in ECM, the DTC does not disappear unless the
though a command to close EGR valve has been malfunction is fixed. To clear the DTC, follow the
given, and DTC is set when EGR gas temperature procedure below. Further, as DTC can be checked at
becomes abnormally high. the time of inspection or repair, recording and
• Lack of output
Diagnostic Aids - Terminal breaking loose from connector
ECM connector

Check the DTC.
Go to applicable
cracks, and damage.
necessary.

necessary.

sensor 2 - ECM.
5 3. Turn the starter switch ON, and measure 30/54 and
the voltage between the ECM harness GND: 0V
connector terminal and GND.
necessary.


sensor 2 - ECM.
necessary.

sensor2.
and GND.

operation check.)
8 —
external air pipe.
necessary.

637.4-
to the air port, and check that the valve
882.6kPa
9 opens. Then check that the valve closes
(4781-
when the compression pressure is
6620mmHg)
stopped.
Replace the EGR valve 2.
10 —
Was the action complete? Go to Step 15 —

Check if the EGR gas temperature sensor 2
operates.
2. Turn the starter switch ON to start the
engine.
3. Warm up the engine until the engine
coolant temperature reaches 80?C.
4. Using the scan tool, turn ON the EGR
magnetic valve.
11 —
5. Increase the engine revs gradually, then
check if the EGR gas temperature rises
using the scan tool.
CAUTION:
EGR control is not performed when the
exhaust brake is activated.
Is the EGR gas temperature sensor 2

operating normally? Go to Step 14 Go to Step 12
Replace the EGR gas temperature sensor 2.
12 —
Recheck the DTC.
2. Clear the DTC.
3. Turn OFF the starter switch, then turn it
13 —
ON again after an interval or more than
15 seconds and start the engine.
4. Check the DTC.
Was the DTC P0448 detected? Go to Step 14 Go to Step 16

1. Replace the ECM.
IMPORTANT:
After replacing the ECM, carry out the
14 programming for the following items. —

Recheck the DTC.
2. Clear the DTC.
3. Turn OFF the starter switch, then turn it
15 ON again after an interval or more than —
4. Check the DTC.

Use the scan tool to check whether any other
16 DTC has been detected. — Go to applicable
Was any other DTC detected? DTC Verify repair
EGR Gas Temperature Sensor
LNW31ASH005601
Legend
1. GND
2. Signal
Resistance value of EGR gas temperature sensor

Temperature (°C) Resistance
Characteristic (kΩ)
50 64.1-96.2
100 11.2-15.3
150 2.7-3.8
DTC P0449 (Flash Code 449)
EGR valve 2 gets stuck when commanded to
open.
Engine
Control
Module
(ECM)
33 54 30 34
GND
SIG
SIG
0.5G/W
0.5G/O
0.5G/B
0.5G/Y
0.5G/B
0.5G/B
0.5G/B
0.5G/B
2 1 2 1 2 1

HCW61AMF002901
Circuit Description Condition for Setting the DTC

The opening/closing of EGR valve is controlled by the When EGR is activated and the EGR temperature
magnetic valve which ON/OFF the air supply. The EGR keeps lower than 40?C for 3 minutes, it displays “DTC
valve which is normally closed is open when the P0449” to tell “EGR valve 2 gets stuck when
magnetic valve receives the input signal and turns ON, commanded to open”.
to open the EGR valve when the air is applied to the
valve. The ECM turns ON the EGR magnetic valve, Actions Taken When the DTC Sets
according to conditions such as engine rpm or engine • The MIL (Check Engine lamp) lights.
coolant temperature. Also, it detects the EGR gas
temperature through the EGR gas temperature sensor Condition for Clearing the MIL/DTC
installed on downstream of the EGR valve.
The ECM sets the DTC when the EGR gas If an error occurs in the system and a DTC is recorded
temperature becomes higher than the normal value, by the ECM, the DTC will not be erased unless the
with the EGR valve keeps closed even though it location of the fault is repaired, so follow the procedure
commands the EGR valve to open. below to erase it. DTCs may be checked during
inspection and repairs, so record and clear the DTCs
Main Malfunction Conditions before beginning the inspection.
• Inadequate output DTC Clearing Method

• Black smoke
• Operate the accelerator pedal to clear the DTCs.
(Refer to “Clearing DTCs by operating the
accelerator pedal” in “Failure Diagnosis
Procedure” of this manual)
• Use the scan tool (Tech 2) to clear the DTCs.
Diagnostic Aids - Terminal slipped out from the connector
When suspicious for intermittent condition, it may be - Inappropriate connection between two
caused by the following: terminals
• Bad connection of the harness connector - Connector lock damage
• Bad routing of harness connector - Poor connection between terminal and wiring
• Harness insulation wear-out • Harness damage
• Wire broken inside harness insulation - Inspect the appearance for harness damage
Following inspection procedure is needed to detect the - Check related display items on the scan tool
aforesaid causes. “Data Display” while moving the harness or
• Poor connection between the harness connector connectors that are connected to the sensors.
and the ECM connector. Display items that change when moving the
harness/connectors indicate the fault location.

Perform the On-Board Diagnosis (OBD)
1 systems check. — Go to “OBD
Was the action complete? Go to Step 2 system check”
Check the DTC.
2 1. Use the scan tool, check the DTC. —
Was the DTC P0442 detected? Go to DTC P0442 Go to Step 3
1. Check the EGR pipe that there is any
breakage, deformation or dirt.
3 2. If any fault is detected, repair or replace —
the part as necessary.
Was the fault detected? Go to Step 15 Go to Step 4

Check the mounting condition of EGR gas
temperature sensor 2, EGR magnetic valve 2,
ECM and center connector.
1. Check the mounting condition of
4 connector if there is no looseness or —
slackness.
2. If any fault is detected, repair or replace

Inspect the circuit from EGR temperature
sensor 2 to EMC if there is a short to voltage.
1. Turn “OFF” the starter switch.
2. Remove the connector of ECM.
3. Turn the starter switch ON to measure Between pins
5 the voltage between the ECM harness 30/54 and
connector terminal to ground. GND: 0V



Inspect the circuit from EGR temperature
sensor 2 to EMC if there is any broken wire or
short.
2. Remove the connector of the ECM and
the sensor.
and from ECM harness connector
terminal to ground.
• Between pins 30 and 54:∞Ω
• Between pins 30/54 and GND:∞Ω

Inspect the 5V power source of EGR gas
temperature sensor.
2. Remove the connector of the sensor.
3. “ON/OFF” the starter switch to measure
7 each voltage from the sensor harness —
connector signal terminal to ground.
Is the voltage value correct? Go to Step 8 Go to Step 14

Inspect the air piping.
1. Remove the air piping from EGR valve 2.
2. Operate the scan tool to activate the
magnetic valve. (Refer to the fault
diagnosis test mode magnetic valve
operation check from the scan tool's
“Scan Tool” display.)
8 Check if the air is supplied from the —
disconnected air piping.
Check the EGR valve 2 operation.
1. Remove the EGR valve 2. 637.4-
2. Send the compressed air of specified 882.6kPa
9
pressure value into the air port, to check if (4781-
the valve opens. 6620mmHg)
Does the EGR valve 1 operate normally? Go to Step 11 Go to Step 10
Replace the EGR valve 2.
10 —

Check the operation of the EGR gas
temperature sensor 2.
2. Turn the starter switch “ON” to start the
engine.
3. Warm up the engine until the engine
coolant temperature reaches 80?C.
4. Using the scan tool, turn the EGR
magnetic valve ON.
11 —
5. Raise the engine revs gradually, then
check if the EGR gas temperature rises
using the scan tool.
CAUTION:
EGR control is not performed when the
exhaust brake is activated.
Is the EGR gas temperature sensor 2

operating normally? Go to Step 14 Go to Step 12
Replace the EGR gas temperature sensor 2.
12 —
Recheck the DTC.
2. Clear the DTC.
3. Turn “OFF” the starter switch, then turn it
13 —
“ON” again after an interval or more than
4. Check the DTC.

1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
15 “ON” again after an interval or more than —
4. Check the DTC.

EGR Gas Temperature Sensor
LNW31ASH005601
Legend
1. GND
2. signal
Resistance value of EGR gas temperature sensor

Temperature (°C) Resistance
Characteristic (kΩ)
50 64.1-96.2
100 11.2-15.3
150 2.7-3.8
DTC P0518(Flash Code 518)
ROM Error Condition for Clearing the MIL/DTC
If an error occurs in the system and a DTC is recorded
Description by the ECM, the DTC will not be erased unless the
The Engine Control Module (ECM) includes the Central location of the fault is repaired, so follow the procedure
Processing Unit (CPU), memory (RAM, ROM) and below to erase it. DTCs may be checked during
CPU monitoring IC, etc. These devices are used to inspection and repairs, so record and clear the DTCs
store and delete data of all kinds and carry out control before beginning the inspection.
functions.
DTC Clearing method
Main Malfunction Conditions • Operate the accelerator pedal to clear the DTC
• Inadequate output (Refer to “Clearing DTCs by operating the
Condition for Setting the DTC Procedure” of this manual)
• Use the scan tool (Tech 2) to clear the DTCs.
When the ECM detects a malfunction in the ROM, a
“ROM Error” is diagnosed and “DTC P0518” is
Diagnostic Aids
displayed.
• Poor contact in the connector
Action Taken When the DTC Sets • Internal ECM error
• Lights the MIL (Check Engine lamp). • Check for bad connector contacts, errors due to
abrasion or bending of the harness and broken
wires in the harness causing shorts with other
circuits. Also, inspect the function diagnostics to
check the action and control of each component,
and make repairs if necessary.

Check the engine control module (ECM) Go to “Checking
power supply and GND circuit. Engine Control
2 — Module (ECM)
Was the action complete? Power Supply and
Go to Step 3 GND Circuits”
Check the attaching condition of the ECM
connector.
1. Virtually inspect the attaching condition of
connector if there is no looseness or
3 slackness. —
2. If any fault is detected, correct them as
necessary.

1. Replace the ECM.
IMPORTANT:


Recheck the DTC.
2. Clear the DTC.
5 —
4. Check the DTC.

DTC P0543(Flash Code 543)
Over Speed Condition Condition for Clearing the MIL/DTC
If an error occurs in the system and a DTC is recorded
Description by the ECM, the DTC will not be erased unless the
The Engine Control Module (ECM) uses the signal of location of the fault is repaired, so follow the procedure
the crank position (CKP) sensor to detect the engine below to erase it. DTCs may be checked during
speed. When engine speed exceeds the specified inspection and repairs, so record and clear the DTCs
value, the ECM stops the fuel injection to reduce the before beginning the inspection.
engine speed.
DTC Clearing method
Main Malfunction Conditions • Operate the accelerator pedal to clear the DTCs.
• Engine malfunction (seizure, breakage, etc.) (Refer to “Clearing DTCs by operating the
• There is no response to the movement of the
Procedure” of this manual)
accelerator pedal until the engine speed drops
below the specified level. • Use the scan tool (Tech 2) to clear the DTCs.
Condition for Setting the DTC Diagnostic Aids
When an engine speed above 2,450rpm (6WF1) / • Transmission, clutch malfunction (dropping out of
2700rpm(6WG1)is detected, “Over Speed Condition” is gear, clutch slippage, etc.)
diagnosed, and “DTC P0543” is displayed. • Crank position (CKP) sensor, camshaft position
(CMP) sensor malfunction (signal malfunction etc.)
Action Taken When the DTC Sets • When the driver made a gear change error.
• The ECM remembers only the DTC. MIL (Check • Malfunction of the engine itself.
Engine lamp) will not lit at this time. (Malfunction of the supply pump, injector or engine
• Display the DTC by using the scan tool. itself)
• The ECM shuts off power to the pump control • Internal ECM error
valve (PCV). • Check for bad connector contacts, errors due to
• The ECM engages exhaust braking. abrasion or bending of the harness and broken
wires in the harness causing shorts with other
circuits. Also, inspect the function diagnostics to
check the action and control of each component,
and make repairs if necessary.
• When this DTC is detected, check for a breakdown
of the engine itself (seizure, breakage etc.).

Check the driving status (whether there was
any driving error that might have caused
2 excessive engine speed). (Ask the driver —
about how the vehicle has been behaving)
Was there any driving error? Go to Step 3 Go to Step 4

Inform the driver that excess engine speed
was caused by driver’s error, and provide the
3 driver with instruction. —


Inspect if there is any affected part by the
excess engine speed (malfunction of the
4 engine itself), repair or replace parts when any —
affected parts are found.
Was there any fault? Go to Step 6 Go to Step 5
1. Replace the ECM.
IMPORTANT:

Recheck the DTC.
2. Clear the DTC.
6 —
4. Check the DTC.

Was any other DTC detected? DTC. Verify repair
Symptom List
Symptom Definition
Engine stall Engine cranks normal, but does not start for a long time. The
engine finally starts, or though it stars, it stops immediately.
Engine hunting, rough idle Engine idling is not stable, or the engine idling revolutions vary.
In serious cases, the engine or entire vehicle may shake. In
either case, if the condition gets worse, the engine might stall.
Lack of power, slugginess or hesitation Engine power is below the anticipated level, speed doesn't
increase even if the accelerator pedal is depressed, and
engine response is bad.
Excessive white smoke A lot of white smoke is observed during the actual road test.
Excessive black smoke A lot of black smoke is observed during the actual road test.
Idling revolutions cannot be adjusted Even when the switch is operated, the idling revolutions
cannot be adjusted.
Idling revolutions cannot be adjusted down Idling revolutions are far higher than the reference value.
Engine Stall
Preliminary Inspection • Exhaust system parts faults.
Before using this section, perform an “On-Board
Diagnosis (OBD) Systems Check”, then check all of the Diagnostic Aids
items shown below. • Fuel system faults (out of fuel, frozen fuel, air in the
• The engine control module (ECM) and MIL (Check fuel line, filter faults {main, gauze filter blockage},
Engine lamp) are operating correctly. line/pipe fault, fuel quality, fuel tank (dirt, fuel
suction fault etc.)
• Check the DTC.
• Air intake system faults (filter blockage, air line
• The scan tool (Tech 2) is within the normal
faults etc.)
operating range.
• Supply pump (including feed pump) fault (lack of
• Check the customer's complaint, and find
fuel feed pressure)
appropriate symptoms from the table of contents.
Carry out the procedures shown in the symptoms • Loose supply pump coupling bolt
chart. • Fuel rail fault (flow damper, pressure limiter
• Check with the customer that the specified operation /internal sealing capacity deterioration)
(correct) engine oil and fuel are being used. • Injector fault (doesn't inject fuel)
• System back up (fail safe), system down due to
Visual Inspection fault.
Some symptom diagnosis procedures need careful • Malfunction of the engine itself.
visual inspection. This visual inspection helps correct (Burning, lack of compression pressure, other
the problem with no further inspection, thus saving mechanical failures).
valuable time. • ACG fault
This visual inspection includes the following items.
• Chassis related faults
• Correct connection, loose attachments and broken (Clutch, transmission, brake etc.)
wires in the electrical wiring.
• Effect of newly installed electrical components
• Check that Commercial accessory power supply is (radio, lamps, etc.)
not using a branch of the ECM power supply.
• ECM faults
• Check the ECM earth is not dirty, and it is firmly (ECM main body, power supply, GND etc.)
attached in the correct location.
• Check for bad connector contacts, errors due to
• Pipes and hoses related to fuel, air and oil are not abrasion or bending of the harness and broken
cracked or twisted, and are connected correctly. wires in the harness causing shorts with other
Thoroughly check for any kind of block or leakage. circuits. Also, inspect the function diagnostics to
• Check that there is no fuel leakage, no dents or check the action and control of each component,
damage to the pipes of the fuel system. and make repairs if necessary.
• Air intake system parts faults.

Check the performance of the start-up
2 system. — Go to “Starting
Was the action complete? Go to Step 3 System Check”

Check if a DTC is being detected.
(DTC to stop the engine by the back up
system control)
2. Check if following DTCs are being
3 —
detected.
DTC P0014, P0015, P0033, P0035,
P0051, P0072, P0118, P0158, P0159,
P0227
Go to applicable
Any DTCs detected? DTC Go to Step 4
Use the scan tool to check the signal status of
the CKP and CMP sensors.
4 2. Crank the engine. —
3. Check the scan tool’s data display. Inspect and repair
the CKP and CMP
Are the revolutions displayed? Go to Step 5 sensors
Start the engine to check if the engine stalls
5 again. —
Inspect the ACG.
Check if the charge-warning lamp in the meter
6 is lit while the engine is running. —
Is the charge-warning lamp off? Go to Step 8 Go to Step 7

Replace the ACG. In addition, inspect the
charger warning lamp system, and repair or
7 replace the faulty part if any fault is found. —

Check the condition of newly installed
electrical components, such as radio and
8 lamps. —
Does the engine still stall when newly installed
electrical components is switched OFF ? Go to Step 9 Go to Step 10
Either re-install the electrical components
9 correctly, or remove them entirely. —
10 again. —
1. Replace the ECM.
IMPORTANT:


12 again. —
1. Check the mechanical parts of the
engine, and repair if any faults are found.
• Valve system
• Injector
13 • Compression Pressure —
• Timing Gear
• Piston/Crank, etc. related

14 again. —
Inspect chassis related parts (clutch,
transmission etc. faults), and repair any faulty
15 or damaged parts. —

After repairing the vehicle, verify the repairs.
16 —
Was the action complete? Verify repair —
Engine hunting, rough idle
Preliminary Inspection • Air intake system parts faults.
Before using this section, perform an “On-Board • Exhaust system parts faults.
Diagnosis (OBD) Systems Check”, then check all of the
items shown below. Diagnostic Aids
• The engine control module (ECM) and MIL (Check • Fuel system faults (out of fuel, frozen fuel, air in the
Engine lamp) are operating correctly. fuel line, filter faults {main, gauze filter blockage},
• Check the DTC. line/pipe fault, fuel quality, fuel tank (dirt, fuel
suction fault etc.)
operating range. • Air intake system faults (filter blockage, air line
faults etc.)
appropriate symptoms from the table of contents. • Supply pump (including feed pump) fault (luck of
Carry out the procedures shown in the symptoms fuel feed pressure)
chart. • Switches input circuit system fault (PTO switch,
• Check with the customer that the specified clutch switch, harness, etc.)
(correct) engine oil and fuel are being used. • Sensor input circuit fault (sensor, harness, etc.)
• Accelerator pedal position sensor, PTO remote
Visual Inspection throttle sensor system faults (sensor, harness,
Some symptom diagnosis procedures need careful etc.)
visual inspection. This visual inspection helps correct • System back up (fail safe), due to fault.
the problem with no further inspection, thus saving • Malfunction of the engine itself (Burning, lack of
valuable time. compression pressure, other mechanical failures).
• Chassis related parts (clutch, transmission, brake)
• Correct connection, loose attachments and broken faults
• Check that Commercial accessory power supply is (radio, lamps, etc.)
• ECM faults (ECM main body, power supply, GND
• Check the ECM earth is not dirty, and it is firmly etc.)
attached in the correct location.
• Pipes and hoses related to fuel, air and oil are not abrasion or bending of the harness and broken
cracked or twisted, and are connected correctly. wires in the harness causing shorts with other
Thoroughly check for any kind of block or leakage. circuits. Also, inspect the function diagnostics to
• Check that there is no fuel leakage, no dents or check the action and control of each component,
damage to the pipes of the fuel system. and make repairs if necessary.

Check the fuel.
1. Replace the fuel inside the fuel tank and
fuel lines.
2 2. Start the engine and drive the vehicle to —
check if the same symptom is still
observed.
Does the engine operate normally? Go to Step 22 Go to Step 3

Bleed air from the fuel lines and check again
3 to see if the same symptom is still observed. —
Does the engine operate normal? Go to Step 22 Go to Step 4

Check the performance of the air intake
system. Go to “Checking
4 — the Air Intake
Was the action complete? Go to Step 5 System”
Check the performance of the fuel system.
Was the action complete? Go to Step 6 the Fuel System”
Check the symptom of the engine again.
6 —
7 lamps. —
Inspect the installed condition of the CKP
9 sensor and CMP sensor. —
Are they correctly installed? Go to Step 11 Go to Step 10
Correct the installed condition of the CKP
10 sensor and CMP sensor. —
Inspect the signal detection condition of the
CKP sensor.
2. Remove the harness from the CKP
11 sensor. —
(Always clear the DTC after repairing the
vehicle, since the DTC will be activated
when this action is performed.)
Is the idling condition normal? Go to Step 16 Go to Step 12

Use the scan tool to check the signal status of
the CKP and CMP sensors.
12 2. Crank the engine. —
3. Check the scan tool’s data display. Inspect and repair
the CKP and CMP
Are the revolutions displayed? Go to Step 13 sensors
Inspect the flywheel section and CKP sensor
section. If there is rust or dirt on these
13 sections, repair or replace the affected parts. —


Inspect the signal detection condition of the
CMP sensor.
2. Remove the harness from the CMP
14 sensor. —
(Always clear the DTC after repairing the
vehicle, since the DTC will be activated
when this action is performed.)
Is the idling condition normal? Go to Step 16 Go to Step 15

Inspect the supply pump section and CMP
sensor section, and repair or replace any
15 faulty parts found. —

16 —
Inspect the condition of the accelerator pedal
position sensor and the PTO remote throttle
17 sensor. —
Refer to DTC P0024 and perform inspections.

Refer to DTC P0271-P0278 (Injector), DTC
P0115, P0118, P0151, P0226, P0227, P0245
(diagnosis of fuel rail, supply pump systems)
18 and perform inspections. —
If any fault is detected, repair or replace the
affected parts.

19 —
1. Replace the ECM.
IMPORTANT:

• Valve system
• Injector
• Timing Gear


22 —
Lack of power, slugginess or hesitation
Preliminary Inspection • Air intake system parts faults.
Before using this section, perform an “On-Board • Exhaust system parts faults.
Diagnosis (OBD) Systems Check”, then check all of the
items shown below. Diagnostic Aids
• The engine control module (ECM) and MIL (Check • Fuel system faults (out of fuel, frozen fuel, air in the
Engine lamp) are operating correctly. fuel line, filter faults {main, gauze filter blockage},
• Check the DTC. line/pipe fault, fuel quality, fuel tank (dirt, fuel
suction fault etc.)
operating range. • Air intake system faults (filter blockage, air line
faults etc.)
appropriate symptoms from the table of contents. • Exhaust gas system fault (exhaust brake, exhaust
Carry out the procedures shown in the symptoms pipe fault)
chart. • Sensor input circuit fault (sensor, harness, etc.)
• Check with the customer that the specified • Switches input circuit system fault (PTO switch,
(correct) engine oil and fuel are being used. clutch switch, harness, etc.)
• Main engine faults (compression pressure, valve
Visual Inspection clearance, turbo charger, supply pump, injector,
Some symptom diagnosis procedures need careful fuel rail, and other mechanical faults)
visual inspection. This visual inspection helps correct • System back up (fail safe), due to fault.
the problem with no further inspection, thus saving • Chassis related parts (clutch, transmission, brake)
valuable time. faults
• Correct connection, loose attachments and broken (radio, lamps, etc.)
• ECM faults (ECM main body, power supply, GND
• Check that Commercial accessory power supply is etc.)
• Check the ECM earth is not dirty, and it is firmly abrasion or bending of the harness and broken
attached in the correct location. wires in the harness causing shorts with other
• Pipes and hoses related to fuel, air and oil are not circuits. Also, inspect the function diagnostics to
cracked or twisted, and are connected correctly. check the action and control of each component,
Thoroughly check for any kind of block or leakage. and make repairs if necessary.
• Check that there is no fuel leakage, no dents or
damage to the pipes of the fuel system.

Check the fuel.
fuel lines.
observed.
Bleed air from the fuel lines and check again
3 to see if the same symptom is still observed. —

Check the performance of the exhaust
5 — the Exhaust
7 —
Inspect the accelerator pedal full position.
Switch the starter switch to the “OFF” position,
and fully depress the accelerator pedal.
Check that the clearance between the pedal Clearance: 1-
8
and floor stopper bolt is correct. 2mm
Was the clearance between the pedal and

floor stopper bolt correct? Go to Step 10 Go to Step 9
Adjust the floor stopper bolt.
9 —
position sensor.
10 Refer to DTC P0024 and perform inspections. —

11 lamps. —
Inspect the vehicle speed sensor.
13 Refer to DTC P0025 and perform inspections. —
Check the condition of PTO and boost sensor.
Refer to DTC P0032 and function inspection
14 “PTO check” to perform inspection. —

15 —

P0115, P0118, P0151, P0226, P0227, P0245
affected parts.

17 —
1. Replace the ECM.
IMPORTANT:

19 —
• Valve system
• Injector
• Timing Gear

Inspect chassis related parts (clutch,
transmission etc. faults), and repair any faulty
21 or damaged parts. —

22 —
23 —
Excessive white smoke
Preliminary Inspection • Commercial accessory power module is not used
Before using this section, perform an “On-Board from branch of the Engine Control Module (ECM)
Diagnosis (OBD) Systems Check”, then check all of the power supply.
items shown below. • Check that Check the ECM earth is not dirty, and it
• ECM and MIL (Check Engine lamp) are operating is firmly attached in the correct location.
correctly. • Pipes and hoses related to fuel, air and oil are not
• Check the DTC. cracked or twisted, and are connected correctly.
Thoroughly check for any kind of block or leakage.
operating range. • Check that there is no fuel leakage, no dents or
damage to the pipes of the fuel system.
appropriate symptoms from the table of contents. • Air intake system parts faults.
Carry out the procedures shown in the symptoms • Exhaust system parts faults.
chart.
• Check with the customer that the specified Diagnostic Aids
(correct) engine oil and fuel are being used. • Fuel quality (product other than the specified
product is used, etc.)
Visual Inspection • Air mixed in fuel system
Some symptom diagnosis procedures need careful • Engine coolant temperature sensor, fuel
visual inspection. This visual inspection helps correct temperature sensor, intake air temperature sensor,
the problem with no further inspection, thus saving boost sensor faults
valuable time. • Main engine faults (lack of compression pressure,
This visual inspection includes the following items. piston related, turbo charger, oil rise/drop, etc.)
• Correct connection, loose attachments and broken • ECM faults (ECM main body, power supply, GND
wires in the electrical wiring. etc.)

Check the fuel.
fuel lines.
observed.

1. Check the fuel injection timing.
Inspect the mechanical timing on both the
supply pump and crank pulley.
Adjust the mechanical timing if a fault is
discovered.
3 • Supply pump (coupling): —
Matching of inscribed line with the
pointer


Inspect each sensor, injector, etc.
Refer to DTC P0022, P0023, P0035, P0158,
P0159, P0211　, to perform inspection, and
5 repair or replace the affected parts where —
faults are found.
Inspect the boost sensor and atmospheric
pressure sensor.
Refer to DTC P0032, P0071 to inspect the
6 parts, and repair or replace the affected parts —
where faults are found.

7 —
1. Replace the ECM.
IMPORTANT:

9 —
• Valve system
• Injector
• Timing Gear

11 —
Excessive black smoke
Preliminary Inspection • Check the ECM earth is not dirty, and it is firmly
Before using this section, perform an “On-Board attached in the correct location.
Diagnosis (OBD) Systems Check”, then check all of the • Pipes and hoses related to fuel, air and oil are not
items shown below. cracked or twisted, and are connected correctly.
• The engine control module (ECM) and MIL (Check Thoroughly check for any kind of block or leakage.
Engine lamp) are operating correctly. • Check that there is no fuel leakage, no dents or
• Check the DTC. damage to the pipes of the fuel system.
• The scan tool (Tech 2) is within the normal • Air intake system parts faults.
operating range. • Exhaust system parts faults.
appropriate symptoms from the table of contents. Diagnostic Aids
Carry out the procedures shown in the symptoms • Fuel quality (product other than the specified
chart. product is used, etc.)
• Check with the customer that the specified • Air mixed in fuel system
(correct) engine oil and fuel are being used. • Air intake system faults (filter blockage, air line
faults etc.)
Visual Inspection
• Exhaust gas system fault (exhaust brake, exhaust
Some symptom diagnosis procedures need careful pipe fault)
visual inspection. This visual inspection helps correct • Engine coolant temperature (ECT) sensor fault
the problem with no further inspection, thus saving
valuable time. • Boost sensor fault (sensor, lines etc.)
This visual inspection includes the following items. • Engine oil aging
• Correct connection, loose attachments and broken • Main engine faults (lack of compression pressure,
wires in the electrical wiring. piston related, turbo charger, oil rise, etc.)
• Check that Commercial accessory power supply is • ECM faults (ECM main body, power supply, GND
not using a branch of the ECM power supply. etc.)

Check the engine oil.
1. Replace the engine oil and oil filter.
2. Start the engine and drive the vehicle to
3 —
observed.

1. Check the fuel injection timing.
Inspect the mechanical timing on both the
supply pump and crank pulley.
Adjust the mechanical timing if a fault is
discovered.
4 • Supply pump (coupling): —
Matching of inscribed line with the
pointer


5 —
Check the performance of the exhaust
7 — the Exhaust
8 —
Inspect the boost sensor, atmospheric
pressure sensor, and engine coolant
temperature (ECT) sensor.
9 Refer to DTC P0023, P0032, P0071 to inspect —
the parts, and repair or replace the affected
parts where faults are found.

P0115, P0118, P0151, P0226, P0227, P0245
affected parts.

11 —
Check the mechanical parts of the engine,
and repair if any faults are found.
12 Valve system (valve clearance) —

13 —
1. Replace the ECM.
IMPORTANT:

15 —

• Valve system
• Injector
• Timing Gear

17 —
Idling revolutions cannot be adjusted
Preliminary Inspection • Correct connection, loose attachments and broken
Before using this section, perform an “On-Board wires in the electrical wiring.
Diagnosis (OBD) Systems Check”, then check all of the • Check that Commercial accessory power supply is
items shown below. not using a branch of the ECM power supply.
• The engine control module (ECM) and MIL (Check • Check the ECM earth is not dirty, and it is firmly
Engine lamp) are operating correctly. attached in the correct location.
• Check the DTC.
Diagnostic Aids
operating range. • Idling control switch operation, switch position
• Check the customer's complaint, and find • Idling control switch (UP/DOWN) fault
appropriate symptoms from the table of contents. • Idling control switching circuit fault
Carry out the procedures shown in the symptoms • Switch input circuit fault (idling control switch,
chart. idling control switching switch, etc.)
• Check with the customer that the specified • Sensor input circuit fault (sensor, harness, etc.)
(correct) engine oil and fuel are being used.
• Neutral position switch fault
Visual Inspection • Vehicle speed sensor fault
Some symptom diagnosis procedures need careful • ECM faults (ECM main body, power supply, GND
visual inspection. This visual inspection helps correct etc.)
valuable time.

Adjust the idling revolutions by switching the
idling control switch to [MANU] (pressing the
2 “UP” or “DOWN” side). —
Was idling revolutions adjusted? Go to Step 7 Go to Step 3

Inspect the idling control switch and idling
control switching switch.
2. Shift the gear position to neutral.
3. Turn “ON” the starter switch.
4. Display engine data on scan tool.
5. Operate each switch.
6. Check whether the scan tool screen
display (ON, OFF) changes when the
3 —
switch is operated.
• Idle up switch (idling control switch)
• Idle down switch (idling control
switch)
• Idling control switching switch
If the switch input display (ON, OFF) does
not change, perform repairs/replacement
of the faulty switch/ circuit.


position sensor and accelerator switch.
Refer to DTC P0023, P0024 and repair or
4 replace the affected parts if any faults are —
found.
Adjust the idling revolutions one more time.
5 —
Was Idling revolutions adjusted? Go to Step 7 Go to Step 6
1. Replace the ECM.
IMPORTANT:

7 —
8 —
Idling revolutions cannot be adjusted down
Preliminary Inspection • Correct connection, loose attachments and broken
Before using this section, perform an “On-Board wires in the electrical wiring.
Diagnosis (OBD) Systems Check”, then check all of the • Check that Commercial accessory power supply is
items shown below. not using a branch of the ECM power supply.
• The engine control module (ECM) and MIL (Check • Check the ECM earth is not dirty, and it is firmly
Engine lamp) are operating correctly. attached in the correct location.
• Check the DTC.
Diagnostic Aids
operating range. • Idling control switch operation, switch position
• Check the customer's complaint, and find • Idling control switch (UP/DOWN) fault
appropriate symptoms from the table of contents. • Idling control switching circuit fault
Carry out the procedures shown in the symptoms • Switch input circuit fault (idling control switch,
chart. idling control switching switch, etc.)
• Check with the customer that the specified • Sensor input circuit fault (sensor, harness, etc.)
(correct) engine oil and fuel are being used.
• PTO faults
Visual Inspection • ECM faults (ECM main body, power supply, GND
etc.)
Some symptom diagnosis procedures need careful
visual inspection. This visual inspection helps correct • Injector faults
valuable time.

Adjust the idling revolutions by switching the
idling control switch to [MANU] (pressing the
2 “UP” or “DOWN” side). —

Inspect the idling control switch and idling
control switching switch.
2. Shift the gear position to neutral.
3. Turn “ON” the starter switch.
4. Display engine data on scan tool.
5. Operate each switch.
6. Check whether the scan tool screen
display (ON, OFF) changes when the
3 switch is operated. —
• Idle up switch (idling control switch)
• Idle down switch (idling control
switch)
• Idling control switching switch
If the switch input display (ON, OFF) does
not change, inspect the switch/ circuit and
repair/replace affected parts when any
faults is found.


Check the PTO.
Was the action complete? Go to Step 5 the PTO”
5 —
Idling revolutions adjusted? Go to Step 12 Go to Step 6
Inspect the engine coolant temperature
sensor.
Refer to DTC P0023 to inspect the parts, and
6 repair or replace the affected parts where —
faults are found.

Check the operation of injector.
3. Using the scan tool, perform test on the
injector.
• If the fuel injection from the injector is
insufficient (stopped):
Use the “Each injector injection stop”
test to stop the injector in each
cylinder one by one. It is normal for
7 —
the engine sound to change when a
cylinder is stopped.
• If there is too much fuel injected from
the injector:
Use the “Each injector injection stop”
test to stop the injector in each
cylinder one by one. It is normal for
the engine sound to change when a
cylinder is stopped.
Are the injectors operating normally? Go to Step 9 Go to Step 8

1. Replace the faulty injectors.
IMPORTANT:
8 After replacing the injector, carry out —
programming for the injector ID code.

9 —
1. Replace the ECM.
IMPORTANT:

11 —

12 —
Special tool
Illustration Tool Number/ Description
5-8840-2691-0
Digital multi-meter
Tech2
Scan tool
5-8840-0632-0
Terminal remover
5-8840-0388-0
Weather pack terminal
remover
Programming
Explanation of Functions and Operations • Injector ID code
It is necessary to enter (programming) all data into the
Items When Programming is Required
engine control module (ECM) when the ECM, injector,
and other such parts are replaced. Programming is required when the items below is
replaced.
Prior Check Points When Programming • ECM
When performing programming, check the following • Engine (type, power output range modification)
items as required prior to starting the procedure. • Injector
• Engine type
Each Item
Item Intended use

F0 Q F0 Upload Q Adjustment Used when replacing the ECM, when data is read into the
adjustment Correction Data (Tech 2) Tech2 from the ECM before replacement.
compensat
F1 Download Q adjustment Used when replacing the ECM, when data is registered
ion
compensation data (written) into the ECM from the Tech2 after replacement.
(ECM)
F2 Service Mode Used when replacing the ECM. When data cannot be read from
the ECM before replacement, this is used to write Q adjustment
correction data to the ECM.
F1 Injector ID F0 Injector ID Code Used when checking the injector ID codes of each cylinder.
Code
F1 ID Code Registration Used when replacing the ECM. Used when data cannot be
uploaded from the ECM before replacement, or when
registering the injector ID code when replacing injectors.
F2 Upload ID Code (Tech2) Used when replacing the ECM, when data is read into the
Tech2 from the ECM before replacement.
F3 Download ID Code Used when replacing the ECM, when data is registered
(ECM) (written) into the ECM from the Tech2 after replacement.
F4 History Information Used when viewing the data write history.
Programming Preparations
1. Turn OFF the starter switch.
2. Check that vehicle repairs/replacements are all
completed.
3. Check the vehicle's specifications.
4. Connect the Tech2 adapter to the DLC.
Tech 2
Instrument Panel
Lower Harness
1
3 4
2
5
6 Main Menu
F0: Diagnostics
HCW61ASH004501 F1: Service Programming System (SPS)
F2: View Capture Data

Legend
F3: Tool Options
1. Diagnostics connector (brown)
F4: Download / Upload Help
2. Memory clear connector (white)
3. Diagnostics common connector (green)
HCW46EMH000101
5. Connect the Tech2 to Tech 2 adapter.
3. Use the UP/DOWN arrow keys to select Menu “(4)
6. Shift the selector switch of Tech2 adapter to “2”.
2004”, and press the [ENTER] key.
7. Turn ON the starter switch.
4. Use the UP/DOWN arrow keys to select Menu
8. Refer to the “Performing Fault Diagnosis with the “(C*,E*,L*,F*) Heavy, Medium Duty”, and press the
Scan Tool” in this chapter, and display the menu [ENTER] key.
screen.
Programming
Injector ID Code Registration
1. Press the [ENTER] key.
2. Use the UP/DOWN arrow keys or the F0 (function)
key to select Menu “F0: Diagnostic”, and press the
[ENTER] key.
Diagnostic
Select One Of The Following (C*,E*,L*,F*) Heavy,Medium
Model Year (s)
( ) 20
F0: Engine
F1: Transmission
F2: Chassis
F3: Body
Vehicle Identification Select One Of The Following

Engine
Select One Of The Following
Vehicle Type (s)
6WF1-TC (C/Rail)
(UE)Rodeo/Amigo, Wizard/Mu 6WG1-TC (C/Rail)
(UP)Axiom 6UZ1-TC (C/Rail)
(TF/UC) LUV, Rodeo/Frontier,LAO
(N*)ELF, NPR, NQR, VFR
(C*,E*,L*,F*) Heavy, Medium Duty
HCW6Z0MH000101 HCW6Z0MH000201
5. Use the UP/DOWN arrow keys or the F0 (function) 7. Press [Confirm] on the soft key pad.
key to select Menu “F0: Engine”, and press the At this point, check that the ignition (key position)
[ENTER] key. is “ON”.
6. Use the UP/DOWN arrow keys to select “6WF1 8. Press [Confirm] on the soft key pad.
(Common Rail)”, and press the [ENTER] key. Here, the ECM ID information is displayed.
Engine Engine
F0: Diagnostic Trouble Codes

Turn On Ignition ! F1: Data Display
F2: Snapshot
F3: Actuator Test
F4: Programming
Confirm
Engine Programming
Partnumber XXXXXXXXXX
F0: Fuel Delivery Rate
Hardware Number XXXXXXXXXX
F1: Injector ID Code
Software Version XXXXXXXX
DDI XXXX
Confirm
HCW6Z0MH000301 HCW46EMH000501
9. Use the UP/DOWN arrow keys or the F4 (function) 11. Use the UP/DOWN arrow keys or the F1 (function)
key to select Menu “F4: Programming”, and press key to select Menu “F1: ID Code Registration”, and
the [ENTER] key. press the [ENTER] key.
10. Use the UP/DOWN arrow keys or the F1 (function) 12. When the following screen is displayed, check that
key to select Menu “F1: Injector ID Code”, and the engine is stopped, and press [Confirm] on the
press the [ENTER] key. soft key pad.
ID Code Registration ID Code Registration

Please Select Cylinder.
F1: ID Code Registration
Cylinder 1
F2: Upload ID Code
Cylinder 2
F3: Download ID Code Cylinder 3
F4: History Information Cylinder 4
Cylinder 5
Cylinder 6
(C*,E*,L*,F*) Heavy, Medium Duty (C*,E*,L*,F*) Heavy, Medium Duty

6WF1 (Common Rail)
Current Cylinder ID Code
Check Vehicle Condition !

"************************"
Functions Only During Engine Stop !
Confirm Change
13. Select the cylinder (No.1 Cylinder~No.6 Cylinder) 15. When the input is finished up to the ID code input
that you wish to carry out ID code registration for data byte [MC-D9], press the [ENTER] key.
using the UP/DOWN keys, and press the [ENTER] (The model code (MC) and BCC code (BC) are
key. automatically registered (written) by the Tech2,
(The following explanation shows the procedure therefore it is not necessary to input them.)
when No.1 Cylinder is selected)
14. When the currently registered ID code is
displayed, press [Change] on the soft key pad. 1
5A52 701E
35DD 2157
001F 5A00
0000 BD
HVW4ADSH000101
Legend
1. ID code
2. Injector
Use up/down arrow keys to change value. Use up/down arrow keys to change value.
Use left/right arrow keys to select field. Use left/right arrow keys ti select field.
Input ID Code Byte [MC-D9]
MCD0 D1D2 D3D4 D5D6 D7D8 D9 BC

Input ID Code Byte[MC-D9]
MCD0 D1D2 D3D4 D5D6 D7D8 D9 BC 5A01-2345-6789-ABCD-EF01-23**-****-**
Program Stop
5A01-2345-6789-ABCD-EF01-23**-****-**
Press ENTER key to continue
ID Code Registration
5A01-2345-6789-ABCD-EF01-23**-****-**
Input Place
(Auto)
Data Invalid- Please perform once again!
Model Code
Input ID Code Byte [MC-D9]
5A01-2345-6789-ABCD-EF01-23**-****-**
Press ENTER key to continue
16. When the following screen is displayed, check that 18. If the inputted numerical values are correct, the
there is no mistake in the inputted ID code, and data registration from the Tech2 to the ECM will be
press [Program] on the soft key pad. displayed.
If you wish to cancel programming (registration), 19. If the inputted ID code and ID code registered in
press [Stop] on the soft key pad or the [EXIT] key, the ECM match, a message that states
and the screen will return to procedure 11. “Programming Completed!” will be displayed.
17. If the inputted numerical values are not correct, a If you wish to continue registering ID codes, press
message that states “Data Invalid–Please perform [Yes] on the soft key pad, the screen will return to
once again!” will be displayed. Press the [ENTER] procedure 4, and you can continue registering ID
key and re-enter the values. codes in the same way.
Pressing [No] on the soft key pad will return the
screen to procedure 2.
2. Press [Yes] on the soft key pad to upload. Pressing
[No] on the soft key pad will return the screen to
procedure 2.
Upload ID Code
Programming!

0 % 100
F2: Upload ID Code
F3: Download ID Code
F4: History Information
Upload ID Code

Programming Completed!
Is registaration of the ID code repeated?
Do you really want to upload data?

No Yes
No Yes
HCW6Z0MH000801
20. If the inputted ID code and ID code registered in

the ECM do not match, a message that states
“Programming Failed!” will be displayed. Press
HCW6Z0MH000901
[End] on the soft key pad, and the screen will 3. When the upload has completed, a message
return to procedure 11. Register the ID code again. stating “Upload Completed!” will be displayed.
Pressing [Confirm] on the soft key pad will return
the screen to procedure 1.
4. If the upload fails, a message stating “Upload
Failed!” will be displayed. Press [Confirm] on the
soft key pad and the screen will return to
(C*,E*,L*,F*) Heavy, Medium Duty procedure 1. Retry the upload procedure.
Programming Failed!
End
HCW6Z0SH000101
Injector ID Code Upload (Tech2)

key to select Menu “F2: Upload ID Code”, and
press the [ENTER] key.
Upload ID Code Download ID Code

Upload Completed!
F2: Upload ID Code
F3: Download ID Code
F4: History Information
Confirm
Upload ID Code Download ID Code
Upload Failed! Check Vehicle Condition!
Functions Only During Engine Stop!
Confirm Confirm
3. Press [Yes] on the soft key pad, and the uploaded

ID Code Download (ECM) ID code (No.1 cylinder-No.6 cylinder) will be
1. Use the UP/DOWN arrow keys or the F3 (function) downloaded (registered) to the ECM.
key to select Menu “F3: Download ID Code”, and Pressing [No] on the soft key pad will return the
press the [ENTER] key. screen to procedure 1.
2. When the following screen is displayed, check that
the engine is stopped, and press [Confirm] on the
soft key pad.
Download ID Code
Do you really want to download data?
No Yes
HCW6Z0SH000201
4. The registration to the ECM will start in order from
No.1 cylinder.
If the download was performed successfully, the
screen switches to the following screen after the
No.6 cylinder registration screen is displayed. Download ID Code
If the download is not successfully performed, (C*,E*,L*,F*) Heavy, Medium Duty
each registration from No.1 cylinder to No.6

cylinder will be repeated 3 times, and the screen
will switch to the following screen.
Programming Failed!
Confirm
Download ID Code
Cylinder 1(INJ.# )
Programming! HCW6Z0SH000501
0 % 100
Q Adjustment Correction Data Upload (Tech2)
key to select Menu “F0: Fuel Delivery Rate” and
press the [ENTER] key.
key to select Menu “F0: Upload Fuel Delivery Rate
HCW6Z0SH000301
Data”, and press the [ENTER] key.
5. If the download is performed successfully, the

message stating “Programming Completed!” will
be displayed. Pressing [Confirm] on the soft key Programming
pad will return the screen to procedure 1.

Download ID Code
Fuel Delivery Rate
Confirm
F0: Upload Fuel Delivery Rate Data

F1: Download Fuel Delivery Rate Data
F2: Service Mode
HCW6Z0SH000401
6. If the download fails, a message stating

[Confirm] on the soft key pad and the screen will
return to procedure 1. Retry the download
HCW46EMH001401
procedure.
3. Press [Yes] on the soft key pad to upload. Pressing
[No] on the soft key pad will return the screen to
procedure 2.
4. When the upload has completed, a message Q Adjustment Correction Data Download (ECM)
stating “Upload Successful!” will be displayed. 1. Use the UP/DOWN arrow keys or the F0 (function)
Pressing [Confirm] on the soft key pad will return key to select Menu “F0: Fuel Delivery Rate”, and
the screen to procedure 2. press the [ENTER] key.
key to select Menu “F1: Download Fuel Delivery
Upload Fuel Delivery Rate Data Rate Data”, and press the [ENTER] key.
Programming
Do you really want to upload data?

No Yes
Upload Fuel Delivery Rate Data
Fuel Delivery Rate

Upload Successful!
F0: Upload Fuel Delivery Rate Data

F1: Download Fuel Delivery Rate
Confirm
F2: Service Mode
HCW6Z0MH001201
5. If the upload fails, a message stating “Upload

Failed!” will be displayed. Press [Confirm] on the
soft key pad and the screen will return to HCW46EMH001601
procedure 2. Retry the upload procedure.
3. Press [Yes] on the soft key pad to download.
Pressing [No] on the soft key pad will return the
screen to procedure 2.
4. When the download has completed, a message
stating “Programming Completed!” will be
Upload Fuel Delivery Rate Data
displayed. Pressing [Confirm] on the soft key pad
will return the screen to procedure 2.
Upload Failed!
Confirm
HCW6Z0SH000601
Download Fuel Delivery Rate Data
Do you really want to download data?
No Yes
Confirm
HCW6Z0MH001301
5. If the download fails, a message stating

[Confirm] on the soft key pad and the screen will
return to procedure 2. Retry the download
procedure.
6WF1 (Common Rail)
Programming Failed!
Confirm
HCW46ESH002801
Special tool
Illustration Tool Number/ Description
Tech2
Scan tool
6WFGCEDG2-WE-0661
You are requested to order this manual using the

manual number that is shown above.
This manual is applicable for vehicles in all

countries except the USA and Canada.
All rights reserved. This manual may not be

reproduced in whole or in part, without the
permission in writing of ISUZU MOTORS LIMITED.
Issued by
ISUZU MOTORS LIMITED
INTERNATIONAL SERVICE DEPARTMENT
Tokyo, Japan
First edition Apr. 2006 6604-01K

No. 6WFGCEDG2-WE-0661 PRINTED IN JAPAN

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WORKSHOP MANUAL

ENGINE CONTROL SYSTEM

Before using this Workshop Manual to assist you in performing

All material contained in this Manual is based on latest product

This Manual is applicable to 2006 year model vehicles.

SECTION No. CONTENTS

Engine Control System

Abbreviati Name Meaning, notes

Abbreviati Name Meaning, notes

Symbols Colors Symbols Colors

Explanation of Functions and Operations Electronic Control Fuel Injection System

Injection Volume Control

Atmospheric temperature sensor

Sensor signals Engine control unit

from switches, etc. (ECU)

Atmospheric pressure sensor

Starter motor Fuel rail

Flywheel Feed pump Pre-fuel filter

Engine Control Module

Accelerator pedal position sensor input

Boost pressure sensor input

Compensation Engine coolant temperature sensor input,

Common rail pressure sensor

TWV(Two Way Valve)

Variable Geometry Turbo System (VGS)

Detection VGS steps C

Magnetic Valve control Circuit

Pressurizes Air Atmospheric Open

Idling Control AUTO … Auto mode

Fuel injection characteristic switching

Engine ECM VSS C/U

Fuel Injection Control

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

Cruise control cancel

Downward slope Downward slope Flat way

Exhaust brake and retarder Exhaust brake operates.

Engine control Exhaust brake and

Vehicle speed signal (25pulse)

Vehicle speed sensor

CAN (Controller Area Network) Communications

ABS/ASR EBS Meter MIMAMORI

Communications Methods • EBS control unit: Tractor

Engine Control Module (ECM)

APP Fuel Cut Signal

Fuel Cut Signal

Stop Lamp Switch 2

Cruise Main Switch

Cruise Release Switch 2

Vehicle Speed Sensor Exhaust Retarder

Engine Coolant Signal CAN

Engine Speed Output to the Tachometer

Idle position signal output to the exhaust brake and

Explanation of ECM Voltage

The supply pump uses the rotary force of the ending to

PCV (Pump Control Valve)

The fuel pressure sensor is attached to the fuel rail and

The atmospheric pressure sensor is mounted inside

MFW4ADSH000901 Accelerator Pedal Position (APP) Switch

The boost sensor is connected to the intake duct of the

The Accelerator Pedal Position (APP) switch is

The PTO remote throttle sensor is attached outside the

Diagnostics Connector, Data Link Connector (DLC)

DLC (Data Link Connector)

Engine Component Layout Diagram