1 Removed

Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-37
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
1A-38 Engine Control System (6WF1-TC,6WG1-TC(Common Rail))
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
Cruise Release Switch 2 140

94( 2)
(Exhaust Brake Switch) 141
Engine Control Module (ECM)
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
Cruise Release Switch 2 140

94( 2)
(Exhaust Brake Switch) 141
Engine Control Module (ECM)
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.
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
3. VGS magnetic valve 3
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.

Fuel pressure sensor
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.

Fuel pressure sensor
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
Press (ENTER) To Continue
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)
4. Data link connector (DLC), 20 terminals
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.
Vehicle Identification
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
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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Engine Control System (6WF1-TC,6WG1-TC(Common Rail)) 1A-37

Starter Switch Engine Control Module (ECM)

VGS Fail Safe Relay

Accelerator Switch Signal Output

Back Lamp switch

Cruise Resume Switch

Cruise Set Switch

Exhaust Brake Switch EGR Fail Safe Relay

Idling MANU/AUTO Switch

Idling Down Switch

Cruise Release Switch 2 140

Engine Control Module (ECM)

Starter Switch Engine Control Module (ECM)

VGS Fail Safe Relay

Accelerator Switch Signal Output

Back Lamp switch

Cruise Resume Switch

Cruise Set Switch

Exhaust Brake Switch EGR Fail Safe Relay

Idling MANU/AUTO Switch

Idling Down Switch

Cruise Release Switch 2 140

Engine Control Module (ECM)

167 162 136 129 101 97 69 62 34 28

FUSE10 FU55 0.5B/R

EXCEPT A/T MODEL

ENGINE CONTROL MODULE (ECM)

CONTROL UNIT 22 20 FL656 2 1

J/C:EXHAUST BRAKE SWITCH

FL20(1) STOPLIGHT SWITCH 0.3G 0.3G

FL9(20)COMBINATION SWITCH 0.5L/W J/C:RETARDER

AUTO CRUISE CONTROL ONLY

FL531(6) CAN H 0.5L/W

FL661(3) ENGINE STOP

ENGINE STOP ONLY

TACHO OUT (4P)

ENGINE CONTROL MODULE (ECM)

E72 E71 E72 FL558 FL557 FL558 FL557

COOLANT OUTSIDE ACCELERATION

AUTO CRUISE MAIN

AUTO CRUISE SET

6 OVER HEAT 15 14 0.5V/W

FL559 0.5L/R FL9

FL559 0.5V/R FL9

FL559 0.5V/G FL10

ENGINE CONTROL MODULE (ECM)

AUTO CLUTCH & FL657

ENGINE CONTROL MODULE(ECM)

33 54 30 34 128 126 134 23

H162 0.5L/W SIG

0.5GY H357 0.5GY

EGR EGR BOOST PRESSURE ALL SPEED

FL559 FL559 FL557 FL557 FL557 E71 FL558

ENGINE CONTROL MODULE(ECM)

9 8 11 6 H162 H162 H162 H162

H176 H177 H176 H177

H357 H357 H357 H357 H357

B54 B55 B43 B44 B45

B54 B55 B43 B44 B45