Códigos Erro Motor CX350B

4021
Section
4021
ENGINE ERROR CODE (DTC)
Copyright @ 2007 CNH America LLC.

All rights reserved.
Printed in USA.
CNH Lep SC160B4021-0NA July 2007
4021-2
TABLE OF CONTENTS
Special tools ......................................................................................................................................4
On-board check procedure for sensors .............................................................................................5
DTC: 0087 Common rail low pressure fault (No pressure feed in supply pump) ...............................6
DTC: 0088 Common rail pressure is abnormally high (1st or 2nd stage) ........................................ 11
DTC: 0089 Common rail pressure fault (Excessive pressure feed in supply pump) ........................14
DTC: 0090 SCV drive system open circuit, +B short or ground short..............................................18
DTC: 0107 Barometric pressure sensor circuit fault (low voltage fault) ...........................................22
DTC: 0108 Barometric pressure sensor fault (high voltage fault) ....................................................26
DTC: 0112 IAT (Intake air temperature) sensor fault (low voltage fault) ...........................................30
DTC: 0113 IAT (Intake air temperature) sensor fault (high voltage fault) .........................................34
DTC: 0117 Engine coolant temperature sensor fault (low voltage fault) ..........................................39
DTC: 0118 Engine coolant temperature sensor fault (high voltage fault) .........................................44
DTC: 0182 FT (Fuel temperature) sensor fault (low voltage fault) ...................................................50
DTC: 0183 FT (Fuel temperature) sensor fault (high voltage fault)..................................................54
DTC: 0192 Common rail pressure sensor fault (low voltage fault) ...................................................59
DTC: 0193 Common rail pressure sensor fault (high voltage fault) .................................................64
DTC: 0201 Open circuit in No.1 injection nozzle drive system ........................................................68
DTC: 0219 Overrun..........................................................................................................................84
DTC: 0237 Boost sensor pressure fault (low voltage fault) ..............................................................86
DTC: 0238 Boost sensor pressure fault (high voltage fault).............................................................90
DTC: 0335 CKP (crankshaft position) sensor fault (no signal).........................................................94
DTC: 0336 CKP (crankshaft position) sensor fault (signal fault) ......................................................98
DTC: 0340 CMP (camshaft position) sensor fault (no signal) ........................................................102
DTC: 0341 CMP (camshaft position) sensor fault (signal fault) .....................................................106
DTC: 0380 Glow relay circuit fault.................................................................................................. 110
DTC: 0487 EGR position sensor fault ............................................................................................ 115
DTC: 0488 EGR valve control fault ................................................................................................ 119
DTC: 0522 Engine oil pressure sensor fault (low voltage fault) .....................................................123
DTC: 0523 Engine oil pressure sensor fault (high voltage fault) ....................................................127
DTC: 0601 ROM fault.....................................................................................................................132
DTC: 0603 EEPROM fault .............................................................................................................133
DTC: 0606 CPU fault .....................................................................................................................134
DTC: 0611 Charge circuit fault (bank 1).........................................................................................135
DTC: 0612 Charge circuit fault (bank 2).........................................................................................137
Lep SC160B4021-0NA Issued 07-07

4021-3
DTC: 1093 No pump pressure feed ...............................................................................................139
DTC: 1095 Pressure limiter open...................................................................................................144
DTC: 1112 Boost temperature sensor fault (low voltage fault) .......................................................150
DTC: 1113 Boost temperature sensor fault (high voltage fault)......................................................155
DTC: 1173 Overheat ......................................................................................................................159
DTC: 1261 Injection nozzle common 1 drive system fault .............................................................163
DTC: 1262 Injection nozzle common 2 drive system fault .............................................................169
DTC: 1345 CMP (camshaft position) sensor out of phase.............................................................175
DTC: 1625 Main relay fault ............................................................................................................177
DTC: 1630 A/D conversion fault .....................................................................................................182
DTC: 1632 Voltage fault in 5 V power supply 2 ..............................................................................183
DTC: 2104 CAN Bus fault ..............................................................................................................195
DTC: 2106 CAN time out fault........................................................................................................198

4021-4
SPECIAL TOOLS
CNH-EST DIAGNOSTIC TOOL (SCAN TOOL)
The EST (Electronic Service Tool) system allows diagnoses on machines and engines by detecting the
operating parameters of electronic control components (control units, sensors etc.). It is also capable of
reading fault codes.
To use this tool, please refer to the book provided during the CXB series training sessions.
BREAKER BOX AND DMM
Name
1. Breaker box
2. DMM

4021-5
ON-BOARD CHECK PROCEDURE FOR SENSORS
Name
1. Coupling connector between
engine - the machine
2. Machine harness
3. Sensor connector
4. Engine harness
A. Disconnect the coupling connector, and check the sensor from engine harness connector.
B. Disconnect the connector from sensor, and short the wiring of sensor connector.
C. Check the harness from coupling connector for open circuit.
• If both steps 1 and 2 are faulty, repair the harness.
Check from step 1 again.
• If only step 1 is faulty, replace the sensor.

4021-6
DTC (error code): 0087 Common rail low pressure fault (No pressure feed in supply pump)
• Intense engine vibration

• Rough idling
• Output lowering
• Black smoke emitted
• Excessive output is possible.
Step 1
Perform the Service Support check.
Step 2
Is the procedure completed? No Go to
Check the fuel system in the following
procedure. Service Support check.
1. Check the high pressure pipe and low Yes
pressure pipe for looseness in the
connection (fuel leakage), crush or clogging.
2. Check the fuel pipe, fuel filter, and inside of
the fuel tank for freeze or waxing. (at cold No Is the fuel system normal?
temperature)
3. Check the feed pipe inside the fuel tank for
clogging of foreign matter.
Yes
Step 3
Repair or replace the faulty parts.
Is the procedure completed?
Yes
Go to Step 18.
Step 4
Check for rise of fuel level in the oil level gauge
or light oil odor.
No Is the trouble detected?

Step 5
Check the connection of the fuel pipe in each Yes
injector, and replace the injector if oil leakage
is confirmed.
Note:
For work procedure, refer to “Engine section” in
the service manual.
Yes
Go to Step 18.
Step 7
Check the injector.
1. Clear the DTC.
Step 6 No
Refer to the screen of DIAG (Trouble
Is the scan tool (KW communication) Go to Step 20.
Diagnosis) in the Service Support for how to
available?
clear DTCs.
2. Start the engine.
3. Select the “Boost temperature sensor” from
the menu.
4. Select the “Injection stop at each injector” in
the “Common rail system”.
Is there any cylinder of which engine
5. Press the “OFF” soft key to stop the fuel No
injection in the cylinder one by one, and vibration and engine sound did not
check the change in engine sound. change when it is stopped?
Yes
Go to Step 9.
Step 8
Replace the injector in the cylinder of which
engine sound did not change when it is
stopped.
Note:
the service manual.
Yes
Go to Step 18.
4021-7
Step 9
From Step 7
Check the common rail pressure.
1. Turn the key switch to “ON”.
2. Check for “Common rail pressure” on the
data display using scan tool.
3. Start the engine and run it at idle.
4. Check for “Differential fuel rail pressure” on
the data display using scan tool. Specified value
5. Race it quickly about 5 times. At engine stopped: Differential pressure
6. Check for “Differential fuel rail pressure” on -30 MPa
the data display using scan tool. At idling, racing: ±5 Mpa
No
Is “Differential fuel rail pressure”
within the specified value?
Step 10
Yes
Go to Step 16.
1. Turn the key switch to “OFF”.
2. Disconnect the common rail pressure sensor
connector.
4. Check for “Common rail pressure sensor” on
the data display using scan tool. Specified value
4.8V
Is the “Common rail pressure sensor”
No
the specified value or more?
Yes
Step 11
1. Check the signal circuit between common
rail pressure sensor and ECM for short
circuit to signal circuits of other sensors
using breaker box or DMM.
2. If the trouble is detected, repairs as required. No Is the trouble detected?
Step 13 Yes
Go to Step 18.
Check the version of ECM software.
1. Refer to “Flash Tool (EMPS)” in this section
for check and rewriting of ECM.
2. Rewrite the software if version upgraded is
Step 12
necessary. No
Note: Is EMPS available?
EGR valve position learning is required after
replacing or rewriting the ECM. Yes
[EGR valve position learning procedure]
3. Wait for 10 seconds or more.
No Is the procedure completed?
Step 14
Replace the ECM. Yes
Note: Go to Step 1.
replacing or rewriting the ECM.
2. Turn the key switch to “OFF”. No Is the procedure completed?
Yes
Go to Step 16.
Step 15
Replace the common rail (common rail
pressure sensor).
Yes
Go to Step 18.

4021-8
Step 16 From Step 14

Clear the DTC.
1. Refer to the screen of DIAG (Trouble
clear DTCs.
Specified value
the menu.
±5MPa
4. Select the “Rail pressure control” in the
No Is “Differential fuel rail pressure” within
Common rail system”.
the specified value?
5. Press the “Up” soft key to check the value of
“Differential fuel pressure”.
Yes
Step 17
Replace the supply pump.
Step 18
Check the DTC again. Is the procedure completed?
1. Connect all the harnesses.
2. Clear the DTC. Yes
clear DTCs.
3. Turn the key switch to “OFF” for 10 seconds
or more. No Is DTC:0087 detected?
4. Test run with the “Preconditions when DTC
is set”.
Yes
5. Check the DTC. Go to Step 2.
Step 19
Check if DTC is detected.
Is other DTC detected? No

Verify repair.
Yes
Go to each DTC diagnosis.
Step 20 From Step 6

Use the injector checker to stop injection in the
injector, and check the change in engine
sound.
No vibration and engine sound did not
Step 21 change when it is stopped?
Replace the injector in the cylinder of which
engine sound did not change when it is Yes
stopped.
Note:
the service manual.
Step 22
Yes
1. Turn the key switch to OFF.
connector.
3. Measure the voltage between the common
Specified value
rail pressure sensor power supply terminal
4.8V
and the ground.
No Is the DMM indication the specified value
or more?
Yes
Go to Step 23. Go to Step 24.

4021-9

1. Check the signal circuit between common
rail pressure sensor and ECM for short
using Breaker box or DMM. No
2. If the trouble is detected, repair as required. Is the trouble detected? Go to Step 12.
Yes
Go to Step 18.
From Step 22
Step 24
Check the DTC again.
2. Clear the DTC.
Diagnosis) in the Service Support for how to No Is DTC:0087 detected?
clear DTCs.
or more. Yes
5. Test run with the “Preconditions when DTC Go to Step 17.
is set”.
6. Check the DTC.
Go to Step 19.
Block diagram

4021-10
Diagnostic aid
Followings are suspected as the cause.
• Injector internal trouble
• Supply pump internal trouble
• Air in the fuel system
• Fuel system pipe fault (fuel leakage, clogging, crush, etc.)
• Fuel filter fault (clogging)
• Fuel tank fault (clogging)
• Pressure limiter trouble (operation under specified pressure, degradation of sealability)
• ECM trouble
• Common rail pressure sensor trouble
Breaker box inspection procedure

Perform the inspection in the following procedure if there is such an instruction to use breaker box in the step.
After inspection, return to the diagnostic step.
Step Item to be Inspection Measuring condition Breaker box Normal Abnormal

checked method terminal No. Value value
11, 23 Short circuit to Voltage • Disconnect the 82-Ground 0V 1V
other signal circuit measurement sensor connector 90- Ground or more
• Key switch “ON”

4021-11
DTC (error code): 0088 Common rail pressure is abnormally high (1ｓt or 2nd stage)
• Rough idling
• Output lowering
• Engine blow up fault
Step 1
Step 2 Is the procedure completed? No Go to

1. Start the engine. Service Support check.
2. Check the DTC. Yes
3. Are the fuel-related parts only just replaced?
Air bleeding may not be performed
sufficiently after replacing fuel-related parts.
Bleed air again. Check the DTC after
bleeding air. No
Is any of the DTC:0088, 0192, 0193, or
1635 detected?
Yes Go to the relevant

DTC detected.
Step 4
1. Turn the key switch to “OFF” for 30 seconds Step 3
No
or more. Is the scan tool (KW communication)
2. Start the engine. available?
the data display using scan tool. Yes
Step 5 Specified value

1. Check the fuel return pipe between the Differential pressure ±5 MPa
supply pump and the fuel tank for breakage, (at idle) No
twist, etc. Is “Differential fuel rail pressure” within Go to “Diagnostic aid”.
2. Check for clogging or twisting in the vent the specified value?
hose of the fuel tank.
3. Check for foreign matter in the fuel tank.
4. If the trouble is detected, repair as required.
Yes
Step 6
1. Replace the common rail (common rail No Is the procedure completed?
pressure sensor) since it seems that
abnormal value of the pressure sensor is
detected. Yes
Note:
the service manual.
2. Check the DTC.
Step7
Note: Yes
the service manual.
Step8
Check the DTC again. Yes
2. Clear the DTC.
Diagnosis) in the Service Support for how to No
Is DTC:0088 detected?
clear DTCs.
or more.
Yes
Go to Step 9.
is set”.
6. Check the DTC. From Step 8

4021-12
Step 9
Check if other DTC is detected.

Verify repair.
Yes
Block diagram
Preconditions when DTC is set.

1st stage
• Key switch input voltage is 18V or more.
• DTC: 0088, 0192, 0193, or 1635 is not detected.
• Actual rail pressure is 2 MPa or more and 70 min-1 or more.
2nd stage
• Key switch input voltage is 18 V or more.
• Actual rail pressure is 2 MPa or more and 70 min-1 or more.
Diagnostic aid
If the intermittent trouble is suspected, followings may be the cause.
Lep• Improper
SC160B4021-0NA
connection of harness connector Issued 07-07
4021-13

4021-14
DTC (error code): 0089 Common rail pressure fault (Excessive pressure feed in supply
pump)
• Rough idling
• Output lowering
Step 1

Step 2 Service Support check.
1. Start the engine. Yes
2. Check the DTC.
Is any of the DTC: 0089, 0192, 0193, or

No
1635 detected?
Yes Go to each
DTC diagnosis.
Step 4 Step3
1. Turn the key switch to “OFF” for 30 seconds Is the scan tool (KW communication) No
or more. available? Go to Step 12.
3. Check for “Differential fuel rail pressure” on Yes
the data display using scan tool.
Specified value
Differential pressure: ±5 MPa
Step 5
Is “Differential fuel rail pressure” within
1. Turn the key switch to “OFF”. No the specified value?
2. Wait for 2 minutes before the common rail
internal pressure goes down.
3. Turn the key switch to “ON”. Do not start Yes
engine. Go to “Diagnostic aid”.
Step 6
2. Disconnect the SCV connector. Specified value
3. Check the SCV harness connector terminal Differential pressure: -30 MPa
for poor contact, intermittent trouble, etc.
No Is “Differential fuel rail pressure” the
4. Disconnect the ECM harness connector. specified value?
5. Check the ECM harness connector terminal
for poor contact, intermittent trouble, etc. Yes
Step 7 Is the trouble detected? No

Go to Step 9.
2. Disconnect the common rail pressure sensor Yes
connector. Go to Step 10.
3. Check the common rail pressure sensor
harness connector terminal for poor contact
intermittent trouble, etc.
4. Disconnect the ECM harness connector.
5. Check the ECM harness connector terminal No Is the trouble detected?
for poor contact, intermittent trouble, etc.
6. If the trouble is detected, repair as required. Yes
Go to Step 10.
Step 8
pressure sensor).
Note:
the service manual.
Yes
Go to Step 10.

4021-15
Step 9
From Step 6
Note:
the service manual.

Step 10
1. Connect all the harnesses. Yes
2. Clear the DTC.
No Is DTC: 1093 detected?
clear DTCs.
4. Turn the key switch to “OFF” for 10 seconds Yes
or more. Go to Step2.
is set”.
6. Check the DTC.
Is other DTC detected?

No
Verify repair.
Step 11
Check if other DTC is detected. Yes
Step 12 Go to each DTC diagnosis.

1. Visually check the harness between the
ECM and the common rail pressure sensor
for damage.
Is the procedure completed? No
Go to Step 5.
Yes
Go to Step 5.

4021-16
Block diagram

• Key switch input voltage is 18V or more.
• Engine coolant temperature is 60 °C or more and 375 min-1 or more.
• Duty to SCV is 40 % or less, or SCV target pressure feed is 90 mm3/sec or less.

4021-17
Diagnostic aid
• Improper connection of harness connector
• Worn harness cladding
• Wire disconnection inside harness cladding
Following inspections are necessary to detect these causes.
• Improper connection of harness connector and ECM connector
– Poor connection of terminal from connector
– Unmatched terminals are fitted.
– Damage of connector lock
– Poor contact between terminal and wire
• Damaged harness
– Visually check the harness for damage.
– Check the relevant items on the scan tool data display while moving the connector and the harness
which are related to the sensor. The variation of the display indicates the faulty part.

4021-18
DTC (error code): 0090 SCV drive system open circuit, +B short or ground short
• Engine stall and/or engine blow up are possible

depending on the condition of open/short circuit.
• Excessive output
Step 1

No Go to
Service Support check.
Yes
Step 2
No
Is the scan tool (KW communication)
Step 3
available?
1. Connect the scan tool.
3. Check for “SCV F/B” on the data display
Yes
using scan tool.
Specified value
No 50mA
Is the “SCV F/B” the specified value or
less?
Step 4
1. Check for followings in the circuit between Yes
SCV and ECM using breaker box or DMM.
Refer to “Breaker box inspection procedure”.
Note:
If breaker box is not available, refer to
“On-board check procedure for sensors”. Is the trouble detected?
No
• Short circuit to ground
• Open circuit
• High resistance Yes
2. If the trouble is detected, repair or replace as Go to Step 12.
required.
Step5
1. Check for followings in the circuit between
SCV and ECM using breaker box or DMM.
Note:
“On-board check procedure for sensors”.
• Short circuit between terminals Is the trouble detected?
• Short circuit to power supply circuit or No
ignition power supply circuit
2. If the trouble is detected, repair or replace as
required.
Yes
Go to Step 12.
Go to Step 6.

4021-19
From Step 5
Step 6
Check the SCV body.
2. Remove the harness from the SCV.
3. Measure the resistance between the SCV Specified value
connector terminals. Between terminals: 3.2±0.3 Ω;
Each terminals to SCV body: ∞Ω
No (at nomal temperature )
Is the resistance specified value?
Step 7
Replace the supply pump (SCV). Yes
Note:
the service manual.
Step 8
3. Refer to the screen of DIAG (Trouble Go to Step 12.
clear DTCs.
or more.
is set”.
6. Check the DTC.
Is DTC:0090 detected? No
Go to “Diagnostic aid”.
Step 10
1. Check the version of ECM software. Yes
Refer to “Flash Tool (EMPS)” for check and Step 9
rewriting of ECM. No
2. Rewrite the software if version upgraded is Is EMPS available?
necessary.
Yes
Note:
replacing or rewriting the ECM. No Is the procedure completed?
2. Turn the key switch to “OFF”. Yes
Step 11
Replace the ECM.
Note:
replacing or rewriting the ECM. Is the procedure completed?
No Is DTC:0090 detected?
Step 12
Go to Step 2.
2. Clear the DTC.
clear DTCs.
or more.
is set”. Is other DTC detected? No
6. Check the DTC. Verify repair.
Step 13 Yes

4021-20
Block diagram
Diagnostic aid
• Defective harness routing
• Damaged harness

4021-21
Perform the inspection in the following procedure if there is such an instruction to use breaker box in the
step.
Step Item to be checked Inspection Measuring condition Breaker box Terminal Normal Abnormal
method No. value value
4 Open circuit/ Resistance • Disconnect the 105 – SCV terminal 5Ohm or 10 Mega
high resistance measurement SCV connector. 113 – SCV terminal less Ohm
• Key switch “OFF” 89 – SCV terminal or
97 – SCV terminal more
Short circuit to Resistance • Disconnect the 105 – Ground 10 Mega 100 Ohm
ground measurement SCV connector. 113 – Ground Ohm or
• Key switch “OFF” 89 – Ground or less
97 – Ground more
5 Short circuit Resistance • Disconnect the 105 – 89 10 Mega 100 Ohm

between terminals measurement SCV connector. 105 – 97 Ohm or
• Key switch “OFF” 113 – 89 or less
113 – 97 more
Short circuit to Voltage • Disconnect the 105 - GND 0V 18V

power supply measurement SCV connector. 113 - GND or
circuit • Key switch “ON” 89 - GND more
97 - GND
Short circuit to Voltage • Disconnect the 105 - GND 0V 1V

other signal circuit measurement SCV connector. 113 - GND or
• Key switch “ON” 89 - GND more
97 - GND

4021-22
DTC (error code): 0107 Barometric pressure sensor circuit fault (low voltage fault)
Due to back-up equivalent to 2,000 m
• Black smoke emitted at high altitude

• Output lowering at low altitude
Step 1
Perform the
Step 3 Is the procedure completed? No
Check the value for barometric pressure
sensor using scan tool. Yes
3. Check the value for “Barometric pressure
Step 2
sensor” using scan tool.
Is the scan tool (KW communication) No
available? Go to Step 14.
Step 4
Check for installation condition of the Yes
barometric pressure sensor, ECM and coupling
connector.
1. Check for play or looseness in the
connection. Specified value
2. If the trouble is detected, repair or 0.5V
replace as Is the “Barometric pressure sensor” No Go to
required the specified value or less? “Diagnostic aid”.
Step 5
2. Disconnect the barometric pressure sensor
connector.
3. Short between the barometric pressure
sensor connector power supply terminal and
the signal terminal using jump cable.
4. Turn the key switch to “ON”. Yes
5. Check the value for “Barometric pressure Go to Step 9.
Specified value
Step 6 4.8V
1. Check for followings in the power supply Is the “Barometric pressure sensor”
circuit between ECM and barometric No
pressure sensor using breaker box or DMM.
Refer to “Breaker box inspection procedure.” Yes
Note: Go to Step 8.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace as No Is the trouble detected?
required.
Yes
Step 7 Go to Step 9.
1. Check for followings in the signal circuit
between ECM and barometric pressure
sensor using breaker box or DMM.
Refer to “Breaker box inspection procedure”. No
Note: Is the trouble detected?
“On-board check procedure for sensors”. Yes
• Short circuit to barometric pressure sensor Go to Step 12.
ground circuit
• Open circuit Go to Step 9.
• High resistance
required.

4021-23
From Step 5 and 17 From Step 4 and 6

Step 8
Replace the barometric pressure sensor.
Go10to Step 9.
Step
1. Check the version of ECM software.
Refer to “Flash Tool (EMPS)” for check and Is the procedure completed?
rewriting of ECM.
necessary. Yes
Note:
[EGR valve position learning procedure] Step 9
No Is EMPS available?
3. Wait for 10 seconds or more. Yes
Step 11
Replace the ECM.
Note: Is the procedure completed?
Yes
Step 12 Is the procedure completed?

clear DTCs.
4. Turn the key switch to “OFF” for 10 seconds No Is DTC: 0107 detected?
or more.
is set”. Yes
Step 13

Verify repair.
Yes
From Step 2
Step 14
2. Check the display of barometric pressure.
Specified value No Go to
Step 15 127kPa (error value) “Diagnostic aid”.
Check for installation condition of the Does the display of “Barometric pressure”
barometric pressure sensor, ECM and coupling show error value?
connector. (Check the barometric pressure
sensor circuit for open circuit or ground short.) Yes
1. Check for disconnection, play or looseness
in the connection.
2. If the trouble is detected, repair or replace as Is the trouble detected?
No
required.
Yes
Go to Step 16.

4021-24
From Step 15
Step 16
1. Check for followings in the power supply
circuit between ECM and barometric
Note:
• Open circuit No Is the trouble detected?
• High resistance
required.
Yes
Go to Step 12.
Step 17
Refer to “Breaker box inspection
procedure”.
Note:
• Short circuit to barometric pressure sensor
ground circuit
• Open circuit Yes
• High resistance Go to Step 12.
required.
Go to Step 8.
Block diagram

• DTC: 1630 or 1632 is not detected.

4021-25
Diagnostic aid
• Damaged harness
– Check the relevant items on the scan tool data display while moving the connector and the harness which
are related to the sensor. The variation of the display indicates the faulty part.

Step Item to be checked Inspection Measuring condition Breaker box Normal Abnormal
method Terminal No. value value
61 – Sensor 100Ω 10MΩ
Open circuit/ Resistance • Disconnect the connector power
6, 16 high resistance measurement sensor connector. supply terminal or less or more
• Key switch “OFF”
71 – 60 10MΩ 100Ω
Short circuit to Resistance • Disconnect the
7, 17 ground circuit/ measurement sensor connector. 71 – GND or more or less
ground • Key switch “OFF”
Open circuit/ Resistance • Disconnect the connector signal
high resistance measurement sensor connector. terminal or less or more

4021-26
DTC (error code): 0108 Barometric pressure sensor fault (high voltage fault)

• Output lowering at low altitude
Step 1
Step 3 Perform the

Check the value for barometric pressure Service Support check.
sensor using scan tool.
1. Connect the scan tool. Yes
sensor” using scan tool. Step 2
No
Step 4 available?
Check for installation condition of the
barometric pressure sensor, ECM and coupling Yes
connector.
2. If the trouble is detected, repair or replace as 3.8V
required. Is the “Barometric pressure sensor” No Go to
Step 5 “Diagnostic aid”.
connector.
3. Turn the key switch to “ON”. No Is the trouble detected?
Yes
Go to Step 12.
Step 6
1. Check the signal circuit between ECM and
barometric pressure sensor for short circuit
to the power supply circuit or ignition power
supply circuit using breaker box or DMM. Specified value
Refer to “Breaker box inspection procedure”. 0V
Note: Is the “Barometric pressure sensor”
No
If breaker box is not available, refer to the specified value or less?
On-board check procedure for sensors”.
Important: Yes
If the barometric pressure sensor circuit is Go to Step 8.
shorted to the power supply circuit, the sensor
may be broken.
required.
Yes
1.Check for followings in the ground circuit
• High resistance
required. Go to Step 9.

4021-27
Step 8
From Step 5 and 17 From Step 7
Replace the barometric pressure sensor.
Step 10
1. Check the version of ECM software. Is the procedure completed?
Refer to“Flash Tool (EMPS)” for check and
rewriting of ECM.
2. Rewrite the software if version upgraded is Yes
necessary.
Note:
replacing or rewriting the ECM. Step 9
No
[EGR valve position learning procedure] Is EMPS available?
Step 11
Replace the ECM. No Is the procedure completed?
Note:
Yes
Step 12
2. Clear the DTC.
clear DTCs. No Is DTC:0108 detected?
or more.
5. Test run with the “Preconditions when DTC Yes
is set”. Go to Step 2.
6. Check the DTC.
Step 13
No
Is other DTC detected? Verify repair.
Yes
Step 14 From Step 2

2. Check the display of barometric pressure.
Specified value
127kPa
Step 15 (error value)
Check for installation condition of the No
Does the display of “Barometric pressure”
barometric pressure sensor, ECM and coupling Go to
show error value?
connector. “Diagnostic aid”.
(Check the barometric pressure sensor circuit
for short to +5V line or battery power supply Yes
circuit.)
connection. No Is the trouble detected?
required.
Yes
Go to Step 16.

4021-28

barometric pressure sensor for short circuit
supply circuit using breaker box or DMM.
Note:
Important:
If the barometric pressure sensor circuit is
may be broken. No Is the trouble detected?
Yes
1. Check for followings in the ground circuit
sensor
using breaker box or DMM. Refer to
“Breaker box inspection procedure”.
Note:
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace as Yes
Go to Step 8.
Block diagram


4021-29
Diagnostic aid
• Damaged harness

Step Item to be checked Inspection Measuring condition Breaker box Normal Abnormal
method Terminal No. value value
0V 18V
6,16 power supply circuit measurement sensor connector. 71 – Ground or more
100Ω 10MΩ
Open circuit/ Resistance • Disconnect the 60 – Sensor
7,17 high resistance measurement sensor connector. connector ground or less or more
• Key switch “OFF” terminal

4021-30
DTC (error code): 0112 IAT (Intake air temperature) sensor fault (low voltage fault)
• White smoke emission possible when

starting at low temperatures
Step 1
Perform the
Yes
Step 3 Step 2
Check the value for IAT sensor using scan tool. No
1. Connect the scan tool. available?
3. Check the value for “Intake air temperature
Yes
Specified value
Step 4 0.1V
Check for installation condition of the IAT Is the “Intake air temperature sensor” less No
sensor, ECM and coupling connector. than the specified value? Go to “Diagnostic aid”.
connection. Yes
required.
Step 5
Yes
1. Turn the key switch to “OFF”. Go to Step 11.
2. Disconnect the IAT sensor connector.
Specified value
4.8V
Step 6
1.Check for followings in the signal circuit No Is the “Intake air temperature sensor”
more than the specified value?
between ECM and IAT sensor using breaker
box or DMM. Yes
Note:
• Short circuit to IAT sensor ground circuit
• Short circuit to ground No Is the trouble detected?
required.
Yes
Go to Step 11.
Step 7
Replace the IAT sensor.
Yes

4021-31
Step 9 From Step 6
Refer to “Flash Tool (EMPS)” for check and
rewriting of ECM.
necessary. Step 8
No
Step 10
Replace the ECM.
Note:
Yes
3. Wait for 10 seconds or more. Is the procedure completed?
Step 11 Yes
2. Clear the DTC.
clear DTCs.
or more. Yes
is set”.
6. Check the DTC.
Step 12

Verify repair.
Yes
Step 13
From Step 2
2. Check the display of intake air temperature.
Specified value
Step 14 214°C
Check for installation condition of the IAT (error value)
No
sensor, ECM and coupling connector. (Check Does the display of “Intake air temperature” Go to “Diagnostic aid”.
the IAT sensor circuit for ground short.) show error value?
connection. Yes
required.
No Is the trouble detected
Yes
Go to Step 11.
Go to Step 15.

4021-32
From Step 14
Step 15
1.Check for followings in the signal circuit
box or DMM.
Refer to “Breaker box inspection procedure”. No Id the trouble detected?
Note:
• Short circuit to IAT sensor ground circuit Go to Step 11.
required.
Go to Step 7.
Block diagram
Recovery from failure.

• Fault judgement needs 3 to 10 minutes.

4021-33
Diagnostic aid
• To make sure the correct performance of the IAT
sensor, check with various temperatures using the
reckoner table between temperature and resistance.
If the sensor is faulty, operationality may be affected.
If the intermittent trouble is suspected, followings may
be the cause.
Following inspections are necessary to detect these
causes.
• Damaged harness
– Check the relevant items on the scan tool data display
while moving the connector and the harness which are related to the sensor. The variation of the display
indicates the faulty part.

checked method Terminal No. value value
72 – 60 10MΩ 100MΩ
6,15 ground circuit/ measurement sensor connector. 72 – Ground or more or less
ground
Intake air temperature - resistance table

1000
100
10
)
Resistance(
0.1
0.01
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Intake air temperature( ) E0112-5

4021-34
DTC (error code) :0113 IAT (Intake air temperature) sensor fault (high voltage fault)
• White smoke emission possible when

starting at low temperatures
Step 1
Perform the
Check the value for IAT sensor using scan tool.
Yes
Step 2
No
Step 4 available?
Check for installation condition of the IAT
sensor, ECM and coupling connector. Yes
connection.
2. If the trouble is detected, repair or replace as Specified value
required. 4.95V
Is the “Intake air temperature sensor”
No
Step 5 Go to “Diagnostic aid”.
2. Disconnect the IAT sensor connector.
Yes
3. Short the IAT sensor connector signal
terminal to the ground terminal using jump No Is the trouble detected?
cable.
5. Check the value for “Intake air temperature Yes
sensor” using scan tool. Go to Step 13.
Step 6
Specified value
IAT sensor for short circuit to the power
0V
supply circuit or ignition power supply circuit
Is the “Intake air temperature sensor”
using breaker box or DMM. No
the specified value or less?
Note:
If breaker box is not available, refer to Yes
Go to Step 9.
Important:
If the IAT sensor circuit is shorted to the power
supply circuit, the sensor may be broken.
2. If the trouble is detected, repair as required. No Is the trouble detected?
Step 7 Yes
1. Check for followings in the signal circuit Go to Step 13.
box or DMM.
Note:
“On-board check procedure for sensors”. No
• Open circuit Is the trouble detected?
• High resistance
Go to Step 8.

4021-35
From Step 7
Step 8
box or DMM.
Note:
• Open circuit
• High resistance
required. Yes
Step 9 From Step 5 and 19

Replace the IAT sensor.

1. Check the version of ECM software. Refer to
“Flash Tool (EMPS)” for check and rewriting
of ECM. Yes
necessary.
Note:
EGR valve position learning is required after Step 10
No
replacing or rewriting the ECM. Is EMPS available?
No
Replace the ECM.
Note: Yes
Step 13 Yes
2. Clear the DTC.
3. Refer to the screen of DIAG (Trouble No Is DTC:0113 detected?
clear DTCs.
or more. Go to Step 2.
is set”.
6. Check the DTC.
Step 14
Check if other DTC is detected. Is other DTC detected? No
Verify repair.
Yes

4021-36
From Step 2
Step 15
2. Check the display of intake air temperature.
3. Display of intake air temperature is 214°C
due to back-up mode after fault judgment.
Specified value
214°C
(error value) No
Step 16
Check for installation condition of the IAT
Does the display of “Intake air Go to “Diagnostic aid”.
temperature” show error value?
sensor, ECM and coupling connector.
1. Check for play or looseness in the Yes
connection.
2. If the trouble is detected, repair or replace
required.
Step 17
1. Check the signal circuit between ECM and Yes
IAT sensor for short circuit to the power Go to Step 13.
Note:
If breaker box is not available, refer to No Is the trouble detected?
Important:
If the IAT sensor circuit is shorted to the power Yes
supply circuit, the sensor may be broken. Go to Step 13.
Step 18
1. Check for followings in the signal
circuitbetween ECM and IAT sensor using
breakerbox or DMM.
Note:
• Open circuit
• High resistance
required.
Yes
Go to Step 13.
Step 19
1. Check for followings in the ground
circuitbetween ECM and IAT sensor using
breaker box or DMM.
Note:
• Open circuit
• High resistance
required. Yes
Go to Step 13.
Go to Step 9.

4021-37
Block diagram

• Fault judgment needs 3 to 10 minutes.
Diagnostic aid
• To make sure the correct performance of the IAT
sensor, check with various temperatures using the reckoner table between temperature and resistance.
be the cause.
causes.
• Damaged harness
– Check the relevant items on the scan tool data display
while moving the connector and the harness which are related to the sensor. The variation of the
display indicates the faulty part.

4021-38


72 – Ground 0V 18V
Short circuit to Voltage • Disconnect the
6, 17 Power supply measurement sensor connector. or more
circuit
72 – Sensor 10MΩ 100MΩ

Open circuit / Resistance • Disconnect the
7, 18 high resistance measurement sensor connector. connector signal or less or more
terminal

Open circuit / Resistance • Disconnect the
8, 19 measurement sensor connector. connector signal or less or more
high resistance
terminal
Intake air temperature - resistance table

1000
100
10
)
Resistance(
0.1
0.01
-40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Intake air temperature( ) E0113-4

4021-39
DTC (error code): 0117 Engine coolant temperature sensor fault (low voltage fault)
• At normal temperature: Black smoke emission, greater engine

combustion noise possible.
• During idling at low atmospheric temperatures: Rough idling,
engine stall, white smoke emission possible.
Step 1
Perform the
Yes
Step 3
Check the value for ECT sensor using scan Step 2
tool. No
1. Connect the scan tool. available?
3. Check the value for “Engine coolant Yes
temperature sensor” using scan tool.
Specified value
Step 4 0.1V
Check for installation condition of the ECT Is the “Engine coolant temperature
sensor, ECM and coupling connector. sensor” the specified value or less? No
1. Check for play or looseness in the Go to “Diagnostic aid”.
connection.
required.
Step 5
2. Disconnect the ECT sensor connector.
Yes
Go to Step 11.
4. Check the value for “Engine coolant
temperature sensor” using scan tool.

1. Check for followings in the signal circuit 4.8V
between ECM and ECT sensor using Is the “Engine coolant temperature sensor”
No the specified value or more?
breaker box or DMM.
Note: Yes
• Short circuit to ECT sensor ground circuit
2. Measure the resistance of ECT sensor to
check that the value is within normal range.
required. Yes
Go to Step 11.
Step 7
Replace the ECT sensor.
Yes
Go to Step 11.
No Step 8 Yes
Is EMPS available?

4021-40
Step 9
1. Check the version of ECM software. From Step 8
rewriting of ECM.
necessary.
Note:
replacing or rewriting the ECM. No Is the procedure completed?
Step 10
Replace the ECM.
Note:
Step 11
2. Clear the DTC.
3. Refer to the screen of DIAG (Trouble No Is DTC:0117 detected?
clear DTCs.
is set”.
6. Check the DTC.
Step 12

Verify repair.
Yes
Step 13
1. Start the engine. From Step 2
2. Check the display of the engine coolant
temperature.
Display of engine coolant temperature
is 214°C due to back-up mode
Specified value
after fault judgment.
214°C
(error value)
Does the display of “Engine coolant No
temperature” show error value? Go to Step 11.
Step 14
Check for installation condition of the ECT Yes
connection.
required.
Go to Step 15.

4021-41
From Step 14
Step 15
between ECM and ECT sensor using
breaker box or DMM.
Note:
If breaker box is not available, refer to No Is the procedure completed?
• Short circuit to ECT sensor ground circuit
2. Measure the resistance of ECT sensor to Go to Step 7.
check that the value is within normal range.
required.
Block diagram


4021-42
Diagnostic aid
• DTC may be set at a overheat condition.
• After starting the engine, the thermostat begins to
open when the engine coolant temperature rises
(85°C {185°F}), and the engine coolant temperature is stabilized.
• To make sure the correct performance of the ECT sensor, check with various temperatures using the
be the cause.

• Improper connection of harness connector and
ECM connector
• Damaged harness
– Check the relevant items on the scan tool data
display while moving the connector and the harness

4021-43


84 – 79 10MΩ 100Ω
6, 15 Ground circuit/ measurement sensor connector. 84 - Ground or more or less
ground
Engine coolant temperature - resistance table
100
Resistance (K ohm)
10
0.1
-50 0 50 100
Engine coolant temperature (˚C)
E0117-4

4021-44
DTC (error code): 0118 Engine coolant temperature sensor fault (high voltage fault)
• At normal temperature: Black smoke
emission, greater engine combustion noise
possible.
• During idling at low atmospheric
temperatures: Rough idling, engine stall,
white smoke emission possible.
Step 1
Perform the
Check the value for ECT sensor using scan
tool.
3. Check the value for “Engine coolant
temperature sensor” using scan tool. Step 2
No
available?
Step 4
Check for installation condition of the ECT Yes
connection.
Specified value
4.85V
required.
Is the “Engine coolant temperature No
sensor” the specified value or more?
Step 5
Yes
3. Short the ECT sensor connector signal
terminal to the ground terminal using jump No Is the trouble detected?
cable.
5. Check the value for “Engine coolant Yes
temperature sensor” using scan tool. Go to Step13.
Step 6
Specified value
ECT sensor for short circuit to the power
0V
No Is the “Engine coolant temperature
sensor” the specified value or less?
Note:
Yes
Go to Step 9.
Important:
If the ECT sensor circuit is shorted to the
power supply circuit, the sensor may be
broken.

Step 7
1.Check for followings in the signal circuit
between ECM and ECT sensor using Yes
breaker box or DMM. Go to Step 13.
Note:
• High resistance
Go to Step 8.

4021-45
Step 8
1. Check for followings in the ground circuit From step 7
breaker box or DMM.
Note:
• Open circuit
required.
From step 5
Step 9

Step 11
Refer to “Flash Tool (EMPS)” for check and Yes
rewriting of ECM.
necessary.
Note: Step 10
No
EGR valve position learning is required after Is EMPS available?
[EGR valve position learning procedure] Yes
3. Wait for 10 seconds or more. No Is the procedure completed?
Step 12 Yes
Replace the ECM.
Note:
Yes
Step 13
2. Clear the DTC.
Diagnosis) in the Service Support for how to No Is DTC: 0118 detected?
clear DTCs.
or more.
Yes
Go to Step 2.
is set”.
6. Check the DTC.
Step 14

Verify repair.
Yes

4021-46
Step 15 From Step 2

2. Check the display of the “Engine coolant
temperature”.
Display of engine coolant temperature is
214°C due to back-up mode after fault Specified value
judgment. 214°C
(error value)
No
Step 16 Does the display of “Engine coolant Go to “Diagnostic aid”.
Check for installation condition of the ECT temperature” show error value?
connection.
required.
Step 17 Yes
1. Check the signal circuit between ECM and Go to Step 13.
ECT sensor for short circuit to the power
Note:
Important: Go to Step 13.
If the ECT sensor circuit is shorted to the
power supply circuit, the sensor may be
broken.
Step 18
breaker box or DMM.
Note:
• Open circuit
• High resistance
required. Yes
Go to Step 13.
Step 19
1.Check for followings in the ground circuit
breaker box or DMM.
Note:
“On-board check procedure for sensors”. No Is the trouble detected?
• Open circuit
required.
Go to Step 9.

4021-47
Block diagram

• 3 minutes or more has elapsed after starting engine.

4021-48
Diagnostic aid
• After starting the engine, the thermostat begins to open
when the engine coolant temperature rises ( 85°C {185°F}),
and the engine coolant temperature is stabilized.
• To make sure the correct performance of the ECT sensor,
check with various temperatures using the
causes.
ECM connector
• Damaged harness
– Check the relevant items on the scan tool data
display while moving the connector and the harness
which are related to the sensor. The variation
of the display indicates the faulty part.

4021-49


84 – Ground 0V 18V
6, 17 Power supply measurement sensor connector. or more
circuit
Open circuit / Resistance • Disconnect the connector signal
7, 18 high resistance measurement sensor connector. terminal or less or more
Open circuit / Resistance • Disconnect the connector ground
8, 19 measurement sensor connector. terminal or less or more
high resistance
Engine coolant temperature - resistance table
100
Resistance (K ohm)
10
0.1
-50 0 50 100
Engine coolant temperature (˚C)
E0117-4

4021-50
DTC (error code): 0182 FT (Fuel temperature) sensor fault (low voltage fault)
Operationality is affected.
Step 1
Perform the
Yes
Step 2
No
Step 3 Is the scan tool (KW communication) Go to Step 13.
Check the value for FT sensor using scan tool. available?
2. Start the engine. Yes
3. Check the value for “Fuel temperature
Specified value
0.1V
Step 4 Is the “Fuel temperature sensor” the No
specified value or less? Go to “Diagnostic aid”.
Check for installation condition of the FT
connection.
required. No Is the trouble detected?
Step 5 Yes
2. Disconnect the FT sensor connector.
Specified value
4.8V
Step 6 Is the “Fuel temperature sensor” the
No specified value or more?
between ECM and FT sensor using breaker
box or DMM. Yes
Note:
If breaker box is not available, refer “On-board
check procedure for sensors”.
• Short circuit to FT sensor ground circuit
• Short circuit to ground No Is the trouble detected?
required.
Yes
Go to Step 11.
Step 7
Replace the supply pump (FT sensor).
Yes
Go to Step 11.
Go to Step 8.

4021-51
Step 9 From Step 6

rewriting of ECM.
2. Rewrite the software if version upgraded is No Step 8
necessary. Is EMPS available?
Note:
EGR valve position learning is required after Yes
2. Turn the key switch to “OFF”. No
Step 10
Note:
Yes
Step 11
2. Clear the DTC.
Diagnosis) in the Service Support for how to No
clear DTCs. Is DTC:0182 detected?
or more. Yes
5. Test run with the “Preconditions when DTC Go to Step 2
is set”.
6. Check the DTC.
Step 12

Verify repair.
Yes
From Step 2
Step 13
2. Check the display of “Fuel temperature”.
Display of fuel temperature is 214°C due to Specified value
back-up mode after fault judgment. 214°C
(error value)
Does the display of “Fuel temperature”
Step 14 Show error value?
No
Check for installation condition of the FT Go to “Diagnostic aid”.
connection.
Yes
required. No Is the trouble detected?
Yes
Go to Step 11.
Go to Step 15.

4021-52
From Step 14
Step 15
box or DMM.
Refer to “Breaker box inspection procedure”. No Is the trouble detected?
Note:
• Short circuit to FT sensor ground circuit Go to Step 11.
required.
Go to Step 6.
Block diagram


4021-53
Diagnostic aid
• When the engine cold (before starting engine),
check if the temperatures of the FT sensor and IAT sensor are close.
ECM connector
• Damaged harness


6, 15 83 – 79 10MΩ 100Ω
Ground circuit/ measurement sensor connector. 83 - Ground or more or less
ground

4021-54
DTC (error code): 0183 FT (Fuel temperature) sensor fault (high voltage fault)
Not in particular
Step 1
Perform the
Yes
Step 3 Step 2
Check the value for FT sensor using scan tool. Is the scan tool (KW communication) No
1. Connect the scan tool. available? Go to Step 15.
3. Check the value for “Fuel temperature Yes

Check for installation condition of the FT 4.85V
sensor, ECM and coupling connector. Is the “Fuel temperature sensor” the No
1. Check for play or looseness in the specified value or more? Go to “Diagnostic aid”.
connection.
required.
Step 5 No Is the trouble detected?

2. Disconnect the FT sensor connector.
3. Short the FT sensor connector signal Yes
terminal to the ground terminal using jump Go to Step 13.
cable.
sensor”using scan tool.
Specified value
0V
Step 6
No Is the “Fuel temperature sensor” the
specified value or less?
FT sensor for short circuit to the power
using breaker box or DMM. Yes
Go to Step 9.
Note:
Important: No Is the trouble detected?
If the FT sensor circuit is shorted to the power
supply circuit, the sensor may be broken.
Go to Step 13.
Step 7
box or DMM.
Note: No Is the trouble detected?
• High resistance
Go to Step 13.
required.
Go to Step 8.

4021-55
Step 8 From Step 7

box or DMM.
Note:
• Open circuit
required.
From Step 5
Step 9
Replace the supply pump (FT sensor).
Step 11 Yes
rewriting of ECM.
Step 10
necessary. No

Step 12 N
Replace the ECM.
Note: Yes
Yes
Step 13
2. Clear the DTC.
clear DTCs. No Is DTC: 0183 detected?
or more.
Yes
Go to Step 2.
is set”.
6. Check the DTC.
Step 14

Verify repair.
Yes

4021-56
From Step 2
Step 15
2. Check the display of “Fuel temperature”.
Display of fuel temperature is 214°C due to
back-up mode after fault judgment.
Specified value
214°C
Step 16 (error value)
Check for installation condition of the FT Does the display of “Fuel temperature”
sensor, ECM and coupling connector. show error value? No
1. Check for play or looseness in the Go to “Diagnostic aid”.
connection.
required.

FT sensor for short circuit to the power
supply circuit or ignition power supply circuit Yes
using breaker box or DMM. Go to Step 13.
Note:
Important:
If the FT sensor circuit is shorted to the power
supply circuit, the sensor may be broken. Yes
2. If the trouble is detected, repair as required. Go to Step 13.
Step 18
box or DMM.
Note:
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace as Is the trouble detected?
required.
N
Yes
box or DMM.
If breaker box is not available, refer to N
Yes
• High resistance
required.
Go to Step 9.

4021-57
Block diagram

• 3 minutes or more has elapsed after starting engine.

4021-58
Diagnostic aid
• When the engine cold (before starting engine),
check if the temperatures of the FT sensor and IAT sensor are close.
ECM connector
• Damaged harness

step.

6 83– GND 0V 18V
power supply circuit measurement sensor connector. or more
7 83 – Sensor 100MΩ 10MΩ

8 109 – Sensor 100Ω 10MΩ

Open circuit/ Resistance • Disconnect the connector ground

4021-59
DTC (error code): 0192 Common rail pressure sensor fault (low voltage fault)

• Hunting
Step 1
Step 3 Perform the

Check the value for common rail pressure Service Support check.
sensor using scan tool.
3. Check the value for “Common rail pressure
sensor” using scan tool. Step 2
Step 4
Check for installation condition of the common Yes
rail pressure sensor, ECM and coupling
connector.
1. Check for play or looseness in the Specified value
connection. 0.7V (at idle)
2. If the trouble is detected, repair or replace as Is the “Common rail pressure sensor”
required. output voltage the specified
value or less?
No
Step 5 Yes
connector.
4. Check the value for “Common rail pressure Yes
Step 6
Specified value
circuit between ECM and common rail
0V
Is the “Common rail pressure sensor”
Refer to “Breaker box inspection procedure”. No output voltage specified value?
Note:
• High resistance
required.
Step 7
Yes
between ECM and common rail pressure
Note:
• Short circuit to common rail pressure No Is the trouble detected?
sensor ground circuit
Yes
Go to Step 12.
required.
Go to Step 9.

4021-60
From Step 5
Step 8
pressure sensor).
Note:
the service manual. Is the procedure completed?
Step 10
rewriting of ECM. From Step 7
necessary.
Note: No Step 9
EGR valve position learning is required after Is Flash Tool (EMPS) available?
Step 11 No Is the procedure completed?

Replace the ECM.
Note:
Step 12
Yes
2. Clear the DTC.
clear DTCs.
or more.
is set”. Yes
Go to Step 2.
6. Check the DTC.
Step 13

Verify repair.
Yes

4021-61
From Step 2
Step 14
Check for installation condition of the common
connector.
1. Check for play or looseness in No Is the trouble detected?
Yes
Go to Step 12.
Step 15
connector.
Specified value
0V
4. Connect the DMM between the common rail No Does the DMM indicate the specified
pressure sensor signal terminal and the
value?
ground.
Yes
Go to Step 8.
Go to Step 6.

4021-62
Block diagram


4021-63
Diagnostic aid
• Damaged harness

step.

6 100Ω 10MΩ
Open circuit/ Resistance • Disconnect the 87 – Sensor
high resistance measurement sensor connector. connector signal or less or more
7 82 – 101 10MΩ 100Ω

Open circuit/ Resistance • Disconnect the 90 – 101
high resistance measurement sensor connector. 82 – Ground or more or less
• Key switch “OFF” 90 – Ground
82– Sensor 100Ω 10MΩ
• Key switch “OFF” 90 – Sensor
connector signal
terminal

4021-64
DTC (error code): 0193 Common rail pressure sensor fault (high voltage fault)
• Engine stall possible

• Output lowering
Step 1
Perform the
Check the value for common rail pressure
sensor using scan tool. Yes
3. Check the value for “Common rail pressure Step 2
sensor” using scan tool. Is the scan tool (KW communication) No
Step 4
Yes
connector.
connection. 4.5V
2. If the trouble is detected, repair or replace as Is the “Common rail pressure sensor”
required. more than the specified value?
No
Step 5 Yes
2. Disconnect the common rail pressure sensor No
connector. Is the trouble detected?
4. Check the value for “Common rail pressure Yes

1. Check for followings in the power supply 4.8V
circuit between ECM and common rail Is the “Common rail pressure sensor”
pressure sensor using breaker box or DMM. No the specified value or less?
Note:
Yes
If breaker box is not available, refer to Go to Step 9.
• Open circuit
• High resistance
required.
Step 7
1. Check for followings in the signal circuit No
between ECM and common rail pressure Is the trouble detected?
Refer to “Breaker box inspection procedure”. Yes
Note: Go to Step 13.
• Open circuit
• High resistance
required.
Yes
Go to Step 13.
Go to Step 8.

4021-65
From Step 7
Step 8
between ECM and common rail pressure
sensor using breaker box or DMM. No Is the trouble detected?
Note:
• Open circuit
• High resistance From Step 5 and 16
required.
Step 9
Replace the common rail (common rail Is the procedure completed?
pressure sensor).
Note:
For work procedure, refer to “Engine section” in Yes
the service manual.
Step 11 Step 10
1. Check the version of ECM software. No
Is EMPS available?
rewriting of ECM.
Yes
necessary.
Note: No Is the procedure completed?
Step 12
Replace the ECM. Is the procedure completed?
Note:
Step 13
1. Connect all the harnesses. No Is DTC: 0193 detected?
2. Clear the DTC.
Diagnosis) in the Service Support for how to Yes
clear DTCs. Go to Step 2.
or more.
is set”.
6. Check the DTC.
Step 14 No
Check if other DTC is detected. Verify repair.
Yes

4021-66
Step 15
From Step 2
connector.
connection.
2. If the trouble is detected, repair or replace as No Is the trouble detected?
required.
Yes
Step 16
Go to Step 13.
connector.
3. Turn the key switch to “ON”. Specified value
4. Connect the DMM between the common rail 4.8V
pressure sensor power supply terminal and Is the DMM indication less than the
the signal terminal. No specified value?
Yes
Go to Step 9.
Go to Step 6.
Block diagram

4021-67
Diagnostic aid
• Damaged harness


6 82 – Ground 0Ｖ 18Ｖ
power supply measurement sensor connector. 90 – Ground or more
circuit • Key switch “ON”
7 82 – Sensor 100Ω 10MΩ

• Key switch “OFF” 90 – Sensor
connector signal
terminal
8 101– Sensor 100Ω 10MΩ
high resistance measurement sensor connector. or less or more
terminal

4021-68
DTC (error code): 0201 Open circuit in No.1 injection nozzle drive system
• Rough idling
• Output lowering
Step 1
Perform the
Check the DTC.
or more.
3. Check the DTC.
Step 3 Is DTC detected? No

1. Turn the key switch to “OFF”. Go to “Diagnostic aid”.
2. Remove the coupling connector (CN.A3)
Yes
from the cylinder head cover case.
3. Measure the resistance between the
coupling connector terminals (power supply Specified value
terminal — 0.45±0.1 Ώ
No. 1 cylinder injector drive signal terminal). (20°C)
No Is the resistance the specified
value or less?
Step 4
ECM and coupling connector (CN.A3) using
Yes
breaker box or DMM.
Is the trouble detected?
Note: Go to Step 8.
• High resistance
Step 5
Check for installation condition of the injector
terminal nut.
1. Remove the cylinder head cover.
2. Check the injector terminal nut for looseness No Is the trouble detected?
etc.
Yes
Go to Step 13.
Step 6
Check for installation condition of the coupling
connector.
1. Check for play or looseness in the No Is the trouble detected?
connection.
Yes
Go to Step 13.
Step 7
1. Check for following in the circuit between
injector terminal and coupling connector.
• Open circuit
• High resistance
2. If the trouble is detected, repair or replace as No Is there any trouble in the circuit?
required.
Yes
Go to Step 13.
Go to Step 9.

4021-69
Step 8
Check for installation condition of the ECM From Step 4
connector.
2. Remove the ECM.
Yes
Step 9
From Step7
1. Replace the No. 1 cylinder injector.
Note:
the service manual.
Step 11 Yes
“Flash Tool (EMPS)” for check and rewriting
of ECM.
necessary. Step 10
Note: No
Is EMPS available?
Yes

Step 12
Replace the ECM.
Note: Yes
Yes
Step 13
2. Clear the DTC.
or more. Yes
is set”.
6. Check the DTC.
Step 14
No
Yes

4021-70
Block diagram
Cylinder No. and injection
Name
1. Cylinder No. 1
2. Cylinder No. 2
3. Cylinder No. 3
4. Cylinder No. 4
5. Cylinder block
6. Engine front
Fuel injection is performed to each
cylinder in the order of 1 — 3 — 4 — 2.

4021-71
• Main relay power supply voltage is 18 V or more.
• 70 min-1 or more.
• DTC: 0201, 0611, or 1261 is not detected.
Diagnostic aid
• Damaged harness


4 119– Coupling 100Ω 10MΩ
Open circuit/ Resistance • Remove the coupling connector
high resistance measurement connector terminal (H-94) or less or more
• Key switch “OFF” (No.5)

4021-72
DTC (error code): 0202 Open circuit No.2 injection nozzle drive system
• Rough idling
• Output lowering
Step 1
Step 2 Perform the

Check the DTC. Service Support check.
or more. Yes
3. Check the DTC.
Step 3
Is DTC detected? No
from the cylinder head cover case. Yes
coupling connector terminals (power supply
Specified value
terminal — No. 2 cylinder injector drive
0.45±0.1Ώ
signal terminal).
(20°C)
value or less?
Step 4
1. Check for followings in the circuit between Yes
breaker box or DMM.
Refer to “Breaker box inspection procedure”. Is the trouble detected? No
Note: Go to Step 8.
Go to Step 13.
• Open circuit
• High resistance
Step 5
terminal nut. No
1. Remove the cylinder head cover. Is the trouble detected?
2. Check the injector terminal nut for looseness
etc. Yes
Step 6
connector. No
1. Check for play or looseness in the Is the trouble detected?
connection.
Go to Step 13.
Step 7
• Open circuit
• High resistance No Is there any trouble in the circuit?
required.
Yes
Go to Step 13.
Go to Step 9.

4021-73
Step 8 From Step 4

Check for installation condition of the ECM
connector.
2. Remove the ECM.
Yes
Step 9
From Step7
Note:
the service manual.
Yes
Step 11
rewriting of ECM.
2. Rewrite the software if version upgraded is Step 10
necessary. No
Is EMPS available?
Note:
Yes
Step 12
Note:
2. Turn the key switch to “OFF”. Is the procedure completed?
Yes
Step 13
2, Clear the DTC.
4, Turn the key switch to “OFF” for 10 seconds
or more.
Yes
5, Test run with the “Preconditions when DTC Go to Step 2.
is set”.
6. Check the DTC.
Step 14
No
Verify repair.
Yes

4021-74
Block diagram
Name
1. Cylinder No. 1
2. Cylinder No. 2
3. Cylinder No. 3
4. Cylinder No. 4
5. Cylinder block
6. Engine front
Fuel injection is performed to each
cylinder in the order of 1 — 3 — 4 — 2.

4021-75
• DTC:0202, 0612, or 1262 is not detected.
Diagnostic aid
• Damaged harness


4 118– Coupling 100Ω 10MΩ

4021-76
• Rough idling
• Output lowering
Step 1
Perform the
Check the DTC.
1. Turn the key switch to “OFF” for more than
10 seconds. Yes
3. Check the DTC.

from the cylinder head cover case. Yes
coupling connector terminals (power supply Specified value
terminal — No. 3 cylinder injector drive 0.45±0.1Ω
signal terminal). (20°C)
Step 4 value or less?
ECM and coupling connector (CN.A3) using Yes
breaker box or DMM.
Note:
If breaker box is not available, refer to Is the trouble detected? No
“On-board check procedure for sensors”. Go to Step 8.
• Open circuit
• High resistance
Yes
Go to Step 13.
required.
Step 5
terminal nut.
etc.
Go to Step 13.
Step 6
connector.
connection.
Yes
Go to Step 13.
Step 7
• Open circuit
• High resistance
required.
Yes
Go to Step 13.
Go to Step 9.

4021-77
From Step 4
Step 8
connector.
2. Remove the ECM.
connection.
Yes
From Step 7
Step 9
Note:
Yes
Step 11
rewriting of ECM.
necessary. No
Is EMPS available?
Note:
Yes
Step 12
Yes
Replace the ECM.
Note:
1. Turn the key switch to “ON”. Is the procedure completed?
Yes
Step 13
2. Clear the DTC.
Diagnosis) in the Service Support for how to No Is DTC:0203 detected?
clear DTCs.
10 seconds. Yes
is set”.
6. Check the DTC.
Step 14

Verify repair.
Yes

4021-78
Block diagram
Name
1. Cylinder No. 1
2. Cylinder No. 2
3. Cylinder No. 3
4. Cylinder No. 4
5. Cylinder block
6. Engine front
Fuel injection order is 1 — 3 — 4 — 2.

4021-79
Diagnostic aid
• Damaged harness

4 120 – Coupling 100Ω 10MΩ

4021-80
• Rough idling
• Output lowering
Step 1
Perform the
Check the DTC.
10 seconds.
Yes
3. Check the DTC.

2. Remove the coupling connector (CN.A3) Yes
from
the cylinder head cover case.
3. Measure the resistance between the Specified value
coupling connector terminals (power supply 0.45±0.1Ω
terminal — No. 4 cylinder injector drive (20°C)
signal terminal). No Is the resistance the specified value or less?
Step 4 Yes
breaker box or DMM. Is the trouble detected? No
Note: Go to Step 8.
“On-board check procedure for sensors, Yes
Go to Step 13.
• Open circuit
• High resistance
required.
Step 5
terminal nut.
etc. Yes
Step 6
connector. No
1. Check for play or looseness in the Is the trouble detected?
connection.
Go to Step 13.
Step 7
• Open circuit
• High resistance
required.
Yes
Go to Step 13.
Go to Step 9.

4021-81
From Step 4
Step 8
connector.
2. Remove the ECM.
connection.
Yes
Step9 From Step7
Note:
the service manual.
Step 11
rewriting of ECM.
necessary.
Note: Step 10
No
EGR valve position learning is required after Is EMPS available?
Step 12 No Is the procedure completed?

Replace the ECM.
Note:
Yes
Step 13 Yes
2. Clear the DTC.
clear DTCs.
4. Turn the key switch to “OFF” for 10 seconds No Is DTC:0204 detected?
or more.
6. Check the DTC.
Step14

Verify repair.
Yes

4021-82
Block diagram
Name
1. Cylinder No. 1
2. Cylinder No. 2
3. Cylinder No. 3
4. Cylinder No. 4
5. Cylinder block
6. Engine front
Fuel injection order is 1 — 3 — 4 — 2.

4021-83
Diagnostic aid
• Damaged harness


4 • Remove the coupling 117 – Coupling 100Ω 10MΩ
Open circuit/ Resistance connector connector
high resistance measurement • Key switch “OFF” terminal (H-94) or less or more
(No.8)

4021-84
DTC (error code): 0219 Overrun
Output lowering
Step 1

Confirm the driving status (improper operation
of the vehicle due to engine over speed).
Yes
(Interview the operator for driving status in the
past.)
Has the vehicle been operated
No improperly?
Step 3
Tell the operator that it is the over speed
caused by improper operation, and give a
Yes
driving instruction.
Step 4
Yes
Check for adverse effect (fault in the engine
body) caused by the engine over speed.
Repair or replace if fault is found.

Step 5
2. Clear the DTC.
Diagnosis) in the Service Support for how to Is other DTC detected? No
clear DTCs. Verify repair.
or more. Yes
is set”.
6. Check the DTC.

4021-85
Block diagram
Yes

Diagnostic aid
• Load (fluid pressure pump etc.) is light.
• Crankshaft position (CKP) sensor, camshaft position (CMP) sensor fault (signal fault etc.)
• Engine body fault (supply pump, injector, body, etc.)
• ECM internal trouble
• Check the connector for poor contact, the harness for fault such as wear or bend, and the wire inside the
harness for loosened wire causing short circuit to other circuits. Also, perform the function diagnosis to check
the operation and control of each part.
Repair if faulty.
• When this DTC is detected, check the engine body for trouble such as seizure and breakage.

4021-86
DTC (error code): 0237 Boost sensor pressure fault (low voltage fault)
Black smoke emitted
Step 1

2. Check for “MAP (manifold absolute
pressure) sensor” on the data display using
Step 2
scan tool.
Step 4
Check for installation condition of the boost Yes
pressure sensor connector, ECM connector
and coupling connector.
connection. 0.1V
2. If the trouble is detected, repair as required. Is the “MAP (manifold absolute pressure) No
sensor” the threshold value or less? Go to “Diagnostic aid”.
Step 5
2. Disconnect the boost pressure sensor Yes
connector.
3. Short between the boost pressure sensor
connector power supply terminal and the
signal terminal using jump cable.
5. Check for “MAP (manifold absolute Go to Step 12.
scan tool.
Step 6
1. Check for followings in the power supply Specified value
circuit between ECM and boost pressure 4.8V
sensor using breaker box or DMM. No Is the “MAP (manifold absolute pressure)
Refer to “Breaker box inspection procedure”. sensor” the specified value or more?
Note:
Go to Step 8.
• Open circuit
• High resistance
Step 7
1. Check for followings in the signal circuit Yes
between ECM and boost pressure sensor Go to Step 12.
Note:
• Short circuit to boost pressure sensor
ground circuit
Go to Step 9.

4021-87
From Step 5 and 17

Step 8
Replace the boost pressure sensor.
Step 10
rewriting of ECM. Yes
necessary. From Step 7
Note:
replacing or rewriting the ECM. No
Yes
No
Replace the ECM.
Note: Yes
Step 12 Yes
2. Clear the DTC.
clear DTCs.
is set”.
6. Check the DTC.
Step 13

Verify repair.
Yes
From Step 2
Step 14
2. Check the display of boost pressure sensor.
Specified value
508Mpa
error value
Does the display of “Boost pressure No
sensor” show error value? Go to “Diagnostic aid”.
Yes
Go to Step 15.

4021-88
From Step 14
Step 15
Check for installation condition of the boost
connection.
Yes
Go to Step 13.
Step 16
circuit between ECM and boost pressure
Note:
Go to Step 12.
• Open circuit
• High resistance
Step 17
between ECM and boost pressure sensor
Note:
• Short circuit to boost pressure sensor No Is the trouble detected?
ground circuit
Yes
• High resistance
Go to Step 8.
Block diagram


4021-89
Diagnostic aid
• Damaged harness


6,16 • Disconnect the 95 – Sensor 100Ω 10MΩ
Open circuit/ Resistance sensor connector. power supply or less or more
high resistance measurement • Key switch “OFF” terminal
7,17 • Disconnect the 91 – 109 10MΩ 100Ω

Short circuit to Resistance sensor connector. 91 – Ground or more or less
ground circuit/ measurement • Key switch “OFF”
ground
• Disconnect the 91– Sensor 100Ω 10MΩ
Open circuit/ Resistance sensor connector. connector signal or less or more

4021-90
DTC (error code): 0238 Boost sensor pressure fault (high voltage fault )
Black smoke emitted
Step 1

Step 3
2. Check for “MAP (manifold absolute
Step 2
scan tool.
Step 4
Yes
2. If the trouble is detected, repair as required. 4.9V
Is the “MAP (manifold absolute pressure)
No
sensor” the specified value or more? Go to “Diagnostic aid”.
Step 5
connector.
4. Check for “MAP (manifold absolute No Is the trouble detected?
scan tool.
Yes
Go to Step 12.
Step 6
boost pressure sensor for short circuit to the
power supply circuit or ignition power supply Specified value
circuit using breaker box or DMM. 0.1V
Refer to “Breaker box inspection procedure”. No Is the “MAP (manifold absolute pressure)
Note: sensor” the specified value or more?
Important:
Yes
If the boost pressure sensor circuit is shorted Go to Step 8.
to the power supply circuit, the sensor may be
broken.
Step 7
Yes
Go to Step 12.
Note:
• Open circuit
• High resistance No Is the trouble detected?
Yes
Go to Step 12.
Go to Step 9.

4021-91
From Step 5
Step 8
Replace the boost pressure sensor.
Step 10
Refer to “Flash Tool (EMPS)” for check Is the procedure completed?
and rewriting of ECM.
necessary.
Note: From Step 7
replacing or rewriting the ECM. Step 9
[EGR valve position learning procedure] No
1. Turn the key switch to “ON”. Is EMPS available?
Yes
Step 11 No
Note:
Step 12
2. Clear the DTC.
or more.
Yes
Go to Step 2.
is set”.
5. Check the DTC.
Step 13

Verify repair.
Yes
From Step 2
Step 14
2. Check the display of boost pressure sensor.
Specified value
508Mpa
error value
Does the display of “Boost pressure No
sensor” show error value? Go to “Diagnostic aid”.
Yes
Go to Step 15.

4021-92
connection.
Step 16
1. Check the signal circuit between ECM and Yes
Go to Step 12.
boost pressure sensor for short circuit to the
power supply circuit or ignition power supply
circuit using breaker box or DMM.
Note: No Is the trouble detected?
If breaker box is not available, refer to ,
Important: Yes
If the boost pressure sensor circuit is shorted Go to Step 12.
to the power supply circuit, the sensor may be
broken.
Step 17
Note:
• Open circuit
Go to Step 8.
Block diagram


4021-93
Diagnostic aid
ECM connector
• Damaged harness


6,16 • Disconnect the 0V 18V
Short circuit to Voltage sensor connector. 91 – Ground or more
Power supply measurement • Key switch “ON”
circuit
7,17 • Disconnect the 109– Sensor 100Ω 10MΩ

Open circuit/ Resistance sensor connector. connector ground or less or more

4021-94
DTC (error code): 0335 CKP (crank position) sensor fault (no signal)
• Output lowering
• White smoke emitted
• Intense engine vibration possible
• Engine stall possible (restart is possible when CMP (camshaft
position) sensor is normal.)
Step 1

Step 2
Check for installation condition of the CKP
sensor.
Yes
2. Visually check the sensor for installation
condition such as play or looseness.
Step 3
Check for installation condition of the CKP Yes
connection.
2. If the trouble is detected, repair or replace as Is the procedure completed?
required.
Yes
Step 4
1. Clear the DTC.
Refer to “How to clear DTC:rocedure of
Trouble Diagnosis” in this section for how to Is DTC detected? No
or more.
Yes
3. Start the engine, and test run with the
“Preconditions when DTC is set”.
4. Check the DTC.

Check the CKP sensor body. Between terminals: 108.5 - 142.5 Ω
1. Turn the key switch to “OFF”. Each terminal -- ground: ∞ Ω
2. Remove the harness from the CKP sensor. No (at normal temperature)
3. Measure the resistance between the sensor
connector terminals. Is the resistance within the specified
value?
Step 6
ECM and CKP sensor using breaker box or
Yes
DMM.
Note: No
Is the trouble completed?
“On-board check procedure for sensors.
• Short circuit between terminals
• Short circuit to power supply circuit or
Step 7
Replace the CKP sensor. Yes
Go to Step 11.

4021-95
From Step 6
Step 9
rewriting of ECM.
Step 8
necessary. No
Is EMPS available?
Note:
1. Turn the key switch to “ON”. No
Step 10
Yes
Replace the ECM.
Note:
[EGR valve position learning procedure] Is the procedure completed?
Step 11
1. Connect all the harnesses. No Is DTC: 0335 detected?
2. Clear the DTC.
Diagnosis) in the Service Support for how to Yes
or more.
is set”.
5. Check the DTC.
Step 12
Check if other DTC is detected. Verify repair.
Yes

4021-96
Block diagram

• Fault judgement needs cranking for about 10 seconds.
• CMP sensor pulse is normal.
• DTC: 0335, 0336, 0340, 0341, or 1345 is not detected.
• Engine is running.
Diagnostic aid
• Damaged harness
• For crank sensor fault, DTC won’t be detected unless the engine cranks for 14 revolutions. Especially when
running with low speed such as idling, engine stalls before cranking for 14 revolutions if no crank signal exist.
In this case, the back-up mode will not be active because DTC is not detected. Therefore, the engine can be
restarted even after it stalls, making it difficult to identify the fault. If the engine experienced stall, raise the
engine speed up to No Load Max, and check if crank sensor fault is detected while cranking for 14
revolutions. If crank sensor fault is detected at No Load Max, DTC will be detected. If intermittent trouble is
found, raise the engine speed up to No Load Max, and check if DTC is detected.

4021-97


6 • Disconnect the 106 – Sensor 100Ω 10MΩ
Open circuit/ Resistance sensor connector. connector(-) or less or more
107 - Sensor
connector(+)
terminal
Short circuit • Disconnect the 106 – GND 10MΩ 100Ω
to ground Resistance sensor connector. or more or less
measurement • Key switch “OFF” 107 – GND
Short circuit • Disconnect the 106 – 107 10MΩ 100Ω

between terminals Resistance sensor connector. or more or less
measurement • Key switch “OFF”
Short circuit • Disconnect the 106 – GND 0V 18V

to power supply Voltage sensor connector. or more
circuit measurement • Key switch “ON” 107 – GND

4021-98
DTC (error code): 0336 CKP (crank position) sensor fault (signal fault)
• Output lowering
• White smoke emitted
• Intense engine vibration possible
• Engine stall possible (restart is possible when CMP (camshaft
position) sensor is normal.)
Step 1
Step 2 Go to
Check for installation condition of the CKP Service Support check.
sensor.

Check for installation condition of the CKP
connection.
required. Is the procedure completed?
Step 4
Yes
1. Clear the DTC.
Refer to “How to clear DTC , Procedure of
Trouble Diagnosis” in this section for how to
clear DTCs.
Is DTC detected? No
2. Turn the key switch to “OFF” for 10 seconds Go to Step 12.
or more.
3. Start the engine, and test run with the Yes
4. Check the DTC.
Step 5
1. Check the CKP sensor circuit for short circuit
to other signal circuit using breaker box or No Is the trouble detected?
DMM.
required.
Step 6
Check the CKP sensor body. Specified value
Between terminals: 108.5 - 142.5 Ω
2. Remove the harness from the CKP sensor.
Each terminal -- ground: ∞ Ω
3. Measure the resistance between the sensor (at normal temperature)
connector terminals. No
Is the CKP sensor normal?
4. Remove the CKP sensor and check the
sensortip for scratch or damage.
Yes
Go to Step 8.
Step 7
Replace the CKP sensor.
Yes
Go to Step 12.

4021-99
From Step 6
Step 8
1. Visually check the flywheel for chipped
tooth.
2. If the trouble is detected, replace it.
Step 10
rewriting of ECM.
necessary.
Note:
Is EMPS available?
Yes
No
Replace the ECM.
Note: Yes
Step 12 Yes
2. Clear the DTC.
clear DTCs.
is set”.
5. Check the DTC.
Step 13

Verify repair.
Yes

4021-100
Block diagram

• CMP sensor pulse is normal.
• DTC: 0335, 0336, 0340, 0341, or 1345 is not detected.

4021-101
Diagnostic aid
• Damaged harness
• For crank sensor fault, DTC won’t be detected unless the engine cranks for 14 revolutions. Especially when
running with low speed such as idling, engine stalls before cranking for 14 revolutions if
no crank signal exist. In this case, the back-up mode will not be active because DTC is not detected.
Therefore, the engine can be restarted even after it stalls, making it difficult to identify the fault. If the engine
experienced stall, raise the engine speed up to No Load Max, and check if crank sensor fault is detected while
cranking for 14 revolutions. If crank sensor fault is detected at No Load Max, DTC will be detected. If
intermittent trouble is found, raise the engine speed up to No Load Max, and check if DTC is detected.


5 Short circuit • Disconnect the 106 – Gound 0V 1V
to other signal Voltage sensor connector. or more
circuit measurement • Key switch “ON” 107 – Gound

4021-102
DTC (error code): 0340 CMP (cam position) sensor fault (no signal)
• Engine does not start (restart).

• Behavior does not change during engine running.
Step 1
Step 2 No Go to
Check for installation condition of the CMP Is the procedure completed?
sensor.

Check for installation condition of the CMP
sensor,ECM and coupling connector. Yes
connection.
Step 4
Yes
1. Clear the DTC. No
Refer to “How to clear DTC, procedure of Is DTC detected?
Go to Step 11.
Trouble Diagnosis” for how to clear DTCs.
or more.
3. Start the engine, and test run with the
4. Check the DTC.
Step 5 No
Is the CMP sensor normal?
Remove the CMP sensor, and check the Go to Step 9.
sensor tip for scratch or damage.
Yes
Step 6
circuit between ECM and CMP sensor using
breaker box or DMM.
Note:
• High resistance
Yes
Go to Step 15.
required.
Step 7
between ECM and CMP sensor using
breaker box or DMM.
Note: Yes
• Open circuit
• High resistance
Go to Step 8.
required.

4021-103
From Step 7
Step 8
1. Check for followings in the shield circuit
between ECM and CMP sensor using
breaker box or DMM.
Note:
• Open circuit
• High resistance
ignition power supply circuit From Step 5
required.
Step 9
Replace the CMP sensor. Is the procedure completed?
Step 10 Yes
1. Visually check the camshaft gear for fault.
2. Check the alignment mark in the timing gear.
3. If the trouble is detected, repair or replace it.
Step 11
Replace the supply pump. Yes
Note:
the service manual.

rewriting of ECM. Yes
necessary.
Note:
No
Step 14
Replace the ECM.
Note:
Yes
Step 15
Yes
1. Clear the DTC.
Refer to “How to clear DTC:rocedure of
Trouble Diagnosis” how to clear DTCs. No Is DTC: 0340 detected?
or more.
“Preconditions when DTC is set”. Go to Step 2.
4. Check the DTC.
Go to Step 16.

4021-104
From Step 15
Step 16

Verify repair.
Yes
Block diagram

• CKP (crankshaft position) sensor pulse is normal.
• DTC:0335, 0336, 0340, 0341, 1345, or 1635 is not detected.

4021-105
Diagnostic aid

• Damaged harness
• The cam gears are out of installation phase by one tooth.


6 Open circuit/ • Disconnect the 99– Sensor 100Ω 10MΩ
high resistance Resistance sensor connector. connector power or less or more
measurement • Key switch “OFF” supply terminal
Short circuit • Disconnect the 99 – Ground 10MΩ 100Ω

to ground Resistance sensor connector. or more or less
measurement • Key switch “OFF”

high resistance Resistance sensor connector. connector signal or less or more
measurement • Key switch “OFF” terminal
Short circuit • Disconnect the 98 – Ground 0V 18V

to power supply Resistance sensor connector. or more
circuit measurement • Key switch “ON”

high resistance Resistance sensor connector. connector shield or less or more
measurement • Key switch “OFF” terminal
Short circuit • Disconnect the 100 – Ground 0V 18V

to power supply Resistance sensor connector. or more
circuit measurement • Key switch “OFF”

4021-106
DTC:0341 CMP (cam position) sensor fault (signal fault)
• Engine does not start (restart).

• Behavior does not change during engine running.
Step 1

Check for installation condition of the CMP Service Support check.
sensor.

Step 3
Check for installation condition of the CMP
connection.
Step 4 Yes
1. Clear the DTC.
Refer to “How to clear DTC, Procedure of
Trouble Diagnosis” for how to clear DTCs. No
2. Turn the key switch to “OFF” for 10 seconds Is DTC detected?
Go to Step 11.
or more.
4. Check the DTC.
Step 5
Remove the CMP sensor, and check the Is the CMP sensor normal? No
Go to Step 8.
sensor tip for scratch or damage.
Yes
Step 6
2. Remove the harness from the CMP sensor.
3. Connect the breaker box or DMM between
the CMP sensor terminals.
Note:
If breaker box is not available, refer to Specified value
“On-board check procedure for sensors”. 0V
No
4. Turn the key switch to “ON”. Is the DMM indication specified value?
Yes
1. Check the CMP sensor circuit for short
circuit to other signal circuit using breaker
box or DMM.
Note:
required.
Yes
Go to Step 14.
Go to Step 9.

4021-107
From Step 6
Step 8
Replace the CMP sensor.
Yes
From Step 7
Step 9
1. Visually check the camshaft gear for fault.
2. Check the alignment mark in the timing gear.
3. If the trouble is detected, repair or replace it.
Step 10 Yes
Note:
the service manual.

rewriting of ECM.
Step 11
2. Rewrite the software if version upgraded is No
Is EMPS available
necessary.
Note:
Step 13
Note:
Yes
Step 14
1. Clear the DTC.
Trouble Diagnosis” for how to clear DTCs. No Is DTC:0341 detected?
or more.
“Preconditions when DTC is set”. Go to Step 2.
4. Check the DTC.
Step 15

Verify repair.
Yes

4021-108
Block diagram

• CKP sensor pulse is normal.
• DTC: 0335, 0336, 0340, 0341, 1345, or 1635 is not detected.
Diagnostic aid
• Damaged harness

4021-109


7 Short circuit • Disconnect the 98 – Ground 0V 1V
to other signal Voltage sensor connector. or more
circuit measurement • Key switch “ON”

4021-110
DTC (error code): 0380 Glow relay circuit fault
Deterioration of startability
Step 1

Yes
Step 2
Step 3
2. Check for “Glow relay” on the data display
using scan tool.
No Is the “Glow relay” displayed “ON”?
Step 4
2. Hold it for 10 seconds or more.
using scan tool.
Is the “Glow relay” displayed “OFF”? No
Go to Step 9.
Step 5 Yes
Check for installation condition of the glow Go to “Diagnostic aid”.
relay, ECM connector and coupling connector.
connection.
Step 6
2. Remove the glow relay. Go to Step 12.
3. Short between the terminals 2 - 4 in the glow
relay installing portion using jump cable.
using scan tool. No Is the “Glow relay” displayed “ON”?
Step 7
Yes
Go to Step 11.
1. Check for following in the circuit between the
fuse and the glow relay.
• Open circuit
• Short circuit to ground circuit
• High resistance
Yes
Go to Step 12.
Go to Step 8.

4021-111
Step 8
glow relay and ECM using breaker box or
DMM.
Refer to “Breaker box inspection procedure”. From Step 7
Note:
• Open circuit
• High resistance No
2. If the trouble is detected, repair as required. Is the trouble detected?
Yes
Step 9
2. Remove the glow relay.
using scan tool.
No Is the “Glow relay” displayed “OFF”?
Yes
Step 10
1. Check the circuit between glow relay and
ECM for short circuit to the power supply
circuit ignition power supply circuit using
breaker box or DMM.
Note:
Yes
Step 11
Replace the glow relay.

rewriting of ECM.
necessary. No Is EMPS available?
Note:
Yes
Step 14
Replace the ECM.
Yes
Go to Step 15.
Note:
Yes
Go to Step 15.

4021-112
From Step 13 and 14

Step 15
2. Clear the DTC.
Trouble Diagnosis” in this section for how to
clear DTCs.
or more.
is set”. Yes
Step 16

Verify repair.
Yes
From Step 2
Step 17
Check for installation condition of the glow
Is the trouble detected? No
Go to Step 7.
1. Check for play or looseness in
Yes
Go to Step 12.

4021-113
Block diagram

• Key switch input voltage is 16 V or more and 32 V or less.

4021-114
Diagnostic aid
• Damaged harness


8
Open circuit/ Resistance • Disconnect the 10 - FL12 10MΩ 10MΩ
high resistance measurement relay. connector or less or more
• Key switch “OFF” No.1 terminal
Short circuit Resistance • Disconnect the 10 - Ground 10MΩ 10MΩ

to ground measurement relay. or more or less
10
Short circuit Voltage • Disconnect the 100 - Ground 0V 18V
to power supply measurement relay. or more

4021-115
DTC (error code): 0487 EGR position sensor fault
Exhaust gas is affected.
Step 1

Check for installation condition of the EGR Service Support check.
valve connector, ECM connector and coupling
connector.
Yes
connection.
Step 3
ECM and EGR position sensor using
Yes
Go to Step 10.
breaker box or DMM.
Note:
• Short circuit to EGR position sensor
ground circuit
• Short circuit to ground Yes
• High resistance
Step 4
2. Clear the DTC.
Diagnosis) in Service Support for how to
clear DTCs. Is DTC:0487 detected? No
3. Turn the key switch to “OFF” for 10 seconds Go to “Diagnostic aid”.
or more, and then start the engine.
4. Warm-up the engine until the engine coolant Yes
temperature exceeds 80°C.
5. Check the DTC.
Step 5
Replace the EGR valve (EGR position sensor).
Note:
the service manual.

Step 6
2. Clear the DTC.
clear DTCs.
3. Turn the key switch to “OFF” for than 10 Is DTC:0487 detected? No
seconds or more, and then start the engine. Go to Step 11.
4. Warm-up the engine until the engine coolant
Yes
5. Check the DTC. Step 7
No
Is EMPS available?
Yes

4021-116
Step 8
From Step 7
rewriting of ECM.
2. Rewrite the software if version upgraded
necessary.
Note:
Step 9
Replace the ECM.
Note:
Step 10
2. Clear the DTC.
Refer to the screen of DIAG(Trouble
Diagnosis) in Service Support for how to No
Is DTC:0487 detected?
clear DTCs.
or more. Yes
4. Warm-up the engine until the engine coolant Go to Step 2.
5. Check the DTC.
Step 11
Verify repair.
Yes

4021-117
Block diagram

• Main relay input voltage is 18 V or more.
• DTC:1630 or 1635 is not detected.
Diagnostic aid
• Damaged harness

4021-118

3 • Disconnect the 87 – EGR valve 100Ω 10MΩ
Open circuit/ Resistance EGR valve connector. connector or less or more
high resistance measurement • Key switch “OFF” sensor power
supply terminal
4 • Disconnect the 92 - 101 10MΩ 10MΩ
Short circuit Resistance EGR valve connector. 93 - 101 or more or less
to ground circuit/ measurement • Key switch “OFF” 94 - 101
ground 92 - GND
93 - GND
94 - GND
• Disconnect the 92 - EGR valve 100Ω 10MΩ
Open circuit/ Resistance EGR valve connector. connector position or less or more
high resistance measurement • Key switch “OFF” sensor signal W
terminal
93 - EGR valve
connector position
sensor signal V
terminal
94 - EGR valve
connector position
sensor signal U
terminal

4021-119
DTC (error code): 0488 EGR valve control fault
Exhaust gas is affected.
Step 1

Yes
Step 2
Step 3
1. Perform “EGR control test” using scan tool. Yes
2. Press the “Up” “Down” soft key.
3. Check the value for “EGR position”.

Check the DTC again. No ± 3%
1. Connect all the harnesses. Is “EGR position” within the specified
2. Clear the DTC. value?
Diagnosis) in Service Support for how to Yes
clear DTCs.
or more, and then start the engine.
4. Warm-up the engine until the engine coolant Is DTC: 0488 detected? No
5. Check the DTC.
Yes
Go to Step 8.
Step 5
1. Check for followings in the motor drive circuit
between ECM and EGR motor using breaker
box or DMM.
Note:
• Open circuit
• Short circuit to power supply circuit or Yes
ignition power supply circuit Go to Step 11.
• High resistance
Step 6
Replace the EGR valve.
Note:
the service manual.
Step 7
2. Clear the DTC.
Refer to the screen of DIAG (Trouble No
Diagnosis) in Service Support for how to Is DTC: 0488 detected? Go to Step 12.
clear DTCs.
Yes
more than, and then start the engine.
temperature exceeds 80°C. Go to Step 8.
5. Check the DTC.

4021-120
From Step 7
Step 9
rewriting of ECM.
Step 8
2. Rewrite the software if version upgraded is No
Note:
Yes
Step 10
Replace the ECM.
Note:
Step 11 Yes
2. Clear the DTC.
clear DTCs.
3. Turn the key switch to “OFF” for 10 seconds No
or more, and then start the engine. Is DTC:0488 detected?
temperature exceeds 80°C. Yes
Step 12

Verify repair.
Yes
Step 13 From Step 2

1. Remove the EGR valve.
2. Check the EGR valve for anchoring,
clogging, etc.
Go to Step 4.
Yes
Go to Step 5.

4021-121
Block diagram

• Main relay input voltage is 20 V or more and 32 V or less.
• DTC:0487, 0488, 1630, or 1635 is not detected.
Diagnostic aid
• Damaged harness

4021-122


5 Short circuit to Voltage • Disconnect the 111 – Ground 0V 18V

power supply measurement EGR valve connector. 103 – Ground or more
circuit • Key switch “ON” 110 – Ground
111 – Ground
Short circuit to Resistance • Disconnect the 103 – Ground 10 MΩ 100Ω
ground measurement EGR valve connector. 110 – Ground or more or less
111 – EGR valve
Open circuit/ Resistance • Disconnect the connector 100Ω 10 MΩ
high resistance measurement EGR valve connector. motor drive U or less or more
103 – EGR valve
connector
motor drive V
terminal
110 – EGR valve
connector
motor drive W
terminal

4021-123
DTC (error code): 0522 Engine oil pressure sensor fault (low voltage fault)
Operationality is not affected.
Step 1
Perform the
Yes
Step 2
Step 3 No
Check the value for engine oil pressure sensor available?
using scan tool.
Yes
3. Check the value for “Engine oil pressure
sensor” using scan tool. Specified value
0.1V
Is the “Engine oil pressure sensor” the No
Step 4 specified value or less? Go to “Diagnostic aid”.
Check for installation condition of the engine oil
pressure sensor, ECM and coupling connector.
connection.
required.
Step 5
2. Disconnect the engine oil pressure sensor Go to Step 11.
connector.

1. Check for followings in the signal circuit 0V
between ECM and engine oil pressure No Is the “Engine oil pressure sensor” the
sensor using breaker box or DMM. specified value or more?
Note: Yes
• Short circuit to engine oil pressure sensor
ground circuit
required.
Yes
Go to Step 11.
Step 7
Replace the engine oil pressure sensor.
Yes
Go to Step 11.
Go to Step 8.

4021-124
From Step 6
Step 9
rewriting of ECM. Step 8
No
2. Rewrite the software if version upgraded is Is EMPS available?
necessary.
Note: Yes
1. Turn the key switch to “ON”. No Is the procedure completed?
Step 10
Replace the ECM.
Note:
Yes
Step 11
2. Clear the DTC.
clear DTCs.
or more.
5. Check the DTC.
Step 12
2. Check the display of engine oil pressure. Specified value
1016 kPa
No
Step 13 (error value) Go to “Diagnosis aid”.
Check for installation condition of the engine oil Does the display of engine oil pressure show
pressure sensor, ECM and coupling connector. error value?
connection.
Yes
required.
Step 14
between ECM and engine oil pressure
Yes
Go to Step 11.
Note:
• Short circuit to engine oil pressure sensor
ground circuit
required.
Go to Step 7.

4021-125
Block diagram

• DTC:1633 is not detected.

4021-126
Diagnostic aid
• Damaged harness

6
Short circuit to Resistance • Disconnect the 67 – 79 10 MΩ 100Ω
ground circuit/ measurement sensor connector. 67 – Ground or more or less
ground • Key switch “OFF” 80 – 79
80 – Ground

4021-127
DTC:0523 Engine oil pressure sensor fault (high voltage fault)
Step 1
Step 3 Perform the

Check the value for engine oil pressure sensor Service Support check.
using scan tool.
Step 2
Step 4
Check for installation condition of the engine oil
Yes
pressure sensor, ECM and coupling connector.
connection.
2. If the trouble is detected, repair or replace as Specified value
required. 4.85V
Is the “Engine oil pressure sensor” the No
specified value or more? Go to “Diagnostic aid”.
Step 5
2. Disconnect the engine oil pressure sensor Yes
connector.
3. Short the engine oil pressure sensor
connector signal terminal to the ground
terminal using jump cable. No Is the trouble detected?
Yes
Specified value
Step 6 0V
No Is the “Engine oil pressure sensor” the
engine oil pressure sensor for short circuit to specified value or less?
the power supply circuit or ignition power
supply circuit, using breaker box or DMM. Yes
Refer to “Breaker box inspection procedure”. Go to Step 9.
Note:
Important:
If the engine oil pressure sensor circuit is No Is the trouble detected?
may be broken. Yes
Go to Step 7.

4021-128
Step 7 From Step 6
Note:
• Open circuit
required.
Step 8
sensor, using breaker box or DMM.
Note:
• High resistance
2. If the trouble is detected, repair or replace
as required.
From Step 5
Step 9
Replace the engine oil pressure sensor.

rewriting of ECM.
necessary.
Note: Step 10
EGR valve position learning is required after No
Step 12
Replace the ECM.
Note: Yes
Step 13
Yes
2. Clear the DTC.
Refer to the screen of DIAG (Trouble No Is DTC: 0523 detected?
clear DTCs.
Go to Step 2.
or more.
is set”.
5. Check the DTC.
Go to Step 14.

4021-129
From Step 13
Step 14
Check if other DTC detected.

Verify repair.
Yes
Step 15
1. Start the engine. Go to each DTC diagnosis.
2. Check the display of engine oil pressure.
From Step 3
Step 16
engine oil pressure sensor for short circuit to
the power supply circuit or ignition power
supply circuit, using breaker box or DMM. Specified value
Refer to “Breaker box inspection procedure”. 1016 kPa No
Note: (error value) Go to “Diagnosis aid”.
If breaker box is not available, refer to Does the display of engine oil pressure
“On-board check procedure for sensors”. show error value?
Important:
If the engine oil pressure sensor circuit is Yes
may be broken.
Step 17
Go to Step 13.
Note:
• Open circuit
• High resistance
Yes
Go to Step 13.
required.
Step 18
Note:
• Open circuit
• High resistance
Go to Step 9.

4021-130
Block diagram

• DTC: 1633 is not detected.

4021-131
Diagnostic aid
• Damaged harness


6
Short circuit to Voltage • Disconnect the 0V 18V
Power supply measurement sensor connector. 67 – Ground or more
7
Open circuit/ Resistance • Disconnect the 67 – Sensor 100Ω 10MΩ
• Key switch “OFF terminal
8
high resistance measurement sensor connector. connector ground or less or more

4021-132
DTC (error code): 0601 ROM fault
Engine stopped
Step 1

1. Clear the DTC.
Refer to the screen of DIAG (Trouble Yes
clear DTCs.
or more. No
3. Test run with the “Preconditions when DTC Is DTC: 0601 detected?
Go to “Diagnosis aid”.
is set”.
Step 4
Step 3
1. Check the version of ECM software. No
Is EMPS available?
rewriting of ECM.
necessary.
Note:
EGR valve position learning is required after No Is the procedure completed?
Step 5
Replace the ECM.
Note:
Step 6

Verify repair.
Yes

4021-133
DTC (error code): 0603 EEPROM fault
Step 1
Step 2 No
Is the procedure completed? Go to
1. Clear the DTC. Service Support check.
clear DTCs.
10 seconds.
3. Test run with the “Preconditions when DTC Is DTC:0603 detected? No
is set”.
Step 4
Step 3
1. Check the version of ECM software. No Is EMPS available?
rewriting of ECM.
necessary.
Note:
Step 5
Replace the ECM.
Note:
EGR valve position learning is required after Is the procedure completed?
Step 6

Verify repair.
Yes

4021-134
DTC (error code): 0606 CPU fault
• Output lowering
• Unable to start
Step 1

1. Clear the DTC.
clear DTCs.
or more. No
3. Test run with the “Preconditions when DTC Is DTC:0606 detected?
is set”.
Step 4 Step 3
No
1. Check the version of ECM software. Is EMPS available?
rewriting of ECM.
Yes
necessary.
P
Note:
Step 5
Replace the ECM.
Note:
Step 6

Verify repair.
Yes

4021-135
DTC (error code): 0611 Charge circuit fault (bank 1)
• Rough idling
• Output lowering
Step 1

Yes
Step 2
Step 3 available? Go to Step 12.
1. Make sure all the communication between
ECU and scan tool is normal. Yes
2. Make sure the system which require
programming operates normally.
3. Check the DTC.
Yes
between ECM terminals (1, 3, 4, 43, 62, 81)
and ECM ground terminal (E2) using breaker
box or DMM.
• Open circuit
Yes
Go to Step 10.
Step 5
2. Remove the ECM ground terminal (E2).
3. Check the ECM ground terminal (E2) for
intermittent trouble or poor contact.
Step 6
Yes
Go to Step 10.
2. Remove the ECM.
3. Check the ECM terminals (1, 3, 4, 43, 62,
81) for intermittent trouble or poor contact.
Yes
Go to Step 10.
Step 7
No
Is EMPS available?
Yes

4021-136
Step 8
From Step 7
rewriting of ECM.
necessary. No Is the procedure completed?
Note:
Step 9
Replace the ECM.
Note:
Step 10
2. Clear the DTC.
or more.
is set”.
Go to Step 2.
5. Check the DTC.
Step 11
Check if other DTC is detected. No
Verify repair.
Yes
From Step 2
No Step 12
Is DTC: 0611 detected?
Yes
Go to Step 4.
Block diagram


4021-137
DTC (error code): 0612 Charge circuit fault (bank 2)
• Rough idling
• Output lowering
Step 1

Yes
Step 2
1. Make sure all the communication between
ECU and scan tool is normal. Yes
2. Make sure the system which require
programming operates normally.
3. Check the DTC.
Go to Step 10.
Step 4
between ECM terminals (1, 3, 4, 43, 62, 81)
and ECM ground terminal (E2) using breaker
box or DMM.
• Open circuit
Yes
2. Remove the ECM ground terminal (E2).
3. Check the ECM ground terminal (E2) for
intermittent trouble or poor contact.
Step 6
Yes
Go to Step 10.
2. Remove the ECM.
3. Check the ECM terminals (1, 3, 4, 43, 62,
81) for intermittent trouble or poor contact.
Yes
Go to Step 10.
Step 7
No
Is EMPS available?
Yes

4021-138
Step 8
From Step 7
rewriting of ECM.
necessary. No Is the trouble detected?
Note:
Step 9
Replace the ECM.
Note:
Step 10
2. Clear the DTC.
clear DTCs. No Is DTC: 0612 detected?
or more.
is set”.
Go to Step 2.
5. Check the DTC.
Step 11
Verify repair.
Yes
From Step 2
No Step 12
Is DTC: 0612 detected?
Yes
Go to Step 4.
Block diagram


4021-139
DTC (error code): 1093 No pump pressure feed
• Intense engine vibration • Rough idling

• Output lowering • Engine blow up fault
• Black smoke emitted • Engine stall
• Excessive output is possible.
Step 1
Step 2 Go to
Check the fuel system in the following Service Support check.
procedure.
1. Check the high pressure pipe and low Yes
connection (fuel leakage), crush or
clogging.
Check the clogging in the following No Is the fuel system normal?
procedure.
• Fuel filter (main fuel filter, pre-fuel
filter, gauze filter) Yes
• Fuel tank (pump strainer)
• Fuel system pipe
2. Check the fuel pipe, fuel filter, and
inside of the fuel tank for freeze or
waxing. (at cold temperature)
3. Check the feed pipe inside the fuel tank
for clogging of foreign matter.
Step 3
Check the electromagnetic pump. Is the procedure completed?
1. Inspect the electromagnetic pump by
referring to “Electromagnetic pump Yes
inspection procedure”.
2. Repair or replace the faulty part.
Step 4
Check for rise of fuel level in the oil level gauge No
or light oil odor. Is the trouble detected?
Step 5 Yes
Check the connection of the fuel pipe in each
injector, and replace the injector if oil leakage
is confirmed.
Note:
For work procedure, refer to “Engine section” in Is the procedure completed?
the service manual.
Step 7
Yes
Go to Step 17.
Check the injector.
1. Clear the DTC.
Step 6
clear DTCs. Is the scan tool (KW communication) Go to Step 20.
2. Start the engine. available?
the menu. Yes
4. Select the “Injection stop at each injector” in
the “Common rail system”.
5. Press the “OFF” soft key to stop the fuel
injection in the cylinder one by one, and Is there any cylinder of which engine
check the change in engine sound. No vibration and engine sound did not
change when it is stopped?
Yes
Go to Step 8.
Go to Step 9.

4021-140
From Step 7
Step 8
1. Replace the injector in the cylinder of which
engine sound did not change when it is
stopped in step 7.
Note:
For work procedure, refer to “Engine section” in Is the procedure completed?
the service manual.
Step 9
Yes
Go to Step 18.
1. Turn the key switch to “ON”. From Step 7
5. Race it quickly about 5 times. Specified value
6. Check for “Common rail pressure” on the At engine stopped:
data display using scan tool. -30MPa
At addling, racing:
±5MPa
Is each value of “Common rail pressure”
No (at engine stopped, idling and racing)
Step 10 around specified value?
connector. Go to Step 16.
Specified value
Step 11 4.8V
No
1. Check the signal circuit between common Is the “Common rail pressure sensor” the
rail pressure sensor and ECM for short specified value or more?
Note:
2. If the trouble is detected, repair as required. No
Step 13
Yes
1. Check the version of ECM software. Go to Step 18.
rewriting of ECM.
Step 12
necessary. No
Is EMPS available?
Note:
2. Turn the key switch to “OFF”. No
Step 14 Yes
Replace the ECM. Go to Step 18.
Note:
Go to Step 18.

4021-141
Step 15
From Step 10
pressure sensor).
Note:
Step 16
Yes
1. Clear the DTC.
clear DTCs. From Step 9
the menu.
“Common rail system”.
5. Press the “Up” soft key to check the value of No Specified value
“Common rail pressure”. ±5Mpa
Is “Common rail pressure” within the
specified value?
Step 17 Yes
Note:
the service manual.

Step 18
2. Clear the DTC.
clear DTCs.
or more.
5. Check the DTC.
Step 19

Verify repair.
Yes
From Step 6
Step 20
Check the injector using injector checker.
Refer to “How to use injector checker, How
to Inspect Injector” for how to use injector
checker.
No vibration and engine sound did not
change when it is stopped?
Yes
Go to Step 8.
Go to Step 11.

4021-142
Block diagram

• DTC: 0090, 0192, 0193, 1093, 1291, 1292, or 1635 is not detected.
• Engine coolant temperature is 60 °C or more.
Diagnostic aid
• Fuel system pipe fault (fuel leakage, clogging, crush, etc.)
• Fuel filter fault (clogging)
• Fuel tank fault (clogging)
• ECM trouble

4021-143


11 82 – Ground 0V 1V
Short circuit Voltage • Disconnect the
to other signal measurement sensor connector. 90 – ground or more

4021-144
DTC (error code): 1095 Pressure limiter open
• Output lowering
• Hunting
Step 1

Check the DTC again. Service Support check.
1. Check and record the DTC.
Diagnosis) in Service Support for for how to
clear DTCs.
Is DTC: 1095 detected? No
3. Check the fuel amount, and add fuel as Refer to “Diagnostic aid”.
required. If fuel is low, DTC:1095 may be
detected due to entry of air. Yes
4. Bleed air from the fuel.
• If air bleeding is insufficient, overshoot
exceeds 200 MPa and DTC will be
detected.
Note:
• Bleeding air from fuel must be performed
correctly, following the procedure.
• For work procedure, refer to “Engine
section” in the service manual.
5. Race it quickly about 5 times.
6. Check the DTC.
Step 3
Narrow down the cause.
1. Clear the DTC.
clear DTCs. Is DTC: 1095 detected?
2. Connect another pipe to the supply pump
inlet duct, and test run while supplying fuel. Yes
(At this time, replace the fuel hose with a Go to Step 16.
transparent hose to visually check for air
mixture in the fuel.)
3. Check the DTC.
Step 4
Check the fuel system in the following
procedure.
1. Check the high pressure pipe and low
connection (fuel leakage), crush or clogging.
Check the clogging in the following
No Is the fuel system normal?
procedure.
• Fuel filter (main fuel filter, pre-fuel filter, Yes
gauze filter) Go to Step 6.
• Fuel tank (pump strainer)
• Fuel system pipe
2. Check the fuel pipe, fuel filter, and inside of
the fuel tank for freeze or waxing. (at cold
temperature)
3. Check the feed pipe inside the fuel tank for
clogging of foreign matter.

Step 5
Repair or replace the faulty part.
Yes
Go to Step 17.

4021-145
From Step 4
Step 6
5. Race it quickly about 5 times. Specified value
6. Check for “Differential fuel rail pressure” on At engine stopped:
the data display using scan tool. -30 MPa
At idling, racing:
±5 MPa
Is each value of “Fuel rail pressure” (at
No engine stopped, idling and racing) around
Step 8
2. Disconnect the common rail pressure sensor Go to Step 14.
connector.
Specified value
Step 9 0V
1. Check the signal circuit between common No Is the “Common rail pressure sensor”
rail pressure sensor and ECM for short specified value?
Note:
Yes
rewriting of ECM.
No
Note:
Step 12
Yes
Go to Step 13.
Replace the ECM.
Note:
Go to Step 13.

4021-146
Step 13
From Step 8, 11, 12 and 20
pressure sensor).
Note:
Step 14
1. Restore the machine.
3. Clear the DTC.
From Step 7
clear DTCs.
is set”. Is DTC:1095 detected? No
Step 15
Yes
1. Replace the common rail.
Note:
the service manual.
3. Clear the DTC.
Refer to the screen of DIAG (Trouble Is DTC:1095 detected? No
clear DTCs.
is set”.
5. Check the DTC.
Step 16
1. Clear the DTC.
clear DTCs.
Specified value
If Tech2 is available, go to step 3.
±5Mpa
If Tech2 is not available, Go to Step 17.
No Is “Differential fuel rail pressure” within
the menu.
“Common rail system”.
Yes
5. Press the “Up” soft key to check the value of
“Differential fuel pressure”.
Step 17
Note:
• Bleed air completely after the parts are
replaced. If air bleeding is not sufficient,
DTC:1095 may be detected due to
overshoot of fuel pressure.
• For work procedure, refer to “Engine
section” in the service manual. Is the procedure completed?
Step 18
Yes
2. Clear the DTC.
Diagnosis) in Service Support for how to No Is DTC:0195 detected?
clear DTCs.
or more. Yes
is set”.
Go to Step 19.
5. Check the DTC.

4021-147
From Step 14 and 19
Step 19

Verify repair.
Yes
Step 20
1. Turn the key switch to “OFF”. From Step 6
connector.
4. Connect the DMM between the common rail
pressure sensor connector signal terminal
and the ground.
Note: Specified value
If the display of DMM is not specified value, 0V
No Is the DMM indication specified value?
ECM side wiring, wrap-around in ECM or short
circuit may be the cause.
If it is specified value, ECM side wiring is Yes
normal. Go to Step 13.
Go to Step 9.

4021-148
Block diagram

• DTC: 0090, 0192, 0193, 1093, 1291, 1292, or 1635 is not detected.
Diagnostic aid
• Air mixed in the high-pressure fuel pipe.
• Fuel system pipe fault (clogging etc.)
• Fuel filter fault (temporary clogging due to waxing at low temperatures, improper tightening of filter
cartridge, etc.)
• Fuel tank fault (temporary clogging, air mixed due to fuel shortage, air mixed due to modified fuel pipe
for additional tank etc.)
• ECM trouble
• Running out of fuel

4021-149


9 82 – Ground 0V 1V
Short circuit Voltage • Disconnect the
to other signal measurement sensor connector. 90 – ground or more

4021-150
DTC (error code): 1112 Boost temperature sensor fault (low voltage fault)
Step 1

Yes
Step 2
2. Check for “Boost temperature sensor” on the Yes

0.1V
Check for installation condition of the boost No
temperature sensor connector, ECM connector Is the “Boost temperature sensor” less Go to “Diagnostic aid”.
and coupling connector. than the specified value?
connection. Yes

2. Disconnect the boost temperature sensor
connector. Yes
3. Short between the boost temperature sensor Go to Step 12.
connector ground terminal and the signal
terminal using jump cable.
5. Check for “Boost temperature” on the data
display using scan tool. Specified value
4.8V
Step 6
No Is the “Boost temperature” more than the
1. Check for followings in the power supply specified value?
circuit between ECM and boost temperature
sensor, using breaker box or DMM. Yes
Note:
• Open circuit
• High resistance
Step 7
between ECM and boost temperature Go to Step 12.
Note:
• Short circuit to boost temperature sensor
ground circuit No Is the trouble detected?
• Open circuit
Yes
Go to Step 9.

4021-151
From Step 5 and 8
Step 8
Replace the boost temperature sensor.
Yes
Step 10
rewriting of ECM.
necessary. Step 9
No
Step 11
Note:
Yes
Step 12
2. Clear the DTC.
Diagnosis) in Service Support for how to No Is DTC:1112 detected?
clear DTCs.
or more. Yes
4. Test run with the “Preconditions when DTC Go to step 2.
is set”.
5. Check the DTC.
Step 13

Verify repair.
Yes

4021-152
From Step 2
Step 14
2. Check the display of boost temperature.

Check for installation condition of the boost 214°C
temperature sensor connector, ECM connector (error value) No
and coupling connector. Does the display of “Boost temperature” Go to “Diagnostic aid”.
1. Check for play or looseness in the show error value?
connection.
Step 16
circuit between ECM and boost temperature
• Open circuit
• High resistance
Step 17 Yes
between ECM and boost temperature
Note:
• Short circuit to boost temperature sensor
ground circuit
• High resistance
Go to Step 8.

4021-153
Block diagram

Diagnostic aid
• Damaged harness

4021-154

6 Open circuit/ Resistance • Disconnect the 74 – Sensor 100Ω 10MΩ
7 Short circuit to Resistance • Disconnect the 7 4 – 109 10MΩ 100Ω

ground circuit/ measurement sensor connector. 74 – Ground or more or less
ground • Key switch “OFF”


4021-155
DTC (error code): 1113 Boost temperature sensor fault (high voltage fault)
Step 1

Yes
Step 3 Step 2
1. Turn the key switch to “ON”. Is the scan tool (KW communication) No
2. Check for “Boost temperature sensor” on the available? Go to Step 14.
Yes
Specified value
Step 4 4.95V
Check for installation condition of the boost No
Is the “Boost temperature sensor” the Go to “Diagnostic aid”.
temperature sensor connector, ECM connector specified value or more?
Yes
connection.

boost temperature sensor for short circuit to
the power supply circuit or ignition power Yes
Go to Step 12.
supply circuit, using breaker box or DMM.
Note:
Important:
If the boost temperature sensor circuit is
shorted to the power supply circuit, the sensor Yes
may be broken. Go to Step 11.
Step 6
between ECM and boost temperature
Note:
“On-board check procedure for sensors”. Is the trouble detected? No
• High resistance
Go to Step 11.
From Step 15
Step 7
Replace the boost temperature sensor. Is the procedure completed?
Yes
Go to Step 11.

4021-156
From Step 6
Step 9
No
rewriting of ECM. Is EMPS available?
necessary. Yes
Note:
1. Turn the key switch to “ON”. No Is the procedure completed?
Step 10
Replace the ECM.
Note:
Yes
Step 11
2. Clear the DTC. No Is DTC: 1112 detected?
clear DTCs.
Yes
Go to Step 2.
or more.
is set”.
5. Check the DTC.
Step 12
Verify repair.
Yes

4021-157
From Step 2
Step 13
2. Check the display of boost temperature.
Specified value
214°C
(error value)
Step 14 Does the display of “Boost temperature” No
Check for installation condition of the boost show error value? Go to “Diagnostic aid”.
temperature sensor connector, ECM connector
and coupling connector. Yes
connection.
Step 15
between ECM and boost temperature Yes
sensor, using breaker box or DMM. Go to Step 11.
Note:
• High resistance
Go to Step 11.
Go to Step 7.
Block diagram

• Engine coolant temperature is 50 °C or more.
• 5 minutes have passed after engine starting.

4021-158
Diagnostic aid
• Damaged harness


5 Short circuit to Voltage • Disconnect the 74 – Ground 0V 18V
power supply measurement sensor connector. or more
6 Open circuit/ Resistance • Disconnect the 109 – Sensor 100Ω 10MΩ

high resistance measurement sensor connector. connector ground or less or more

4021-159
DTC (error code): 1173 Overheat
• Output lowering
• Fuel flow is regulated during overheat when
the temperature exceeds 108°C.
Step 1

Step 2 Yes
2. Check the DTC.
No Is DTC: 0088, or 1093 detected?
Yes Go to
the each DTC detected.
Step 3
Step 4
No
1. Turn the key switch to “OFF”. available?
2. Disconnect the ECT (engine coolant
temperature) sensor connector. Yes
4. Check for “Engine coolant temperature
Specified value
4.9V / - 40°C
Is the “Engine coolant temperature
Step 5 No sensor” the specified value or more?
1. Check the signal circuit between ECT
sensor and ECM for short circuit to signal
circuits of other sensors using breaker box or Yes
DMM.
Note:
Step 6
1. Check the engine coolant amount. Go to Step 10.
2. If insufficient, add engine coolant.
Refer to the screen of DIAG (Trouble Go to Step 13.
clear DTCs.
or more.
5. Start the engine, and check the DTC.

Go to Step 13.
Step 7
1. Check for following mechanical defects. Yes
(Refer to “Cooling system” of “Engine
section” in the service manual.)
• Clogging of radiator
• Defective radiator cap
• Loose fan belt No Is the trouble detected?
• Defective thermostat
• Defective water pump
• Defective cylinder head gasket Yes
2. If the trouble is detected, adjust or replace
Go to Step 13.
Go to Step 8.
as required.

4021-160
From Step 7
Step 8

Step 9
1. Clear the DTC. Go to Step 13.
clear DTCs. From Step 5
or more.
is set”.
4. Check the DTC.
Step 11
Yes
rewriting of ECM.
necessary.
Step 10
Note: No Is EMPS available?
Step 12
Yes
Replace the ECM.
Note:
Yes
Step 13

Verify repair.
Yes
From Step 3
Step 14
4. Check the display of the “Engine coolant
temperature”.
Specified value
- 40°C
Is the “Engine coolant temperature” the No
specified value or more? Go to Step 5.
Yes
Go to Step 6.

4021-161
Block diagram

• DTC:0117, 0118, 1630, or 1633 is not detected.

4021-162
Diagnostic aid
• Damaged harness


Short circuit to Voltage • Disconnect the 84 – Ground 0V 1V
5
other signal circuit measurement sensor connector. or more

4021-163
DTC (error code): 1261 Injection nozzle common 1 drive system fault
• Rough idling
• Output lowering
Step 1

1. Turn the key switch to “OFF”. Service Support check.
2. Remove the ECM-side harness connector
from the coupling connector (CN.A3).
Yes
3. Connect the DMM between the injector
power supply 1 circuit and the ground. Specified value
4. Turn the key switch to “ON”. 7.0V
CN.A3 female-side No. 1 Is the DMM indication the specified
No value or more?
Step 3
3. Measure the resistance between the injector
harness connector terminals.
Specified value
1.0Ω
CN.A3 male-side No. 1 and No. 4
Is the resistance the specified
value or less? No
Go to Step 18.
Step 4 Yes
harness connector, ECM connector and
coupling connector.
connection. No
2. If the trouble is detected, repair as required. Is the trouble detected?
Step 5 Yes
1. Check for followings in the injector power Go to Step 23.
supply 1 circuit using breaker box or DMM.
Note:
• Open circuit
• Short circuit to ground Go to Step 23.
Step 6
3. Measure the resistance between the No. 1 Specified value
cylinder injector drive circuit and the ground. 10MΩ
CN.A3 male-side No. 5 Is the resistance the specified
value or more? No
Go to Step 8.
Step 7
Yes
from the coupling connector (CN.A3). Specified value
10MΩ No
3. Measure the resistance between the No. 4
cylinder injector drive circuit and the ground. Is the resistance the specified Go to Step 9.
CN.A3 male-side No. 8 value or more?
Yes
Go to Step 10.

4021-164
Step 8
From Step 6
1. Check the No. 1 cylinder injector drive circuit
between ECM and coupling connector
(CN.A3) for ground short circuit using
breaker box or DMM.
Note:
Yes
Go to Step 23.
From Step 7
Step 9
(CN.A3) for ground short circuit, using
breaker box or DMM.
Refer to “Breaker box inspection procedure”. Is the trouble detected? No
From Step 7
Step 10
2. Check for installation condition of the
injector harness. Is the trouble detected?
Yes
1. Remove the injector harness from the
injector.
No. 1 cylinder, No. 4 cylinder
2. Measure the resistance between each Specified value
injector terminal and the ground. 10MΩ
value or more? No
2. Remove the injector-side harness connector Yes
3. Connect the DMM between the No. 1
cylinder injector drive circuit and the ground. Specified value
CN.A3 female-side No. 5 0V
4. Turn the key switch to “ON”. Is the DMM indication specified value?
No
Yes
Go to Step 15.
Go to Step 13.

4021-165
From Step 12
Step 13
2. Remove the injector-side harness connector
3. Connect the DMM between the No. 4 0V
cylinder injector drive circuit and Is the DMM indication the specified
the ground. No value or more?
CN.A3 female-side No. 8
Yes
Go to Step 16.
Step 14
3. Connect the DMM between the injector 7.0V
power supply 1 circuit and the ground. Is the DMM indication the specified
CN.A3 female-side No. 1 value or less? No
4. Turn the key switch to “ON”. Go to Step 21.
Yes
Go to Step 22.
Step 15
(CN.A3) for short circuit to the power supply From Step 12
circuit or ignition power supply circuit using
breaker box or DMM.
Note:
Go to Step 23.
Step 16
circuit or ignition power supply circuit, using
breaker box or DMM.
Note:
If breaker box is not available, refer to No
Go to Step 20.
Yes
Go to Step 23.
Step 17
1. Check the injector power supply 1 circuit
breaker box or DMM.
Note:
“On-board check procedure for sensors”. Is the trouble detected? No
Yes
Go to Step 23.

4021-166
From Step 14
Step 18
Replace the injector harness.
Yes
Go to Step 23.
From Step 11
Step 19
Replace the injector.
Note:
For work procedure, refer to “Engine section”
in the service manual.
Yes
Go to Step 23.
Step 21
rewriting of ECM. From Step 5, 8, 9 and 15
necessary.
Note:
Is EMPS available?
Yes
Step 22
Replace the ECM.
Note:

2. Clear the DTC.
clear DTCs.
or more.
is set”. Yes
Go to Step 2.
5. Check the DTC.
Step 24

Verify repair.
Yes

4021-167
Block diagram

Diagnostic aid
ECM connector
• Damaged harness

4021-168


5 Open circuit/ Resistance • Remove the ECM-side 121 – 100Ω 10MΩ
high resistance measurement harness connector from the Female-side or less or more
coupling connector. terminal
• Key switch “OFF” (CN.A3 No. 1)
Short circuit to Resistance • Remove the ECM-side 121 – Ground 10MΩ 100Ω
ground measurement harness connector from the or more or less
coupling connector.
8 Short circuit to Resistance • Remove the ECM-side 119 – Ground 10MΩ 100Ω
coupling connector.
coupling connector.
15 Short circuit to Voltage • Remove the ECM-side 119 – Ground 0V 18V
Power supply measurement harness connector from the or more
circuit coupling connector.

4021-169
DTC (error code): 1262 Injection nozzle common 2 drive system fault
• Rough idling
• Output lowering
Step 1

1. Turn the key switch to “OFF”. Service Support check.
from the coupling connector (CN.A3). Yes
CN.A3 female-side No. 3 Is the DMM indication the specified
No value or more?
Step 3
2. Remove the ECM-side harness connector Yes
3. Measure the resistance between the injector
harness connector terminals.
CN.A3 male-side No. 3 and No. 2
Specified value
1.0Ω
Step 4 value or less? No
Check for installation condition of the injector Go to Step 18.
harness connector, ECM connector and
coupling connector. Yes
connection.

1. Check for followings in the injector power
supply 2 circuit using breaker box or DMM.
• Open circuit
• High resistance No
• Short circuit to ground Go to Step 20.
Yes
Go to Step 23.
Step 6
3. Measure the resistance between the No. 2
cylinder injector drive circuit and the ground.
Specified value No
CN.A3 male-side No. 7
10MΩ Go to Step 8.
Step 7 value or more?
3. Measure the resistance between the No. 3 Specified value
cylinder injector drive circuit and the ground. 10MΩ No
CN.A3 male-side No. 6 Is the resistance the specified Go to Step 9.
value or more?
Yes
Go to Step 10.

4021-170
From Step 6
Step 8
1. Check the No.2 cylinder injector drive circuit
(CN.A3) for ground short circuit using
breaker box or DMM.
Note:
Yes
Go to Step 23.
Step 9
From Step 7
(CN.A3) for ground short circuit, using
breaker box or DMM.
Note:
Yes
Go to Step 23.
From Step 7
Step 10
2. Check for installation condition of the
injector harness.
Step 11 Yes
Go to Step 23.
1. Remove the injector harness from the
injector.
No. 2 cylinder, No. 3 cylinder
2. Measure the resistance between each
injector terminal and the ground. Specified value
10MΩ
Step 12 value or more? No
from the coupling connector (CN.A3). Yes
3. Connect the DMM between the No. 2
cylinder injector drive circuit and the ground.
CN.A3 female-side No.7 Specified value
4. Turn the key switch to “ON”. 0V
Is the DMM indication specified value?
No
Yes
Go to Step 15.
Go to Step 13.

4021-171
From Step 12
Step 13
3. Connect the DMM between the No. 3 Specified value
cylinder injector drive circuit and 0V
the ground. Is the DMM indication the specified
CN.A3 female-side No. 6 No value or more?
Yes
Go to Step 16.
Step 14
CN.A3 female-side No. 3 7.0V
4. Turn the key switch to “ON”. Is the DMM indication the specified
value or less? No
Go to Step 17.
Yes
Go to Step 18.
Step 15
breaker box or DMM.
Note:
Yes
Go to Step 23.
Step 16
circuit or ignition power supply circuit, using
breaker box or DMM.
Note:
Yes
Go to Step 23.

4021-172
From Step 14
Step 17
1. Check the injector power supply 2 circuit
(CN.A3) for short circuit to the power supply
circuit or ignition power supply circuit using Is the trouble detected? No
breaker box or DMM.
Note:
Yes
Go to Step 23.
2. If the trouble is detected, repair as required. From Step 14

Replace the injector harness.
Yes
Go to Step 23.
Step 19
From Step 11
Replace the injector.
Note:
For work procedure, refer to “Engine section”
in the service manual.
Step 21 Yes
1. Check the version of ECM software. Go to Step 23.
rewriting of ECM.
necessary.
Step 20
Note: No
Is EMPS available?
Step 22
Yes
Replace the ECM.
Note:
Yes
Step 23
2. Clear the DTC.
clear DTCs. Yes
or more.
is set”.
5. Check the DTC. No
Verify repair.
Step 24

4021-173
Block diagram

Diagnostic aid
ECM connector
• Damaged harness

4021-174
step.

5 Open circuit/ Resistance • Remove the ECM-side 116 – Female-side 100Ω 10MΩ
high resistance measurement harness connector from the terminal or less or more
coupling connector. (No. 3)
Short circuit to Resistance • Remove the ECM-side 116 – Ground 10MΩ 100Ω
coupling connector.
coupling connector.
coupling connector.

4021-175
DTC (error code): 1345 CMP (camshaft positon) sensor out of phase
• Behavior does not change during engine

running.
• After engine stops, engine will not start.
Step 1
Step 2
1. Check the CMP sensor condition.
• Loose installation and rattling of sensor Yes
Step 3
1. Check for the condition of the CKP
(crankshaft position) sensor. Is the procedure completed?
• Loose installation and rattling of sensor
Yes
Step 4
1. Clear the DTC.
clear DTCs.
or more.
is set”.
4. Check the DTC.
• Stop the engine once, crank the engine for
4 to 5 seconds, and then check if
DTC:0340 is detected.
• If DTC:0340 is detected, judge as an open
circuit in cam sensor, and check and
repair the open circuit in CMP sensor.
After repair, crank the engine for 10 Is DTC:1345 detected?
seconds, and confirm that DTC:0340 and
DTC:1345 disappear.
Yes
Step 5
1. Check that the camshaft gear is installed
properly.
Step 6 Yes
1. Check that the flywheel is installed properly.
Step 7
1. Clear the DTC.
clear DTCs.
or more. No Is DTC: 1345 detected?
is set”.
4. Check the DTC.
Yes
Step 8
Check if other DTC detected. No
Yes
4021-176
Block diagram

• Fault judgment needs cranking for about 10 seconds.
• DTC: 0335, 0336, 0340, 0341, 1345, or 1635 is not detected.
• CMP sensor signal is normal.
• CKP sensor signal is normal.
Diagnostic aid
ECM connector
• Damaged harness

4021-177
DTC:1625 Main relay fault
Engine does not start or power supply cannot be

shut off.
Step 1

Yes
Step 2
Step 3
2. Check for “Main relay voltage” on the data
display using scan tool.
Specified value
Step 4
1. Turn the key switch to “OFF”. 1V
No
2. Check the DTC. Is the “Main relay voltage” the specified
value or more?
Yes
Step 5
1. Remove the main relay.
2. Check the DTC. Is DTC: 1625 detected? No Go to
Note: “Diagnostic aid”.
Refer to the machine’s manual for installing
position and installation/removal procedures of Yes
the main relay.
Step 6 Is DTC: 1625 detected? No

1. Check the circuit (contact point side) Go to Step 11.
between main relay and ECM for short circuit
to the power supply circuit or ignition power Yes
Note:
If breaker box is not available, refer to No
Go to Step 15.
Yes
Go to Step 12.
Step 7
Check for installation condition of the main
connection.
No
Yes
3. Short between the terminals 1 - 2 and 3 - 5
in the main relay installing portion Specified value
respectively using jump cable. 24V
4. Turn the key switch to “ON”. Is the “Main relay voltage” the specified
5. Check for “Main relay voltage” on the data
No
value or more?
display using scan tool.
Yes

4021-178
From Step 8
Step 9
slowblow fuse and main relay.
• Open circuit
• High resistance
Yes
Go to Step 15.
Step 10
main relay and ECM using breaker box or
DMM.
Note:
• Open circuit
From Step 5, 8, 19 and 22

Step 11
Replace the main relay.
Step 13
rewriting of ECM.
Yes
necessary.
Note:
No Step 12
Step 14 No
Note:
Step 15
1. Connect all the harnesses. From 6, 7 and 9
2. Clear the DTC.
clear DTCs. Is DTC:1261 detected?
or more. Yes
is set”.
5. Check the DTC.
Step 16
Yes No

4021-179
Step 17 From Step 2

4. Connect the DMM between the main relay
connector coil-side terminal and the ground.
Specified value
1V
No Is the DMM indication the specified
value or more?
Step 18 Yes
2. Check the DTC.
Step 19 Go to
1. Remove the main relay. “Diagnostic aid”.
Note:
Refer to the machine’s manual for installing
position and installation/removal procedures of
the main relay. Is DTC:1625 detected?
No
Go to Step 11.
Step 20 Yes
1. Check the circuit (contact point side)
between main relay and ECM for short circuit
No
Is the trouble detected? Go to Step 15.
Note:
Go to Step 12.
Step 21
Check for installation condition of the main
connection.
Step 22
Yes
Go to Step 15.
4. Connect the DMM between the main relay
connector terminal (contact point side) and Specified value
the ground. 24V
Is the DMM indication the specified No
value or more? Go to Step 9.
Yes
Go to Step 11.

4021-180
Block diagram

• 3 seconds or more has elpsed after turning the key switch to "ON".
• Main relay drive command is "ON".
Diagnostic aid
ECM connector
• Damaged harness
4021-181

Step Item to be Inspection Measuring condition Breaker box Terminal Normal Abnormal
checked method No. value value
6 Short circuit to Voltage • Disconnect the relay. 2 – Ground 0V 18V
Power supply measurement • Key switch “ON” or more
circuit 5 – Ground
Open circuit/ Resistance • Disconnect the relay. 2 – Relay installing 100Ω 10MΩ
10
high resistance measurement terminal No.2 or less or more
• Key switch “OFF” 5 – Relay installing
terminal No.2
21 – Relay installing
terminal No.2
40 – Relay installing
terminal No.2
Short circuit to Resistance • Disconnect the relay. 2 – Ground 10MΩ 100Ω

ground measurement 5 – Ground or more or less
• Key switch “OFF” 21 – Ground
40 – Ground

4021-182
DTC (error code): 1630 A/D conversion fault
• Output lowering
Step 1
Step 2
Check the DTC again. No Go to
1. Clear the DTC. Service Support check.
clear DTCs.
or more.
3. Test run with the “Preconditions when DTC Go to
is set”. Is DTC E1630 detected? No “Diagnostic aid”.
4. Check the DTC.
Yes
Step 4
Refer to “Flash Tool (EMPS)” for check and No Step 3
necessary. Yes
Note:
Step 5
Replace the ECM.
Note:
EGR valve position learning is required after Is the procedure completed?
Step 6

Verify repair.
Yes

4021-183
DTC (error code): 1632 Voltage fault in 5V power supply 2

• Output shortage at low altitude
Step 1

Step 2
connector.
3. Connect the DMM between the barometric
pressure sensor power supply terminal and
the ground. Specified value
2. Disconnect the barometric pressure sensor Yes
connector.
3. Connect the DMM between the barometric
the ground.
Specified value
4.5V
Is the DMM indication the specified
value or less? No Go to
Step 4
1. Check the power supply circuit between “Diagnostic aid”.
barometric pressure sensor and ECM for Yes
short circuit to the battery power supply
breaker box or DMM.
Note:
Yes
Go to Step 9.
Step 5
1. Check the power supply circuit between
barometric pressure sensor and ECM for
ground short circuit using breaker box or
DMM.
Note:
Step 6 No
Is EMPS available? Go to Step 8.
Yes
Go to Step 7.

4021-184
Step 7
rewriting of ECM.
necessary.
3. Wait for 10 seconds or more. From Step 6
Step 8
Replace the ECM.
Note:
From Step 4 and 5
Step 9
2. Clear the DTC.
Refer to the screen of DIAG (Trouble No Is DTC: 1632 detected?
clear DTCs. Yes
or more.
is set”.
5. Check the DTC.
Step 10

Verify repair.
Yes

4021-185
Block diagram


4021-186
• At normal temperature: Black smoke

emission, greater engine combustion
noise possible.
• During idling at low atmospheric
temperatures: Rough idling, engine stall,
white smoke emission possible.
Yes
Step 1
No Go to
connector.
3. Connect the DMM between the engine oil
the ground. Specified value
connector.
3. Connect the DMM between the engine oil
the ground.
Specified value
4.5V
Step 4 value or less? No Go to
1. Check the power supply circuit between “Diagnostic aid”.
engine oil pressure sensor and ECM for Yes
short circuit to the battery power supply
breaker box or DMM.
Note:
On-board check procedure for sensors”. No Is the trouble detected?
Yes
Go to Step 9.
Step 5
engine oil pressure sensor and ECM for
DMM.
Note:
Step 6 No
Yes
Go to Step 7.

4021-187
Step 7
rewriting of ECM.
necessary.
3. Wait for 10 seconds or more. From Step 6
Step 8
Replace the ECM.
Note:
From Step 4 and 5
Step 9
2. Clear the DTC.
clear DTCs.
or more.
is set”. Yes
Step 10

Verify repair.
Yes

4021-188
Block diagram


4021-189
Black smoke emitted
Step 1

Step 2
connector.
3. Connect the DMM between the boost
the ground.
5.5V
connector.
3. Connect the DMM between the boost
the ground.
Specified value
4.5V
value or less? No
Step 4
1. Check the power supply circuit between Yes
boost pressure sensor and ECM for short
circuit to the battery power supply circuit or
ignition power supply circuit using breaker
box or DMM.
Note:
Yes
Go to Step 9.
Step 5
boost pressure sensor and ECM for ground
short circuit using breaker box or DMM.
Note:
Step 6 No
Yes
Go to Step 7.

4021-190
Step 7
rewriting of ECM.
necessary.
Step 8
Replace the ECM. From Step 6
Note:
Yes
Step 9
1. Connect all the harnesses. From Step 4 and 5
2. Clear the DTC.
clear DTCs.
or more.
5. Check the DTC.
Step 10

Verify repair.
Yes

4021-191
Block diagram


4021-192
• Engine blow up • Output lowering

• Black smoke emitted • Engine stall
Step 1

Step 2
connector.
the ground.
5.5V
Step 3
1. Turn the key switch to “OFF”. value or more?
connector. Yes
the ground.
Specified value
4.5V
Step 4 Is the DMM indication the specified
value or less? No
1. Check the power supply circuit between Go to “Diagnostic aid”.
common rail pressure sensor and ECM for
short circuit to the battery power supply Yes
breaker box or DMM.
Note:
Yes
Go to Step 9.
Step 5
common rail pressure sensor and ECM for
DMM.
Note:
If breaker box is not available, refer to,
Step 6
No
Yes
Go to Step 7.

4021-193
Step 7
rewriting of ECM.
necessary.
From Step 6
Step 8
Replace the ECM.
Note:
Yes
Step 9
Check the DTC again. From Step 4 and 5
2. Clear the DTC.
clear DTCs.
or more.
5. Check the DTC.
Step 10

Verify repair.
Yes

4021-194
Block diagram


4021-195
DTC:2104 CAN Bus fault
Set to idle speed.
Step 1

Step 2
10 seconds. Yes
3. Check the DTC.
Step 3 Go to “Diagnostic aid”.
1. If the DTC:2104 is detected, and the history
and present troubles of DTC:2106 are
Yes
alternately detected, check the circuit
between ECM terminals (32) and (18) for the
following conditions.
• Short circuit
required. No Is the procedure completed?
3. Check if DTC is not detected again.
Step 4
Step 5
Is the breaker box available? Go to Step 15.
2. Remove the ECM. Yes
3. Connect the breaker box to the ECM.
4. Connect the breaker box with the ECM
harness.
CAN-High-side terminal and CAN-Low-side Specified value
terminal using breaker box. 50 - 70Ω
No Is the resistance within the specified
value?
Yes
Go to Step 13.
Step 6
1. Remove the ECM from the breaker box.
CAN-High- side terminal and CAN-Low-side
terminal using breaker box. Specified value
Approx. 120Ω
Is the resistance specified value? No
Go to Step 8.
Step 7
1. Connect the ECM to the breaker box.
2. Remove the computer A and the harness. Yes
terminal using breaker box.
Specified value No
Approx. 120Ω Go to Step 10.
Is the resistance specified value?
Yes
Go to Step 13.

4021-196
Step 8
1. Check the CAN-Low circuit and CAN-High
circuit between ECM and machine control From Step 6 and 15
unit for short circuit to the power supply
breaker box or DMM.
Note:
2. If the trouble is detected, replace the Yes
harness. Go to Step 2.
Step 9
1. Check for followings in the CAN-Low circuit
and CAN-High circuit between ECM
machine control unit using breaker box
DMM.
Note: Is the trouble detected? No Replace
If breaker box is not available, refer to the machine control unit.
• High resistance
Go to Step 2.
From Step 7 and 16
Step 10
Step 11 No
Is EMPS available?
rewriting of ECM.
necessary.
Note:
Yes
3. Wait for 10 seconds or more. Verify repair.
Step 12
Replace the ECM.
Note:
Yes
From Step 16
Step 13
2. Clear the DTC.
Diagnosis) in Service Support for how to No Is DTC: 2104 detected?
clear DTCs.
or more. Yes
is set”.
5. Check the DTC.
Verify repair.
Step 14

4021-197
From Step 4
Step 15
Remove the ECM, and measure the resistance
between the CAN-High-side terminal and CAN
Low- side terminal of the ECM connector.
Specified value
Approx. 120Ω
Is the resistance specified value? No
Go to Step 8.
Step 16
1. Install the ECM, and remove the machine Yes
control unit.
terminal of the machine control unit Specified value
connector. Approx. 120Ω
Is the resistance specified value? No Go to Step 10.
Yes
Go to Step 13.
Block diagram



8 • Remove all the relevant 18 – Ground 0V 18V
Short circuit to Voltage ECU connectors. 37 – Ground or more
Power supply measurement • Key switch “ON”
circuit
9 • Remove all the relevant 37 – Machine 100Ω 10MΩ

Open circuit/ Resistance ECU connectors. control unit or less or more
high resistance measurement • Key switch “OFF” 18 – Machine
control unit
Short circuit to • Remove all the relevant 18 – Ground 10MΩ 100Ω

Resistance ECU connectors. 37 – Ground or more or less
ground measurement • Key switch “OFF”

4021-198
DTC (error code): 2106 CAN timeout fault
• It can not be controlled from the machine side
since CAN communication is disabled. The
engine speed becomes back-up speed specified
by each machine manufacturer. (1,500 min-1)
Step 1

Step 2
or more. Yes
3. Check the DTC.
Step 3
1. Check for followings in the CAN-Low circuit Yes
and CAN-High circuit between ECM and
computer A using breaker box or DMM.
Note:
• High resistance
Yes
Go to Step 11.
Step 4
1. Check for followings in the CAN-Low circuit
and CAN-High circuit between ECM and
computer A using breaker box or DMM.
Note:
• Short circuit to power supply circuit or No Is the trouble detected?
Yes
Go to Step 11.
Step 5
2. Clear the DTC.
clear DTCs.
or more.
is set”.
5. Check the DTC. Is DTC:2106 detected? No
Step 6
Yes
1. If the DTC:2104 is detected, and the history
and present troubles of DTC:2106 are
alternately detected, check the circuit
between ECM terminals (32) and (18) for the No Is the procedure completed?
following conditions.
• Short circuit
3. Check if DTC is not detected again. Go to Step 7.

4021-199
From Step 6
Step 7
Replace the computer A.
Yes
From Step 6
Step 9
No
necessary. Yes
Note:
No
Yes
Step 10
Replace the ECM.
Note:

2. Clear the DTC.
Refer to the screen of DIAG (Trouble From Step 3 and 4
clear DTCs.
or more.
is set”.
5. Check the DTC.
Yes
Go to Step 2.
Step 12

Verify repair.
Yes

4021-200
Block diagram

Diagnostic aid
ECM connector
• Damaged harness

4021-201


4 Open circuit/ Resistance • Remove the machine 18 – Machine 100Ω 10MΩ
high resistance measurement control unit (ECU) control unit (ECU) or less or more
connector. connector
37 – Machine
control unit (ECU)
connector
terminal
5
Short circuit to Resistance • Remove the machine 18 – Ground 10MΩ 100Ω
ground measurement control unit (ECU) 37 – Ground or more or less
connector.
Short circuit to Voltage • Remove the machine 18 – Ground 0V 18V
power supply measurement control unit (ECU) 37 –Ground or more
circuit connector.

4021-202
NOTA:
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Códigos Erro Motor CX350B

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4021

ENGINE ERROR CODE (DTC)

Copyright @ 2007 CNH America LLC.

Lep SC160B4021-0NA Issued 07-07

Lep SC160B4021-0NA Issued 07-07

BREAKER BOX AND DMM

Lep SC160B4021-0NA Issued 07-07

Lep SC160B4021-0NA Issued 07-07

• Intense engine vibration

Is the procedure completed?

No Is the trouble detected?

Lep SC160B4021-0NA Issued 07-07

Step 16 From Step 14

Is other DTC detected? No

Step 20 From Step 6

Lep SC160B4021-0NA Issued 07-07

Step 23 From Step 22

Lep SC160B4021-0NA Issued 07-07

Breaker box inspection procedure

Step Item to be Inspection Measuring condition Breaker box Normal Abnormal

Lep SC160B4021-0NA Issued 07-07

Step 2 Is the procedure completed? No Go to

Yes Go to the relevant

Step 5 Specified value

Lep SC160B4021-0NA Issued 07-07

Is other DTC detected? No

Preconditions when DTC is set.

Lep SC160B4021-0NA Issued 07-07

Is the procedure completed? No Go to

Is any of the DTC: 0089, 0192, 0193, or

Step 7 Is the trouble detected? No

Lep SC160B4021-0NA Issued 07-07

Is the procedure completed?

Is other DTC detected?

Step 12 Go to each DTC diagnosis.

Lep SC160B4021-0NA Issued 07-07

Preconditions when DTC is set.

Lep SC160B4021-0NA Issued 07-07

Lep SC160B4021-0NA Issued 07-07

• Engine stall and/or engine blow up are possible

Is the procedure completed?

Lep SC160B4021-0NA Issued 07-07

Lep SC160B4021-0NA Issued 07-07

Lep SC160B4021-0NA Issued 07-07

5 Short circuit Resistance • Disconnect the 105 – 89 10 Mega 100 Ohm

Short circuit to Voltage • Disconnect the 105 - GND 0V 18V

Short circuit to Voltage • Disconnect the 105 - GND 0V 1V

Lep SC160B4021-0NA Issued 07-07

• Black smoke emitted at high altitude

Lep SC160B4021-0NA Issued 07-07

From Step 5 and 17 From Step 4 and 6

Step 12 Is the procedure completed?

Is other DTC detected? No

Lep SC160B4021-0NA Issued 07-07

Preconditions when DTC is set.

Lep SC160B4021-0NA Issued 07-07

Breaker box inspection procedure

Lep SC160B4021-0NA Issued 07-07

Due to back-up equivalent to 2,000 m