Common Rail Diagnosis - V6108-Tie3 - M128X

DIAGNOSIS MANUAL
COMMON RAIL SYSTEM
V6108-TIE3
KiSC issued 04, 2008 A

V6108-TIE3, DIAGNOSIS MANUAL SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
SAFETY FIRST
This symbol, the industry’s “Safety Alert Symbol”, is used throughout this manual and on labels on
the machine itself to warn of the possibility of personal injury. Read these instructions carefully.
It is essential that you read the instructions and safety regulations before you attempt to repair or use
this unit.
DANGER : Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
WARNING : Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION : Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury.
■ IMPORTANT : Indicates that equipment or property damage could result if instructions are not
followed.
■ NOTE : Gives helpful information.
BEFORE SERVICING AND REPAIRING

• Read all instructions and safety instructions in this
manual and on your machine safety decals.
• Clean the work area and machine.
• Park the machine on a firm and level ground, and set
the parking brake.
• Lower the implement to the ground.
• Stop the engine, and remove the key.
• Disconnect the battery negative cable.
• Hang a “DO NOT OPERATE” tag in operator
station.

1
SAFETY STARTING
• Do not start the engine by shorting across starter
terminals or bypassing the safety start switch.
• Do not alter or remove any part of machine safety
system.
• Before starting the engine, make sure that all shift
levers are in neutral positions or in disengaged
positions.
• Never start the engine while standing on ground.
Start the engine only from operator’s seat.
SAFETY WORKING
• Do not work on the machine while under the influence
of alcohol, medication, or other substances or while
fatigued.
• Wear close fitting clothing and safety equipment
appropriate to the job.
• Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
• When servicing is performed together by two or more
persons, take care to perform all work safely.
• Do not work under the machine that is supported
solely by a jack. Always support the machine by
safety stands.
• Do not touch the rotating or hot parts while the engine
is running.
• Never remove the radiator cap while the engine is
running, or immediately after stopping. Otherwise, hot
water will spout out from radiator. Only remove
radiator cap when cool enough to touch with bare
hands. Slowly loosen the cap to first stop to relieve
pressure before removing completely.
• Escaping fluid (fuel or hydraulic oil) under pressure
can penetrate the skin causing serious injury. Relieve
pressure before disconnecting hydraulic or fuel lines.
Tighten all connections before applying pressure.
• Do not open high-pressure fuel system.
High-pressure fluid remaining in fuel lines can cause
serious injury. Do not disconnect or attempt to repair
fuel lines, sensors, or any other components between
the high-pressure fuel pump and injectors on engines
with high pressure common rail fuel system.
• High voltage exceeding 100 V is generated in the
ECU and injector.
Pay sufficient caution to electric shock when
performing work activities.

2
AVOID FIRES
• Fuel is extremely flammable and explosive under
certain conditions. Do not smoke or allow flames or
sparks in your working area.
• To avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first and
connect it last.
• Battery gas can explode. Keep sparks and open
flame away from the top of battery, especially when
charging the battery.
• Make sure that no fuel has been spilled on the engine.
VENTILATE WORK AREA

• If the engine must be running to do some work, make
sure the area is well ventilated. Never run the engine
in a closed area. The exhaust gas contains poisonous
carbon monoxide.
PREVENT ACID BURNS

• Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and cause
blindness if splashed into eyes. Keep electrolyte
away from eyes, hands and clothing. If you spill
electrolyte on yourself, flush with water, and get
medical attention immediately.
DISPOSE OF FLUIDS PROPERLY

• Do not pour fluids into the ground, down a drain, or
into a stream, pond, or lake. Observe relevant
environmental protection regulations when disposing
of oil, fuel, coolant, electrolyte and other harmful
waste.

3
PREPARE FOR EMERGENCIES

• Keep a first aid kit and fire extinguisher handy at all
times.
• Keep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.

4
1 OUTLINE

CONTENTS
1. OVERALL DIAGNOSTIC PROCEDURE ........................................................ 1-1

2. QUESTIONING ................................................................................................. 1-2
3. ACTIONS FOR NON-REOCCURRING MALFUNCTIONS ............................ 1-5

V6108-TIE3, DIAGNOSIS MANUAL COMMON RAIL SYSTEM
1. OVERALL DIAGNOSTIC PROCEDURE

1-1
2. QUESTIONING
1. Use the trouble check sheet to ensure that the customer’s explanation is fully understood.
(Reference)
• Do not ask random questions. Ask questions that will aid in narrowing down the possible malfunctioning system
while making educated guesses based on the malfunction symptoms.
2. Accurately judge information concerning the malfunction.
Grasp the situation firmly, using five 5W1H (Who, What, When, Where, Why, How) as a basis.
Ex: Low ambient temperature, starting, normal conditions, proximity to engine, metallic noise, etc.
Questioning Points
●What? Malfunction symptom

●When? Date, time, frequency of occurrence.
●Where? Field conditions
●What were conditions like at the time of malfunction? Driving conditions, operating conditions, weather.
●What happened? Type of malfunction.
Trouble Check Sheet for KUBOTA Common Rail System
When the vehicle is received from the customer, it is necessary
to verify the "malfunction symptoms" and the "generated malfunction
data" with the customer. This is performed based on the trouble
check sheet.
(1) Trouble Check Sheet
W1011137
Because :
1. The malfunction symptom may not be reproduced at the workshop.
2. The customer’s complaint does not always match the malfunction.
3. If the person performing repairs is not working from the correct malfunction symptoms, man-hours will be wasted.
• The question chart can aid the service person in diagnosing, repairing and verifying repair work.

1-2

1-3

1-4
3. ACTIONS FOR NON-REOCCURRING MALFUNCTIONS

1. In cases where the malfunction does not reoccur, perform the actions below to determine the cause of the
malfunction.
2. In cases where the malfunction does not reoccur at the dealer, sales company or workshop, perform the work that
actually caused the malfunction.
3. Check the fuel pipe system [including the fuel pump (electromagnetic pump) and tank], intake system and exhaust
system.
4. If the malfunction does not reoccur, there may be an ECU malfunction. For diagnostic purposes only, temporarily
replace the ECU with a unit that functions normally to perform the check procedure. At the same time, be sure to
perform difference learning for the supply pump and input QR Code for injectors. If there would be no change, ECU
should not be replaced.
Malfunction symptom
Idle speed
abnormal
Action Engine will Engine stall
Dead battery
not start Sluggish
Poor
acceleration
Verify that there is no Diagnostic Trouble Code (DTC) stored
– ❍ ❍
in the memory.
Using the trouble check sheet as a base, perform a
reoccurrence test in "Reoccurrence" mode. Use this data
❍ ❍ ❍
(engine ECU (PCM) voltage value, etc.) to determine the
cause of the malfunction.
Assume that an electrical
system wiring harness or
connector is the cause of the
malfunction and vibrate
– ❍ ❍
these components by hand
to verify whether or not a
malfunction occurs and a
DTC is generated.
Assume that an electrical system female connector terminal
is the cause of the malfunction and verify that the connection
points are not defective.
Recommended Tools : KOWA Precision Handling
Feeling Tool Set (KLM-10-
20)
Depending on the terminal,
a matching size may not be
available.
– ❍ ❍
Insert the male terminal that

matches the shape of the
female terminal and check
for looseness.

1-5
Malfunction symptom
Idle speed
abnormal
Action Engine will Engine stall
Dead battery
not start Sluggish
Poor
acceleration
Heat the accelerator sensor
and other electrical
components with a hair
dryer. Verify whether or not
the voltage value (resistance
value) changes. – – ❍
■ NOTE
• Do not exceed 60 °C
(140 °F) (still touchable by hand) when heating.
• Do not remove the component case and add heat
directly to electronic parts.
Verify whether or not malfunction symptoms occur under
heavy engine loads (headlights, A/C, wiper, etc. switches ❍ – ❍
ON).
If any commercial electrical products have been installed,
remove them and verify whether or not the malfunction ❍ ❍ ❍
symptoms occur.
If it is thought that the malfunction occurs in rainy or high temperature weather,
spray the vehicle with water and verify whether or not the malfunction occurs.
■ NOTE
• Do not spray water directly onto the engine. Spray water mist on the
entire surface of the radiator to indirectly change the temperature and
humidity of the engine compartment.
• Do not spray water directly on
electrical parts. ❍ ❍

1-6
2 INSPECTION PROCEDURE
FOR EACH SYSTEM

CONTENTS
1. AIR INTAKE SYSTEM INSPECTION PROCEDURE.................................... 2-1

2. FUEL SYSTEM INSPECTION PROCEDURE ............................................... 2-3
3. ELECTRIC SYSTEM INSPECTION PROCEDURE....................................... 2-7
[1] BASICS OF CHECKING ELECTRICAL / ELECTRONIC CIRCUIT
SYSTEMS ................................................................................................... 2-7
(1) Measure the ECU Terminal Voltage and Resistance ........................... 2-7
(2) Open Circuit Check............................................................................... 2-7
(3) Short Circuit Check ............................................................................... 2-9
[2] CONNECTOR CONNECTION FAULT VERIFICATION METHOD....... 2-10
[3] CHECKING THE POWER AND GROUND SYSTEM (MAIN RELAY,
ECU CIRCUIT)......................................................................................... 2-11

1. AIR INTAKE SYSTEM INSPECTION PROCEDURE

1. Check the air cleaner
1. Check the air cleaner for clogging.
• Clean air cleaner element (Primary and Secondary) every 100
hours.
• Replace air cleaner element :
Once yearly or after every sixth cleaning, whichever comes first.
NG Clean or replace.
(1) Air Cleaner Indicator (3) Air Cleaner Switch
(2) Air Cleaner
W1019028
OK

2-1
2. Check the suction path

1. Check the suction path for leaks. (including EGR valve,
turbocharger, intercooler, etc.)
• Suction path joints.
• Suction pipes, hoses.
■ NOTE
• A small amount of gas and water bleeds from the valve
chamber gas bleeding hole of the EGR valve. This is normal.
NG Repair or replace the malfunctioning component.
(1) Hose (4) Intercooler
(2) Hose Clamp (5) EGR Valve
(3) Turbocharger
W1019349
OK
Normal.

2-2
2. FUEL SYSTEM INSPECTION PROCEDURE

1. Check the fuel system (remaining fuel quantity and properties)
1. Check the amount of fuel remaining in the tank.
2. Check properties of fuel. Request fuel analysis from a third party
as necessary.
• Color (no color, brownish, white turbidit).
• Odor (kerosene, heavy oil, irritating odor).
• Separation of materials (water, foreign objects).
• Viscosity (high / low viscosity, wax consistency).
■ NOTE
• Always use the specified fuel.
NG Add fuel or change fuel (clean tank).
(1) Fuel Gauge (2) Fuel Tank
W1019633
OK
2. Check the inside of the tank (checking for tank modification / additions, position of
fuel pipe inlet / outlet, clogging and holes)
1. Check the tank for modifications or additions. Consult with the
customer.
• Fuel inlet / outlet position, tank piping.
• Foreign material inside the tank, water separation, rust.
■ NOTE
• Use resin tanks when making tank additions.
2. Check the tank internal fuel piping for the following.
• Inlet / outlet position (below position "Empty").
• Inlet clogging, whether there is bent or deformed piping (crushed
pipe).
• Crushing at pipe connections.
NG Restore the fuel tank.
(1) Fuel Tank
W1019875
OK

2-3
3. Tank external fuel path conditions (crushed hose, clogging, air introduction at hose
connection)
1.Check the condition of the hose.
•Crushing around bands, over bending.
•Pinched or crushed by other parts.
2.Check the connection (air introduction).
•Looseness.
•Hose deterioration (verify that there is no rubber hardening /
splitting by hand or visually).
■ NOTE
• Be cautious when vacuum pressure is present, as air will be
drawn into the hose.
NG Repair or replace the hose.
(1) Fuel Hose
W1020156
OK
4. Check the water separator

1. Check the water level of the water separator and discharge some
water as necessary.
2. Check for element deformation and dirt.
Clean or replace the element as necessary.
Replace the filter and drain the water from the water
NG
separator.
(1) Water Separator
W1020565
OK

2-4
5. Check the fuel pump

1. Set the key switch to the ON position, check the fuel pump alone,
and check and repair the wiring harnesses.
2. Check the operation of the fuel pump by touching it directly by
hand.
■ NOTE
• If there is a fuel pump malfunction, the fuel cannot be
supplied and so there is greater likelihood of improper
recognition of DTC codes related to the pressure and
injector.
(Items where improper recognition is possible.)
• Injector COM1TWV actuation system short
• SCV actuation system abnormality
• Others
NG Repair the wiring harness, and replace the fuel pump.
(1) Fuel Pump
W1020754
OK
6. Fuel filter clogged

1. Check the fuel filter for clogging and dirt.
■ NOTE
• Replace the fuel filter according to the specified
maintenance interval.
NG Clean or replace the fuel filter and fuel pipe system.
(1) Fuel Filter
W1021144
OK
7. Engine oil level increase (engine internal leak)

1. Check the engine oil level increase with dipstick.
2. Request fuel dilution analysis or oil analysis from a third party as
necessary.
NG Check and repair interior pipes.
(1) Dipstick
W1021385
OK

2-5
8. Check the high pressure piping and CRS components (such as the fuel injector and the
supply pump) for fuel leakage (engine external leak)
1. Visually check and specify areas leaking fuel.
2. Be cautious because there may be oil leaks in the high pressure
pipe and injector areas.
Repair leaking high pressure pipe, etc. or replace
NG
leaking parts.
(1) Supply Pump (3) Injection Pipe
(2) Rail
W1021537
OK
Normal.

2-6
3. ELECTRIC SYSTEM INSPECTION PROCEDURE

[1] BASICS OF CHECKING ELECTRICAL / ELECTRONIC CIRCUIT
SYSTEMS
(1) Measure the ECU Terminal Voltage and Resistance
1. When measuring the voltage and resistance of each terminal,
insert the multimeter probe into the rear side of the wiring
harness connector. If connectors are small making it difficult to
insert the probe, insert a fine metal wire into the rear of the
connector and touch the wire to the probe.
■ IMPORTANT
• When inserting a fine metal wire for measurement purposes,
ensure that the connector waterproof rubber is not
damaged.
(1) Needle (3) Wiring Harness Side Connector
(2) ECU Side Connector
W1012866
(2) Open Circuit Check

When dealing with a wiring harness open circuit like that depicted
in Figure A-1, check continuity or voltage to determine the location
of the open circuit.
(1) Sensor (3) ECU
(2) Open Circuit
W1013074

2-7
Check for continuity

1. Remove connectors "A" and "C" and measure resistance
between the two.
Factory spec. Less than 1 Ω

(Reference)
• Measure resistance while gently shaking the wiring harness up
and down, and side-to-side.
2. In the case of Figure A-2, there is no continuity (open circuit)
between terminal 1 of connector "A" and terminal 1 of connector
"C". However, there is continuity between terminal 2 of
connector "A" and terminal 2 of connector "C". As a result, it can
be said that there is an open circuit between terminal 1 of
connector "A" and terminal 1 of connector "C".
(1) Sensor (2) ECU
W1013117
3. Remove connector "B" and measure the resistance in the
connector.
4. In the case of Figure A-3, there is continuity between terminal 1
of connector "A" and terminal 1 of connector "B1". However,
there is no continuity (open circuit) between terminal 1 of
connector "B2" and terminal 1 of connector "C". As a result, it
can be said that there is an open circuit between terminal 1 of
connector "B2" and terminal 1 of connector "C".
(1) Sensor (2) ECU
W1013376
Check voltage
1. In the case of the circuit that supplies voltage to the ECU
connector terminals, check for an open circuit by performing a
voltage check.
2. As depicted in Figure A-4, measure the voltage of the ECU 5V
output terminal between the body ground and terminal 1 of
connector "A" with all connectors connected.
Next, measure in order the voltage between terminal 1 of
connector "B" and the body ground, and terminal 1 of connector
"C" and the body ground.
3. The faulty circuit and measurement results are as per below.
(Measurement Results)
• Voltage between terminal 1 of connector "A" and the body
ground is 5 V.
• Voltage between terminal 1 of connector "B" and the body
ground is 5 V.
• Voltage between terminal 1 of connector "C" and the body
ground is 0 V.
(Faulty Circuit)
• There is an open circuit between terminal 1 of connector "B" and
terminal 1 of connector "C".
(1) Sensor (2) ECU
W1016875

2-8
(3) Short Circuit Check

As per Figure A-5, if there is a short in the wiring harness ground,
perform a "Ground continuity check" to determine the source of
the short.
(1) Sensor (3) ECU
(2) Short Circuit
W1017090
Ground continuity check

1. Remove connector "A" and connector "C", then measure the
resistance between terminals 1 and 2 of connector "A" and
ground.
Factory spec. No continuity

(Reference)
• Measure resistance while gently shaking the wiring harness up
and down, and side-to-side.
2. In the case of Figure A-6, there is continuity between terminal 1
of connector "A" and the body ground (short circuit). However,
there is no continuity between terminal 2 of connector "A" and
the body ground. As a result, it can be said that there is a short
circuit between terminal 1 of connector "A" and terminal 1 of
connector "C".
(1) Sensor (2) ECU
W1017151
3. Remove connector "B" and measure the resistance between
terminal 1 of connector "A" and the body ground, and between
terminal 1 of connector "B2" and the body ground.
4. The faulty circuit and measurement results are as per below.
(Measurement Results)
• No continuity between terminal 1 of connector "A" and the body
ground.
• Continuity between terminal 1 of connector "B2" and the body
ground.
(Faulty Circuit)
• There is a short circuit between terminal 1 of connector "B2" and
terminal 1 of connector "C".
(1) Sensor (2) ECU
W1023436

2-9
[2] CONNECTOR CONNECTION FAULT VERIFICATION METHOD
(1) Diagnosis Tool Data Monitor (2) Voltage Measurement (A) Sensor Example (a) CAN2 Connector
(Sensor Output Voltage)
As per the diagram above, measure both the data monitor and connector voltage simultaneously.
Ex.) Coolant temperature sensor
(1) Read in the "Coolant Temperature Output Voltage" value from the data monitor.
(2) Measure the voltage directly from the corresponding ECU terminal.
Judge as a connector connection fault if (2) is satisfactory and (1) is unsatisfactory. Since some malfunctions only
occur intermittently, measure voltage while pulling and shaking the wires in order to try to get the malfunction to
reoccur.

2-10
[3] CHECKING THE POWER AND GROUND SYSTEM (MAIN RELAY, ECU
CIRCUIT)
If the ECU is not operating, check the following.
Malfunction symptoms :
• Engine does not start.
• Engine warning light is not lit.
• A diagnosis tool communication error occur.
(1) OFF (4) START (7) Terminal 3 (a) Key Switch

(2) ACC (5) Terminal 1 (8) Terminal 4 (b) Main Relay
(3) ON (6) Terminal 2 (c) Main Relay Terminal Layout

2-11
1. Measure the ECU +B and ground voltage

1. Turn the key switch ON and measure the voltage between the
ECU +B terminals (119, 120) and ground (body / battery
terminal). Then measure voltage between the ECU ground
terminals (114) and ground (body / battery terminal).
+B terminal ; greater than or equal to 10 V

Factory spec.
Ground terminal ; Less than or equal to 0.5 V
+B terminal unsatisfactory
Check battery, wiring
NG NG Repair or replace.
harness, ground wire.
OK
Go to Step 2 (Check the relay terminal voltage).
Ground terminal unsatisfactory

NG Check ECU wiring harness ground.
W1017826
OK
Normal.
2. Check the relay terminal voltage

1. Turn the key switch ON and measure voltage at relay terminal 2
(2).
Factory spec. Greater than or equal to 10 V
Check wiring between relay and ECU → Repair.

OK
Check for connector connection fault → Repair.
(1) Terminal 1 (a) Main Relay Terminal Layout
(2) Terminal 2
(3) Terminal 3
(4) Terminal 4
W1018473
NG
1. Measure voltage at relay terminal 1 (1).
Check for a wiring harness open circuit and / or

NG connector connection fault → Repair.
Inspect fuse → Replace.
(2) Terminal 2
(3) Terminal 3
(4) Terminal 4
W1018610
OK

2-12
1. Measure voltage at relay terminal 3 (3).
Check for a wiring harness open circuit and / or

NG connector connection fault → Repair.
Inspect fuse → Replace.
(2) Terminal 2
(3) Terminal 3
(4) Terminal 4
W1018726
OK
1. Turn the key switch OFF and measure voltage at relay terminal 4
(4).
■ NOTE
• Perform measurement two seconds after cycling the the key
switch ON → OFF.
NG Check the relay → Repair.

(2) Terminal 2
(3) Terminal 3
(4) Terminal 4
W1018842
OK
1. With the key switch OFF, measure voltage at the ECU main relay
terminals (105, 113).
Check wiring harness between relay and ECU and

NG
connectors → Repair.
OK

2-13
1. Turn the key switch ON and measure voltage at relay terminal 4

(4).
Factory spec. Approx. 0 V
NG Go to Step 3 (Check the key switch signal).

(2) Terminal 2
(3) Terminal 3
(4) Terminal 4
W1027356
OK
Faulty relay contacts → Replace.
3. Check the key switch signal

1. Connect the diagnosis tool to diagnostic connector (CAN2
connector) and turn the key switch ON.
2. Using the diagnosis tool data monitor function, verify the "Key
Switch" data when the key switch is turned ON then OFF.
When the key switch is set to the ON and OFF,

Factory spec. the data output is turned ON and OFF
respectively.
■ IMPORTANT
• Do not keep the key switch in the OFF position for more than
2 seconds, otherwise a communication error will occur.
OK ECU internal fault → Replace ECU.
NG : Consistently ON ECU internal fault → Replace ECU.

(a) CAN2 Connector
W1019178
NG : Consistently OFF
1. Place the key switch in the ON position, and measure the voltage
at ECU terminal 107.
Factory spec. 10 V or higher
Check whether the

OK connector is poorly OK Replace the ECU.
connected.
NG
Repair the connector.
W1019503
NG

2-14
4. Check the key switch

1. Set the key switch to the ON position, and measure the voltage
at the key switch output terminal.
OK Wiring harness open circuit → Repair.

(1) OFF (a) Key Switch
(2) ACC
(3) ON
(4) START
W1020914
NG
1. Measure the voltage at the key switch input terminal.
OK Check the key switch. → Replace.

(1) OFF (a) Key Switch
(2) ACC
(3) ON
(4) START
W1021030
NG
Check the wiring harness between the battery and key switch, and the fuse. → Repair or replace.

2-15
3 PROBLEMS CAUSED BY NON-CRS
COMPONENTS

CONTENTS
1. LIST OF MALFUNCTION SYMPTOM............................................................ 3-1

1. LIST OF MALFUNCTION SYMPTOM

Malfunctions and corresponding symptoms resulting from the CRS may also be generated from other sources,
such as the engine (mechanical parts), the fuel system, etc. When performing CRS troubleshooting, the aim is not to
quickly determine that the CRS is the cause of a malfunction. Rather, the cause should be exhaustively considered
while verifying the causes listed below.
Malfunction
Area of Fault Cause Action
Symptom
Fuel system Poor fuel. Switch to the correct fuel (No.2-D diesel
(compression pressure) fuel).
Engine oil deterioration. Change engine oil.
Engine Inappropriate engine oil. Replace with the appropriate engine oil
overheat (API Service Classification CF grade or
Lubrication system
higher).
Faulty oil pump. Replace oil pump.
Insufficient engine oil. Add engine oil.
Intake system Clogged air cleaner element. Clean or replace air cleaner element.
Air mixed with the fuel system. Perform fuel system air bleeding.
Faulty fuel filter. Replace fuel filter.
Fuel system
Poor or inappropriate fuel. Switch to the correct fuel (No.2-D diesel
Insufficient
fuel).
power
Reduced compression pressure Refer to "Engine Overheat" items.
Engine Worn cylinder liner and the Refer to "Engine Overheat" items.
piston ring of the piston.
Other Overheat Refer to "Engine Overheat" items.
Intake system Clogged air cleaner element. Clean or replace air cleaner element.
Insufficient fuel. Add fuel and perform fuel system air
bleeding.
Fuel system clogged. Clean the fuel system.
Large amount of intermixing Clean or replace.
water to the water separator,
element clogging and
Fuel system
deformation.
Air being introduced through fuel Tighten connections.
system connection points.
Fuel filter clogged. Replace fuel filter.
Fuel pump operation fault. Replace fuel pump.
Faulty Injection pipe connection loose. Tighten connecting nut.
starting Faulty battery. Inspect battery.
Faulty starter wiring. Replace starter wiring.
Loose battery cable. Tighten battery terminal connections, or
Electrical system replace cables.
Faulty starter operation. Replace starter assembly.
Starting assist device (glow Replace starting assist device (glow
plug) fault. plug).
Lubrication system Excessive engine oil viscosity. Replace with oil of appropriate viscosity.
Burnt pistons. Replace piston, piston ring and cylinder
block.
Engine
Burnt bearing. Replace bearing and crankshaft.
Low compression pressure. Overhaul engine.
Other Ring gear damage. Flywheel / starter replacement.

3-1
Malfunction
Area of Fault Cause Action
Symptom
Poor valve clearance. Adjust valve clearance.
Poor valve seat contact. Break in valve and valve seat, or
replace.
Idle fault Engine
Low coolant temperature. Perform warm-up operation.
Large difference in cylinder-to- Overhaul engine.
cylinder compression pressure.

3-2
4 DIAGNOSTIC TOOL CONNECTION
PROCEDURE

CONTENTS
1. DIAGNOSTIC CONNECTOR POSITIONS ..................................................... 4-1

2. DIAGNOSTIC TOOL CONNECTION PROCEDURE ..................................... 4-2
3. CHECKING THE COMMUNICATION OPERATION OF THE
INTERFACE (PYTHON) .................................................................................. 4-3

1. DIAGNOSTIC CONNECTOR POSITIONS

The CAN2 connectors (a) for connecting the diagnostic tool are in the positions shown in the figure below.
(1) Terminal IG-SW (107) (3) Terminal PIM RTN (71) (4) Terminal CAN2-L (88) (a) CAN2 Connector
(2) Terminal CAN2-H (96)

4-1
2. DIAGNOSTIC TOOL CONNECTION PROCEDURE

■ IMPORTANT
• At first time usage, it is necessary to do "Communication Setting" with administrator user account.
• Prepare a PC on which the diagnostic software has already been installed.
• When connecting the diagnosis cable, ensure that the key switch on the vehicle side is OFF.
1. Start up a PC on which the diagnostic software has been installed
with administrator user account.
2. Connect the vehicle-side CAN2 connector (1) to the interface (To
Vehicle) (3) with the cable (VEH) (2).
3. Connect the cable (USB) (5) to the interface (To PC) (4) and then
connect the USB connector to the USB port on PC.
4. Start the diagnostic software.
5. Select "Communication Setting" from "System Setting" in the
menu and execute. (Only when performing the initial settings.)
■ NOTE
• The USB port used while the "Communication Setting"
process, should always be used.
Otherwise, communication can’t be established.
(1) CAN2 Connector (4) Interface (To PC)
(2) Cable (VEH) (5) Cable (USB)
(3) Interface (To Vehicle)
W1010720

4-2
3. CHECKING THE COMMUNICATION OPERATION OF

THE INTERFACE (PYTHON)
The communication operation can be checked with the illuminating
condition of the three lights (Link Status, Power, USB) on the
PYTHON unit.
If a communication error occurs, check the illuminating condition of
each light and repair or replace the malfunction (including cable
open circuits).
(1) Link Status Lamp (3) USB Lamp
(2) Power Lamp
W1011101
1. Light operation during normal conditions

■ Communication ready
The PC connection and vehicle connection / power supply are normal and the system is ready for communication
with the vehicle.
Link Status Lamp : Red light flashing

Power Lamp : Red light ON
USB Lamp : Green light ON
■ Communication in progress
Light operation status when communication with the vehicle is actually being performed.
Link Status Lamp : Green light flashing

USB Lamp : Green light flashing
2. Light operation during abnormal operation

■ Is power being supplied to the PYTHON? (When the vehicle key switch is ON)
When the USB port connection of the PC is normal and there is a problem in the vehicle connection / power supply.
Link Status Lamp : Light OFF

Power Lamp : Light OFF
USB Lamp : Green light ON
■ Is the connection to the USB port of the PC normal? (When the vehicle key switch is ON)
When the vehicle connection / power supply are normal and there is a problem in the USB port connection of the
PC.
Link Status Lamp : Red light flashing

USB Lamp : Light OFF
■ When there is a problem with both the previous items. (When the vehicle key switch is ON)
When there is a problem in the USB port connection of the PC and in the vehicle connection / power supply.
Link Status Lamp : Light OFF

Power Lamp : Light OFF
USB Lamp : Light OFF

4-3
5 BASIC SYSTEM INFORMATION

CONTENTS
1. SYSTEM CONFIGURATION ........................................................................... 5-1

2. FUEL SYSTEM ................................................................................................ 5-2
3. INTAKE AND EXHAUST SYSTEM ................................................................ 5-3
4. SYSTEM WIRING DIAGRAM ......................................................................... 5-4
5. AVAILABLE DATA MONITOR SIGNALS AND THEIR NORMAL
VALUES ............................................................................................................ 5-5
[1] MONITOR ITEMS ...................................................................................... 5-5
[2] NORMAL VALUE ....................................................................................... 5-8
6. ECU TERMINAL LAYOUT AND NORMAL VALUES ................................. 5-10
[1] ECU TERMINAL LAYOUT ...................................................................... 5-10
[2] ECU TERMINAL NORMAL VALUES (WAVEFORMS)......................... 5-12

1. SYSTEM CONFIGURATION
(1) Accelerator Position Sensor (9) Engine Warning Light (17) EGR Lift Sensor (a) To Fuel Tank
(2) Key Switch On Signal (10) Glow Lamp (18) Intake Air Pressure Sensor
(3) Starter Switch Signal (11) Glow Relay (19) Intake Air Temperature
(4) Vehicle Speed Signal (12) Supply Pump Sensor
(5) Neutral Switch Signal (13) Fuel Temperature Sensor (20) Glow Plug
(6) Rail Pressure Sensor (14) Suction Control Valve (21) Coolant Temperature Sensor
(7) Rail (15) Injector (22) Crankshaft Position Sensor
(8) Pressure Limiter (16) EGR DC Motor (23) Camshaft Position Sensor

5-1
2. FUEL SYSTEM
(1) Injector (5) Fuel Cooler (9) Fuel Pump A: Engine ECU
(2) Pressure Limitter (6) Fuel Filter (10) Water Separator B: Sensors
(3) Rail (7) Check Valve (11) Fuel Tank C: Injected Fuel Flow
(4) Supply Pump (8) SCV (Suction Control Valve) D: Returned Fuel Flow

5-2
3. INTAKE AND EXHAUST SYSTEM
(1) Air Cleaner (5) Injector (9) Intake Air Temperature A : Intake Air Flow
(2) Intercooler (6) Glow Plug Sensor B : Exhaust Gas Flow
(3) Turbocharger (7) EGR Valve (10) Coolant Temperature Sensor
(4) EGR Cooler (8) Intake Air Pressure Sensor (11) Crankshaft Position Sensor
(12) Camshaft Position Sensor

5-3
4. SYSTEM WIRING DIAGRAM
(1) Main Relay (7) Battery (15) Injector 4 (23) Suction Control Valve
(2) Fuel Pump (8) Body Earth (16) Connector (24) Fuel Temperature Sensor
(3) CAN1 Connector (9) Engine Body Earth (17) Crankshaft Position Sensor (25) Coolant Temperature Sensor
(For Vehicle) (10) Glow Relay (18) Camshaft Position Sensor (26) Rail Pressure Sensor
(4) CAN2 Connector (11) Glow Lamp (19) Engine Warning Light (27) Intake Air Pressure Sensor
(For Service) (12) Injector 1 (20) Neutral Switch (28) Intake Air Temperature
(5) EGR DC Motor (13) Injector 2 (21) Accelerator Position Sensor 1 Sensor
(6) EGR Lift Sensor (14) Injector 3 (22) Accelerator Position Sensor 2 (29) Vehicle Speed Sensor

5-4
5. AVAILABLE DATA MONITOR SIGNALS AND THEIR

NORMAL VALUES
[1] MONITOR ITEMS
Terminal Terminal ECU Monitor
Classification Signal Name Unit
Name No. Label
Engine speed min-1(rpm) NE+/- 46/65 KWPNE
Pulse / Engine speed active flag - - - XNEACT
Rotary signal Cam angle active flag - - - XCGACT
Vehicle speed km/h SPD 97 KWPSPD
Final accelerator opening % - - KWPACCPF
Accelerator position sensor 1
V APS1 83 KWPVACCP1
voltage output
Accelerator position sensor 2
V APS2 91 KWPVACCP2
voltage output
Intake air pressure kPa - - KWPPIM
Intake air pressure sensor
V PIM 52 KWPVPIM
voltage output
Fuel temperature °C - - KWPTHL
Fuel temperature sensor voltage
Input V THF 50 KWPVTHL
Analog signal output
Coolant temperature °C - - KWPTHW
Coolant temperature sensor
V THW 51 KWPVTHW
voltage output
Intake air temperature °C - - KWPTHA
Intake air temperature voltage
V THA 55 KWPVTHA
output
Atmospheric pressure kPa - - KWPPATM
Atmospheric pressure voltage
V PATM - KWPVPATM
output
Battery voltage V +BP 119/120 KWPVB
Key switch - IG-SW 107 XKEY
Switch signal Starter switch - STA-SW 99 XST
Neutral switch - N-SW 110 XNEU

5-5

Name No. Label
Engine stop flag - - - XENST
General
Start-up mode flag - - - XSTART
Final fuel injection quantity mm3 /st - - KWPQFIN
3
Pre-injection quantity mm /st - - KWPQPRE
Injection quantity
Final injection timing °BTDC - - KWPTFIN
Pre-interval μsec - - KWPTINT
Target rail pressure MPa - - KWPPFIN
Actual rail pressure MPa - - KWPNPC
Rail pressure sensor voltage
V PFUEL 48/49 KWPVPC
output
Target SCV current mA - - KWPIPMPF
Output
Rail pressure Actual SCV current mA SCV+/- 10/29 KWPISCVS
Pump deviation learning status - - - XIPMPSTDY
Pump deviation learning
mA - - KWPIPMPSTDY
correction value
Pressure feedback integral guard
- - - XQPMPFIGD
execution flag
Idle speed Target idle speed min-1(rpm) - - KWPNEF
Target EGR valve opening % - - KWPLEGRFINO
EGR valve Actual EGR valve opening % - - KWPLEGR
EGR lift sensor output voltage V LEGR 81 KWPVLEGR
Relay Glow relay - GRLY 37 XGLREL
-1
Engine speed min (rpm) FFNEk
Vehicle speed km/h FFSPDk
Final accelerator opening % FFACCPFk
Intake air pressure kPa FFPIMk
Input
Fuel temperature °C FFTHLk
Coolant temperature °C FFTHWk
Atmospheric pressure kPa FFPATMk
FF Battery voltage V FFVBk

3
Final fuel injection quantity mm /st FFQFINk
Final injection timing - FFTFINk
Target rail pressure MPa FFPFINk
Output Actual rail pressure MPa FFNPCk

mA FFIPMPSTDYk
correction value
Pressure feedback integral
- FFXQPMPFIGDk
guard execution flag

5-6

Name No. Label
QR code (#1 cylinder) μsec
QRDTQ***
Registration history (#1 cylinder) - QRWRITE
Individual engine Number of registrations - CQRWRITE1

Others data related to (#1 cylinder)
Injector Number of registrations
- CQRWRITE2
(#2 cylinder)
Number of registrations
- CQRWRITE3
(#3 cylinder)
Number of registrations
- CQRWRITE4
(#4 cylinder)
Q correction number for QLQC1 - ESMNUMLQC1
Injection timing correction deg KWPTFIT

5-7
[2] NORMAL VALUE

During
During
Engine During No-load
Classification Signal Name Unit Idling Acceler-
Stopped Start-Up Max.
ation
Speed
0→
min-1 800 to 850 2350 to
Engine speed 0 800 to 850 825 → 2400
(rpm) (Ordinary 2400
Pulse /
temperature)
Rotary
signal Engine speed active flag - OFF ON ON ON ON
Cam angle active flag - OFF ON ON ON ON
Vehicle speed km/h - - - - -
Final accelerator
% 0 0 0 0 → 100 100
opening
Approx. 0.9 4.2 or more
Accelerator position Approx. Approx. Approx.
V → 4.2 or (Approx.
sensor 1 output voltage 0.9 0.9 0.9
more 4.5)
Approx. 0.9 4.2 or more
Accelerator position Approx. Approx. Approx.
V → 4.2 or (Approx.
sensor 2 output voltage 0.9 0.9 0.9
more 4.5)
(When cold)
Max. 140
Approx. Approx. Approx.
Intake air pressure kPa (When -
100 100 100
warm)
Max. 135
Intake air pressure Approx. Approx. Approx. Max.
Input V -
sensor output voltage 1 1 1 Approx. 1.5
Analog Fuel temperature °C Example : Approx. 1.2 V if the temperature is approx. 50 °C
signal Fuel temperature sensor (122 °F) [depending on the ambient temperature and the
V engine warming up].
output voltage
Coolant temperature °C
Example : Approx. 1.2 V if the temperature is approx. 80 °C
Coolant temperature (176 °F) [depending on the engine warming up].
V
sensor output voltage
Intake air temperature °C
Example : Approx. 1.6 V if the temperature is approx. 37 °C
Intake air temperature (99 °F) [depending on the engine warming up].
V
sensor output voltage
Atmospheric pressure kPa Example : Approx. 3.7 V if pressure is approx. 100 kPa
Atmospheric pressure (1.02 kgf/cm2, 14.5 psi) [depending on the atmospheric
V pressure].
output voltage
When stopped : Approx. 12.5 V,
When operating : Approx. 14 V
Battery voltage V
[depends on the battery charging condition, whether or not
there is a load voltage, rotation rate]
Key switch - ON ON ON ON ON
Switch
Starter switch - OFF ON OFF OFF OFF
signal
Neutral switch - During neutral : ON

5-8
During
During
Engine During No-load
Classification Signal Name Unit Idling Acceler-
Stopped Start-Up Max.
ation
Speed
Engine stop flag - ON OFF OFF OFF OFF
General
Start-up mode flag - OFF ON OFF OFF OFF
0 → 120 12 or less 30 or less
Final fuel injection
mm3/st 0 (Ordinary (After - (After
quantity
temperature) warm-up) warm-up)
Injection Pre-injection quantity Approx. Approx. Approx.
mm3/st 0 0 to 3
quantity 3 3 3
Final fuel injection timing °BTDC Depends on the coolant temperature, rotation rate, load
Approx. Approx. Approx.
Pre-interval μsec - -
1.0 ms 0.7 ms 0.8 ms
Depends on the rotation rate, load
During idle : Approx. 36 MPa (370 kgf/cm2, 5200 psi),
During no-load max. speed : Approx. 75 MPa (760 kgf/cm2,
Target rail pressure MPa
11000 psi),
During acceleration : 36 to 160 MPa (370 to 1630 kgf/cm2,
5300 to 23200 psi)
Actual rail pressure MPa - Approx. the same as the target value
Depends on the rotation rate, load
Rail pressure sensor During idle : Approx. 1.6 V,
V
output voltage During no-load max. speed : Approx. 2.2 V,
During acceleration : 1.6 to 3.4 V
Approx. 1300 to Approx.
Target SCV current mA 0 0 to 1700
1700 1700 1600
Output Rail
pressure Actual SCV current mA - Approx. the same as the target value
Indicates the following depending on the learning status :
2 (Normal operation),
0 (Actual learning),
- 1 (Provisional learning completion),
status
2 (Actual learning completion),
3 (Relearning),
255 (Default value)
mA Varies depending on the individual difference of pump.
correction value
Pressure feedback
integral guard execution - Normally OFF
flag
Idle min-1
Target idle speed 825
speed (rpm)
Target EGR valve Approx. 25 →
% 0 0 Approx. 15
opening 25 Approx. 15
Actual EGR valve
EGR % Approx. the same as the target EGR opening
opening
valve
Approx. 1.7
EGR lift sensor output Approx. Approx. Approx. Approx.
V → Approx.
voltage 0.9 0.9 1.7 1.4
1.4
Relay Glow relay - ON only during cold start-up

5-9
6. ECU TERMINAL LAYOUT AND NORMAL VALUES

[1] ECU TERMINAL LAYOUT
No. Terminal Name Signal Name No. Terminal Name Signal Name
1 P-GND POWER GROUND 62
2 P-GND POWER GROUND 63 A-VCC5 SENSOR (POWER SUPPLY)
3 P-GND POWER GROUND 64 A-VCC6 SENSOR (POWER SUPPLY)
CRANKSHAFT POSTION
4 COMMON INJECTION COMMON 65 NE-
SENSOR-
CAMSHAFT POSTION
5 COMMON INJECTION COMMON 66 G-
SENSOR-
6 67 SHIELD GND1 SHIELD GROUND
RAIL PRESSURE SENSOR
7 EGR- EGR DC MOTOR (-) 68 PFUEL RTN
RTN
FUEL TEMPERATURE
8 EGR+ EGR DC MOTOR (+) 69 THF RTN
SENSOR RTN
COOLANT TEMPERATURE
9 70 THW RTN
SENSOR RTN
INTAKE AIR PRESSURE
10 SCV+ SUCTION CONTROL VALVE+ 71 PIM RTN
SENSOR RTN
11 72
12 73
INTAKE AIR TEMPERATURE
13 74 THA RTN
SENSOR RTN
14 75
15 76
16 77 LEGR RTN EGR LIFT SENSOR RTN
17 78
18 ENG-WL ENGINE WARNING LIGHT 79
19 80
20 81 LEGR EGR LIFT SENSOR
21 TWV4 INJECTION DRIVE4 82 A-VCC1 SENSOR (POWER SUPPLY)
ACCELERATOR POSTION
22 TWV4 INJECTION DRIVE4 83 APS1
SENSOR1
23 TWV2 INJECTION DRIVE2 84 APS1GND SENSOR GROUND
24 TWV2 INJECTION DRIVE2 85 SHIELD GND2 SHIELD GROUND
25 86
26 87 CAN1-L CAN1-L (FOR VEHICLE)

5-10
No. Terminal Name Signal Name No. Terminal Name Signal Name
27 88 CAN2-L CAN2-L (FOR SERVICE)
28 89
29 SCV- SUCTION CONTROL VALVE- 90 A-VCC2 SENSOR (POWER SUPPLY)
ACCELERATOR POSTION
30 91 APS2
SENSOR2
31 92 APS2GND SENSOR GROUND
32 93
33 94
34 95 CAN1-H CAN1-H (FOR VEHICLE)
35 96 CAN2-H CAN2-H (FOR SERVICE)
36 97 SPD VEHICLE SPEED SENSOR
37 GRLY GLOW RELAY 98
38 GL-LAMP GLOW LAMP 99 STA-SW STARTER SWITCH
39 100
40 TWV3 INJECTION DRIVE3 101
44 A-VCC3 SENSOR (POWER SUPPLY) 105 M-REL MAIN RELAY
45 A-VCC4 SENSOR (POWER SUPPLY) 106 TACHO TACHOMETER PULSE
CRANKSHAFT POSTION
46 NE+ 107 IG-SW KEY SWITCH ON
SENSOR+
CAMSHAFT POSTION
47 G+ 108
SENSOR+
48 PFUEL RAIL PRESSURE SENSOR 109
49 PFUEL RAIL PRESSURE SENSOR 110 N-SW NEUTRAL SWITCH
FUEL TEMPERATURE
50 THF 111
SENSOR
COOLANT TEMPERATURE
51 THW 112
SENSOR
INTAKE AIR PRESSURE
52 PIM 113 M-REL MAIN RELAY
SENSOR
53 114 C-GND SIGNAL GROUND
54 115 CASE-GND CASE GROUND
INTAKE AIR TEMPERATURE
55 THA 116
SENSOR
56 117
57 118
58 119 +BP BATTERY+ (MAIN RELAY)
59 120 +BP BATTERY+ (MAIN RELAY)
60 121 BATT BATTERY+
61
W1064302

5-11
[2] ECU TERMINAL NORMAL VALUES (WAVEFORMS)

Measurement
Normal Waveforms (When Engine is Idling after Warming Up)
Terminal
G+ (C-GND)
|
NE+ (C-GND)

5-12
Measurement
Terminal
SCV+ (SCV-)
EGR+ (EGR-)
When motor is
operating (EGR
opening is
changing)

5-13
Measurement
Terminal
TWV1-4 (P-GND)
COMMON1-2
(TWV1-4)
W1067087

5-14
6 DIAGNOSIS

CONTENTS
1. DIAGNOSIS BY MALFUNCTION SYMPTOM ............................................... 6-1

[1] LIST OF MALFUNCTION CAUSES BY SYMPTOM.............................. 6-1
[2] DIAGNOSIS BY MALFUNCTION SYMPTOM ......................................... 6-5
(1) Engine Warning Light Comes On ......................................................... 6-5
(2) Engine Does Not Start (Including Engine Stalls While Running) .......... 6-5
(3) Takes A Long Time Before Engine Starts............................................. 6-9
(4) Idling Failure ....................................................................................... 6-14
(5) Engine Noise....................................................................................... 6-19
(6) Large Fuel Consumption..................................................................... 6-22
(7) Poor Acceleration (Insufficient Output) ............................................... 6-28
(8) Black Smoke Emitted .......................................................................... 6-34
(9) White Smoke Emitted ......................................................................... 6-40
(10)Engine Stalls On Deceleration............................................................ 6-46
2. ACTIVE TEST AND SUPPLY PUMP DIFFERENCE LEARNING............. 6-51
3. DIAGNOSIS BY DTC .................................................................................... 6-53
[1] DTC LIST ................................................................................................. 6-53
[2] DIAGNOSTIC PROCEDURE BY DTC................................................... 6-66
(1) NE - G Phase Gap (DTC P0016) ........................................................ 6-67
(2) Pressure Limiter Opening Abnormality (DTC P0087) ......................... 6-68
(3) High Rail Pressure Abnormality (DTC P0088) .................................... 6-74
(4) SCV Stuck (DTC P0089) .................................................................... 6-79
(5) Fuel Leak (DTC P0093) ...................................................................... 6-84
(6) Intake Air Temperature Sensor Abnormality (DTC P0112, P0113) .... 6-90
(7) Coolant Temperature Sensor Abnormality (DTC P0117, P0118) ....... 6-93
(8) Fuel Temperature Sensor Abnormality (DTC P0182, P0183) ............ 6-97
(9) Rail Pressure Sensor Abnormality (DTC P0192, P0193) ................. 6-100
(10)Overcharge (DTC P0200)................................................................. 6-105
(11)TWV* Actuation System Open Circuit (DTC P0201, P0202, P0203,
P0204) .............................................................................................. 6-107
(12)Overheat (DTC P0217)..................................................................... 6-110
(13)Overrun (DTC P0219)....................................................................... 6-112
(14)Intake Air Pressure Sensor Abnormality (DTC P0237, P0238) ........ 6-113
(15)Non-Injection Abnormality (Rotational Fluctuation Abnormality)
(DTC P0263, P0266, P0269, P0272)................................................ 6-117
(16)Crankshaft Position Sensor (NE Sensor) Abnormality (DTC P0335,
P0336) .............................................................................................. 6-120
(17)Camshaft Position Sensor (G Sensor) Abnormality (DTC P0340,
P0341) .............................................................................................. 6-125
(18)EGR Feedback Abnormality (DTC P0400) ....................................... 6-130
(19)EGR DC Motor Estimated Temperature Abnormality (DTC P0404). 6-133
(20)EGR Lift Sensor Abnormality (DTC P0405, P0406) ......................... 6-136
(21)Vehicle Speed Sensor Abnormality (DTC P0501, P0503)................ 6-140
(22)Battery Voltage Abnormality (DTC P0561, P0562, P0563) .............. 6-143
(23)QR Abnormality (DTC P0602) .......................................................... 6-147
(24)ECU Flash-ROM Abnormality and CPU Abnormality (DTC P0605,
P0606) .............................................................................................. 6-148
(25)Low Charge (DTC P0611) ................................................................ 6-150
(26)Starter Switch Abnormality (DTC P0616, P0617)............................. 6-152
(27)SCV Abnormality (DTC P0628, P0629)............................................ 6-154
(28)Sensor Voltage 1 Abnormality (DTC P0642, P0643) ........................6-157
(29)Sensor Voltage 2 Abnormality (DTC P0652, P0653) ........................6-159
(30)Main Relay Abnormality (DTC P0687) ..............................................6-161
(31)Pump Protection Failure Flag (DTC P1274) .....................................6-164
(32)Pump Replacement Failure Flag (DTC P1275) ................................6-168
(33)Accelerator Position Sensor 1 Abnormality (DTC P2122, P2123) ....6-173
(34)Accelerator Position Sensor 2 Abnormality (DTC P2127, P2128) ....6-176
(35)Common 1 System Open Circuit and Common 2 System Open
Circuit (DTC P2146, P2149) .............................................................6-179
(36)Common 1 TWV Actuation System Ground Short and Common 1
TWV Actuation System +B Short (DTC P2147, P2148)....................6-183
(37)Atmospheric Pressure Sensor Abnormality (DTC P2227, P2228,
P2229)...............................................................................................6-187
(38)Glow Relay Actuation Abnormality (DTC P0380) .............................6-189

1. DIAGNOSIS BY MALFUNCTION SYMPTOM

[1] LIST OF MALFUNCTION CAUSES BY SYMPTOM
• Verify the malfunction symptom, and perform diagnosis according to the appropriate number.
• Many diagnostic procedures include check and verification of malfunction symptom while it occurs. Be sure to
perform work while verifying the malfunction symptom.
No. Malfunction Symptom Detail
1 Engine warning light comes on. -
• Engine does not crank (starter motor does
not rotate).
Engine does not start
2 • Engine stops when the key switch returns to
(including engine stalls while running).
the ON position from the ST position
(engine does not rotate under its own power).
• Takes a long time before engine starts.
3 Takes a long time before engine starts.
• May accompany idle failure.
• Idle speed is lower than the standard value or
4 Idle failure unstable.
• Engine may stall.
• Abnormal noises come from inside the
5 Engine noise engine.
• Engine sound is loud.
6 Large fuel consumption • Fuel consumption has increased significantly.
• Acceleration is slower than before when
depressing the accelerator pedal.
7 Poor acceleration (insufficient output)
• Power feels insufficient compared with
previously. Large amount of rotation drop.
• Black smoke in the exhaust gas has
8 Black smoke emitted.
increased.
• White smoke in the exhaust gas has
9 White smoke emitted.
increased.
• Engine speed drops when releasing the
accelerator pedal.
• Engine stalls on deceleration with the
10 Engine stalls on deceleration. accelerator pedal fully closed.
• Engine stalls immediately after the vehicle
stops when decelerating with the accelerator
pedal fully closed.
W1010697

6-1
[Table of malfunction causes by symptom]

Control System Engine
Malfunction Cause
Coolant temperature sensor

Accelerator position sensor
Crankshaft position sensor
Camshaft position sensor

Damaged sensor pulsar gear
Damaged sensor pulsar gear
Low compression pressure
Insufficient engine oil level

Low engine oil viscosity
Air gap size is too large
Air gap size is too large
Valve clearance fault

Engine internal fault
False signal output
False signal output
Valve timing fault

No signal output
No signal output
No signal output
No signal output
Maladjustment
Malfunction Symptom
❍ ❍ ❍ ❍ ❍ ❍ ❍
1 Engine warning light comes on ❍
*1 *1
❍
*1 *1
❍ ❍ ❍
*2 *2 *3

2 ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
(including engine stalls while running)
3 Takes a long time before engine starts ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
4 Idle failure ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
5 Engine noise ❍ ❍ ❍ ❍ ❍ ❍ ❍
6 Large fuel consumption ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
7 Poor acceleration (insufficient output) ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
8 Black smoke emitted ❍ ❍ ❍ ❍ ❍ ❍ ❍
9 White smoke emitted ❍ ❍ ❍ ❍ ❍ ❍
10 Engine stalls on deceleration ❍ ❍ ❍ ❍ ❍
*1 There is a lighting case.

*2 When the engine rotation change is large, it lights.
*3 It lights for a timing positional wrong gear.
W1691584

6-2
Engine
Control System Electrical Intake Syatem
System
Malfunction Cause
Intake air presuure sensor
Intake system components

Fuel temperature sensor
Rail pressure sensor
Glow system
Battery
Turbocharge malfunction
Charging system failure
Main relay malfunction
Clogged air cleaner

Does not discharge
False signal output
False signal output
False signal output

SCV malfunction
Does not charge

No signal output
No signal output
No signal output
Faulty glow plug

Faulty relay
Malfunction Symptom
Leak
❍ ❍ ❍ ❍
1 Engine warning light comes on ❍
*1
❍ ❍
*1 *1
❍ ❍
*2
❍

2 ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
3 Takes a long time before engine starts ❍ ❍ ❍ ❍ ❍ ❍
4 Idle failure ❍ ❍ ❍
5 Engine noise ❍ ❍ ❍ ❍
6 Large fuel consumption ❍ ❍ ❍ ❍ ❍ ❍
7 Poor acceleration (insufficient output) ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
8 Black smoke emitted ❍ ❍ ❍ ❍ ❍ ❍
9 White smoke emitted ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
10 Engine stalls on deceleration ❍ ❍

*2 When pressure doesn't hang to the intake air pressure sensor, it is likely to light.
W1035769

6-3
Cooling
Fuel System Others
System
Cooling sysrtem failure (radiator, hoses, thermostat, cooling fan, etc.)

Malfunction Cause
Power transmission malfunction (including clutch slipping) *2

Damaged fan belt or misadjusted belt tension
Fuel line
Injectors
Improper concentration of antifreeze
Large dragging (including brake) *2

Blockage, leake, malfunction
Supply pump learning failure
Faulty fuel pressure limiter

Supply pump malfunction
Clogged fuel filter
Loose fit parts

Fuel quality
Malfunction Symptom
Blockage
Leak
❍ ❍ ❍ ❍
1 Engine warning light comes on *1
❍
*1
❍
*1 *1

2 ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
3 Takes a long time before engine starts ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
4 Idle failure ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
5 Engine noise ❍ ❍ ❍ ❍ ❍ ❍ ❍
6 Large fuel consumption ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
7 Poor acceleration (insufficient output) ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
8 Black smoke emitted ❍ ❍ ❍ ❍ ❍ ❍
9 White smoke emitted ❍ ❍ ❍ ❍ ❍ ❍ ❍ ❍
10 Engine stalls on deceleration ❍ ❍ ❍ ❍ ❍ ❍

*2 It emphatically searches for the vehicle side.
W1680605

6-4
[2] DIAGNOSIS BY MALFUNCTION SYMPTOM

(1) Engine Warning Light Comes On
1. Turn the key switch ON and check that the fuel pump is operating.
If it is not operating, check in accordance with "2.2. FUEL SYSTEM INSPECTION PROCEDURE - 5. Check the
fuel pump".
2. Connect diagnosis tool and read DTC. Refer to pertinent DTC diagnosis guidelines and implement diagnosis.
(2) Engine Does Not Start (Including Engine Stalls While Running)
Possible causes :
1. Fuel pump operation fault
2. Starting assist device (glow plug)
• Applicable only when the temperature is low : -10 °C (14 °F) or less
• Refer to the operator’s manual for this device and check the glow plug, relay and related wiring harness
*Refer to the previous "Table of malfunction causes by symptom" for the subsequent details.
3. Engine fault
• Low compression pressure
• Internal engine fault
• Valve timing fault
4. Control system
• Damage to the pulsar gear of the crankshaft position sensor
• Air gap of the crankshaft position sensor is large
• Damage to the pulsar gear of the camshaft position sensor
• SCV operation fault
• Main relay operation fault
5. Engine electrical system
• Battery fault
• Charging system malfunction
6. Intake system
• Glow relay fault
• Glow plug fault
7. Fuel system
• Fuel quality
• Fuel filter clogging
• Fuel pressure limiter fault
• Fuel line clogging, leak
8. CRS (including the wiring harness)
• Power supply system
• Output system (supply pump, injector and common rail)
• Input system (sensors and switches)
• ECU
9. Others
• Large amount of drag (including the brakes, etc.)
1. Check the fuel pump operation

1. Turn the key switch ON and check that the fuel pump is
operating.
Factory spec. Operates when the key switch is turned ON.
Check in accordance with "2.2. FUEL SYSTEM

NG INSPECTION PROCEDURE - 5. Check the fuel
pump".
(1) Fuel Pump
W1189791
OK

6-5
2. Check the DTC

1. Turn the key switch ON and check the DTC.
Factory spec. No DTC is output.
NG1 : Communication error
Go to Step 6 (Check the ECU power supply and
NG
grounding).
NG2 : DTC presently existing
Check in accordance with the troubleshooting
NG
procedures for each DTC.
NG3 : Past DTC only
Reproduce defect by referring to the freeze frame data,
NG
etc.
(a) CAN2 Connector
W1019178
OK
3. Check the starting assist device

1. Refer to the operator’s manual for this device and check the glow
plug, relay and related wiring harness.
2. Perform an active test for models that have relay control in the
ECU on the engine side.
Operates repeatedly between ON and OFF in
Factory spec.
accordance with the specified cycle.
Checking and repair of starting assist device (glow

NG
plug).
(a) CAN2 Connector
W1190589
OK
4. Check the intake system

1. Check in accordance with "2.1. AIR INTAKE SYSTEM
INSPECTION PROCEDURE".
Repair in accordance with "2.1. AIR INTAKE SYSTEM
NG
(1) Air Cleaner (2) Air Cleaner Switch
W1191141
OK

6-6
5. Check the fuel system

1. Check in accordance with "2.2. FUEL SYSTEM INSPECTION
PROCEDURE".
Repair in accordance with "2.2. FUEL SYSTEM
NG
(1) Supply Pump (2) Rail
W1191347
OK
6. Check the ECU power supply and grounding

ECU +BP terminals (119,120) and ground (body / battery
terminal) and ECU C-GND terminal (114) and ground (body /
battery terminal).
+BP terminal : 10 V or higher
Factory spec.
C-GND terminal : 0.5 V or lower
Diagnose by referring to "2.3. ELECTRIC SYSTEM

INSPECTION PROCEDURE - [3] CHECKING THE
NG
POWER AND GROUND SYSTEM (MAIN RELAY ECU
CIRCUIT)".
W1013857
OK
7. Check the crankshaft position sensor and camshaft position sensor signal
1. Set the key switch to START position and crank the engine.
Check the "Engine speed active flag" and "Cam speed active
flag" using the diagnosis tool data monitor function.
Factory spec. Both sides ON and constant.
OK Normal.
NG
Both flags are unsatisfactory.
Cause of the engine starting failure has been determined. Determine
the malfunction area by referring to sections in P0335, P0336 and
P0340, P0341 in "6.2. DIAGNOSIS BY DTC".
Only one side of the flag is unsatisfactory.
Care should be taken as this does not cause engine starting failure.
Since the sensor signal is abnormal, determine the malfunction area
by referring to sections in P0335, P0336 and P0340, P0341 in "6.2.
DIAGNOSIS BY DTC" as was the case in the above.
(a) CAN2 Connector
W1014470
NG

6-7
8. Supply pump difference learning and checking the monitor

1. Perform difference learning for the supply pump in accordance
with "6.2. ACTIVE TEST AND SUPPLY PUMP DIFFERENCE
LEARNING".
2. In accordance with the previous "Table of malfunction causes by
symptom", use the diagnosis tool for a monitor check of the mode
flags during start-up, such as the coolant temperature, rail
pressure, SCV current value and battery voltage.
NG Repair the malfunction.
(a) CAN2 Connector
W1194682
OK
9. Check the engine

1. Check the compression pressure, valve timing and the inside of
the engine.
(1) Compression Tester (2) Aligning Mark
W1194897
OK
Normal.
■ NOTE
• It wishes contacting to Kubota through the Kubota distributor when problem does not solve by the above-
mentioned treatment.

6-8
(3) Takes A Long Time Before Engine Starts

Possible causes :
2. Engine fault
3. Control system
• Damage to the pulsar gear of the camshaft position sensor
4. Engine electrical system
• Battery fault
5. Intake system
• Glow plug fault
6. Fuel system
• Fuel quality
• ECU
8. Others

operating.

pump".
(1) Fuel Pump
W1196159
OK

6-9
2. Check the DTC

NG
NG2 : Past DTC only
NG
etc.
(a) CAN2 Connector
OK

Factory spec.

NG
plug).
(a) CAN2 Connector
OK

NG
OK

6-10

PROCEDURE".
NG
OK
6. Check the crankshaft position sensor

1. Refer to DTC P0335 and P0336, and implement checking of the
crankshaft position sensor.
Repair and replacement of the crankshaft position
NG
sensor-related parts.
(1) Crankshaft Position Sensor
(NE Sensor)
OK
7. Check the camshaft position sensor

camshaft position sensor.
Repair and replacement of camshaft position sensor-
NG
related parts.
(G Sensor)
OK

6-11
8. Check the rail pressure sensor and supply pump

1. Measure the "Target rail pressure" and "Actual rail pressure"
when accelerator is operated as indicated below using the
diagnosis tool data monitor function.
1. Approx. 36 MPa (370 kgf/cm2, 5200 psi)
when idling
2. (Disengaged clutch) No-load max. speed
Factory spec. approx. 75 MPa (760 kgf/cm2, 11000 psi)
3. The target values and actual pressure reading
should be approximately the same under all
conditions.
Go to Step 10 (Check the injector (including the pipes,

OK
etc.)).
(a) CAN2 Connector
NG
9. Check the rail pressure sensor and monitor

1. Using the data monitor function of diagnosis tool, measure the
"Actual rail pressure" and "Rail pressure sensor output voltage".
Two values shall always match the normal
Factory spec.
values.
(Check the rail pressure sensor)

Refer to items P0192 and P0193 in "6.3. [2]
DIAGNOSTIC PROCEDURE BY DTC", perform
NG
diagnosis for the ECU (sensor power supply), wiring
harness and rail pressure sensor, and repair or replace
the required parts.
OK
(Check pressure-related malfunctions)
Refer to the pressure system items (P0087, P0088, P0089,
P0093) in "6.3. [2] DIAGNOSTIC PROCEDURE BY DTC",
perform diagnosis for the ECU, wiring harness and sensor, and
repair or replace the required parts.
symptom", use the diagnosis tool for a monitor check of the mode
flags during start-up, such as the coolant temperature, rail
pressure, SCV current value and battery voltage.
(a) CAN2 Connector
OK

6-12
10. Check the injector (including the pipes, etc.)

1. Perform the diagnosis tool active test (stopping the injector
injection by cylinder) and check the injector performance.
Engine vibration and noise are increased and the
rotation rate is reduced when the injection for the
Factory spec. corresponding cylinder is stopped.
The same results must be attained from all the
cylinders.
Check and repair faulty parts including the

NG
high pressure line of the defective cylinder.
(a) CAN2 Connector
OK
11. Check the engine

the engine.
W1250581
OK
Normal.
■ NOTE

6-13
(4) Idling Failure

Possible causes :
2. Engine fault
3. Control system
4. Fuel system
• Supply pump learning has not been performed
• Fuel quality
• ECU
6. Others

operating.

pump".
(1) Fuel Pump
W1252200
OK
2. Check the DTC

NG
NG2 : Past DTC only
NG
etc.
(a) CAN2 Connector
OK

6-14

The same results must be attained from all the
cylinders.

NG
(a) CAN2 Connector
W1017716
OK

NG
OK

PROCEDURE".
NG
OK

6-15
6. Check the accelerator position sensor

1. Refer to DTC P2122, P2123, P2127 and P2128, and implement
checking the accelerator position sensor.
CAUTION
• When checking, pay attention to the angle of mounting
instead of the output signal quality.
NG Replacement of accelerator position sensor.
(1) Accelerator Position Sensor
OK

NG
(NE Sensor)
OK

NG
related parts.
(G Sensor)
OK

6-16

when idling
conditions.
OK Go to Step 11 (Check the engine).
(a) CAN2 Connector
NG

Factory spec.
values.

NG
the required parts.
OK
(Check the supply pump)
P0093) and SCV system items (P0628, P0629) in "6.3. [2]
DIAGNOSTIC PROCEDURE BY DTC", perform diagnosis for the
ECU, wiring harness and sensor, and repair or replace the
required parts.
symptom", use the diagnostic tool for a monitor check of the
coolant temperature, rail pressure, SCV current value and
battery voltage.
(a) CAN2 Connector
OK

6-17

the engine.
OK
Normal.
■ NOTE

6-18
(5) Engine Noise

Possible causes :
*Refer to the previous "Table of malfunction causes by symptom" for details.
1. Engine fault
• Valve clearance fault
2. Control system
3. Intake system
• Leak from the intake system parts
4. Fuel system
• Fuel quality
5. Cooling system
• Fan belt damage or tension maladjustment
6. CRS (including related fuel line)
• Input system (sensors)
• ECU
7. Others
• Loose parts (including part interference sound)
1. Check the DTC


NG
procedure for the DTC.
(a) CAN2 Connector
OK

NG
(NE Sensor)
OK

6-19

NG
related parts.
(G Sensor)
OK

The same results must be attained for all the
cylinders.

NG
(a) CAN2 Connector
OK

6-20
5. Check the engine and vehicle body

1. Check the compression pressure, valve clearance, valve timing
and the inside of the engine.
2. Check for loose parts in the engine and on the vehicle body
(including part interference sound).
3. Check for a large amount of drag (including the brakes, etc.).
OK
Normal.
■ NOTE

6-21
(6) Large Fuel Consumption

Possible causes :
(A) Reduced engine performance is detected and the fuel consumption is higher for this reason
1. The engine performance is reduced and the fuel consumption is higher for this reason
(B) Reduced engine performance is not detected but the fuel consumption is higher
1. Usage habits of the user or use of non-standard parts
• Not the standard specification
- Tires, wheels
- Intake / exhaust system parts
• Used for a long time under poor fuel consumption conditions
- Engine used for a long time under a high load
- Long idling time
• Frequently used under driving conditions with a large injection quantity
- Low mileage for each drive (frequently used before the engine has warmed up)
• Faulty maintenance
- Engine oil (dirt)
- Air filter, fuel filter (dirt, clogging)
- Radiator clogging
2. Powertrain malfunctions not involving the engine
• Large driving resistance
- Large resistance for actuation
- Tire air pressure
- Brake drag
• Clutch slipping
4. Engine fault
• Engine oil viscosity fault
5. Control system
• Air gap of the crankshaft position sensor is large.
6. Intake system
• Air cleaner clogging
• Turbocharger operation fault
7. Fuel system
• Fuel quality
8. CRS (including related parts)
• Output system (supply pump and injector)
• Input system (sensors) *A cause for larger injection quantity

6-22

operating.

pump".
(1) Fuel Pump
OK
2. Check the DTC


NG
procedure for each DTC.
(a) CAN2 Connector
OK
3. Comparison of fuel economy

1. Compare with a normal device working under the same operating
conditions and measure the amount of consumed fuel (amount
left in the tank).
Use a specific example to explain and make the user
understand that under some operating conditions the
OK
fuel consumption will increase and that the vehicle is
not malfunctioning.
(1) Fuel Tank
NG

6-23
4. Check the engine and vehicle condition

1. Check for the usage habits of the user or use of non-standard
parts.
• Use of non-standard parts such as tires, wheels and intake /
exhaust system parts
• Used under poor fuel consumption conditions
- Engine used for a long time under a high load
- Long idling time
• Faulty maintenance
- Engine oil level and dirt
- Air filter, fuel filter dirt and clogging
- Radiator clogging
NG Give guidance to the user.
2. Check for malfunctions in the powertrain.
• Check the driving resistance
- Is a large resistance required for actuation?
- Is the tire air pressure correct?
- Is there brake drag?
• Check the clutch slipping
NG Adjust or repair the malfunction.
OK

PROCEDURE".
(Reference)
• Pay attention particularly to the following two points :
- Service fuel (for summer / winter seasons, and cold region)
- Fuel leak from the fuel line
OK

(Reference)
• Pay attention particularly to the following point :
- Intake air leak
OK

6-24
7. Check the coolant temperature increase rate

1. Check the speed of the coolant temperature increase on the
coolant temperature gauge in the instrument panel (compared
with a normal device).
NG Check and repair the cooling system.
(1) Coolant Temperature Gauge
OK

NG
(NE Sensor)
OK

NG
related parts.
(G Sensor)

6-25

when idling
conditions.
Go to Step 12 (Check the injector (including the pipes,

OK
etc.)).
(a) CAN2 Connector
NG

Factory spec.
values.

NG
the required parts.
OK
required parts.
symptom", use the diagnosis tool for a monitor check of the
coolant temperature, rail pressure and SCV current value.
(a) CAN2 Connector
OK

6-26

cylinders.

NG
(a) CAN2 Connector
OK

1. Check the compression pressure, valve clearance, valve timing,
the inside of the engine and engine oil viscosity.
2. Check the turbocharger.
NG Repair or replace the related parts.
(1) Compression Tester (3) Turbocharger
(2) Aligning Mark
OK
Normal.
■ NOTE
6-27
(7) Poor Acceleration (Insufficient Output)

Possible causes :
2. Large driving resistance due to problems in the vehicle itself that do not involve the engine
• Large resistance for actuation
• Tire air pressure
• Power transmission fault (including clutch slipping, etc.)
• Brake drag
3. Engine fault
4. Control system
• Accelerator position sensor maladjustment
5. Intake system
6. Fuel system
• Fuel quality
7. CRS (including related parts)
• Input system (sensors) *A cause for larger injection quantity
• ECU
8. Others

operating.

pump".
(1) Fuel Pump
W1291821
OK

6-28
2. Check the DTC

NG
NG2 : Past DTC only
NG
etc.
(a) CAN2 Connector
OK

checking of the accelerator position sensor.
CAUTION
OK
4. Check the idle condition

1. Check if idling is normal.
Factory spec. Stable at specified speed.
Refer to "(4) Idling Failure", and implement checking

NG
and repair.
OK

6-29
5. Malfunction verification - 1
1. Reproduce running conditions (engine speed, vehicle speed,
gear shift, etc.) as pointed out by the driver. Compare with
another vehicle of the same model and check whether poor
acceleration and power shortage can be sensed.
Factory spec. No malfunction should be detected.
Explain to the driver that the vehicle is in a normal

condition.
(Reference)
OK
• Give appropriate advice to the driver about matters
concerning anything noticed that is related to his
driving manner (such as selection of shift, etc.).
NG
6. Malfunction verification - 2
1. Check for a large driving resistance due to problems in the
vehicle itself that do not involve the engine.
• Large resistance for actuation
• Tire air pressure
• Brake drag
NG Repair or adjust the malfunction.
OK

NG
W1295853
OK

6-30

PROCEDURE".
NG
W1303339
OK

NG
(NE Sensor)
OK

NG
related parts.
(G Sensor)
OK

6-31

when idling
conditions.

(a) CAN2 Connector
NG

Factory spec.
values.

NG
the required parts.
OK
required parts.
coolant temperature, rail pressure, SCV current value and intake
air pressure.
(a) CAN2 Connector
OK

6-32

cylinders.

NG
(a) CAN2 Connector
OK

2. Check the timing gear.
OK
Normal.
■ NOTE

6-33
(8) Black Smoke Emitted

Possible causes :
2. Engine fault
3. Control system
4. Intake system
5. Fuel system
• Fuel quality
• ECU

operating.

pump".
(1) Fuel Pump
OK

6-34
2. Check the DTC

NG
NG2 : Past DTC only
NG
etc.
(a) CAN2 Connector
OK

NG
OK

PROCEDURE".
NG
OK

6-35

CAUTION
OK

NG
(NE Sensor)
OK

NG
related parts.
(G Sensor)
OK

6-36
8. Check the EGR valve

Refer to "6.3. [2] DIAGNOSTIC PROCEDURE BY DTC" for the detailed EGR-related check. A simplified version
is shown below.
1. Use the monitor function to check whether the actual opening
meets the target opening.
Refer to "5.3. [2] NORMAL VALUE".
Factory spec. In addition, for the check procedures refer to "6.3.
[2] DIAGNOSTIC PROCEDURE BY DTC".
■ NOTE
• Check that the EGR valve does not open before the engine
has warmed up [coolant temperature : 65 °C (149 °F)].
2. Perform an active test (EGR actuation test).
(Low side)
When target EGR valve openings of 0% and 15%
are given alternately, there must not be disparity
in the actual EGR valve opening.
Factory spec.
(High side)
When target EGR valve openings of 35% and
60% are given alternately, there must not be
disparity in the actual EGR valve opening.
NG Replace the EGR valve.

(a) CAN2 Connector
W1314277
OK

when idling
conditions.

(a) CAN2 Connector
NG

6-37

Factory spec.
values.

NG
the required parts.
OK
required parts.
(a) CAN2 Connector
OK

cylinders.

NG
(a) CAN2 Connector
OK

6-38

2. Check the turbocharger.
OK
Normal.
■ NOTE

6-39
(9) White Smoke Emitted

Possible causes :
2. Starting assist device fault (after-heat does not operate)
3. Engine fault
4. Control system
5. Intake system
6. Fuel system
• Fuel quality
• ECU

operating.

pump".
(1) Fuel Pump
OK

6-40
2. Check the DTC

NG
NG2: Past DTC only
NG
etc.
(a) CAN2 Connector
OK

Factory spec.

NG
plug).
(a) CAN2 Connector
OK

Factory spec. Stable at specified speed

NG
and repair.
OK

6-41

NG
OK

PROCEDURE".
NG
OK

NG
(NE Sensor)
OK

6-42

NG
related parts.
(G Sensor)
OK
9. Check the EGR valve

Refer to "6.3. [2] DIAGNOSTIC PROCEDURE BY DTC" for the detailed EGR-related check. A simplified version
is shown below.
1. Use the monitor function to check whether the actual opening
meets the target opening.
Refer to "5.3. [2] NORMAL VALUE".
Factory spec. In addition, for the check procedures refer to "6.3.
[2] DIAGNOSTIC PROCEDURE BY DTC".
■ NOTE
• Check that the EGR valve does not open before the engine
has warmed up [coolant temperature : 65 °C (149 °F)].
2. Perform an active test (EGR actuation test).
(Low side)
When target EGR valve openings of 0% and 15%
are given alternately, there must not be disparity
in the actual EGR valve opening.
Factory spec.
(High side)
When target EGR valve openings of 35% and
60% are given alternately, there must not be
disparity in the actual EGR valve opening.
NG Replace the EGR valve.

(a) CAN2 Connector
OK

6-43

when idling
conditions.

(a) CAN2 Connector
NG

Factory spec.
values.

NG
the required parts.
OK
required parts.
(a) CAN2 Connector
OK

6-44

injection by cylinder) and check the injector performonce.
cylinders.

NG
(a) CAN2 Connector
OK

1. Check the compression pressure, valve clearance, valve timing
and the inside of the engine.
OK
Normal.
■ NOTE

6-45
(10) Engine Stalls On Deceleration

Possible causes :
2. Engine fault
3. Control system
4. Intake system
5. Fuel system
• Fuel quality
• ECU

operating.

pump".
(1) Fuel Pump
OK
2. Check the DTC

NG
NG2 : Past DTC only
NG
etc.
(a) CAN2 Connector
OK

6-46

Factory spec. Stable at specified speed.

NG
and repair.
OK

NG
OK

PROCEDURE".
NG
OK

6-47

CAUTION
OK

NG
(NE Sensor)
OK

NG
related parts.
(G Sensor)
OK

6-48

when idling
conditions.

(a) CAN2 Connector
NG

Factory spec.
values.

NG
the required parts.
OK
required parts.
(a) CAN2 Connector
OK

6-49

cylinders.

NG
(a) CAN2 Connector
OK

the engine.
OK
Normal.
■ NOTE

6-50
2. ACTIVE TEST AND SUPPLY PUMP DIFFERENCE

LEARNING
The four items below are used (including the supply pump difference learning)
1. Injector non-injection instruction

2. EGR actuation test → From the active test screen
3. Glow relay actuation test
4. Supply pump difference learning (clear the learning value) → From the utility screen
(Operating conditions → specified tool conditions)

1. The conditions below are required for 1. Injector non-injection instruction and 4. Supply pump difference learning :
• Vehicle is stopped (KWPSPD = 0)
• Neutral switch is ON (XNEU = 1 or ON)
[Operation details]
1. Injector non-injection instruction
1. Stop the injection for each cylinder injector in accordance with the requests from the tool.
Engine vibration and noise are increased when the injection for the corresponding cylinder is
Factory spec. stopped.
The same results should be obtained for all cylinders.
■ NOTE
• Do not judge with the corresponding cylinder only : also compare with the symptoms in the other
cylinders.
2. EGR actuation test
1. Operate as shown in the figure below and in accordance with the requests from the tool.
(1) Opening (2) Operation check on the fully closed (3) Operation check on the fully (4) Fully open → impact
valve side open valve side dampening when fully closed
Low side : When target EGR valve openings of 0% and 15% are given alternately, there must not
be disparity in the actual EGR valve opening.
Factory spec.
High side : When target EGR valve openings of 35% and 60% are given alternately, there must not
be disparity in the actual EGR valve opening.
■ NOTE
• In some cases the actual opening may be different from the target opening.
The reason for this is because the learning value is always reflected for 0 lift, after being used for a long
time 0 points are shifted.
As such, the factory spec. is a relative evaluation and not an absolute evaluation.
6-51
3. Glow relay actuation test

■ NOTE
• This test cannot be performed on some models.
1. Operate as shown in the diagram below and in accordance with the requests from the tool.
Factory spec. Operates repeatedly between ON and OFF in accordance with the specified cycle.
4. Supply pump difference learning (clear the learning value)

■ IMPORTANT
• Must be performed after replacing the supply pump or ECU.
1. Clear the learning completion flag in accordance with the requests from the tool. (Initialize)
A difference learning completion message comes from the tool.

Factory spec. In addition, when the "Pump difference learning status" is checked with the monitor function, the
status is 2 or 3.

6-52
3. DIAGNOSIS BY DTC
[1] DTC LIST
Period for Judgment Check
Management Behaviour DTC
DTC Set or Number of Engine
Name Unit for DTC DTC Name Detected Item DTC Set Conditions System Action During Recovery
Preconditions Occurrence for Warning
Detected Part Malfunction Conditions
Judgment Light
NE-G phase gap NEGUM P0016 NE-G phase gap • Large phase gap • Engine is operating (Approximate) • 10 or more times • None (Invalid G signal) ON • Recovers when
malfunction between NE pulse [Idle speed to • Phase difference • Engine hesitates the key switch
NE : Crankshaft and G pulse 900 min-1 (rpm)] between NE pulse and at start-up is OFF
position sensor • Battery voltage is normal G pulse within ±15°
G : Camshaft • Sensor supply voltage
position sensor VCC2 is normal
• NE signal is normal
• G signal is normal
• Coolant temperature is
10 °C (50 °F) or higher
Pressure limiter PLACT P0087 Pressure • Pressure • Rail pressure sensor is • Condition A and B are • 1 or more times • Output restriction : • Insufficient output ON • Recovers when
opening limiter opening limiter opening normal fulfilled Q ≤ Approx. 50 % of the key switch
abnormality abnormality abnormality • Sensor supply voltage A. Fuel leak (FLEAK) is normal operation is OFF
VCC2 is normal detected • Accelerator opening
B. Condition (1) or (2) is limit : ACCPF ≤ 50 %
filled • Rail pressure
(1) Fuel pressure is more restriction :
than 191 MPa (1950 Command
kgf/cm2, 27700 psi) pressure ≤ 80 MPa
(2) Within 1 second, after (820 kgf/cm2, 12000 psi)
the fuel pressure drops
to less than 191 MPa
(1950 kgf/cm2, 27700 psi)
[Prior to pressure drop,
the fuel pressure
becomes more than
191 MPa (1950 kgf/cm2,
27700 psi)]
High rail pressure PCEX P0088 High rail pressure • Actual pressure is • Rail pressure sensor is • Actual pressure • 1 sec. or more • Output restriction : • Insufficient output ON • Recovers when
abnormality abnormality excessive when normal (For the corresponding Q ≤ Approx. 50 % of the diagnostic
compared to • Sensor supply voltage time period) ≥ 197 MPa normal operation counter = 0
command pressure VCC2 is normal (2010 kgf/cm2, 28600 psi) • Accelerator opening
(When high limit : ACCPF ≤ 50 %
pressure is • Rail pressure
detected that restriction :
has exceeded Command
the pressure pressure ≤ 80 MPa
usage range) (820 kgf/cm2, 12000 psi)
SCV stuck SCVS P0089 SCV stuck • Stuck with the • Supply pump is normal • Supply pump discharge • 1 or more times • Output restriction : • Insufficient output ON • Recovers when
diagnosis SCV open and learning has been request is 0 mm3/st Q ≤ Approx. 50 % of the key switch
(When a state is performed or lower normal operation is OFF
detected where • Simultaneously, engine is • Simultaneously, actual rail • Accelerator opening
the actual rail operating pressure is at least 10 MPa limit : ACCPF ≤ 10 %
pressure is (Q : 4 mm3/st or higher) (100 kgf/cm2, 1400 psi) • Rail pressure
continuously • Injector is normal higher than the command restriction :
excessive when • Battery voltage is normal rail pressure Command
compared to the • Sensor supply voltage pressure ≤ 80 MPa
command rail VCC2 is normal When the state above (820 kgf/cm2, 12000 psi)
pressure) • Rail pressure sensor is continues for 26 seconds
normal or more
9-M1
6-53 KiSC issued 04, 2008 A

Judgment Light
Fuel leak FLEAK P0093 Fuel leak • Fuel leak from • Battery voltage is normal • When the engine • 1 or more times • Engine stops • Engine stops ON • Recovers when
(High-pressure the high-pressure • Sensor supply voltage speed < 1200 min-1 (rpm) : the key switch
fuel system) fuel system VCC2 is normal (a) is the fuel flow quantity is OFF
(When excessive • Rail pressure sensor is as calculated from the
fuel consumption normal rail pressure deviation
is detected, • Supply pump (SCV) is (reduction quantity).
as calculated from normal (b) is the sum (pump
changes in the • Injector and injector discharge quantity) of the
rail pressure actuation circuit are normal injection quantity and
before and after • NE signal is active internal leak quantity.
fuel injection) [Engine is operating
(700 min-1 (rpm) A fuel leak is judged if the
or higher)] difference between (a) and
• PLACT, PCEX and SCVS (b) exceeds the judgment
are not abnormal value (400 mm3/st),
value (a) is larger than
value (b), and there is
no fuel leak due to
an open P/L
(pressure limitter).
Intake air THAL P0112 Intake air • Sensor / wiring • Battery voltage is normal • Intake air temperature • 2.8 sec. or more • 40 °C (104 °F) • Amount of white ON • Recovers when
temperature temperature harness ground sensor voltage is [default value] smoke increases the diagnostic
sensor abnormality sensor abnormality short 0.05 V or lower at low counter = 0
(Low side) temperatures
THAH P0113 Intake air • Sensor / wiring • Battery voltage is normal • Intake air temperature • 2.8 sec. or more • 40 °C (104 °F) • Amount of white ON • Recovers when
temperature harness open sensor voltage is [default value] smoke increases the diagnostic
sensor abnormality circuit, +B short 4.9 V or higher at low counter = 0
(High side) temperatures
Coolant temperature THWL P0117 Coolant • Sensor / wiring • Battery voltage is normal • Coolant temperature • 2.8 sec. or more • During start-up = • Amount of white ON • Recovers when
sensor abnormality temperature harness ground sensor voltage is -25 °C (-13 °F) smoke increases the key switch
sensor abnormality short 0.1 V or lower [default value] at low is OFF
(Low side) All other times = temperatures
80 °C (176 °F) • Insufficient output
[default value] • Worsening
• Output restriction : exhaust gas
Q ≤ Approx. 50 % of performance
normal operation
• Accelerator opening
limit : ACCPF ≤ 50 %
• EGR stops
THWH P0118 Coolant • Sensor / wiring • Battery voltage is normal • Coolant temperature • 2.8 sec. or more • During start-up = • Amount of white ON • Recovers when
temperature harness open sensor voltage is -25 °C (-13 °F) smoke increases the key switch
sensor abnormality circuit, +B short 4.9 V or higher [default value] at low is OFF
(High side) All other times = temperatures
80 °C (176 °F) • Insufficient output
[default value] • Worsening
• Output restriction : exhaust gas
Q ≤ Approx. 50 % of performance
normal operation
• EGR stops


Judgment Light
Fuel temperature THLL P0182 Fuel temperature • Sensor / wiring • Battery voltage is normal • Supply pump internal • 2.8 sec. or more • During start-up = ON • Recovers when
sensor abnormality sensor abnormality harness ground temperature sensor -20 °C (-4 °F) the diagnostic
(Low side) short voltage is 0.1 V or lower [default value] counter = 0
All other times = -
45 °C (113 °F)
[default value]
THLH P0183 Fuel temperature • Sensor / wiring • Battery voltage is normal • Supply pump internal • 2.8 sec. or more • During start-up = ON • Recovers when
sensor abnormality harness open temperature sensor -20 °C (-4 °F) the diagnostic
(High side) circuit, +B short voltage is 4.9 V or higher [default value] counter = 0
-
All other times =
45 °C (113 °F)
[default value]
Rail pressure sensor PCL P0192 Rail pressure • Sensor / wiring • Battery voltage is normal • Rail pressure sensor • Momentary (0.2 sec.) • Output restriction : • Insufficient output ON • Recovers when
abnormality sensor abnormality harness ground • Sensor supply voltage voltage is 0.7 V or lower Q ≤ Approx. 50 % of • Worsening the key switch
(Low side) short VCC5 is normal normal operation exhaust gas is OFF
• Sensor malfunction • Accelerator opening performance
limit : ACCPF ≤ 10 % • Worsening
• Rail pressure running noise
restriction : • Increase in white
Command smoke
pressure ≤ 80 MPa • Engine stops
(820 kgf/cm2,
12000 psi)
• Engine stops 60
seconds after the
above restrictions
PCH P0193 Rail pressure • Sensor / wiring • Battery voltage is normal • Rail pressure sensor • Momentary (0.2 sec.) • Output restriction : • Insufficient output ON • Recovers when
sensor abnormality harness open • Sensor supply voltage voltage is 4.9 V or higher Q ≤ Approx. 50 % of • Worsening the key switch
(High side) circuit, +B short VCC5 is normal normal operation exhaust gas is OFF
• Sensor malfunction • Accelerator opening performance
restriction : • Increase in white
Command smoke
pressure ≤ 80 MPa • Engine stops
(820 kgf/cm2,
12000 psi)
• Engine stops 60
seconds after the
above restrictions
Overcharge OCHG P0200 ECU injector • Injector charge • Battery voltage is normal • Injector charge current • Momentary (0.1 sec.) • Output restriction : • Insufficient output ON • Recovers when
charge current current exceeded • CPU is normal exceeded Q ≤ Approx. 50 % of • Worsening the key switch
exceeded • ECU charge circuit • ECU charge circuit normal operation exhaust gas is OFF
malfunction malfunction • Accelerator opening performance
restriction :
Command
pressure ≤ 80 MPa
(820 kgf/cm2,
12000 psi)
• Main injection only
is permitted
9-M1

Judgment Light
TWV * actuation NCTWV1 P0201 Engine No. 1 • Wiring harness • Engine running • During wiring harness • 8 or more times • Engine stops • Engine stops ON • Recovers when
system open circuit cylinder injector open circuit • Battery voltage is normal open circuit the key switch
(TWV1) wiring • Injector coil • During injection • During injector coil is OFF
harness open open circuit • CPU is normal open circuit
circuit, coil open
circuit
NCTWV2 P0202 Engine No. 3 • Wiring harness • Engine running • During wiring harness • 8 or more times • Engine stops • Engine stops ON • Recovers when
cylinder injector open circuit • Battery voltage is normal open circuit the key switch
circuit, coil open
circuit
circuit, coil open
circuit
circuit, coil open
circuit
Overheat OVERH P0217 Engine overheat • Engine coolant • Coolant temperature • Engine coolant • 5 sec. or more • Output restriction : • Overheat ON • Recovers when
high temperature sensor is normal temperature ≥ Q ≤ About 50 % of the diagnostic
abnormality 128 °C (262 °F) normal operation counter = 0
• Rail pressure
restriction :
Command
pressure ≤ 80 MPa
(820 kgf/cm2,
12000 psi)
Overrun NEOR P0219 Engine overrun • Engine speed • Key switch is ON • Engine speed ≥ • 3 turns or more • Injection stops • Overrun ON • Recovers when
abnormality exceeds the 3500 min-1 (rpm) (Q = 0 mm3/st) the diagnostic
specified value counter = 0
Intake air pressure PIML P0237 Intake air pressure • Sensor / wiring • Battery voltage is normal • Intake air pressure sensor • 2.8 sec. or more • 101.3 kPa • Insufficient output ON • Recovers when
sensor abnormality sensor abnormality harness open • Sensor supply voltage voltage is 0.2 V or lower (1.033 kgf/cm2, the key switch
(Low side) circuit, ground short VCC6 is normal 14.69 psi) is OFF
• Sensor malfunction [default value]
PIMH P0238 Intake air pressure • Sensor / wiring • Battery voltage is normal • Intake air pressure sensor • 2.8 sec. or more • 101.3 kPa • Insufficient output ON • Recovers when
sensor abnormality harness +B short • Sensor supply voltage voltage is 4.9 V or higher (1.033 kgf/cm2, the key switch
(High side) • Sensor malfunction VCC6 is normal 14.69 psi) is OFF
[default value]
9-M1 6-56 KiSC issued 04, 2008 A


Judgment Light
Non-injection NOINJ1 P0263 Injector function • Non-injection of • Battery voltage is normal • Average rotational • 10 or more times • Output restriction : • Large vibration ON • Recovers when
abnormality (Non-injection) - No. 1 cylinder is • During idling fluctuation of all Q ≤ Approx. 50 % of the key switch
(Rotational Engine No. 1 detected by • Injector control is normal cylinders - Rotational normal operation is OFF
fluctuation cylinder rotational BSTWV1, GSTWV1, fluctuation of No. 1 • Accelerator opening
abnormality) fluctuation NCTWV*, NCCOM* cylinder > 200 µs limit : ACCPF ≤ 50 %
LCHG and OCHG are • Rail pressure
normal restriction :
• No request from the tool Command
for stopping injection pressure ≤ 80 MPa
• Coolant temperature (820 kgf/cm2,
sensor is normal and 12000 psi)
• Vehicle is stopped
• Injection quantity
≤ 20 mm3/st
NOINJ4 P0266 Injector function • Non-injection of • Battery voltage is normal • Average rotational • 10 or more times • Output restriction : • Large vibration ON • Recovers when
(Non-injection) - No. 4 cylinder is • During idling fluctuation of all Q ≤ Approx. 50 % of the key switch
Engine No. 4 detected by • Injector control is normal cylinders - Rotational normal operation is OFF
cylinder rotational BSTWV1, GSTWV1, fluctuation of No. 4 • Accelerator opening
fluctuation NCTWV*, NCCOM* cylinder > 200 µs limit : ACCPF ≤ 50 %
≤ 20 mm3/st
NOINJ2 P0269 Injector function • Non-injection of • Battery voltage is normal • Average rotational • 10 or more times • Output restriction : • Large vibration ON • Recovers when
(Non-injection) - No. 2 cylinder is • During idling fluctuation of all Q ≤ Approx. 50 % of the key switch
Engine No. 2 detected by • Injector control is normal cylinders - Rotational normal operation is OFF
cylinder rotational BSTWV1, GSTWV1, fluctuation of No. 2 • Accelerator opening
fluctuation NCTWV*, NCCOM* cylinder > 200 µs limit : ACCPF ≤ 50 %
≤ 20 mm3/st
9-M1

Judgment Light
Non-injection NOINJ3 P0272 Injector function • Non-injection of • Battery voltage is normal • Average rotational • 10 or more times • Output restriction : • Large vibration ON • Recovers when
abnormality (Non-injection) - No. 3 cylinder is • During idling fluctuation of all Q ≤ Approx. 50 % of the key switch
(Rotational Engine No. 3 detected by • Injector control is normal cylinders - Rotational normal operation is OFF
fluctuation cylinder rotational BSTWV1, GSTWV1, fluctuation of No. 3 • Accelerator opening
abnormality) fluctuation NCTWV*, NCCOM* cylinder > 200 µs limit : ACCPF ≤ 50 %
[Continued] LCHG and OCHG are • Rail pressure
≤ 20 mm3/st
Crankshaft NENOP P0335 No NE sensor • Sensor / wiring • Battery voltage is normal • No NE sensor pulse • 10 or more times • Output restriction : (Running only ON • Recovers when
position sensor pulse input harness open • Sensor supply voltage recognized Q ≤ Approx. 50 % of with G signal) the key switch
(NE sensor) circuit, short VCC3 is normal normal operation • Faulty starting is OFF
abnormality • Sensor malfunction • Engine is not stalled • Accelerator opening • Vibration is
limit : ACCPF ≤ 10 % slightly large
NEPUM P0336 NE sensor • Sensor / wiring • Battery voltage is normal • Pulse count per rotation • 10 or more times • Output restriction : (Running only ON • Recovers when
pulse count harness open • Sensor supply voltage is not 56 teeth Q ≤ Approx. 50 % of with G signal) the key switch
abnormality circuit, short VCC3 is normal normal operation • Faulty starting is OFF
• Sensor malfunction • 350 min-1 (rpm) or higher • Accelerator opening • Vibration is
limit : ACCPF ≤ 10 % slightly large
Camshaft GNOP P0340 No G sensor • Sensor / wiring • Battery voltage is normal • No G sensor pulse • 10 or more times • None (G signal invalid ) ON • Recovers when
position sensor pulse input harness open • Sensor supply voltage recognized • Engine hesitates the diagnostic
(G sensor) circuit, short VCC4 is normal at start-up counter = 0
abnormality • Sensor malfunction • Engine is not stalled
GPUM P0341 G sensor • Sensor / wiring • Battery voltage is normal • Pulse count per rotation • 10 or more times • None (G signal invalid ) ON • Recovers when
pulse count harness open • Sensor supply voltage is not 5 teeth • Engine hesitates the diagnostic
abnormality circuit, short VCC4 is normal at start-up counter = 0
• Sensor malfunction • 350 min-1 (rpm) or higher
EGR feedback EGRFB P0400 EGR feedback • DC motor • Battery voltage is normal (Approximate) • 5 sec. or more • EGR stops • Worsening ON • Recovers when
abnormality abnormality feedback control • During duty abnormal exhaust gas the key switch
abnormality operation, a feedback performance is OFF
abnormality is judged if it (NOx)
does not recover after
performing 30 recovery
operation cycles
EGR DC motor EGRDCM P0404 EGR DC motor • DC motor • Battery voltage is normal • Estimated temperature • 1 sec. or more • EGR stops • Worsening ON • Recovers when
estimated temperature estimated is 45 °C (113 °F) or higher exhaust gas the diagnostic
temperature abnormality temperature performance counter = 0
abnormality abnormality (NOx)
EGR lift sensor LEGRL P0405 EGR lift • Sensor / wiring • Battery voltage is normal • EGR lift sensor voltage • 2.8 sec. or more • EGR stops • Worsening ON • Recovers when
abnormality sensor abnormality harness open • Sensor supply voltage is 0.3 V or lower exhaust gas the key switch
(Low side) circuit, ground short VCC6 is normal performance is OFF
• Sensor malfunction (NOx)
LEGRH P0406 EGR lift Sensor / wiring • Battery voltage is normal • EGR lift sensor voltage • 2.8 sec. or more • EGR stops • Worsening ON • Recovers when
sensor abnormality harness +B short • Sensor supply voltage is 4.5 V or higher exhaust gas the key switch
(High side) • Sensor malfunction VCC6 is normal performance is OFF
(NOx)
9-M1 6-58 KiSC issued 04, 2008 A

Judgment Light
Vehicle SPDH P0501 Abnormal vehicle • Excessive vehicle • Battery voltage is normal • Vehicle speed : • 2.8 sec. or more • None • None in particular ON • Recovers when
speed sensor speed (High) speed • Engine is operating 100 km/h or higher when driving the diagnostic
abnormality (However, it has counter = 0
a negative effect
on the learning
conditions and
diagnostic
conditions)
SPDSG P0503 Vehicle speed • Vehicle speed • Battery voltage is normal • Vehicle speed • 2.8 sec. or more • None • None in particular ON • Recovers when
change rate change rate • Engine is operating change rate : when driving the diagnostic
abnormality abnormality 20 km/h (16 ms) or higher (However, it has counter = 0
a negative effect
on the learning
conditions and
diagnostic
conditions)
Battery voltage VBP P0561 System voltage • System voltage • Key switch is ON • Difference between • 13 sec. or more • Output restriction : • Faulty starting ON • Recovers when
abnormality instability instability • 500 min-1 (rpm) or higher average processing Q ≤ Approx. 50 % of • Insufficient output the diagnostic
abnormality continues for 120 sec. voltage and raw voltage normal operation • Worsening counter = 0
or longer is 1 V or higher • Accelerator opening running noise
• Rail pressure exhaust gas
restriction : performance
Command
pressure ≤ 80 MPa
(820 kgf/cm2,
12000 psi)
• Only main injection
is allowed
• EGR stops
VBBL P0562 Battery voltage • Wiring harness • Key switch is ON • Battery voltage at ECU • 1 sec. or more • Output restriction : • Faulty starting ON • Recovers when
abnormality open circuit, short, • No ST signal is recognized as 0.964 V Q ≤ Approx. 50 % of • Insufficient output the diagnostic
(Low side) damage or lower (8 V equivalent) normal operation • Worsening counter = 0
• Battery abnormality • Accelerator opening running noise
Command
pressure ≤ 80 MPa
(820 kgf/cm2,
12000 psi)
is allowed
• EGR stops
9-M1

Judgment Light
Battery voltage VBBH P0563 Battery voltage • Wiring harness • Key switch is ON • Battery voltage at ECU • 1 sec. or more • Output restriction : • Faulty starting ON • Recovers when
abnormality abnormality open circuit, short, • No ST signal is recognized as 1.928 V Q ≤ Approx. 50 % of • Insufficient output the key switch
[Continued] (High side) damage or higher (16 V equivalent) normal operation • Worsening is OFF
• Battery abnormality • Accelerator opening running noise
Command
pressure ≤ 80 MPa
(820 kgf/cm2,
12000 psi)
is allowed
• EGR stops
QR abnormality QRERR P0602 QR data • QR code • Key switch is ON • QR correction data • Momentary (0.1 sec.) • Output restriction : • Insufficient output ON • Recovers when
abnormality correction data exceeds threshold value Q ≤ Approx. 50 % of the key switch
abnormality • Multiple check error normal operation is OFF
(QR correction data for • Accelerator opening
each injector has been limit : ACCPF ≤ 50 %
stored in three locations.
When this data is read
and compared, an error is
determined if there is
difference in all three
values.)
QRNOT P0602 QR data writing • QR code correction • Key switch is ON • When QR correction • Momentary (0.1 sec.) • Output restriction : • Insufficient output ON • Recovers when
failure malfunction data writing failure data fails to write to Q ≤ Approx. 50 % of the key switch
the EEPROM normal operation is OFF
(When the initial ECU • Accelerator opening
value is "0", an error limit : ACCPF ≤ 50 %
that QR data is not
written to the disc at
the time of vehicle
shipment is detected.)
ECU Flash-ROM FROM P0605 ECU Flash-ROM • Internal Flash-ROM • Key switch is ON • Three times or more • 1 or more times • Output restriction : • Insufficient output ON • Recovers when
abnormality abnormality transformation consecutive Q ≤ Approx. 50 % of the key switch
abnormality inconsistencies in normal operation is OFF
monitor checksum • Accelerator opening
6 6-60 KiSC issued 04, 2008 A


Judgment Light
CPU abnormality MCPU P0606 ECU CPU • CPU malfunction • Key switch is ON • Battery voltage ≥ 10 V • 1 or more times • Engine stops • Engine stops ON • Recovers when
abnormality • Starter switch is OFF the key switch
(Main IC • CPU abnormality is OFF
abnormality) counter ≥ 5 times
(RUN pulse abnormality
occurs 5 times or more)
SCPU P0606 ECU CPU • CPU monitoring • Key switch is ON • Battery voltage ≥ 10 V • 1 or more times • Engine stops • Engine stops ON • Recovers when
abnormality use IC malfunction • Starter switch is in OFF the key switch
(Monitoring IC condition continuously for is OFF
abnormality) 500 msec or more
• Abnormality continues for
2000 msec or more after
the ECU is turned ON
• RUN pulse abnormality
Above conditions occur

continuously for 700 msec
or more
Low charge LCHG P0611 ECU injector • Injector charge • Battery voltage is normal • Injector charge current • Momentary (0.1 sec.) • Output restriction : • Insufficient output ON • Recovers when
charge current current insufficient • CPU is normal insufficient Q ≤ Approx. 50 % of • Worsening the key switch
insufficient • ECU charge circuit • ECU charge circuit normal operation exhaust gas is OFF
malfunction malfunction • Accelerator opening performance
restriction :
Command
pressure ≤ 80 MPa
(820 kgf/cm2,
12000 psi)
is allowed
Starter switch STSWGD P0616 Starter switch • Starter switch / • Battery voltage is normal • Engine speed is • Momentarily • None • Decreased ON • Recovers when
abnormality ground short ground short • Key switch 150 min-1 (rpm) or lower after start-up startability the key switch
(ST signal is not OFF → ON • Simultaneously, ST signal is OFF
recognized) • Engine speed is is not recognized
150 min-1 (rpm) • Simultaneously,
or lower abnormality is judged
if the engine speed
exceeded 150 min-1 (rpm)
during start-up in a state
where a battery voltage
reduction equivalent to
start-up was recognized.
STSWBT P0617 Starter switch • Starter switch / • Battery voltage is normal • ST signal is recognized • 1 or more times • Engine stops • Engine stops ON • Recovers when
battery short wiring harness • Key switch under the conditions the key switch
short OFF → ON on the left column is OFF
(ST signal is • Engine speed is
recognized during 1200 min-1 (rpm) or higher
engine operation)
9-M1

Judgment Light
SCV abnormality DRSCV P0628 SCV actuation • SCV open circuit, • Engine is operating • SCV open circuit, • 0.7 sec. or more • Engine stops • Engine stops ON • Recovers when
system abnormality ground short (with pump high- ground short the key switch
pressure control mode) is OFF
• Battery voltage is normal
• Cases other than sudden
changes in the pump
control duty
BSSCV P0629 SCV +B short • SCV battery short • Engine is operating • SCV battery shot • 0.7 sec. or more • Engine stops • Engine stops ON • Recovers when
(with pump high- the key switch
pressure control mode) is OFF
• Battery voltage is normal
• Cases other than sudden
changes in the pump
control duty
Sensor voltage 1 VCC1L P0642 Sensor voltage 1 • Sensor supply • Battery voltage is normal • Sensor voltage is • Momentary (0.1 sec.) • Accelerator • Insufficient output ON • Recovers when
abnormality abnormality voltage 1 • Key switch 3.89 V or lower opening limit the diagnostic
(Low side) abnormality or OFF → ON 0 ←→ 25 % counter = 0
recognition • No ST signal
abnormality
VCC1H P0643 Sensor voltage 1 • Sensor supply • Battery voltage is normal • Sensor voltage is • Momentary (0.1 sec.) • Accelerator • Insufficient output ON • Recovers when
abnormality voltage 1 • Key switch 4.12 V or higher opening limit the diagnostic
(High side) abnormality or OFF → ON 0 ←→ 25 % counter = 0
recognition • No ST signal
abnormality
Sensor voltage 2 VCC2L P0652 Sensor voltage 2 • Sensor supply • Battery voltage is normal • Sensor voltage is • Momentary (0.1 sec.) • Output restriction : • Faulty starting ON • Recovers when
abnormality abnormality voltage 2 • Key switch 3.89 V or lower Q ≤ Approx. 50 % of • Insufficient output the key switch
(Low side) abnormality or OFF → ON normal operation • Worsening is OFF
recognition • No ST signal • Accelerator running noise
abnormality opening limit : • Worsening
ACCPF ≤ 10 % exhaust gas
• Rail pressure performance
restriction :
Command
pressure ≤ 80 MPa
(820 kgf/cm2,
12000 psi)
• EGR stops
VCC2H P0653 Sensor voltage 2 • Sensor supply • Battery voltage is normal • Sensor voltage is • Momentary (0.1 sec.) • Output restriction : • Faulty starting ON • Recovers when
abnormality voltage 2 • Key switch 4.12 V or higher Q ≤ Approx. 50 % of • Insufficient output the key switch
(High side) abnormality or OFF → ON normal operation • Worsening is OFF
recognition • No ST signal • Accelerator running noise
abnormality opening limit : • Worsening
ACCPF ≤ 10 % exhaust gas
• Rail pressure performance
restriction :
Command
pressure ≤ 80 MPa
(820 kgf/cm2,
12000 psi)
• EGR stops
9-M1 6-62 KiSC issued 04, 2008 A


Judgment Light
Main relay MRYCS P0687 Main relay stuck • Main relay • Key switch is OFF • Battery voltage ≥ 8 V, • 2 or more times • None • Dead battery OFF • Recovers when
abnormality closed malfunction • Engine stall simultaneously, no main the diagnostic
relay command counter = 0
(Light does not turn off
even after 1 minute or
longer has passed since
turning the key OFF)
Pump protection PMPPR P1274 Pump protection • Abnormally high • Sensor supply voltage (Approximate) • 1 or more times • Engine stops • Engine stops ON • Recovers when
failure flag failure flag pressure 1 VCC2 is normal • Rail pressure of 197 MPa the key switch
• Rail pressure sensor (2010 kgf/cm2, 28600 psi) is OFF
is normal or higher, or 230 MPa
(2350 kgf/cm2, 33400 psi)
or lower continues
for 2 hours
[The threshold varies
depending on the engine
speed.
Use 2200 min-1 (rpm)
as a guideline]
Alternatively,
• Rail pressure of 80 MPa
(820 kgf/cm2, 12000 psi)
or higher continues
for 10 sec.
at 500 min-1 (rpm) or lower
speed.
Use 200 min-1 (rpm)
as a guideline]
Pump replacement PMPEX P1275 Pump replacement • Abnormally high • Sensor supply voltage (Approximate) • 1 or more times • Engine stops • Engine stops ON • Recovers when
failure flag failure flag pressure 2 VCC2 is normal • Rail pressure of 230 MPa the key switch
• Rail pressure sensor (2350 kgf/cm2, 33400psi) is OFF
is normal or higher continues for
1 sec. at 500 min-1 (rpm)
or higher
speed.
Use 2200 min-1 (rpm)
as a guideline]
9-M1

Judgment Light
Accelerator position ACCP1L P2122 Accelerator position • Sensor / wiring • Battery voltage is normal • Accelerator position • Momentary (0.1 sec.) • Accelerator • Insufficient output ON • Recovers when
sensor 1 abnormality sensor 1 harness open • Sensor supply voltage sensor voltage 1 is 0.3 V opening limit the diagnostic
abnormality circuit, ground VCC1 is normal or lower 0 ←→ 25 % counter = 0
(Low side) short
ACCP1H P2123 Accelerator position • Sensor / wiring • Battery voltage is normal • Accelerator position • Momentary (0.1 sec.) • Accelerator • Insufficient output ON • Recovers when
sensor 1 harness power • Sensor supply voltage sensor voltage 1 is 4.7 V opening limit the diagnostic
abnormality supply short VCC1 is normal or higher 0 ←→ 25 % counter = 0
(High side)
Accelerator position ACCP2L P2127 Accelerator position • Sensor / wiring • Battery voltage is normal • Accelerator position • Momentary (0.1 sec.) • Accelerator • Insufficient output ON • Recovers when
sensor 2 abnormality sensor 2 harness open • Sensor supply voltage sensor voltage 2 is 0.3 V opening limit the diagnostic
abnormality circuit, ground VCC2 is normal or lower 0 ←→ 25 % counter = 0
(Low side) short
ACCP2H P2128 Accelerator position • Sensor / wiring • Battery voltage is normal • Accelerator position • Momentary (0.1 sec.) • Accelerator • Insufficient output ON • Recovers when
sensor 2 harness power • Sensor supply voltage sensor voltage 2 is 4.7 V opening limit the diagnostic
abnormality supply short VCC2 is normal or higher 0 ←→ 25 % counter = 0
(High side)
Common 1 system NCCOM1 P2146 Injector actuation • Wiring harness • Engine is operating • During wiring harness • 8 or more times • Engine stops • Engine stops ON • Recovers when
open circuit circuit open circuit open circuit • Battery voltage is normal open circuit the key switch
[Common 1 system • During injection is OFF
or TWV1, 3 • CPU is normal
(No. 1, 4 cylinders)
simultaneously]
Common 1 TWV GSTWV1 P2147 Common 1 TWV • Wiring harness • Engine is operating • During wiring harness • 8 or more times • Engine stops • Engine stops ON • Recovers when
actuation system actuation system ground short • Battery voltage is normal ground short the key switch
ground short ground short is OFF
[ECU-side
(Common1, 2
system) or
injector side
all cylinders
simultaneously]
Common 1 TWV BSTWV1 P2148 Common 1 TWV • Wiring harness • Engine is operating • During wiring harness • 8 or more times • Engine stops • Engine stops ON • Recovers when
actuation system actuation system +B short • Battery voltage is normal battery short the key switch
+B short +B short is OFF
[ECU-side
(Common 1, 2
system) or
injector side
all cylinders
simultaneously]
Common 2 system NCCOM2 P2149 Injector actuation • Wiring harness • Engine is operating • During wiring harness • 8 or more times • Engine stops • Engine stops ON • Recovers when
open circuit circuit open circuit open circuit • Battery voltage is normal open circuit the key switch
[Common 2 system • During injection is OFF
or TWV2, 4 • CPU is normal
(No. 3, 2 cylinders)
simultaneously]
9-M1 6-64 KiSC issued 04, 2008 A


Judgment Light
Atmospheric PATMP P2227 Abnormal • Abnormal • Battery voltage is normal • Difference with intake air • 2.8 sec. or more • Atmospheric (At high altitude) ON • Recovers when
pressure sensor atmospheric atmospheric • Sensor supply voltage pressure when stopped pressure = 101.3 kPa • Increase in white the diagnostic
abnormality pressure sensor pressure sensor VCC2 is normal or idling is within 10 kPa (1.033 kgf/cm2, smoke counter = 0
characteristics characteristics • Atmospheric pressure (0.10 kgf/cm2, 1.4 psi) 14.69 psi) • Worsening
sensor is normal exhaust gas
(High, Low) performance
• Intake air pressure
sensor is normal
• Coolant temperature
sensor is normal
• Intake air temperature
sensor is normal
PATML P2228 Abnormal • Sensor / ECU • Battery voltage is normal • Atmospheric pressure • 2.8 sec or more • Atmospheric (At high altitude) ON • Recovers when
atmospheric internal circuit sensor voltage is 1.65 V pressure = 101.3 kPa • Increase in white the diagnostic
pressure sensor ground short or lower (1.033 kgf/cm2, smoke counter = 0
(Low side) 14.69 psi) • Worsening
exhaust gas
performance
PATMH P2229 Abnormal • Sensor / ECU • Battery voltage is normal • Atmospheric pressure • 2.8 sec or more • Atmospheric (At high altitude) ON • Recovers when
atmospheric internal circuit sensor voltage is 4.8 V pressure = 101.3 kPa • Increase in white the diagnostic
pressure sensor +B short or higher (1.033 kgf/cm2, smoke counter = 0
(High side) 14.69 psi) • Worsening
exhaust gas
performance
Glow relay actuation GLRYBT P0380 Glow relay • Glow relay • Battery voltage is normal • During a wiring harness • 1 sec. or more • None (At low ON • Recovers when
abnormality actuation circuit actuation circuit +B • Glow relay actuation battery short temperature) the diagnostic
battery short short command is being • Faulty starting counter = 0
performed • Increase in
white smoke
GLRYGD P0380 Glow relay • Glow relay • Battery voltage is normal • During a wiring harness • 1 sec. or more • None (At low ON • Recovers when
actuation circuit actuation circuit • When there is no open circuit, temperature) the diagnostic
ground short open circuit, ground glow relay actuation ground short • Faulty starting counter = 0
short command • Increase in
white smoke
9-M1
[2] DIAGNOSTIC PROCEDURE BY DTC

If a DTC output indicates a malfunction, locate the malfunction by following the diagnostic procedure in the
following pages.
Follow the instructions of the diagnostic procedure when required to refer to other items.
In this manual, the diagnostic procedures are listed according to the Diagnostic Trouble Code (DTC) numbers as
shown. (In exceptional cases, some procedures are given in different positions.)
DTC Name DTC Name
P0016 NE - G phase gap P0501
Vehicle speed sensor abnormality
P0087 Pressure limiter opening abnormality P0503
P0088 High rail pressure abnormality P0561
P0089 SCV stuck P0562 Battery voltage abnormality
P0093 Fuel leak P0563
P0112 Intake air temperature sensor P0602 QR abnormality
P0113 abnormality P0605 ECU Flash - ROM abnormality
P0117 Coolant temperature sensor P0606 CPU abnormality
P0118 abnormality P0611 Low charge
P0182 P0616
Fuel temperature sensor abnormality Starter switch abnormality
P0183 P0617
P0192 P0628
Rail pressure sensor abnormality SCV abnormality
P0193 P0629
P0200 Overcharge P0642
Sensor voltage 1 abnormality
P0201 TWV 1 actuation system open circuit P0643
Sensor voltage 2 abnormality
P0204 TWV 4 actuation system open circuit P0687 Main relay abnormality
P0217 Overheat P1274 Pump protection failure flag
P0219 Overrun P1275 Pump replacement failure flag
P0237 P2122 Accelerator position sensor 1
Intake air pressure sensor abnormality
P0238 P2123 abnormality
P0263 P2127 Accelerator position sensor 2
P0266 P2128 abnormality
Non-injection abnormality (Rotational
P0269 fluctuation abnormality) P2146 Common 1 system open circuit
Common 1 TWV actuation system
P0272 P2147
ground short
Common 1 TWV actuation system +B
P0335 Crankshaft position sensor (NE P2148
short
sensor) abnormality
P0336 P2149 Common 2 system open circuit
P0340 Camshaft position sensor (G sensor) P2227
abnormality Atmospheric pressure sensor
P0341 P2228
abnormality
P0400 EGR feedback abnormality P2229
EGR DC motor estimated temperature
P0404 P0380
abnormality Glow relay actuation abnormality
P0405 P0380
EGR lift sensor abnormality
P0406
W1040817

6-66
(1) NE - G Phase Gap (DTC P0016)

• Primary malfunction symptom :
(Invalid G signal)
■ Engine hesitates at start-up
• Detected item : Large phase gap between NE pulse and G pulse
• DTC set preconditions :
■ Engine is operating : Idle speed to 900 min-1 (rpm)
■ Battery voltage is normal
■ Sensor supply voltage VCC2 is normal
■ NE signal is normal
■ G signal is normal
■ Coolant temperature is 10 °C (50 °F) or higher
• DTC set conditions :
■ Phase difference between NE pulse and G pulse within ±15°
• Check engine warning light : ON
• System action :
■ None
• DTC recovery conditions : Recovers when the key switch is OFF
1. Check the crankshaft position sensor and camshaft position sensor signals
1. Run the engine and check the values of the "Engine speed active
flag" and "Cam speed active flag" with the data monitor.
Factory spec. Constantly ON
Check each pulsar

Check the DTC (speed
for damage and
OK signal phase gap) NG
deviation, and
again.
correct.
■ NOTE
(Crankshaft position sensor side)
• The NE pulsar has deviated.
• A large magnetic substance has adhered to the pulsar,
hardened and rotates together with it, or the teeth have been
ground down.
(Camshaft position sensor side)
• The G pulsar plate is disconnected.
• The cam gear unit is disconnected, etc. (large side
clearance).
• A large magnetic substance has adhered to the pulsar,
hardened and rotates together with it, or the teeth have been
ground down.
(a) CAN2 Connector
NG
Refer to "Crankshaft position sensor (NE sensor) abnormality" and "Camshaft position sensor (G sensor)
abnormality".

6-67
(2) Pressure Limiter Opening Abnormality (DTC P0087)

• Primary malfunction symptom : Insufficient output
• Detected item : Pressure limiter opening abnormality
■ Rail pressure sensor is normal
■ Condition A and B are fulfilled.
A. Fuel leak (FLEAK) is detected.
B. Condition (1) or (2) is filled.
(1) Fuel pressure is more than 191 MPa (1950 kgf/cm2, 27700 psi).
(2) Within 1 second, after the fuel pressure drops to less than 191 MPa (1950 kgf/cm2, 27700 psi),
[Prior to pressure drop, the fuel pressure becomes more than 191 MPa (1950 kgf/cm2, 27700 psi)]
• System action :
■ Output restriction : Q ≤ Approx. 50 % of normal operation
■ Accelerator opening limit : ACCPF ≤ 50 %
■ Rail pressure restriction : Command pressure ≤ 80 MPa (820 kgf/cm2, 12000 psi)

6-68

6-69
■ NOTE
• If the pressure limiter is opened, it will be kept open until the engine stops running. Therefore, the rail
pressure is kept at 40 to 60 MPa (410 to 610 kgf/cm2, 5800 to 8700 psi) regardless of its target rail pressure.
This point must be considered when measuring the rail pressure.
However, when the engine is stopped and the rail pressure reduces enough, the pressure limiter is closed
and the rail pressure will start to increase again.
• Even when the problem indicated by this DTC cannot be reproduced, the high pressure will have occurred
for certain reasons. Therefore, the cause of the high pressure must be identified.
1. Check the data related to the rail pressure

1. Connect the diagnosis tool to the CAN2 connector, and select the
"Actual rail pressure" and "Target rail pressure" on the data
monitor.
2. Observe the data signals by operating the accelerator pedal and
others and by performing the actual run test.
"Actual rail pressure" and "Target rail pressure"
when idling
Factory spec.
approx. 75 MPa (760 kgf/cm2, 11000 psi)
conditions.
Use all of the available information and try to

reproduce the problem by operating the accelerator
OK
pedal in different ways and by changing the
environmental conditions.
(a) CAN2 Connector
NG

6-70
2. Check the fuel system for the existence of air

1. Check each joint of the fuel system for the existence of air.
To detect the existence of air effectively, replace the fuel hose
with a transparent one.
Locate the position of the fuel leakage in the piping and
NG
repair it.
(1) Fuel Hose
OK

PROCEDURE".
CAUTION
• Visually check there is no leak in the high pressure fuel pipe
system.
• A visual check is not possible if a leak (high pressure
system) occurs inside the head cover, so check that the oil
level has not increased.
NG
(1) Supply Pump (3) Dipstick
(2) Rail
OK

6-71
4. Check the rail pressure sensor (Refer to items P0192 and P0193)
1. Check the rail pressure sensor.
■ NOTE
• Closely check sensor signals for a noise component and an
abnormality that exists for a short time.
Repair or replace the rail pressure sensor or its related
NG parts. (Follow the diagnostic procedure of items P0192
and P0193.)
(a) CAN2 Connector
OK
5. Check the DTC again

1. Clear the past malfunction data, and make sure that the same
DTC is output again in the reproduction test.
Factory spec. Normal (No DTC is output.)
■ NOTE
• Use all of the available information and try to reproduce the
problem by operating the accelerator pedal in different ways
and by changing the environmental conditions.
OK Normal.
(a) CAN2 Connector
NG

6-72
6. Check the SCV-related data

1. Check the "Target rail pressure", "Actual rail pressure", "Target
SCV current", "Actual SCV current", "Pump deviation learning
status", "Pump deviation learning correction value" and
"Pressure feedback integral guard execution flag" on the data
monitor.
1. The "Target SCV current" and the "Actual SCV
current" must always approximately match.
• During idle : Approx. 1700 mA
• Accelerator opening 0 to 100 % :
Approx. 1300 mA minimum
• The figures must be stable.
Factory spec.
* The current shall be used as a reference only as
this value varies depending on the pump used.
2. The "Pressure feedback integral guard
executing flag" must be OFF.
3. The "Pump deviation learning correction value"
must be within ± 200 mA.
■ NOTE
• "Pump difference learning status"
It must be "2" (Learning completed) or "3" (During
relearning). If not, keep idling the engine after warming up
and when the learning status becomes "2" or "3", make the
judgment.
NG Replace the supply pump.
(a) CAN2 Connector
OK
After confirming that an intermittent malfunction (such as power supply system or noise generation) does not occur
in relation to the ECU, replace the ECU.

6-73
(3) High Rail Pressure Abnormality (DTC P0088)

• Detected item : Actual pressure is excessive when compared to command pressure
(When high pressure is detected that has exceeded the pressure usage range)
■ Actual pressure (for the corresponding time period) ≥ 197 MPa (2010 kgf/cm2, 28600 psi)
• System action :
• DTC recovery conditions : Recovers when the diagnostic counter = 0

6-74

6-75

monitor.
when idling
Factory spec.
conditions.

OK
(a) CAN2 Connector
NG

Locate the position of the fuel leakage in the piping and
NG
repair it.
(1) Fuel Hose
OK

6-76

PROCEDURE".
CAUTION
system.
NG
(2) Rail
OK
■ NOTE
and P0193.)
(a) CAN2 Connector
OK

■ NOTE
OK Normal.
(a) CAN2 Connector
NG

6-77

monitor.
Factory spec.
■ NOTE
judgment.
(a) CAN2 Connector
OK

6-78
(4) SCV Stuck (DTC P0089)

• Detected item : Stuck with the SCV open
(When a state is detected where the actual rail pressure is continuously excessive when compared to the
command rail pressure)
■ Supply pump is normal and learning has been performed
■ Simultaneously, engine is operating (Q : 4 mm3/st or higher)
■ Injector is normal
■ Supply pump discharge request is 0 mm3/st or lower
■ Simultaneously, actual rail pressure is at least 10 MPa (100 kgf/cm2, 1400 psi) higher than the command rail
pressure
When the state above continues for 26 seconds or more
• System action :

6-79

6-80

monitor.
when idling
Factory spec.
conditions.

OK
(a) CAN2 Connector
NG

Rotate the fuel pump sufficiently and bleed the air.
NG Locate the position of the fuel leakage in the piping and
repair it.
(1) Fuel Hose
OK

6-81

PROCEDURE".
CAUTION
system.
NG
(2) Rail
OK
■ NOTE
and P0193.)
(a) CAN2 Connector
OK

■ NOTE
OK Normal.
(a) CAN2 Connector
NG

6-82

monitor.
Factory spec.
■ NOTE
Must be 2 (Learning completion) or 3 (Relearning).
For cases other than those above, perform pump difference
learning and judge after status 2 or 3 is entered.
Perform repeated sudden accelerations and decelerations, and
check that the target rail pressure and actual rail pressure converge
to approximately the same value.
Converge to within 10 MPa (100 kgf/cm2, 1400
Factory spec.
psi) within 20 seconds or less.
In addition, suddenly release the accelerator while driving at
maximum speed to test the temporary non-injection condition
without applying the brake (engine brake only) and check that the
target rail pressure and actual rail pressure converge to
approximately the same value.
Converge to within 10 MPa (100 kgf/cm2, 1400
Factory spec.
psi) within 20 seconds or less.

(a) CAN2 Connector
OK

6-83
(5) Fuel Leak (DTC P0093)

• Primary malfunction symptom : Engine stops
• Detected item : Fuel leak from the high pressure fuel system
(When excessive fuel consumption is detected, as calculated from changes in the rail pressure before and after
fuel injection)
■ Supply pump (SCV) is normal
■ Injector and injector actuation circuit are normal
■ NE signal is active
[Engine is operating (700 min-1 (rpm) or higher]
■ PLACT, PCEX and SCVS are not abnormal
■ When the engine speed < 1200 min-1 (rpm) :
(a) is the fuel flow quantity as calculated from the rail pressure deviation (reduction quantity).
(b) is the sum (pump discharge quantity) of the injection quantity and internal leak quantity.
A fuel leak is judged if the difference between (a) and (b) exceeds the judgment value (400 mm3/st), value (a) is
larger than value (b), and there is no fuel leak due to an open P/L (pressure limitter).
• System action :
■ Engine stops

6-84

6-85

monitor.
when idling
Factory spec.
conditions.

OK
(a) CAN2 Connector
NG

repair it.
(1) Fuel Hose
OK

6-86

PROCEDURE".
CAUTION
system.
NG
(2) Rail
OK
■ NOTE
and P0193.)
(a) CAN2 Connector
OK
5. Check the pressure limiter for a fuel leakage

1. Check the temperature of the pressure limiter return pipe by
touching it.
Factory spec. Almost the same as the ambient temperature.
(Reference)
• If the fuel leaks from the pressure limiter, the high temperature
and high pressure fuel flows through the return pipe and the pipe
becomes very hot.
NG Replace the common rail (pressure limiter).
(1) Pressure Limiter
OK

6-87
6. Check for a fuel leakage

1. Increase the rail pressure by operating the accelerator pedal, and
check for a fuel leakage.
Factory spec. No fuel leaks.
NG Locate the leakage position and repair it.

(a) CAN2 Connector
OK

■ NOTE
OK Normal.
(a) CAN2 Connector
NG

6-88

monitor.
Factory spec.
■ NOTE
Must be 2 (Learning completion) or 3 (Relearning).
For cases other than those above, perform pump difference
learning and judge after status 2 or 3 is entered.
(a) CAN2 Connector
OK

6-89
(6) Intake Air Temperature Sensor Abnormality (DTC P0112, P0113)

P0112 : Intake air temperature sensor abnormality (Low side)
• Primary malfunction symptom : Amount of white smoke increases at low temperatures
• Detected item : Sensor / wiring harness ground short
■ Intake air temperature sensor voltage is 0.05 V or lower
• System action :
■ 40 °C (104 °F) [default value]
P0113 : Intake air temperature sensor abnormality (High side)
• Primary malfunction symptom : Amount of white smoke increases at low temperatures
• Detected item : Sensor / wiring harness open circuit, +B short
■ Intake air temperature sensor voltage is 4.9 V or higher
• System action :
■ 40 °C (104 °F) [default value]
(1) Terminal THA (2) Terminal THA RTN (a) Intake Air Temperature Sensor (b) Terminal Layout

6-90
1. Check the intake air temperature sensor signals

1. Place the key switch in the ON position, and check the "Intake air
temperature" and "Intake air temperature sensor output voltage"
on the diagnosis tool data monitor.
Factory spec.
Actual intake air Intake air
Output voltage
temperature temperature
20 °C (68 °F) 20 °C (68 °F) Approx. 2.4 V
40 °C (104 °F) 40 °C (104 °F) Approx. 1.5 V
60 °C (140 °F) 60 °C (140 °F) Approx. 0.9 V
80 °C (176 °F) 80 °C (176 °F) Approx. 0.5 V
Clear the DTC and

OK check whether it is NG Replace the ECU.
output again or not.
OK
Normal.
(a) CAN2 Connector

W1017826
NG
2. Measure the resistance between terminals

1. Place the key switch in the OFF position, unplug the ECU cable
connector from the socket, and measure the resistance between
terminals 55 and 74 of the connector.
Factory spec.
Temperature Resistance
20 °C (68 °F) 2.43 kΩ
60 °C (140 °F) 0.58 kΩ
100 °C (212 °F) 0.184 kΩ
OK Go to Step 4 (Measure the ECU terminal voltage).
NG

6-91
3. Check the sensor

1. Turn the key switch OFF, remove the connector from the sensor
side and measure the resistance between the terminals on the
sensor side.
Factory spec.
20 °C (68 °F) 2.43 kΩ
60 °C (140 °F) 0.58 kΩ
100 °C (212 °F) 0.184 kΩ
Intake air temperature sensor fault → Replace the

NG
intake air temperature sensor.
OK
Wiring harness open circuit or connector fault → Check and repair.
4. Measure the ECU terminal voltage

1. Plug the ECU cable connector into socket again, unplug the
sensor connector, and measure the voltage between ECU
terminals 55 and 74 at the ECU side.
Confirm by using other sensors that there is no ground

NG
short malfunction before replacing the ECU.
OK
The ECU connector is faulty or its wiring harness is shorted.

6-92
(7) Coolant Temperature Sensor Abnormality (DTC P0117, P0118)

P0117 : Coolant temperature sensor abnormality (Low side)
■ Amount of white smoke increases at low temperatures
■ Insufficient output
■ Worsening exhaust gas performance
■ Coolant temperature sensor voltage is 0.1 V or lower
• System action :
■ During start-up = -25 °C (-13 °F) [default value]
All other times = 80 °C (176 °F) [default value]
■ EGR stops
P0118 : Coolant temperature sensor abnormality (High side)
■ Amount of white smoke increases at low temperatures
■ Coolant temperature sensor voltage is 4.9 V or higher
• System action :
■ EGR stops

6-93
(1) Terminal THW (2) Terminal THW RTN (a) Coolant Temperature Sensor (b) Terminal Layout
1. Check the coolant temperature sensor signals

1. Place the key switch in the ON position, and check the "Coolant
temperature" and "Coolant temperature sensor output voltage"
Factory spec.
Actual coolant Coolant
Output voltage
temperature temperature
20 °C (68 °F) 20 °C (68 °F) Approx. 3.6 V
40 °C (104 °F) 40 °C (104 °F) Approx. 2.7 V
60 °C (140 °F) 60 °C (140 °F) Approx. 1.8 V
80 °C (176 °F) 80 °C (176 °F) Approx. 1.2 V
100 °C (212 °F) 100 °C (212 °F) Approx. 0.8 V
Clear the DTC and

OK
Normal.
(a) CAN2 Connector
NG

6-94

Factory spec.
20 °C (68 °F) 2.45 kΩ
40 °C (104 °F) 1.15 kΩ
60 °C (140 °F) 0.584 kΩ
80 °C (176 °F) 0.318 kΩ
100 °C (212 °F) 0.184 kΩ
NG
3. Check the sensor

sensor side.
Factory spec.
20 °C (68 °F) 2.45 kΩ
40 °C (104 °F) 1.15 kΩ
60 °C (140 °F) 0.584 kΩ
80 °C (176 °F) 0.318 kΩ
100 °C (212 °F) 0.184 kΩ
Coolant temperature sensor fault → Replace the

NG
coolant temperature sensor.
OK

6-95


NG
OK

6-96
(8) Fuel Temperature Sensor Abnormality (DTC P0182, P0183)

P0182 : Fuel temperature sensor abnormality (Low side)
• Primary malfunction symptom : -
■ Supply pump internal temperature sensor voltage is 0.1 V or lower
• System action :
P0183 : Fuel temperature sensor abnormality (High side)
• Primary malfunction symptom : -
■ Supply pump internal temperature sensor voltage is 4.9 V or higher
• System action :
(1) Terminal THF (2) Terminal THF RTN (a) Fuel Temperature Sensor (b) Terminal Layout

6-97
1. Check the fuel temperature sensor signals

1. Place the key switch in the ON position, and check the "Fuel
temperature" and "Fuel temperature sensor output voltage" on
the diagnosis tool data monitor.
Factory spec.
Actual fuel
Fuel temperature Output voltage
temperature
20 °C (68 °F) 20 °C (68 °F) Approx. 2.4 V
40 °C (104 °F) 40 °C (104 °F) Approx. 1.5 V
60 °C (140 °F) 60 °C (140 °F) Approx. 0.9 V
80 °C (176 °F) 80 °C (176 °F) Approx. 0.5 V
Clear the DTC and

OK
Normal.
(a) CAN2 Connector
NG

Factory spec.
20 °C (68 °F) 2.45 kΩ
40 °C (104 °F) 1.15 kΩ
60 °C (140 °F) 0.584 kΩ
80 °C (176 °F) 0.318 kΩ
NG

6-98
3. Check the sensor

sensor side.
Factory spec.
20 °C (68 °F) 2.45 kΩ
40 °C (104 °F) 1.15 kΩ
60 °C (140 °F) 0.584 kΩ
80 °C (176 °F) 0.318 kΩ
Fuel temperature sensor fault → Replace the supply

NG
pump.
OK


NG
OK

6-99
(9) Rail Pressure Sensor Abnormality (DTC P0192, P0193)

P0192 : Rail pressure sensor abnormality (Low side)
■ Worsening running noise
■ Increase in white smoke
■ Engine stops
• Detected item :
■ Sensor / wiring harness ground short
■ Sensor malfunction
■ Rail pressure sensor voltage is 0.7 V or lower
• System action :
■ Engine stops 60 seconds after the above restrictions
P0193 : Rail pressure sensor abnormality (High side)
■ Increase in white smoke
■ Engine stops
• Detected item :
■ Sensor / wiring harness open circuit, +B short
■ Rail pressure sensor voltage is 4.9 V or higher
• System action :
■ Engine stops 60 seconds after the above restrictions

6-100
(1) Terminal A-VCC5 (3) Terminal PFUEL RTN (a) Rail Pressure Sensor (b) Terminal Layout
(2) Terminal PFUEL

6-101
1. Check the rail pressure sensor signals

1. Place the key switch in the ON position, and check the "Actual rail
pressure" and "Rail pressure sensor output voltage" on the
diagnosis tool data monitor.
2. Next, start the engine, change the accelerator pedal opening,
and check the same items again.
Factory spec.
Engine state Actual rail pressure Output voltage
0 MPa
Key switch ON Approx. 1.0 V
(0 kgf/cm2, 0 psi)
36 to 160 MPa
After engine
(370 to 1630 kgf/cm2, 1.6 to 3.6 V
start-up
5300 to 23200 psi)
■ NOTE
• At idle : Approx. 36 MPa (370 kgf/cm2, 5200 psi)
Max. at no-load : Approx. 75 MPa (760 kgf/cm2, 11000 psi)
• Reference value (Factory spec.) has compiete linearity.
Clear the DTC and
OK
Normal.
(a) CAN2 Connector
NG

1. Move the key switch from the OFF to the ON position, and
measure the voltage between ECU terminals 48 and 68 and
between terminals 49 and 68.
Factory spec.
Engine state Output voltage
Key switch ON 0.9 to 1.1 V
After engine start-up 1.4 to 3.5 V
Check the harness Repair or replace

connectors and ECU the wiring harness,
OK NG
pins. or replace the
ECU.
OK
Faulty ECU → Replace.
NG

6-102
3. Measure the voltage between rail pressure sensor terminals

between terminals (2) and (3) of the rail pressure sensor at the
wiring harness side.
Factory spec.
Key switch ON 0.9 to 1.1 V
Check the wiring harness (between ECU terminals 48 /

OK
49 and sensor terminal (2)).→ Repair the faulty area.
(1) Terminal A-VCC5 (a) Terminal Layout
(2) Terminal PFUEL
(3) Terminal PFUEL RTN
NG
4. Measure the voltage between rail pressure sensor terminals

1. Set the key switch to the OFF position, and unplug the rail
pressure sensor connector from the socket.
between terminals (1) and (3) of the rail pressure sensor
connector (at the wiring harness side).
Factory spec. 4.5 to 5.5 V

connectors and sensor NG the wiring harness.
OK
pins. Replace the rail
assembly.
OK
Faulty rail pressure sensor → Replace.

(2) Terminal PFUEL
(3) Terminal PFUEL RTN
NG

6-103

measure the voltage between ECU terminals 63 and 68.

OK NG
ECU.
OK
NG
Check the wiring harness (between ECU terminal 63 and sensor terminal (1) and between ECU terminal 68 and
sensor terminal (3)). → Repair the faulty area.

6-104
(10) Overcharge (DTC P0200)

■ NOTE
• This DTC is detected when the charge current in the injector actuation circuit is too high.

• Detected item :
■ Injector charge current exceeded
■ ECU charge circuit malfunction
■ CPU is normal
■ Injector charge current exceeded
• System action :
■ Main injection only is permitted
1. Checking whether the DTC is detected again

1. Turn the key switch OFF and then ON again.
2. After clearing the DTC, turn the key switch OFF and then ON
again, and start the engine.
3. Check whether or not the same DTC (P0200) is detected.
Factory spec. DTC is not detected.
It could be a temporary malfunction caused by

OK obstructions to the radio waves, so as long as it
recovers to normal operation there is no problem.
(a) CAN2 Connector
NG
2. Replacing the injector and checking whether the DTC is detected again
1. Replace the injector.
OK Injector fault → Replace the injector.

(a) CAN2 Connector
NG

6-105
3. Replacing the ECU and checking whether the DTC is detected again
1. Replace the ECU.
OK ECU fault → Replace the ECU.

(a) CAN2 Connector

6-106
(11) TWV* Actuation System Open Circuit (DTC P0201, P0202, P0203, P0204)
P0201 : Open circuit in the engine No. 1 cylinder injector (TWV1) wiring harness or coil
• Detected item :
■ Wiring harness open circuit
■ Injector coil open circuit
■ Engine running
■ During injection
■ CPU is normal
■ During wiring harness open circuit
■ During injector coil open circuit
• System action :
■ Engine stops
(1) Terminal COMMON (2) Terminal TWV (a) Injector (d) Control Circuit
(b) Constant Amperage Circuit (e) Terminal Layout
(c) High Voltage Generation Circuit

6-107
1. Measure the resistance between ECU terminals

connector from the socket, and measure the resistance each
terminal of the connector .
Engine cylinder / TWV# Measurement terminal
No. 1 cylinder / TWV1 4 ←→ 42, 43
No. 3 cylinder / TWV2 5 ←→ 23, 24
No. 4 cylinder / TWV3 4 ←→ 40, 41
No. 2 cylinder / TWV4 5 ←→ 21, 22
Factory spec. 1.5 Ω or lower
Go to Step 4 (Measure the resistance between injector

NG
terminals).
OK
2. Check the DTC

1. Plug the ECU connector into socket, and start the engine.
2. Clear the DTCs that occurred previously, and check the currently
existing trouble.
NG Faulty ECU → Replace.

(a) CAN2 Connector
OK
3. Check the connector and wiring harnesses for poor contact

1. Set the key switch to the OFF position, and check the wiring
harness connectors and ECU pins for incorrect connection,
deformation, poor contact or other defects.
Must be free from incorrect connection,
Factory spec.
deformation, poor contact or other defects.
■ NOTE
• Intermediate connector and wiring harness in head cover
should be checked, they are possible cause.
Check the injector wiring harnesses and connectors.
NG
→ Repair.
OK
Check the wiring harness and connector of P- GND terminal (ECU terminals 1, 2 and 3). → Repair.

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4. Measure the resistance between injector terminals

1. Unplug the injector cable connector of the cylinder indicated by
the DTC, and measure the resistance between injector terminals
(1) and (2).
Factory spec. 0.35 to 0.55 Ω
Check the wiring harnesses and connectors for a poor

OK
contact. → Repair.
(1) Terminal COMMON (a) Injector
(2) Terminal TWV
W1606256
NG
Faulty injector → Replace (Using the diagnosis tool, write the QR code of replaced injector in the ECU.)

6-109
(12) Overheat (DTC P0217)

• Primary malfunction symptom : Overheat
• Detected item : Engine coolant high temperature abnormality
■ Coolant temperature sensor is normal
■ Engine coolant temperature ≥ 128 °C (262 °F)
• System action :
(1) Terminal THW (2) Terminal THW RTN (a) Coolant Temperature Sensor (b) Terminal Layout

6-110
1. Check the coolant temperature sensor characteristics for an error

1. Refer to DTC P0117, P0118, and check the ECU, wiring harness
and sensor for an error.
NG Check and repair or replace the faulty parts.
(1) CAN2 Connector (a) Terminal Layout
(2) Terminal THW
(3) Terminal THW RTN
OK
Check the cooling system. → Repair the faulty area.
If the cooling system is operating normally, ask the user about malfunction occurrence based on the freeze-frame
data to determine whether or not the system was used improperly.

6-111
(13) Overrun (DTC P0219)

• Primary malfunction symptom : Overrun
• Detected item : Engine speed exceeds the specified value
■ Key switch is ON
■ Engine speed ≥ 3500 min-1 (rpm)
• System action :
■ Injection stops (Q = 0 mm3/st)


NG obstructions to the radio waves, so as long as it
(a) CAN2 Connector
OK
2. Checking with the user

1. The following actions may have caused the overrun.
• Towing heavy objects
• Drag phenomenon when driving downhill
• Mistaken operation when making a sudden shift change
Question the user in detail about the items above and give guidance.

6-112
(14) Intake Air Pressure Sensor Abnormality (DTC P0237, P0238)

P0237 : Intake air pressure sensor abnormality (Low side)
• Detected item :
■ Sensor / wiring harness open circuit, ground short
■ Intake air pressure sensor voltage is 0.2 V or lower
• System action :
■ 101.3 kPa (1.033 kgf/cm2, 14.69 psi) [default value]
P0238 : Intake air pressure sensor abnormality (High side)
• Detected item :
■ Sensor / wiring harness +B short
■ Intake air pressure sensor voltage is 4.9 V or higher
• System action :
■ 101.3 kPa (1.033 kgf/cm2, 14.69 psi) [default value]
(1) Terminal A-VCC6 (3) Terminal PIM RTN (a) Intake Air Pressure Sensor (b) Terminal Layout
(2) Terminal PIM

6-113
1. Check the intake air pressure signals

1. Place the key switch in the OFF position, attach the diagnosis
tool to the CAN2 connector, and return the key switch to the ON
position again. Then, check the "Intake air pressure" and "intake
air pressure sensor output voltage" on the diagnosis tool data
monitor.
Factory spec.
Actual intake air
pressure
Approx. 100 kPa
(1.02 kgf/cm2, 14.5 psi)
100 to 180 kPa
After engine
(1.02 to 1.83 kgf/cm2, 1.0 to 2.2 V
start-up
14.5 to 26.1 psi)
■ NOTE
• Reference value (Factory spec.) has complete linearity.
Clear the DTC and
OK
Normal.
(a) CAN2 Connector
NG

Factory spec.

OK NG
ECU.
OK
NG

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3. Measure the voltage between intake air pressure sensor terminals

between terminals (2) and (3) of the intake air pressure sensor at
the wiring harness side.
Factory spec.
Check the wiring harness (between ECU terminal 52

OK
and sensor terminal (2)). → Repair the faulty area.
(2) Terminal PIM
(3) Terminal PIM RTN
NG
4. Measure the voltage between intake air pressure sensor terminals

1. Set the key switch to the OFF position, and unplug the intake air
pressure sensor connector from the socket.
between terminals (1) and (3) of the intake air pressure sensor
connector (at the wiring harness side).
Repair or replace
Check the harness the wiring harness.
OK connectors and sensor NG Replace the intake
pins. air pressure
sensor.
OK
Faulty intake air pressure sensor → Replace.

(2) Terminal PIM
(3) Terminal PIM RTN
NG

6-115


OK NG
ECU.
OK
NG
Check the wiring harness (between ECU terminal 64 and sensor terminal (1) and between ECU terminal 71 and
sensor terminal (3)). → Repair the faulty area.
■ NOTE
• Hose between intake manifold and sensor should be checked, when it is damaged, the intake air pressure
can not reach the sensor.

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(15) Non-Injection Abnormality (Rotational Fluctuation Abnormality) (DTC P0263, P0266,

P0269, P0272)
P0263 : Non-injection or rotational fluctuation abnormality in the engine No. 1 cylinder injector
• Primary malfunction symptom : Large vibration
• Detected item : A non-injection state for the injectors of each cylinder is detected with rotational fluctuation
■ During idling
■ Injector control is normal
BSTWV1, GSTWV1, NCTWV*, NCCOM*, LCHG, OCHG are normal
■ No request from the tool for stopping injection
■ Coolant temperature sensor is normal and 68 °C (154 °F) or higher
■ Vehicle is stopped
■ Injection quantity ≤ 20 mm3/st
(Engine No. 1 cylinder)
Average rotational fluctuation of all cylinders - Rotational fluctuation of No. 1 cylinder > 30 μs or higher
• System action :

6-117
(b) Constant Amperage Circuit (e) Terminal Layoutt
Check Malfunction Symptoms

■ NOTE
• Before starting diagnosis, check the cylinder with a malfunction as follows.
1. Place the key switch in the OFF position, attach the
diagnosis tool to the CAN2 connector, and return the key
switch to the ON position again.
Then, start the engine.
2. Use the "#1 to #4 cylinder injector injection stop" of the
active test, and make sure that the malfunctioning cylinder is
the one that the DTC indicates.
*In the following pages, the cylinder with a confirmed
malfunction is called the malfunctioning cylinder.
(a) CAN2 Connector

6-118
1. Checking for high pressure circuit leaks

1. Operate at no-load maximum speed and check that no leaks
occur.
■ NOTE
Repair the leak.
NG (Could be located in the rail, injection pipes or injector
unit.)
(1) Injection Pipe (2) Dipstick
OK
2. Checking for engine malfunctions in the corresponding cylinders

1. Perform engine checks such as the following.
A) Cylinder compression (including the valve seats)
B) Valve clearance, etc.
NG Repair the engine.
(1) Compression Tester

6-119
(16) Crankshaft Position Sensor (NE Sensor) Abnormality (DTC P0335, P0336)
P0335 : No NE sensor pulse input
• Primary malfunction symptom : (Running only with G signal)
■ Faulty starting
■ Vibration is slightly large
• Detected item :
■ Sensor / wiring harness open circuit, short
■ Engine is not stalled
■ No NE sensor pulse recognized
• System action :
P0336 : NE sensor pulse count abnormality
• Primary malfunction symptom : (Running only with G signal)
■ Faulty starting
■ Vibration is slightly large
• Detected item :
■ 350 min-1 (rpm) or higher
■ Pulse count per rotation is not 56 teeth
• System action :

6-120
(1) Terminal A-VCC3 (3) Terminal NE- (a) Crankshaft Position Sensor (c) Terminal Layout
(2) Terminal NE+ (NE Sensor)
(b) NE Sensor Input Circuit
1. Check the crankshaft position sensor signals

1. Rotate the engine, and check the "Engine speed active flag"
value on the diagnosis tool data monitor.
Factory spec. Always ON
It should be confirmed
two or more times
OK OK Normal.
while changing the
accelerator.
NG
Go to Step 2 (Check the voltage between crankshaft
position sensor terminals).
(a) CAN2 Connector

W1550410
NG

6-121
2. Check the voltage between crankshaft position sensor terminals

1. Place the key switch in the OFF position, and unplug the
crankshaft position sensor connector from the socket.
between A-VCC3 terminal and NE- terminal at the wiring harness
side.
NG Go to Step 5 (Measure the ECU terminal voltage).

(2) Terminal NE+
(3) Terminal NE-
OK
3. Check the connectors

1. Check the sensor and wiring harness connectors for incorrect
connection, inappropriate fitting, poor contact or other faulty
areas.
Factory spec.
inappropriate fitting, poor contact.
NG Repair or replace.
(2) Terminal NE+
(3) Terminal NE-
OK
4. Check the wiring harness

1. Check the wiring harness between NE+ terminal of sensor and
ECU for a short or an open circuit.
Factory spec. Must be free from shorts and open circuit.
NG Repair.
(2) Terminal NE+
(3) Terminal NE-
OK
The sensor has abnormality. → Replace.

6-122

1. Place the key switch in the OFF position, and unplug the ECU
cable connector (1) from the socket.
between ECU terminals 44 and 65.
NG Replace the ECU.

(1) ECU Cable Connector
OK

1. Check ECU terminals 44, 46 and 65 (at the ECU side) and the
connectors (at the wiring harness side) for incorrect connection,
Factory spec.
OK

1. Check the wiring harness being connected to ECU terminals 44,
46 and 65 for a short or an open circuit.
NG Repair.
OK

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8. Check the sensor

1. Disconnect the sensor and check the following items.
• Is there a large amount of magnetic foreign material adhering to
the sensor surface?
• Are there any interference marks remaining?
• Are there any pulsar gear abnormalities?
NG Repair or replace the sensor.
(NE Sensor)
OK
Replace the ECU and test.

6-124
(17) Camshaft Position Sensor (G Sensor) Abnormality (DTC P0340, P0341)

P0340 : No G sensor pulse input
• Primary malfunction symptom : (G signal invalid)
• Detected item :
■ Engine is not stalled
■ No G sensor pulse recognized
• System action :
■ None
P0341 : G sensor pulse count abnormality
• Primary malfunction symptom : (G signal invalid)
• Detected item :
■ 350 min-1 (rpm) or higher
■ Pulse count per rotation is not 5 teeth
• System action :
■ None

6-125
(1) Terminal A-VCC4 (3) Terminal G- (a) Camshaft Position Sensor (c) Terminal Layout
(2) Terminal G+ (G Sensor)
(b) G Sensor Input Circuit
1. Check the camshaft position sensor signals

1. Rotate the engine, and check the "Cam speed active flag" value
Factory spec. Always ON
It should be confirmed
two or more times
OK OK Normal.
while changing the
accelerator.
NG
Go to Step 2 (Check the voltage between camshaft
position sensor terminals).
(a) CAN2 Connector
NG

6-126
2. Check the voltage between camshaft position sensor terminals

1. Place the key switch in the OFF position, and unplug the
camshaft position sensor connector from the socket.
between A-VCC4 and G- terminals at the wiring harness side.
NG Go to Step 5 (Measure the ECU terminal voltage).

(2) Terminal G+
(3) Terminal G-
OK

1. Check the sensor and wiring harness connectors for incorrect
connection, inappropriate fitting, poor contact or other faulty
areas.
Factory spec.
(2) Terminal G+
(3) Terminal G-
OK

1. Check the wiring harness between G+ terminal of sensor and
ECU for a short or an open circuit.
NG Repair.
(2) Terminal G+
(3) Terminal G-
OK
The sensor has abnormality. → Replace.

6-127

1. Place the key switch in the OFF position, and unplug the ECU
cable connector (1) from the socket.
NG Replace the ECU.

OK

1. Check ECU terminals 45, 47 and, 66 (at the ECU side) and the
connectors (at the wiring harness side) for incorrect connection,
Factory spec.
OK

1. Check the wiring harness being connected to ECU terminals 45,
47 and 66 for a short or an open circuit.
NG Repair.
OK

6-128
8. Check the sensor

1. Disconnect the sensor and check the following items.
• Is there a large amount of magnetic foreign material adhering to
the sensor surface?
• Are there any interference marks remaining?
• Are there any pulsar gear abnormalities?
NG Repair or replace the sensor.
(G Sensor)
OK
Replace the ECU and test.

6-129
(18) EGR Feedback Abnormality (DTC P0400)

• Primary malfunction symptom : Worsening exhaust gas performance (NOx)
• Detected item : DC motor feedback control abnormality
• DTC set conditions : (Approximate)
■ During duty abnormal operation, a feedback abnormality is judged if it does not recover after performing 30
recovery operation cycles
• System action :
■ EGR stops
(1) Terminal EGR+ (4) Terminal LEGR (a) EGR Valve Motor (c) EGR Valve Motor Control
(2) Terminal EGR- (5) Terminal LEGR RTN (b) EGR Lift Sensor (d) Terminal Layout
(3) Terminal A-VCC6

6-130
1. Check the EGR lift signal

1. After operating the engine to fully warm it up, perform an active
test.
Monitor the "Actual EGR valve opening" and "EGR lift sensor
output voltage", and check the values.
*For details, refer to the active test section.
2. Next, after starting up the engine to fully warm it up [Coolant
temperature : 65 °C (149 °F) or higher], check the "Actual EGR
valve opening" and "EGR lift sensor output voltage" during no-
load maximum speed.
Factory spec.
Actual EGR
valve opening
Key switch is
0% Approx. 0.9 V
turned ON
No-load
Approx. 15 % Approx. 1.4 V
maximum speed
Clear the DTC and

OK check whether it is OK Normal.
NG
Go to Step 2 (Check the wiring harness and
connector).
(a) CAN2 Connector

W1486972
NG
2. Check the wiring harness and connector

1. Remove the connector from both the ECU side and EGR valve
side, and check the state of the wiring harness continuity.
(On both the motor side and lift sensor side)
Factory spec. Continuity
2. Check each connector for poor connection, engagement and
contact. (On both the motor side and lift sensor side)
Factory spec. No poor connection, engagement or contact.
NG Repair or replace the faulty areas.

(1) ECU Side Connector (2) Wiring Harness Side Connector
W1487679
OK

6-131
3. Replace the EGR valve and check the EGR lift signal again
1. Replace the EGR valve.
test.
load maximum speed.
Factory spec.
Actual EGR
valve opening
Key switch is
0% Approx. 0.9 V
turned ON
No-load
maximum speed
OK EGR valve fault → Replace the EGR valve.

(a) CAN2 Connector
W1488406
NG
4. Replace the ECU and check the EGR lift signal again
1. Replace the ECU.
test.
load maximum speed.
Factory spec.
Actual EGR
valve opening
Key switch is
0% Approx. 0.9 V
turned ON
No-load
maximum speed

(a) CAN2 Connector
W1488634

6-132
(19) EGR DC Motor Estimated Temperature Abnormality (DTC P0404)

• Detected item : DC motor estimated temperature abnormality
■ Estimated temperature is 45 °C (113 °F) or higher
• System action :
■ EGR stops
(3) Terminal A-VCC6

6-133

test.
*For details, refer to the active test section.
load maximum speed.
Factory spec.
Actual EGR
valve opening
Key switch is
0% Approx. 0.9 V
turned ON
No-load
maximum speed
■ NOTE
• This item is OK if it operates without a problem when the key
switch is turned OFF and then ON again (or the active test is
OK).
• If it reoccurs, replace the EGR valve and observe the
conditions.
Clear the DTC and
NG
Go to Step 2 (Check the wiring harness and
connector).
(a) CAN2 Connector
NG
2. Check the wiring harness and connector

1. Remove the connector from both the ECU side and EGR valve
side, and check the state of the wiring harness continuity.
(On both the motor side and lift sensor side)
Factory spec. Continuity
2. Check each connector for poor connection, engagement and
contact. (On both the motor side and lift sensor side)

(1) ECU Side Connector (2) Wiring Harness Side Connector
OK

6-134
3. Replace the EGR valve and check the EGR lift signal again
1. Replace the EGR valve.
test.
load maximum speed.
Factory spec.
Actual EGR
valve opening
Key switch is
0% Approx. 0.9 V
turned ON
No-load
maximum speed
OK EGR valve fault → Replace the EGR valve.

(a) CAN2 Connector
NG
4. Replace the ECU and check the EGR lift signal again
1. Replace the ECU.
test.
load maximum speed.
Factory spec.
Actual EGR
valve opening
Key switch is
0% Approx. 0.9 V
turned ON
No-load
maximum speed

(a) CAN2 Connector

6-135
(20) EGR Lift Sensor Abnormality (DTC P0405, P0406)

P0405 : EGR lift sensor abnormality (Low side)
• Detected item :
■ Sensor / wiring harness open circuit, ground short
■ EGR lift sensor voltage is 0.3 V or lower
• System action :
■ EGR stops
P0406 : EGR lift sensor abnormality (High side)
• Detected item :
■ Sensor / wiring harness +B short
■ EGR lift sensor voltage is 4.5 V or higher
• System action :
■ EGR stops
(3) Terminal A-VCC6

6-136

1. Turn the key switch ON and check the "Actual EGR valve
opening" and "EGR lift sensor output voltage" with the data
monitor.
load maximum speed.
Factory spec.
Actual EGR
valve opening
Key switch is
0% Approx. 0.9 V
turned ON
No-load
maximum speed
Clear the DTC and

NG
Go to Step 2 (Measure the voltage between the ECU
terminals).
(a) CAN2 Connector
NG
2. Measure the voltage between the ECU terminals

1. Turn the key switch ON and measure the voltage between ECU
terminal 81 and terminal 77.
temperature : 65 °C (149 °F) or higher], check the voltages above
during no-load maximum speed.
Factory spec.
Key switch is turned ON Approx. 0.9 V
No-load maximum speed Approx. 1.4 V
Check the wiring

ECU fault →
OK harness connector OK
Replace.
and ECU pins.
NG
Repair or replace the faulty areas.
NG

6-137
3. Measure the voltage between the EGR lift sensor terminals

EGR lift sensor terminal (4) and terminal (5) on the wiring
harness side.
temperature : 65 °C (149 °F) or higher], check the voltages above
during no-load maximum speed.
Factory spec.
Key switch is turned ON Approx. 0.9 V
No-load maximum speed Approx. 1.4 V
Check the wiring Check the wiring

OK harness connector OK harness → Repair
and ECU pins. the faulty areas.
(1) Terminal EGR+ (4) Terminal LEGR

(2) Terminal EGR- (5) Terminal LEGR RTN
(3) Terminal A-VCC6
OK
4. Measure the voltage between the EGR lift sensor terminals

1. Turn the key switch OFF and remove the EGR lift sensor
connector.
2. Turn the key switch ON and measure the voltage between
terminal (3) and terminal (5) (on the wiring harness side) of the
EGR lift sensor connector.
Check the wiring

Repair or replace
OK harness connector NG
the faulty areas.
and sensor pins.
OK
EGR lift sensor fault → Replace the EGR valve.
(1) Terminal EGR+ (4) Terminal LEGR

(2) Terminal EGR- (5) Terminal LEGR RTN
(3) Terminal A-VCC6
NG

6-138
5. Measure the voltage between the ECU terminals

1. Turn the key switch ON and check the voltage between ECU
terminal 64 and terminal 77.
Check the wiring

Repair or replace
NG harness connector NG
the faulty areas.
and sensor pins.
OK
ECU fault → Replace.
W1496901
OK
Check the wiring harness → Repair the faulty areas.
(Between terminal 64 and terminal (1), between terminal 77 and terminal (3))

6-139
(21) Vehicle Speed Sensor Abnormality (DTC P0501, P0503)

P0501 : Abnormal vehicle speed (High)
• Primary malfunction symptom : None in particular when driving
(However, it has a negative effect on the learning conditions and diagnostic conditions)
• Detected item : Excessive vehicle speed
■ Engine is operating
■ Vehicle speed : 100 km/h or higher
• System action :
■ None
P0503 : Vehicle speed change rate abnormality
• Primary malfunction symptom : None in particular when driving
(However, it has a negative effect on the learning conditions and diagnostic conditions)
• Detected item : Vehicle speed change rate abnormality
■ Vehicle speed change rate : 20 km/h (16 ms) or higher
• System action :
■ None
(1) Terminal SPD (a) Vehicle Speed Sensor (b) Connector (c) Vehicle Speed Input Circuit

6-140
1. Check the vehicle speed sensor signal (SPD)

1. Monitor the vehicle speed (KWPSPD) data when the vehicle is
stopped and at the maximum vehicle speed, and check the
values.
When stopped : 0 km/h
Factory spec. At maximum vehicle speed : Refer to the
operator’s manual for this device
Clear the DTC and

NG
Replace with an ECU
from a normal device OK Replace the ECU.
and check.
NG
Go to Step 4 (Check the wiring condition and ECU for
the vehicle).
(a) CAN2 Connector
NG
2. Check the connector

1. Check the connector of the wiring harness connected to the
engine ECU for poor connection, engagement and contact.
NG Repair or replace the wiring harness.

2. Check the sensor connector connected to the vehicle for poor
connection, engagement and contact. (Refer to the operator’s
manual for this vehicle)
NG Repair or replace the sensor connector.
OK

6-141
3. Check for wiring harness open circuits

1. Check for open circuits in each sensor wiring harness connected
to the engine ECU.
Factory spec. No open circuit.
NG Repair or replace the wiring harness.

(1) Terminal SPD (a) Connector
W1499809
OK
4. Checking the wiring condition and ECU for the vehicle

1. Check the wiring condition and ECU for the vehicle and repair any malfunctions. (Refer to the operator’s manual
for this vehicle)

6-142
(22) Battery Voltage Abnormality (DTC P0561, P0562, P0563)

P0561 : System voltage instability abnormality
■ Faulty starting
• Detected item : System voltage instability
■ 500 min-1 (rpm) or higher continues for 120 sec. or longer
■ Difference between average processing voltage and raw voltage is 1 V or higher
• System action :
■ Only main injection is allowed
■ EGR stops
P0562 : Battery voltage abnormality (Low side)
■ Faulty starting
• Detected item :
■ Wiring harness open circuit, short, damage
■ Battery abnormality
■ No ST signal
■ Battery voltage at ECU is recognized as 0.964 V or lower (equivalent to 8 V)
• System action :
■ EGR stops

6-143
P0563 : Battery voltage abnormality (High side)

■ Faulty starting
• Detected item :
■ Wiring harness open circuit, short, damage
■ Battery abnormality
■ No ST signal
■ Battery voltage at ECU is recognized as 1.928 V or higher (equivalent to 16 V)
• System action :
■ EGR stops
(a) Main Relay

6-144
1. Check the ECU data

position again. Then, check the "Battery voltage" status on the
data monitor.
2. Change the engine operation status, and check the "Battery
voltage".
During cranking : 8 V or higher
Factory spec.
After engine start-up : 15 V or lower
■ NOTE
• Try to change the engine speed as the generated voltage
changes accordingly.
Clear the DTC and
OK
Normal.
(a) CAN2 Connector
NG
2. Check the ECU terminal voltage (Part 1)

1. Change the engine operation status, and measure the voltage
between ECU terminals 119 and 114 and between terminals 120
and 114.
During cranking : 6 V or higher
Factory spec.
After engine start-up : 15 V or lower
■ NOTE

OK NG
ECU.
OK
NG

6-145
3. Check the ECU terminal voltage (Part 2)

1. Change the engine operation status, and measure the voltage
between ECU terminal 114 and chassis ground terminal.
Factory spec. Always 0.5 V or lower
■ NOTE
Check the wiring harness between ECU terminal and
NG
the body ground terminal. → Repair the defects.
OK
Check the charging system, the battery itself, wiring harness and cables. → Repair the faulty area.
Locate the cause of excessively high or low voltage.

6-146
(23) QR Abnormality (DTC P0602)

P0602 : QR data abnormality
• Detected item : QR code correction data abnormality
■ QR correction data exceeds threshold value
■ Multiple check errors
(QR correction data for each injector has been stored in three locations. When this data is read and compared,
an error is determined if there is a difference in all three values)
• System action :
P0602 : QR data writing failure malfunction
• Detected item : QR code correction data writing failure
■ When QR correction data fails to write to the EEPROM
(When the initial ECU value is "0", an error that QR data is not written to the disc at the time of vehicle shipment
is detected.)
• System action :
1. Write the QR codes and read the DTC again

1. Using the diagnosis tool, write the correct QR codes in the ECU.
2. Clear the DTC and check whether the same DTC is output again
or not.
Factory spec. Normal
NG Faulty Engine ECU.

(a) CAN2 Connector
OK
An electromagnetic interference (EMI) may have caused the temporary malfunction. There is no problem if the
system has recovered.

6-147
(24) ECU Flash-ROM Abnormality and CPU Abnormality (DTC P0605, P0606)
P0605 : ECU Flash-ROM abnormality
• Detected item : Internal Flash-ROM transformation abnormality monitor
■ Three times or more consecutive inconsistencies in checksum
• System action :
P0606 : ECU CPU abnormality (Main IC abnormality)
• Detected item : CPU malfunction
■ Battery voltage ≥ 10 V
■ Starter switch is OFF
■ CPU abnormality counter ≥ 5 times (RUN pulse abnormality : 5 times or more)
• System action :
■ Engine stops
P0606 : ECU CPU abnormality (Monitoring IC abnormality)
• Detected item : CPU monitoring use IC malfunction
■ Battery voltage ≥ 10 V
■ Starter switch in OFF condition continuously for 500 msec or more
■ Abnormality continues for 2000 msec or more after the ECU is turned ON
■ RUN pulse abnormality
Above conditions occur continuously for 700 ms or more
• System action :
■ Engine stops

6-148
1. Check the DTC

position again.
2. Clear the DTC, and check whether the same DTC (P0605 or
P0606) is output again or not.
NG Faulty Engine ECU → Replace.

(a) CAN2 Connector
OK

6-149
(25) Low Charge (DTC P0611)

■ NOTE
• This DTC is detected when the charge current in the injector actuation circuit is too low.

• Detected item :
■ Injector charge current insufficient
■ CPU is normal
■ Injector charge current insufficient
• System action :

6-150


OK obstructions to the radio waves, so as long as it
(a) CAN2 Connector
NG
2. Replacing the injector and checking whether the DTC is detected again
1. Replace the injector.
OK Injector fault → Replace the injector.

(a) CAN2 Connector
NG
3. Replacing the ECU and checking whether the DTC is detected again
1. Replace the ECU.

(a) CAN2 Connector

6-151
(26) Starter Switch Abnormality (DTC P0616, P0617)

P0616 : Starter switch ground short
• Primary malfunction symptom : Decreased startability
• Detected item : Starter switch / ground short (ST signal is not recognized)
■ Key switch OFF → ON
■ Engine speed is 150 min-1 (rpm) or lower
■ Engine speed is 150 min-1 (rpm) or lower
■ Simultaneously, ST signal is not recognized
■ Simultaneously, abnormality is judged if the engine speed exceeded 150 min-1 (rpm) during start-up in a state
where a battery voltage reduction equivalent to start-up was recognized
• System action :
■ None
P0617 : Starter switch battery short
• Detected item : Starter switch / wiring harness short (ST signal recognized during engine operation)
■ Engine speed is 1200 min-1 (rpm) or higher
■ ST signal is recognized under the conditions on the above
• System action :
■ Engine stops
(1) OFF (3) ON (4) START (a) Key Switch

(2) ACC

6-152
■ NOTE
• The distortion of the starter signal is an important factor that negatively affects the starting control.
The starter operation condition while the failure occurs should be confirmed to the customer, to ascertain
thoroughly and deal whether the failure synchronizes with starter operation or is distorted in the circuit.
1. Check the ECU signals
tool the CAN2 connector, and check the "Starter switch" value on
the data monitor.
Key switch in the ON position : OFF
Factory spec.
Key switch in START position : ON
CAUTION
• Check the gear shift position and pay attention for the
surrounding safety.
Clear the DTC and
detected again or not.
OK
Normal.
(a) CAN2 Connector
NG

1. Unplug the ECU cable connector from the socket, operate the
key switch, and measure the voltage between ECU terminal 99
and the ground (at the wiring harness side).
Key switch in the ON position : 0 V
Factory spec. Key switch in the START position : Battery
voltage
CAUTION
• Check the gear shift position and pay attention for the
surrounding safety.
Check the ECU
connectors for
OK NG Repair.
incorrect connection or
poor contact.
OK
NG
Check the key switch and wiring harness. → Repair or replace the faulty area.

6-153
(27) SCV Abnormality (DTC P0628, P0629)

P0628 : SCV actuation system abnormality
• Detected item : SCV open circuit, ground short
■ Engine is operating (with pump high pressure control mode)
■ Cases other than sudden changes in the pump control duty
■ SCV open circuit, ground short
• System action :
■ Engine stops
P0629 : SCV +B short
• Detected item : SCV battery short
■ Engine is operating (with pump high pressure control mode)
■ Cases other than sudden changes in the pump control duty
■ SCV battery short
• System action :
■ Engine stops
(1) Terminal SCV+ (2) Terminal SCV- (a) Suction Control Valve (SCV)

6-154
1. Check the SCV current

1. Place the key switch in the ON position, and check the "Target
SCV current" and "Actual SCV current" on the diagnosis tool data
monitor.
2200 to 1300 mA (It may change depending on
Factory spec.
the engine operation conditions.)
Clear the DTC and

OK
Normal.
(a) CAN2 Connector
NG

Factory spec.
Item Temperature Resistance
Resistance 20 °C (68 °F) 2.1 Ω
Insulation
resistance
20 °C (68 °F) 100 MΩ or higher
(between terminal
valves)
NG

6-155
3. Check the SCV

1. Turn the key switch OFF, remove the connector from the SCV
SCV side.
Factory spec.
Item Temperature Resistance
Resistance 20 °C (68 °F) 2.1 Ω
Insulation
resistance
20 °C (68 °F) 100 MΩ or higher
(between terminal
valves)
NG SCV fault → Replace the supply pump.
OK
Wiring harness open circuit, connector fault → Check, repair.

1. Unplug the ECU cable connector from socket, and measure the
voltage between ECU terminals 10 and 29 and the ground (at the
wiring harness side).
Factory spec. Both must be approx. 0 V.
NG Repair the wiring harness.
OK
Normal.

6-156
(28) Sensor Voltage 1 Abnormality (DTC P0642, P0643)

P0642 : Sensor voltage 1 abnormality (Low side)
• Detected item : Sensor supply voltage 1 abnormality or recognition abnormality
■ No ST signal
■ Sensor voltage is 3.89 V or lower
• System action :
■ Accelerator opening limit : 0 ←→ 25 %
P0643 : Sensor voltage 1 abnormality (High side)
■ No ST signal
■ Sensor voltage is 4.12 V or higher
• System action :

6-157

1. Place the key switch in the OFF position, and unplug ECU cable
connector (1) from the socket.

NG NG
ECU.
OK
OK
Check the wiring harness (ECU terminal 82) for a short. → Repair the faulty area.

6-158
(29) Sensor Voltage 2 Abnormality (DTC P0652, P0653)

P0652 : Sensor voltage 2 abnormality (Low side)
■ Faulty starting
■ No ST signal
■ Sensor voltage is 3.89 V or lower
• System action :
■ EGR stops
P0653 : Sensor voltage 2 abnormality (High side)
■ Faulty starting
■ No ST signal
■ Sensor voltage is 4.12 V or higher
• System action :
■ EGR stops

6-159

1. Place the key switch in the OFF position, and unplug ECU cable
connector (1) from the socket.

NG NG
ECU.
OK
OK
Check the wiring harness (ECU terminal 90) for a short. → Repair the faulty area.

6-160
(30) Main Relay Abnormality (DTC P0687)

• Primary malfunction symptom : Dead battery
• Detected item : Main relay malfunction
■ Key switch is OFF
■ Engine stall
■ Battery Voltage ≥ 8 V
Simultaneously, no main relay command (Light does not turn off even after 1 minute or longer has passed since
turning the key OFF)
• Check engine warning light : OFF
• System action :
■ None
(1) OFF (4) START (7) Terminal 3 (a) Key Switch

(2) ACC (5) Terminal 1 (8) Terminal 4 (b) Main Relay
(3) ON (6) Terminal 2 (c) Main Relay Terminal Layout

6-161

1. Place the key switch in the OFF position, and measure the
voltage between ECU terminals 119 and 120 and the chassis
ground.
Factory spec. 0V
Clear the DTC and

OK
Normal.
NG
2. Check the key switch signal

tool the CAN2 connector, and return the key switch to the ON
position again.
2. Using the data monitor function of diagnosis tool, check the "Key
switch" data when the key switch is placed in the OFF position.
Factory spec. OFF
OK Go to Step 4 (Check the ECU terminal voltage).

(a) CAN2 Connector
NG
3. Check the IG-SW signal

1. Place the key switch in the OFF position, and measure the
voltage at ECU terminal 107.
Factory spec. 0V
Check the wiring harness and the key switch. →

Repair.
NG
Locate the cause of constant voltage supply to the
wiring harness.
OK

6-162
4. Check the ECU terminal voltage

1. Keep the key switch in the OFF position, and measure the
voltage at ECU main relay terminals 105 and 113.
Check the wiring harness between relay and ECU and

connectors. → Repair.
NG
Locate the cause of constant shorted wiring harness to
the ground.
OK
5. Measure the resistance between relay terminals (for confirmation)

1. Remove the main relay, and measure the resistance between
each relay terminal.
Between terminals (3) and (4) : 50 to 200 Ω
Factory spec.
Between terminals (1) and (2) : ∞ Ω
NG Faulty main relay → Replace.

(1) Terminal 1 (a) Terminal Layout
(2) Terminal 2
(3) Terminal 3
(4) Terminal 4

6-163
(31) Pump Protection Failure Flag (DTC P1274)

• Detected item : Abnormally high pressure 1
■ Rail pressure of 197 MPa (2010 kgf/cm2, 28600 psi) or higher, or 230 MPa (2350 kgf/cm2, 33400 psi) or lower
continues for 2 hours
[The threshold varies depending on the engine speed. Use 2200 min-1 (rpm) as a guideline]
■ Alternatively, rail pressure of 80 MPa (820 kgf/cm2, 12000 psi) or higher continues for 10 sec. at 500 min-1 (rpm)
or lower
• System action :
■ Engine stops

6-164
1. Measure the resistance between SCV terminals

Factory spec. Refer to the SCV unit inspection value.
Go to Step 3 (Check the fuel system for the existence

OK
of air).
NG
2. Measure the resistance between terminals of SCV unit

1. Refer to the SCV unit inspection procedures.
NG Faulty SCV → Repair or replace the pump.
(1) SCV
W1594900
OK

repair it.
(1) Fuel Hose
OK

6-165

PROCEDURE".
CAUTION
system.
Repair according to "2.2. FUEL SYSTEM
NG
(2) Rail
W1117880
OK

monitor.
when idling
Factory spec.
conditions.

OK
(a) CAN2 Connector
NG

6-166
6. Check the rail pressure sensor (*Refer to items P0192 and P0193)
■ NOTE
and P0193.)
(a) CAN2 Connector
OK

monitor.
Factory spec.
■ NOTE
judgment.
NG Replace the supply pump and rail.
(a) CAN2 Connector
OK

6-167
(32) Pump Replacement Failure Flag (DTC P1275)

• Detected item : Abnormally high pressure 2
■ Rail pressure of 230 MPa (2350 kgf/cm2, 33400 psi) or higher continues for 1 sec. at 500 min-1 (rpm) or higher
• System action :
■ Engine stops

6-168
1. Measure the resistance between SCV terminals

Factory spec. Refer to the SCV unit inspection value.
Go to Step 3 (Check the fuel system for the existence

OK
of air).
NG
2. Measure the resistance between terminals of SCV unit

1. Refer to the SCV unit inspection procedures.
NG Faulty SCV → Repair or replace the pump.
(1) SCV
W1596882
OK
1. Wiring harness open circuit or connector fault → Check and repair.
2. Replace the supply pump and rail.

6-169

1. Rotate the fuel pump sufficiently and bleed the air.
2. Locate the position of the fuel leakage in the piping
NG
and repair it.
(1) Fuel Hose
OK

PROCEDURE".
CAUTION
system.
Repair according to "2.2. FUEL SYSTEM
NG
(2) Rail
OK

6-170

monitor.
when idling
Factory spec.
conditions.

OK
(a) CAN2 Connector
W1597164
NG
6. Check the rail pressure sensor (*Refer to items P0192 and P0193)
■ NOTE
and P0193.)
(a) CAN2 Connector
OK

6-171

monitor.
Factory spec.
■ NOTE
judgment.
NG Replace the supply pump and rail.
(a) CAN2 Connector
OK
1. After confirming that an intermittent malfunction (such as power supply system or noise generation) does not
occur in relation to the ECU, replace the ECU.

6-172
(33) Accelerator Position Sensor 1 Abnormality (DTC P2122, P2123)

P2122 : Accelerator position sensor 1 abnormality (Low side)
• Detected item : Sensor / wiring harness open circuit, ground short
■ Accelerator position sensor voltage 1 is 0.3 V or lower
• System action :
P2123 : Accelerator position sensor 1 abnormality (High side)
• Detected item : Sensor / wiring harness power supply short
■ Accelerator position sensor voltage 1 is 4.7 V or higher
• System action :
(1) Terminal A-VCC1 (4) Terminal A-VCC2 (a) Accelerator Position Sensor (b) Terminal Layout
(2) Terminal APS1 (5) Terminal APS2
(3) Terminal APS1 GND (6) Terminal APS2 GND

6-173
1. Check the accelerator position sensor signals

1. Place the key switch in the ON position, and check the
"Accelerator position" and "Accelerator position sensor 1 output
voltage" on the diagnosis tool data monitor.
Factory spec.
Corrected
Actual accelerator
accelerator pedal Output voltage
pedal position
position
Fully close 0% Approx. 0.9 V
Fully open 100 % Approx. 4.5 V
■ NOTE
• "Full close" and "Full open" are with the accelerator position
sensor, not with the accelerator pedal or hand accelerator.
Clear the DTC and
OK
Normal.
(a) CAN2 Connector
NG
2. Measure the voltage between sensor terminals

1. Place the key switch in the OFF position, unplug the accelerator
position sensor connector from the socket, and return the key
2. Measure the voltage between terminals (1) and (3) of accelerator
position sensor connector (at the vehicle harness side).

(1) Terminal A-VCC1 (5) Terminal APS2
(2) Terminal APS1 (6) Terminal APS2 GND
(3) Terminal APS1 GND
NG

6-174
3. Measure the terminal voltage

1. Measure the voltage between ECU terminals 82 and 84.
Check the ECU Faulty ECU →

NG OK
connectors. Replace.
NG
Repair the ECU connectors.
W1122904
OK
The wiring harness between the ECU and sensor is faulty. → Repair.

1. Place the key switch in the OFF position, and plug the accelerator
position sensor connector into the socket.
Accelerator pedal fully closed : Approx. 0.9 V
Factory spec.
Accelerator pedal full throttle : Approx. 4.5 V
■ NOTE
OK OK
NG
NG

1. Keep the accelerator position sensor connector plugged into
socket.
position sensor connector (at the vehicle wiring harness side).
Factory spec.
NG Faulty accelerator sensor → Replace.

OK
Wiring harness open circuit, short → Check and repair.

6-175
(34) Accelerator Position Sensor 2 Abnormality (DTC P2127, P2128)

P2127 : Accelerator position sensor 2 abnormality (Low side)
• Detected item : Sensor / wiring harness open circuit, ground short
■ Accelerator position sensor voltage 2 is 0.3 V or lower
• System action :
P2128 : Accelerator position sensor 2 abnormality (High side)
• Detected item : Sensor / wiring harness power supply short
■ Accelerator position sensor voltage 2 is 4.7 V or higher
• System action :
(1) Terminal A-VCC1 (4) Terminal A-VCC2 (a) Accelerator Position Sensor (b) Terminal Layout
(2) Terminal APS1 (5) Terminal APS2
(3) Terminal APS1 GND (6) Terminal APS2 GND

6-176
1. Check the accelerator position sensor signals

"Accelerator position" and "Accelerator position sensor 2 output
voltage" on the diagnosis tool data monitor.
Factory spec.
Corrected
Actual accelerator
accelerator pedal Output voltage
pedal position
position
Fully close 0% Approx. 0.9 V
Fully open 100 % Approx. 4.5 V
■ NOTE
Clear the DTC and
OK
Normal.
(a) CAN2 Connector
NG

1. Place the key switch in the OFF position, unplug the accelerator
position sensor connector from the socket, and return the key
position sensor connector (at the vehicle harness side).

NG

6-177
3. Measure the terminal voltage

1. Measure the voltage between ECU terminals 90 and 92.

NG OK
NG
OK
The wiring harness between the ECU and sensor is faulty. → Repair.

1. Place the key switch in the OFF position, and plug the accelerator
position sensor connector into the socket.
Factory spec.
■ NOTE
OK OK
NG
NG

1. Keep the accelerator position sensor connector plugged into
socket.
position sensor connector (at the vehicle wiring harness side).
Factory spec.
NG Faulty accelerator sensor → Replace.

OK
Wiring harness open circuit, short → Check and repair.

6-178
(35) Common 1 System Open Circuit and Common 2 System Open Circuit
(DTC P2146, P2149)
P2146 : Injector actuation circuit open circuit
[Simultaneously in the common 1 system or TWV1, 3 (cylinders No. 1, 4)]
P2149 : Injector actuation circuit open circuit
[Simultaneously in the common 2 system or TWV2, 4 (cylinders No. 3, 2)]
• Detected item : Wiring harness open circuit
■ During injection
■ CPU is normal
During wiring harness open circuit
• System action :
■ Engine stops

6-179
1. DTC judgment
1. Place the key switch in the OFF position, and attach the
diagnosis tool to the CAN2 connector.
2. Turn the key switch to the ON position, check whether the DTC
(P2146, P2149) is output or not.
Factory spec. Either DTC P2146 or P2149 is output.
Go to Step 4 (Measure the resistance between ECU

OK
terminals).
(a) CAN2 Connector
NG
2. Check the "P- GND" wiring harness

each ECU terminal and the chassis ground (at the wiring harness
side).
Check the "P- GND" wiring harness. → Repair.

NG Locate the cause of open circuit, or increase its
resistance value.
OK
3. Check the "P- GND" wiring harness connector and ECU pins
1. Place the key switch in the OFF position, unplug the ECU
connector from the socket, and check the ECU pins for faulty
connection, deformation, poor contact or other defects.
Must be free from faulty connection, deformation,
Factory spec.
poor contact or other defects.
Repair wiring harness connectors and ECU pins, or

NG
replace them if defective.
OK

6-180
4. Measure the resistance between ECU terminals

connector, and measure the resistance between each terminal at
the connector side as shown on the following table.
DTC ECU Terminals Measured
No. 1 cylinder 42, 43
P2146 4
P2149 5
Factory spec. Both system cables must have 1.5 Ω or lower.
Go to Step 5 (Check the wiring harness connectors

OK
and ECU pins).
NG
5. Check the wiring harness connectors and ECU pins

1. Check the wiring harness connectors of each ECU terminal and
the ECU pins for faulty connection, deformation or other defects.
The connectors or ECU pins are faulty. → Repair them
NG
or replace the ECU.
OK

6-181
6. Check the DTC

2. Start the engine, and clear the past DTCs.
3. Read the DTC again.

(a) CAN2 Connector
OK
Normal.

6-182
(36) Common 1 TWV Actuation System Ground Short and

Common 1 TWV Actuation System +B Short (DTC P2147, P2148)
P2147 : Common 1 TWV actuation system ground short
• Detected item : Wiring harness ground short
■ During a wiring harness ground short
• System action :
■ Engine stops
P2148 : Common 1 TWV actuation system +B short
• Detected item : Wiring harness +B short
■ During a wiring harness battery short
• System action :
■ Engine stops

6-183
1. Check the "P- GND" wiring harness

connector (pin 81) from the socket, and measure the resistance
between each of ECU terminals 1, 2 and 3 and the chassis
ground (at the wiring harness side).
Check the "P- GND" wiring harness. → Repair.

NG Locate the cause of open circuit, or increase its
resistance value.
OK
2. Check the wiring harness connectors and ECU pins

1. Place the key switch in the OFF position, unplug the ECU
connector (pin 81) from the socket, and check the ECU pins for
faulty connection, deformation, poor contact or other defects.
Must be free from faulty connection, deformation,
Factory spec.
poor contact or other defects.
Repair wiring harness connectors and ECU pins, or

NG
replace them if defective.
OK
3. Measure the ECU terminal voltage (Part 1)

between ECU terminal 4 or 5 and "P- GND" terminal.
Go to Step 5 (Measure the ECU terminal voltage (Part

NG
2)).
OK

6-184
4. Check the DTC

2. Start the engine, and clear the past DTCs.
3. Read the DTC again.

(a) CAN2 Connector
OK
Normal.
5. Measure the ECU terminal voltage (Part 2)

connector (pin 81) from the socket, return the key switch to the
ON position again, and measure the voltage between each of
ECU terminal pins 4 and 5 and the "P -GND" terminal (at the
wiring harness side).
OK

6-185

Locate the cause of wiring harness ground short, and repair the faulty area.
Shorted
DTC Relating ECU Terminals
Harness Side
Terminal 4 or 5
P2147 Ground
(42 / 43, 40 / 41, 23 / 24, 21 / 22 occurring simultaneously)
Terminal 4 or 5
P2148 Power supply
(42 / 43, 40 / 41, 23 / 24, 21 / 22 occurring simultaneously)
W1132741
■ NOTE
• If DTC P2147 (Shorted injector actuation circuit to the ground) has occurred, be sure to check the
insulation of injector itself in the following procedure.
1. Place the key switch in the OFF position, unplug each injector
connector from socket, and visually check the connector status.
Factory spec. Must be free from sludge and sparks.
2. Using an insulation resistance tester (megger tester), measure
the resistance between each of terminals (1) and (2) and the
chassis ground (at the injector side).
Factory spec. 10 MΩ or higher
NG Faulty injector → Replace.

(1) Terminal COMMON (a) Injector
(2) Terminal TWV
W1133146
OK
The injector functions normally. Locate another cause.

6-186
(37) Atmospheric Pressure Sensor Abnormality (DTC P2227, P2228, P2229)

P2227 : Abnormal atmospheric pressure sensor characteristics
• Primary malfunction symptom : (At high altitude)
Increase in white smoke, worsening exhaust gas performance
• Detected item : Abnormal atmospheric pressure sensor characteristics
■ Atmospheric pressure sensor (high, low) is normal
■ Intake air pressure sensor is normal
■ Coolant temperature sensor is normal
■ Intake air temperature sensor is normal
■ Difference with intake air pressure when stopped or idling is within 10 kPa (0.10 kgf/cm2, 1.4 psi)
• System action :
■ Atmospheric pressure = 101.3 kPa (1.033 kgf/cm2, 14.69 psi)
P2228 : Atmospheric pressure sensor abnormality (Low side)
• Detected item : Sensor / ECU internal circuit ground short
■ Atmospheric pressure sensor voltage is 1.65 V or lower
• System action :
P2229 : Atmospheric pressure sensor abnormality (High side)
• Detected item : Sensor / ECU internal circuit +B short
■ Atmospheric pressure sensor voltage is 4.8 V or higher
• System action :

6-187
1. Check the atmospheric pressure signals

"Atmospheric pressure" on the diagnosis tool data monitor.
Atmospheric pressure
Factory spec. Actual atmospheric pressure (Approx. 100 kPa
(1.02 kgf/cm2, 14.5 psi))
Clear the DTC and

OK
Normal.
(a) CAN2 Connector
NG
2. Check the DTC

1. Place the key switch to the OFF position first, then return it to the
ON position again.
2. Clear the past DTCs, and check whether the same DTC (P2227,
P2228 or P2229) is output again or not.
Factory spec. Normal
Faulty atmospheric pressure sensor → Replace the

NG
engine ECU.
(a) CAN2 Connector
OK

6-188
(38) Glow Relay Actuation Abnormality (DTC P0380)

■ NOTE
• This item is a check related to the glow relay control. Even if it is normal, glow plug may not work. If this
happens, look for the malfunction in accordance with the operator’s manual for this device.
P0380 : Glow relay actuation circuit battery short
• Primary malfunction symptom : (At low temperature)
Faulty starting, increase in white smoke
• Detected item : Glow relay actuation circuit +B short
■ Glow relay actuation command is being performed
■ During a wiring harness battery short
• System action :
■ None
P0380 : Glow relay actuation circuit ground short
• Primary malfunction symptom : (At low temperature)
Faulty starting, increase in white smoke
• Detected item : Glow relay actuation circuit open circuit, ground short
■ When there is no glow relay actuation command
■ During a wiring harness open circuit, ground short
• System action :
■ None

6-189
(1) OFF (5) Terminal +B (a) Key Switch A : To Main Glow Relay
(2) ACC (6) Terminal MAHR (b) Fuse
(3) ON (7) Terminal IG-SW (c) Glow Relay
(4) START (8) Terminal GRLY
1. Check the GLRY signal

1. Run the engine until the coolant temperature is 10 °C (50 °F) or
higher.
2. Check the "Glow relay" data with the data monitor.
Factory spec. OFF
3. After disconnecting the connector (2) of coolant temperature
sensor and connect the dummy resistor (1) as shown in the left
figure, and turn the key switch ON.
Dummy Resistor : 15 to 25 kΩ [Comparable to Approx. -30 to -20
°C (Approx. -22 to -5 °F)]
4. Check the "Glow relay" data with the data monitor.
Factory spec. ON
OK Normal.
(1) Dummy Resistor (a) Coolant Temperature Sensor
(2) Connector
NG

6-190
2. Check the wiring harness / connector

1. Remove the connector from the ECU side and check the state of
the continuity between terminal 107 and (3).
2. Next, check the state of the continuity between terminal 37 and
(4).
Factory spec. Both have continuity
3. Check the connector for poor connection, engagement and
contact.
Factory spec. No poor connection, engagement or contact

(1) Terminal +B (a) Glow Relay
(2) Terminal MAHR A : To Main Glow Relay
(3) Terminal IG-SW
(4) Terminal GRLY
OK
3. Check the relay

1. After disconnecting the connector (6) of coolant temperature
sensor and connect the dummy resistor (5) as shown in the left
figure, and turn the key switch ON.
Dummy Resistor : 15 to 25 kΩ [Comparable to Approx. -30 to -20
°C (Approx. -22 to -5 °F) ]
2. Measure the voltage between (3) and (4).
When relay is ON : Battery voltage value
Factory spec.
When relay is OFF : Approx. 0 V
3. Check the state of the continuity between (1) and (2).
When relay is ON : Continuity
Factory spec.
When relay is OFF : No continuity
4. Measure the resistance in the relay unit (between (3) and (4)).
Factory spec. 50 to 200 Ω between (3) and (4)
NG Relay fault → Replace.

(1) Terminal +B (a) Glow Relay
(2) Terminal MAHR (b) Coolant Temperature Sensor
(3) Terminal IG-SW
(4) Terminal GRLY
(5) Dummy Resistor
(6) Connector
OK

6-191
4. ECU replacement check

1. Replace the ECU and perform the previous "Check the GLRY
signal".
OK ECU fault → Replace.
(a) CAN2 Connector

6-192
EDITOR:
KUBOTA FARM & INDUSTRIAL MACHINERY SERVICE, LTD.
64, ISHIZU-KITAMACHI, SAKAI-KU, SAKAI-CITY, OSAKA, 590-0823, JAPAN
PHONE : (81)72-241-1129
FAX : (81)72-245-2484
E-mail : [email protected]
KUBOTA Corporation Printed in Japan 2008. 04, S, EI, EI, e Code No.9Y110-00400

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DIAGNOSIS MANUAL

COMMON RAIL SYSTEM

KiSC issued 04, 2008 A

■ NOTE : Gives helpful information.

BEFORE SERVICING AND REPAIRING

KiSC issued 04, 2008 A

KiSC issued 04, 2008 A

VENTILATE WORK AREA

PREVENT ACID BURNS

DISPOSE OF FLUIDS PROPERLY

KiSC issued 04, 2008 A

PREPARE FOR EMERGENCIES

KiSC issued 04, 2008 A

KiSC issued 04, 2008 A

1. OVERALL DIAGNOSTIC PROCEDURE ........................................................ 1-1

KiSC issued 04, 2008 A

1. OVERALL DIAGNOSTIC PROCEDURE

KiSC issued 04, 2008 A

●What? Malfunction symptom

KiSC issued 04, 2008 A

KiSC issued 04, 2008 A

KiSC issued 04, 2008 A

3. ACTIONS FOR NON-REOCCURRING MALFUNCTIONS

Insert the male terminal that

KiSC issued 04, 2008 A

KiSC issued 04, 2008 A

KiSC issued 04, 2008 A

1. AIR INTAKE SYSTEM INSPECTION PROCEDURE.................................... 2-1

KiSC issued 04, 2008 A

1. AIR INTAKE SYSTEM INSPECTION PROCEDURE

KiSC issued 04, 2008 A

2. Check the suction path

KiSC issued 04, 2008 A

2. FUEL SYSTEM INSPECTION PROCEDURE

KiSC issued 04, 2008 A

4. Check the water separator

KiSC issued 04, 2008 A

5. Check the fuel pump

6. Fuel filter clogged

7. Engine oil level increase (engine internal leak)

KiSC issued 04, 2008 A

KiSC issued 04, 2008 A

3. ELECTRIC SYSTEM INSPECTION PROCEDURE

(2) Open Circuit Check

KiSC issued 04, 2008 A

Check for continuity

Factory spec. Less than 1 Ω

KiSC issued 04, 2008 A

(3) Short Circuit Check

Ground continuity check

Factory spec. No continuity

KiSC issued 04, 2008 A

[2] CONNECTOR CONNECTION FAULT VERIFICATION METHOD

KiSC issued 04, 2008 A

(1) OFF (4) START (7) Terminal 3 (a) Key Switch

KiSC issued 04, 2008 A

1. Measure the ECU +B and ground voltage

+B terminal ; greater than or equal to 10 V

Ground terminal unsatisfactory