DI−4

DIAGNOSTICS − ENGINE
DI8NM−02

PRE−CHECK
1. DIAGNOSIS SYSTEM
(a) Description
S When troubleshooting Multiplex OBD (M−OBD) ve-
hicles, the only difference from the usual trouble-
shooting procedure is that you need to connect the
vehicle to the hand−held tester, and read off various
data output from the vehicle’s engine ECU.
FI2547
S The vehicle’s on−board computer lights up the
check engine warning light on the instrument panel
when the computer detects a malfunction in the
computer itself or in the drive system components.
In addition to the check engine warning light lighting
up when a malfunction is detected, the applicable
diagnostic trouble codes are recorded in the engine
ECU memory (See page DI−13).
If the malfunction has been repaired, the check engine warning
light goes off automatically, but the diagnostic trouble codes re-
main recorded in the engine ECU memory.

S To check the diagnostic trouble codes, connect the

Hand−Held Tester hand−held tester to the Data Link Connector 3
(DLC3) on the vehicle or read the number of blinks
of the check engine warning light when the TC and
CG terminals on the DLC3 are connected. The
hand−held tester also enables you to erase the
diagnostic trouble codes and activate the several
actuators and check freeze frame date and various
A18119 forms of engine data (For operating instructions,
see the hand−held tester instruction book.).
S The diagnosis system operates in the normal mode
during a normal vehicle use. It also has a check
(test) mode for technicians to simulate the malfunc-
tion symptoms and make a troubleshooting. Some
diagnostic trouble codes use 2 trip detection logic*
to prevent an erroneous detection and ensure thor-
ough the malfunction detection. By switching the
engine ECU to the check (test) mode using hand−
held tester when troubleshooting, a technician can
cause the check engine warning light to light up for
a malfunction that is only detected once or momen-
tarily (hand−held tester only) (See page DI−13).
S *2 trip detection logic:
When a logic malfunction is first detected, the mal-
function is temporarily stored in the engine ECU
memory.

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DIAGNOSTICS − ENGINE

If the same malfunction is detected again during the second

drive test, this second detection causes the check engine warn-
ing light to light up. The 2 trip repeats the same mode twice.
(However, the ignition switch must be turned OFF between the
1st trip and 2nd trip).
S Freeze frame data:
Freeze frame data records the engine condition
(fuel system, calculator load, engine coolant tem-
perature, fuel trim, engine speed, vehicle speed,
etc.) When troubleshooting, it is useful for determin-
ing whether the vehicle was running or stopped, the
engine was warmed up or not, the air−fuel ratio was
lean or rich, etc. at the time of the malfunction.

(b) Check the DLC3.

The vehicle’s engine ECU uses ISO 14230 for commu-
nication. The terminal arrangement of the DLC3 complies
1 2 34 5 6 78 with SAE J1962 and matches the ISO 14230 format.
9 10 111213141516

DLC3

A04550

Terminal No. Connection/Voltage or Resistance Condition

7 Bus+ Line/Pulse generation During transmission
4 Chassis Ground − Body Ground/1 W or less Always
16 Battery Positive − Body Ground/9 − 14 V Always

HINT:
If the display shows UNABLE TO CONNECT TO VEHICLE
when you have connected the cable of the hand−held tester to
the DLC3, turned the ignition switch ON and operated the
hand−held tester, there is a problem on the vehicle side or tool
side.
S If the communication is normal when the tool is connected
to another vehicle, inspect the DLC3 on the original ve-
hicle.
S If the communication is still impossible when the tool is
connected to another vehicle, the problem is probably in
the tool itself, so consult the Service Department listed in
the tool’s instruction manual.

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DIAGNOSTICS − ENGINE

2. INSPECT DIAGNOSIS (Normal Mode)

(a) Check the check engine warning light.
(1) The check engine warning light comes on when the
ignition switch is turned ON and the engine is not
running.
HINT:
If the check engine warning light does not light up, troubleshoot
the combination meter.
FI2547 (2) When the engine is started, the check engine warn-
ing light should go off. If the light remains on, the
diagnosis system has detected a malfunction or ab-
normality in the system.
(b) When using hand−held tester:
Check the DTC.
NOTICE:
When the diagnosis system is switched from the normal
mode to the check (test) mode, all the DTCs and freeze
frame data recorded in normal mode will be erased. So be-
fore switching modes, always check the DTCs and freeze
frame data, and note them down.
(1) Connect the hand−held tester to the DLC3.
(2) Turn the ignition switch ON and switch the hand−
held tester main switch ON.
(3) Check the DTCs and freeze frame data, and then
note them down (for operating instructions, see the
hand−held tester ’s instruction book.).
(4) Confirm the details of the DTCs.

(c) When not using hand−held tester:

CG Check the DTC.
(1) Turn the ignition switch ON.
1 2 34 5 6 7 8 (2) Using SST, connect terminals 13 (TC) and 4 (CG)
9 10 111213141516
of the DLC3.
SST 09843−18040
DLC3 TC

A04550

(3) Read the diagnostic trouble code from the check

Normal
0.25 sec. engine warning light.
HINT:
ON ON ON ON S If a diagnostic trouble code is not output, check the DLC3
circuit (See page DI−92).
OFF OFF OFF

0.25 sec.
FI0294

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DIAGNOSTICS − ENGINE

0.5 sec. 1.5 sec. S As an example, the blinking patterns for codes; normal,
12 and 31 are as shown in the illustration.
4.5 sec. 4.5 sec.
(4) Check the details of the malfunction using the DTC
2.5 chart on page DI−13.
ON sec. (5) After completing the check, disconnect terminals
OFF
0.5 sec. TC and CG and turn off the display.
Repeat
HINT:
One Cycle If 2 or more malfunction codes are output simultaneously, in-
Start dication will begin from the smaller numbered code and contin-
BR3589

ue in order to the larger numbered code.

NOTICE:
When simulating symptoms without a hand−held tester to
check the DTCs, use the normal mode. For code on the
DTCs chart subject to ”2 trip detection logic”, turn the igni-
tion switch OFF after the symptom is simulated one. Then
repeat the simulation process again. When the problem
has been simulated twice, the check engine warning light
lights up and the DTCs are recorded in the engine ECU.
3. INSPECT DIAGNOSIS (Check (Test) Mode)
HINT:
Hand−held tester only:
Compared to the normal mode, the check mode has an in-
creased sensitivity to detect malfunctions.
Furthermore, the same diagnostic items which are detected in
the normal mode can also be detected in the check (test) mode.
(a) Check the DTC.
(1) Initial conditions.
S Battery positive voltage 11 V or more
S Throttle valve fully closed
S Transmission in neutral position
S Air conditioning switch is OFF
(2) Turn the ignition switch OFF.
(3) Connect the hand−held tester to the DLC3.
(4) Turn the ignition switch ON and push the hand−held
tester main switch ON

(5) Switch the hand−held tester from the normal mode

Flashing to the check (test) mode. (Check that the check en-
gine warning light flashes.)
ON (6) Start the engine. (The check engine warning light
goes off after the engine is started.)
OFF (7) Sim ulat e t he c ondit ions of t he m alf unct ion de-
scribed by the customer.
NOTICE:
0.13 Sec.
FI3605 Leave the ignition switch ON until you have checked the
DTCs, etc.
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(8) After simulating the malfunction conditions, use the

hand−held tester diagnosis selector to check the
DTCs and freeze frame data, etc.
HINT:
Take care not to turn the ignition switch OFF. Turning the ignition
switch OFF switches the diagnosis system from the check (test)
mode to the normal mode, so all the diagnostic codes, etc. will
be erased.
(9) After checking the DTCs, inspect the applicable cir-
cuit.
(b) Clear the DTC.
The following actions will erase the DTCs and freezed frame data.
(1) Operating the hand−held tester to erase the codes. (See the hand−held tester’s instruction book
for operating instructions.)
(2) Disconnecting the battery terminals or ECD fuse.
NOTICE:
If the hand−held tester switches the engine ECU from the normal mode to the check (test) mode or
vice−versa, or if the ignition switch is turned from ON to ACC or OFF during the check (test) mode,
the DTCs and freeze frame data will be erased.
4. FAIL−SAFE CHART
If any of the following codes is recorded, the ECU enters into the fail−safe mode.
DTC No. Fail−Safe Operation Fail−Safe Deactivation Conditions
12 TCV duty is fixed at 30 % 2 of more TDC signals are detected for 4 engine revolution
SFuel cut
13 STCV duty is fixed at 2 % 2 of more NE signals are detected for 0.5 sec.
SClose diesel throttle valve
SEGR off
SIDL SW ON : Diesel throttle is fixed at idle position
15 IG switch OFF
IDL SW OFF : Diesel throttle valve is fully open
SAccelerator pedal position below 25 %

SFuel cut
18 IG switch OFF or starter ON from OFF
SClose diesel throttle valve

Accelerator pedal closed position SW ON :

Accelerator pedal position is fixed at 0 %
19(1) IG switch OFF
Accelerator pedal closed position SW OFF :
Accelerator pedal position is fixed at 8 %

Accelerator pedal closed position SW ON :

Accelerator pedal position is fixed at 0 %
IG switch OFF
19(2) Accelerator pedal closed position SW OFF :
Accelerator pedal position is fixed at 8 %
Accelerator pedal position below 10 % IG switch OFF
19(3) Accelerator pedal position below 10 % IG switch OFF
19(4) Accelerator pedal position below 10 % IG switch OFF
22 Engine coolant temp. is fixed at 9 ˚C (48 F) Return to normal condition
24 Intake air temp. is fixed at 130 ˚C (266 F) Return to normal condition
35 Intake air pressure is fixed at 101.3 kPa (760 mmHg, 30 in.HG) Return to normal condition
39 Fuel temp. is fixed at 20 ˚C (68 F) Return to normal condition
42 Vehicle speed is fixed at 0 km/h (0 mile) Vehicle speed > 10 km/h (6 mile)

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DIAGNOSTICS − ENGINE

5. CHECK FOR INTERMITTENT PROBLEMS

HINT:
Hand−held tester only:
By putting the vehicle’s engine ECU in the check (test) mode, 1 trip detection logic is possible instead of the
2 trip detection logic and the sensitivity to detect open circuits is increased. This makes it easier to detect
intermittent problems.
(a) Clear the DTC (See step 2).
(b) Set the check (test) mode (See step 3).
(c) Perform a simulation test (See page IN−9).
(d) Check the connector and terminal (See page IN−19).
(e) Handle the connector (See page IN−19).
6. BASIC INSPECTION
When no malfunction code can be confirmed in the DTC check, troubleshoot all the possible circuits to be
considered as a cause of the problems. In many cases, by carrying out the basic engine check shown in the
following flow chart, the location causing the problem can be found quickly and efficiently. Therefore, use
of this check is essential in the engine troubleshooting.

1 Is battery positive voltage 11 V or more when engine is stopped ?

NO Charge or replace battery.

YES

2 Is engine cranked ?

NO Proceed to problem symptoms table (See page

DI−18).

YES

3 Check and clean air filter.

NG Repair or replace.

OK

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4 Check fuel quality.

CHECK:
S Check that only diesel fuel is used
S Check that the fuel does not contain any impurity.

NG Replace fuel.

OK

5 Check engine oil level and quality.

NG Add or replace.

OK

6 Check engine coolant level and quality.

NG Replace coolant.

OK

7 Check injection timing.

CHECK:
Using a mirror, check that the punching line of the injection pump flange and the punching line of the timing
belt case aligned.

NG Adjusting injection timing.

OK

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8 Check idle speed and maximum speed.

OK:
Idle speed: 720 −800 rpm
Maximum speed: 4,770 − 5,030 rpm

NG Replace supply pump.

OK

9 Check DLC3 circuit (See page DI−92).

NG Repair or replace.

OK

10 Check vacuum pump.

CHECK:
Using a vacuum gauge, measure the vacuum of the vacuum
pump.
OK:
Vacuum: 86.7 kPa (650 mmHg, 25.6 in.Hg) or more

B06622 NG Repair or replace.

OK

Proceed to problem symptoms table on page DI−18.

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DIAGNOSTICS − ENGINE

7. REFERENCE VALUE OF ENGINE ECU DATA

Hand−Held Tester NOTICE:
The values given below for ”Normal Condition” are repre-
sentative values, so the vehicle may still be normal even if
its values differ from those listed here. So do not decide
whether a part is faulty or not solely according to the ”Nor-
mal Condition” here.
HINT:
A18119 The Engine ECU data can be monitored by the hand−held tes-
ter.
(a) Connect the hand−held tester to the DLC3.
(b) Monitor the engine ECU data by following the prompts on
the tester screen.
Refer to the hand−held tester operator’s manual for fur-
ther detail.
(c) Reference Value
Item Inspection Condition Normal Condition
Engine at idling *1 10 mm3 or less

INJECTION VOLUME Engine racing at 2,000 rpm *1 13 mm3 or less

Engine racing at 3,000 rpm *1 15 mm3 or less
Engine at idling *1 16 − 18 ˚CA

INJECTION TIMING Engine racing at 2,000 rpm *1 19 − 23 ˚CA

Engine racing at 3,000 rpm *1 24 − 28 ˚CA
ENGINE SPD RPM kept stable (Comparison with tachometer) No great changes
98−101 kPa
Engine at idling *1
(735−758 mmHg, 28.9−29.8 in.Hg)
PIM
Engine racing at 2,000 rpm *1 96 − 101 kPa
Engine racing at 3,000 rpm *1 95 − 100 kPa
COOLANT TEMP Engine at normal operating temp. 75−95 ˚C (185−203 ˚F) *2
INTAKE AIR Engine at normal operating temp. Ambient temp. ~100˚C
FUEL TEMP Engine at normal operating temp. Ambient temp. ~90˚C
Accelerator pedal is fully closed 0−6%

ACCELE POSITION Accelerator pedal is fully opened 80 − 100 %

From closed position to wide open accelerator pedal Gradually increases
VEHICLE SPD During driving (Comparison with speedometer) No large differences
Item Inspection Condition Normal Condition
A/C SIG A/C switch ON ON
IDL SIG Accelerator pedal is full closed ON
STARTER SIG During cranking ON
A/C CUT SIG A/C switch OFF ON
EGR SYSTEM Idling *1 ON
*1: All accessories and A/C are switched OFF, and the engine warmed up
*2: If the water temperature sensor circuit is open or short, the engine ECU.

5L, 5L−E ENGINE SUP (RM890E)