Professional Documents
Culture Documents
F&G-SERIES
ENGINE EMISSION
6HK1-TC (COMMON RAIL)
SECTION 6E
NOTICE
Before using this Workshop Manual to assist you in performing
vehicle service and maintenance operations, it is recommended
that you carefully read and thoroughly understand the
information contained in Section 0A under the headings
GENERAL REPAIR INSTRUCTIONS and HOW TO USE THIS
MANUAL.
SECTION 6E
CONTENTS
SUBJECT
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How To Proceed With Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .
Customer Problem Analysis Check . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symbols And Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts For Electrical Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Construction And Operation of Supply Pump . . . . . . . . . . . . . . . . . . . .
Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Strategy Based Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Service Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
On Board Diagnostic (OBD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reading Diagnostic Trouble Codes Using A Tech 2 or Other Scan Tool
System Parts Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ECM System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location Of Sensor And Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Control Module (ECM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appearance Of ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Detail Of 40 Pins Connector For Engine Harness . . . . . . . . . . . . . . . . .
Detail Of 80 Pins Connector For Engine Harness . . . . . . . . . . . . . . . . .
Chart Of ECM Input/Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector Pin Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents Of Diagnostic Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Lamp Patterns In User Mode . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Code Outputting In Dealer Mode. . . . . . . . . . . . . . . . . . . . .
How To Read Flashing Of The Indicator Lamp . . . . . . . . . . . . . . . . . . .
Clearing Method Of Diagnosis Trouble Code . . . . . . . . . . . . . . . . . . . .
Typical Scan Data Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Data Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Symptom Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Hard Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Cranks But Does Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Hunting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Surging, Hesitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Idle Engine Speed/Engine Starts But Will Not Accelerate . . . . . . . . .
Excessive White Or Blue Smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Excessive Black Smoke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lack Of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tachometer Output Error (Not Available DTC) . . . . . . . . . . . . . . . . . . . . .
Exhaust Brake Error (No DTC Set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PTO (Power Take Off) Error (No DTC Set) . . . . . . . . . . . . . . . . . . . . . . .
Vehicle Speed Sensor Error (No DTC Set) . . . . . . . . . . . . . . . . . . . . . . .
Common Rail System Diagnostic Check. . . . . . . . . . . . . . . . . . . . . . . . . .
OBD System Check Diagnosis Chart . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
..............
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
6E- 3
6E- 3
6E- 4
6E- 5
6E- 7
6E- 9
6E-13
6E-16
6E-16
6E-16
6E-17
6E-18
6E-32
6E-37
6E-42
6E-45
6E-45
6E-45
6E-45
6E-46
6E-46
6E-51
6E-51
6E-51
6E-51
6E-52
6E-53
6E-54
6E-56
6E-59
6E-60
6E-61
6E-62
6E-63
6E-64
6E-65
6E-66
6E-67
6E-68
6E-70
6E-72
6E-74
6E-77
6E-78
6E-81
6E-84
6E-86
6E-88
6E-90
6E-93
6E-95
6E-97
6E-99
6E-101
6E-103
6E-105
6E-107
6E-109
6E-113
6E-113
6E-117
6E-121
6E-125
6E-129
6E-133
6E-135
6E-139
6E-142
6E-145
6E-150
6E-152
6E-153
6E-155
6E-159
6E-163
6E-165
6E-170
6E-175
6E-180
6E-185
6E-190
6E-194
6E-197
6E-200
6E-203
6E-206
6E-211
6E-215
6E-219
6E-221
6E-223
6E-225
6E-227
6E-229
6E-231
6E-234
6E-237
6E-240
6E-243
6E-246
6E-249
6E-251
6E-254
6E-257
6E-258
6E-259
6E-265
6E-265
6E-270
GENERAL DESCRIPTION
HOW TO PROCEED WITH TROUBLESHOOTING
Troubleshoot in accordance with the procedure on the following page.
Title side numbers are titles of pages in this manual with the page number indicated in the bottom portion. See the indicated
pages for detailed explanations.
6E-4
Visual Inspection
6E-16
6E-17
Clear DTC.
6E-18
No DTC
Test Drive
6E-109
Malfunction occurs
DTC Check
6E-113
Malfunction DTC
Normal
Recheck Customer Problem Analysis
DTC Chart
Adjustment, Repair
No Good
Verify Repair
OK
End
6E-59
Inspectors
Name
Model and Model
Year
Customers Name
Date Vehicle
Brought in
Frame No
.
Engine Model
License No.
Odometer Reading
Problem symptoms
Drivers Name
km
miles
Engine does
not Start
Difficult to
Start
Poor Idling
Poor
Driveability
Hesitation
Other
Engine Stall
No initial combustion
High (
No complete combustion
rpm)
Low (
rpm)
Surging
Others
Dates Problem
Occurred
Constant
Other
Condition When
Problem Occurs
Problem Frequency
Sometimes (
times per
day/month)
Weather
Fine
Cloudy
Rainy
Snowly
Outdoor
Temperature
Hot
Warm
Cool
Cold (approx.
Place
Highway
Rough road
Engine Temperature
Cold
Engine Operation
Starting
Just after starting (
Driving
Constant speed
A/C switch ON/OFF
Other
Condition of MIL
Suburbs
Other
Warming up
Inner city
Various/Other
Uphill
After warming up
Once only
F/
C)
Downhill
Any temperature
min.)
Idling
Acceleration
Other
Racing
Deceleration
Remains on
Sometimes light up
Normal Mode
(Precheck)
Normal
Check Mode
Normal
DTC Inspection
Fusible link
Motor
Buzzer
Switch
Ground
Condenser
Resistor
Meter
Consent
Battery
Connected portion
Variable resistance
Coil
Crossed portion
Diode
Zener diode
Relay
F07MT001
MEANING
A
A/C
A/D
ACT
APP
A/T
ANALOG
AIR CONDITIONER
ANALOG/DIGITAL
ACTUATOR
ACCELERATOR PEDAL POSITION
AUTOMATIC TRANSMISSION
BARO
BATT
B+
ATMOSPHERIC PRESSURE
BATTERY
BATTERY (+)
CAM
CKP
CONN
CSS
C/U
D
DC
D/CONN
DLC
DTC
DIGITAL
DIRECT CURRENT
DIAGNOSIS CONNECTOR
DATA LINK CONNECTOR
DIAGNOSTIC TROUBLE CODE
EC
ELECTRICAL CONTROL
GOVERNOR
ENGINE CONTROL MODULE
ENGINE COOLANT TEMPERATURE
ELECTRICAL AND HYDRAULIC
TIMER
EXHAUST
ECM
ECT
EH
EXH
ABBREVIATION
MEANING
OFF
ON
OPT
P/BRAKE
PC SENSOR
PCV
PGND
PIN
P/L
PRESS
P/T
PARKING BRAKE
COMMON RAIL PRESSURE SENSOR
PUMP CONTROL VALVE
POWER GROUND (TO BODY EARTH)
PIN or TERMINAL
PRESSURE LIMITER
PRESSURE
POWER TRAIN
Q ADJUSTMENT
INJECTION QUANTITY
ADJUSTMENT
RH
RHD
R/L
RR
SIG
SLD
STA
STD
SW
SIGNAL
SPEED LIMITER
STARTER
STANDARD
SWITCH
TICS
TWV
FRT
FT
VCC
VS
VSS C/U
POWER SOURCE
VEHICLE SPEED
VEHICLE SPEED SENSOR CONTROL
UNIT (SPEED METER CONTROL UNIT)
GND
W/G
W/L
WASTEGATE
WARNING LAMP
IAT
IN
ISC
LH
LHD
MAG
ME/CONN
MIL
M/V
MAGNETIC
MEMORY ERASER CONNECTOR
MALFUNCTION INDICATOR LAMP
MAGNETIC VALVE
N
N-TDC
NR
FCCB
Wiring
0.5
Wire Color
All wires have color-coded insulation.
Single color
Outside diameter
Base color
Stripe color
Colored stripe
Meaning
Color-coding
Meaning
Black
Br
Brown
White
Lg
Light green
Red
Gr
Gray
Green
Pink
Yellow
Sb
Sky blue
Blue
Violet
Orange
Base color
Stripe color
LB
Blue
Black
OB
Orange
Black
PB
Pink
Black
PG
Pink
Green
PL
Pink
Blue
RY
Red
Yellow
VR
Violet
Red
VW
Violet
White
YB
Yellow
Black
YB
Yellow
Green
YV
Yellow
Violet
Wire Size
The size of wire, used in a circuit is determined by the
amount of current (amperage), the length of the circuit,
and the voltage drop allowed. The following wire size
and load capacity, shown below, are specified by SAE.
Outside diameter
Nominal size
Outside diameter
(mm)
Allowable current
(A)
0.3
0.5
0.85
1.25
2
3
5
8
15
20
0.372
0.563
0.885
1.287
2.091
3.296
5.227
7.952
13.36
20.61
1.8
2.0
2.2
2.5
2.9
3.6
4.4
5.5
7.0
8.2
9
12
16
21
28
37.5
53
67
75
97
SYSTEM CONFIGURATION
1. Fuel System
The high-pressure fuel that is generated by the supply
pump is distributed to the cylinders by way of a common
rail. Then, the electromagnetic valves in the injectors
open and close the nozzle needle valve to control the
starting and ending of the injection of fuel.
Electronic Control
Supply Pump
Common Rail
Injector
LFW36ESH000101
2. Control System
Based on the signals received from various sensors that
are mounted on the enigne and on the vehicle, the ECM
controls the timing of the current and the length of time
that the current is applied to the injectors, thus ensuring
Sensor System
Acceleration Sensor
CKP Sensor
(Crank Position Sensor)
Computer
Injector
(Injection Quantity,
Injection Timing Control)
(Engine RPM)
ECM
CMP Sensor
(Pump Position Sensor)
Actuator
Common Rail
Pressure Sensor
Supply Pump
(Injection Pressure Control)
060M200052
ECM
Charging
Circuit
BARO Sensor
(Inside ECM)
Boost Sensor
Accelerator Pedal
Position Sensor
Fuel Temp.
Sensor
Pressure Limiter
Fuel Leak off Pipe
Common Rail
Pressure Sensor
Starter Signal
Flow Damper
Supply Pump
Air
Cleaner
CKP Sensor
CAM. Sensor
(Pump Position)
Fuel Filter
Fuel Tank
LFW36ELF000601
(Dealer)
TECH 2
Scan Tool
Vehicle Speed
Sensor
Flow Damper
Common Rail
Injector
Supply Pump
Pressure Limiter
Boost Sensor
Water Temperature Sensor
Fuel Temperature Sensor
Pump Position Sensor
Intake Air Temperature
BARO Sensor
Cylinder Recognition
Sensor
(inside ECM)
Sensor
Communication
TECH 2 COMMUNICATION
A/T Control
Engine Vehicle
Injection Quantity
Control
Injection Timimg
Control
Injection Pressure
Control
Fuel
injection
ECM
LFW36EXF000101
TWV
Injection Quantity Control
Engine Load
Common
Rail
Injection
Pressure
Control
CAM Sensor
CKP Sensor
PCV
Outlet Orifice
Inlet
Orifice
Control Chamber
Piston
90 Pulse
/720CR
Nozzle
7 Pulse
/720CR
Needle
Supply Pump
Injector
056MY00002
2. Construction
The supply pump consists of a feed pump, which is
similar to that of the conventional inline pump, and the
PCV
Delivery valve
Plunger
CAM sensor
Tappet
3-lobe cam
Feed pump
040MY00007-1
3. Operation
A The PCV remains open during the plungers
downward stroke, allowing the low-pressure fuel to
be drawn into the plunger chamber by way of the
PCV
B Even after the plunger begins its upward stroke, if
the valve remains open because current is not
applied to the PCV, the fuel that was drawn in returns
via the PCV, without becoming pressurized.
C When current is applied to the PCV in order to close
the valve at the timing that accommodates the
required discharge volume, the return passage
closes, causing the pressure in the plunger chamber
to rise.
Accordingly, the fuel passe through the delivery
valve (check valve) to the common rail. As a result,
Suction process
Delivery process
Discharge
d2(H-h)
volume Q=
4
H
h
Cam lift
Pre-stroke
PCV
operation
Valve
closed
Valve open
Increasing
discharge volume
Reducing discharge volume
Pump operation
PCV
Discharging required
discharge volume
Return
Common rail
Delivery valve
Plunger
d
A
A'
040MY00008
Meter
Other C/U
Engine
ECM
VSS C/U
Ve h i c l e S p e e d S e n s o r
(VSS)
LFW36ESF000401
Diagnosis
Strategy-Based Diagnostics
Strategy-Based Diagnostics
The strategy-based diagnostic is a uniform approach to
repair all Electrical/Electronic (E/E) systems. The diagnostic
flow can always be used to resolve an E/E system problem
and is a starting point when repairs are necessary. The
following steps will instruct the technician how to proceed
with a diagnosis:
1. Verify the customer complaint.
To verify the customer complaint, the technician
should know the normal operation of the system.
2. Perform preliminary checks.
Conduct a thorough visual inspection.
Review the service history.
Detect unusual sounds or odors.
Gather diagnostic trouble code information to
achieve an effective repair.
3. Check bulletins and other service information.
This includes videos, newsletters, etc.
4. Refer to service information (manual) system check(s).
System checks contain information on a system
that may not be supported by one or more DTCs.
System checks verify proper operation of the
system. This will lead the technician in an organized
approach to diagnostics.
5. Refer to service diagnostics.
DTC Stored
Follow the designated DTC chart exactly to make an
effective repair.
No DTC
Select the symptom from the symptom tables. Follow the
diagnostic paths or suggestions to complete the repair. You
may refer to the applicable component/system check in the
system checks.
No Matching Symptom
1. Analyze the complaint.
2. Develop a plan for diagnostics.
3. Utilize the wiring diagrams and the theory of operation.
Call technical assistance for similar cases where repair
history may be available. Combine technician knowledge with
efficient use of the available service information.
Intermittents
Conditions that are not always present are called
intermittents. To resolve intermittents, perform the following
steps:
1. Observe history DTCs, DTC modes.
2. Evaluate the symptoms and the conditions described by
the customer.
3. Use a check sheet or other method to identify the circuit
or electrical system component.
4. Follow the suggestions for intermittent diagnosis found
in the service documentation.
Most scan tool, such as the Tech II have data-capturing
capabilities that can assist in detecting intermittents.
No Trouble Found
This condition exists when the vehicle is found to operate
normally. The condition described by the customer may be
normal. Verify the customer complaint against another
vehicle that is operating normally. The condition may be
intermittent. Verify the complaint under the conditions
described by the customer before releasing the vehicle.
1. Re-examine the complaint
When the Complaint cannot be successfully found or
isolated, a re-evaluation is necessary. The complaint
should be re-verified and could be intermittent as
defined in Intermittents, or could be normal.
2. Repair and verify.
After isolating the cause, the repairs should be made.
Validate for proper operation and verify that the
symptom has been corrected. This may involve road
testing or other methods to verify that the complaint has
been resolved under the following conditions:
Conditions noted by the customer.
Maintenance Schedule
Refer to the Maintenance Schedule.
Warm-Up Cycle
A warm-up cycle means that engine at temperature must
reach a minimum of 70C (160F) and rise at least 22C
(40F) over the course of a trip.
Diagnostic Information
The diagnostic charts and functional checks are designed
to locate a faulty circuit or component through a process of
logical decisions. The charts are prepared with the
requirement that the vehicle functioned correctly at the time
of assembly and that there are not multiple faults present.
There is a continuous self-diagnosis on certain control
functions. This diagnostic capability is complemented by the
diagnostic procedures contained in this manual. The
language of communicating the source of the malfunction is a
system of diagnostic trouble codes. When a malfunction is
detected by the control module, a diagnostic trouble code is
set and the Malfunction Indicator Lamp (MIL) is illuminated.
Enable Criteria
The term enable criteria is engineering language for the
conditions necessary for a given diagnostic test to run. Each
diagnostic has a specific list of conditions which must be met
before the diagnostic will run. Enable criteria is another way
of saying conditions required.
LFW36ESH000301
Legend
(1) Dianostic Switch (White)
(2) Memory Clear Switch (Blue)
(3) Data Link Connector (DLC)
1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
LFW36ESH000201
Decimal/Binary/Hexadecimal Conversions
All scan tool manufacturer will display a variety of vehicle
information which will aid in repairing the vehicle. Some scan
tools will display encoded messages which will aid in
determining the nature of the concern. The method of
encoding involves the use of a two additional numbering
systems: Binary and Hexadecimal.
The binary number system has a base of two numbers.
Each digit is either a 0 or a 1. A binary number is an eight digit
number and is read from right to left. Each digit has a position
number with the farthest right being the 0 position and the
farthest left being the 7 position. The 0 position, when
displayed by a 1, indicates 1 in decimal. Each position to the
left is double the previous position and added to any other
position values marked as a 1.
A hexadecimal system is composed of 16 different alpha
numeric characters. The alpha numeric characters used are
numbers 0 through 9 and letters A through F. The
hexadecimal system is the most natural and common
approach for scan tool manufacturers to display data
represented by binary numbers and digital code.
2
060M200030
Legend
(1) Dianostic Switch (White)
(2) Memory Clear Switch (Blue)
(3) Data Link Connector (DLC)
9
2
CH
TE
R
TE
AP
AD
6
8
1
7
8
9
1
W
PS
4
5
6
LFW36ELF001001
Legend
(1) PCMCIA Card
(2) Tech2
(3) DLC Cable
(4) Tech2 Adapter
Tech 2 Features
1 Tech 2 is a 12 volt system. Do not apply 24 volt.
2. After connecting and/or installing, the Vehicle
Communications Interface (VCI) module, PCMCIA card
and DLC connector to the Tech 2, connect the tool to the
vehicle DLC.
3. Make sure the Tech 2 is powered OFF when removing or
installing the PCMCIA card.
4. The PCMCIA card has a capacity of 10 Megabytes
which is 10 times greater than the memory of the Tech 1
Mass Storage Cartridge.
5. The Tech 2 has the capability of two snapshots.
6. The PCMCIA card is sensitive to magnetism and static
electricity, so care should be taken in the handling of the
card.
(5)
(6)
(7)
(8)
(9)
060RW009
2
LFW36ESH000301
Legend
(1) Dianostic Switch (White)
(2) Memory Clear Switch (Blue)
(3) Data Link Connector (DLC)
(ENTER)
F0 : Diagnostics
F1 : Service Programming
F2 : View Capture Data
2
CH
TE
F3 : Tool Options
R
TE
AP
AD
6
F4 : Getting Started
(F0)
7
8
9
1
W
PS
Vehicle Identification
Select one of the following
Model Year(S)
1
2
LFW36ELH000101-1
Vehicle Identification
F0: Diagnostic Trouble Codes
(UE) Rodeo/Amigo,Wizard/MU
(C*,E*,L*,F*) Heavy,MediumDuty
Heavy,MediumDuty
ENTER
F3: Programming
F0: Upload Fuel Delivery Rate Data
F1: Download Fuel Delivery Rate Data
F4: Special Functions
F0: Engine Output Controls
F0 : Engine
F1 : Transmission
F2 : Chassis
F3 : Body
(F0 ENTER)
Vehicle Identification
Select one of the following
Powertrain
(IE) 6HK1 (Common-rail)
LFW36ELH000201
Special Functions
Special Functions
F0 : Engine Output Controls
F1 : Fuel System
Engine
This selection will display all DTCs that have failed during
the present ignition cycle.
History
This selection will display only DTCs that are stored in the
ECMs history memory. It will not display Type B DTCs that
have not requested the MIL. It will display all type A DTCs that
have requested the MIL and have failed within the last 40
warm-up cycles.
LFW36ESH000401
Special Functions
F0 : Engine Output Controls
F1 : Fuel System
(For example)
Data Display
System Voltage
V
Vehicle Speed
km/h
Desired Idle Speed
RPM
Engine Speed
RPM
APP (Accelerator Pedal Position) Sensor V
APP (Accelerator Pedal Position) Angle %
APP Sensor Learned Minimum
V
Final Accelerator Opening
%
Select
Items
Quick
Snapshot
LFW36ESH000601
More
LFW36ESH000801
Special Functions
F0 : Engine Output Controls
F1 : Fuel System
LFW36ESH000501
LFW36ESH000701
Fuel System
F0 : Cylinder Power Balance
Quit
Active
F1 : RPM Control
F2 : Pilot Injector Stop
F3 : Fuel Pressure Control
LFW36ESH000901
F4 : Injection Timing
F5 : Injection Stop
060MX010
Special Functions
Special Functions
F1 : Fuel System
F1 : Fuel System
LFW36ESH000701
4.
LFW36ESH000701
Fuel System
Fuel System
F1 : RPM Control
F1 : RPM Control
F4 : Injection Timing
F4 : Injection Timing
F5 : Injection Stop
F5 : Injection Stop
060MX020
060MX019
Special Functions
Off
LFW36ESH001001
Fuel System
F0 : Cylinder Power Balance
Special Functions
F1 : RPM Control
F2 : Pilot Injector Stop
F1 : Fuel System
F4 : Injection Timing
F5 : Injection Stop
060MX018
LFW36ESH000701
Fuel System
Injection Timing
Tech 2 must be used for this test.
Test Procedure:
1. Connect Tech 2 to the vehicle DLC.
2. Run the Engine at idle.
3. Select F1: Fuel System in the Application Menu.
F4 : Injection Timing
F1 : Fuel System
F5 : Injection Stop
060MX017
LFW36ESH000701
4.
System Voltage
V
Vehicle Speed
km/h
Desired Idle Speed
RPM
Engine Speed
RPM
APP (Accelerator Pedal Position) Sensor V
APP (Accelerator Pedal Position) Angle %
APP Sensor Learned Minimum
V
Final Accelerator Opening
%
Fuel System
F0 : Cylinder Power Balance
F1 : RPM Control
F2 : Pilot Injector Stop
F3 : Fuel Pressure Control
Quit
F4 : Injection Timing
Decrease Increase
F5 : Injection Stop
LFW36ESH001101
Injection Timing
Fuel System
System Voltage
V
Vehicle Speed
km/h
Desired Idle Speed
RPM
Engine Speed
RPM
APP (Accelerator Pedal Position) Sensor V
APP (Accelerator Pedal Position) Angle %
APP Sensor Learned Minimum
V
Final Accelerator Opening
%
Quit
Decrease Increase
LFW36ESH001401
060MX015
Injection Stop
Injector Stop
System Voltage
V
Vehicle Speed
km/h
Desired Idle Speed
RPM
Engine Speed
RPM
APP (Accelerator Pedal Position) Sensor V
APP (Accelerator Pedal Position) Angle %
APP Sensor Learned Minimum
V
Final Accelerator Opening
%
Special Functions
F0 : Engine Output Controls
F1 : Fuel System
Quit
Off
LFW36ESH001301
Programming
IMPORTANT; The replacement ECM must be stored the
capture fuel rate data by Tech 2.
LFW36ESH000701
key.
Programming
Upload successful!
Confirm
LFW36ESH001901
LFW36ESH001701
14.
15.
16.
17.
18.
19.
20.
Programming
F0 : Upload Fuel Delivery Rate Data
F1 : Download Fuel Delivery Rate Data
No
Yes
LFW36ESH001801
LFW36ESH002001
Snapshot Plot
Do you really want to download data?
No
Yes
ECT
Desired Idle Speed
Engine Speed
LFW36ESH002101
Download successful!
Confirm
LFW36ESH002201
If CONTINUE is displayed
under screen after the screen
is changed, select.
060RX085
060RX040
056MV042
Feed Pump
040MX003
Legend
(1) From fuel tank
(2) To fuel filter
4
040MX002
Common Rail
Flow Damper
The flow damper comprises a piston, ball, spring seat, and
spring.
The flow damper is used to damp the pressure pulsating in
the common rail and the injection pipe.
During driving the flow of fuel makes the piston, ball, and
spring seat move a little to the injector side and float.
Should too much fuel pass the flow damper, the ball
moves further toward the injector until the ball comes into
contact with the seat surface of the flow damper unit, thereby
shutting the fuel passages.
040MV049
056MV043
060MX057
Injector
6
5
2
3
7
1
040MV051
060MX044
Legend
(1) Injector gasket
(2) Injector assembly
(3) Injector clamp
(4) Clamp bolt
(5) Fuel return pipe
(6) Eye bolt
(7) Injector sleeve
040MV037
056MV045
101MX00016
056MV044
BARO Sensor
LFW36ESH001201
060MX122
060MX046
060MX123
R/L;
STARTER
KEY SW
B1 S G M1M2 B2 P2 P1
OFF
ACC
ON
HEAT
START
STARTER
M/T
BR LE
A/T
GENERATOR
SW;SUB
STARTER
R/L;
NEUTRAL
BATTERY
SW;
NEUTRAL
R/L;
PCV
R/L;
MAIN
PCV1
+BP
91
MAIN PCV1
R/L
101 118 109
22
PCV2
PCV2
21 32
START
COM COM COM COM INJ INJ INJ INJ INJ INJ
1
2
3
4
5
6
2
2
1
1
13 120 119 110 100 90
89
88
87
86
85
24
KEY
31 23
Engi ne C o n t ro l Mo d u l e ( E C M)
LFW36ELF000201
10 9
20 19 18 17 16 15 14 13 12 11
Data Link
Connector
TACHO
METER
SW;
SW;
DIAGNOSIS MEMORY
CLEAR
P-GND P-GND
112
BARO
114
113
81
82
102
59
25
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36ELF000101
A/T
ST
ON
KEY SW
M/T
SW;
SUB
STARTER
R/L;
EXH
BRAKE
SW;EXH.
BRAKE
R/L;
NEUTRAL
R/L;
STOP LAMP
METER
SW;IDLE
CONT
(AUTO/
MNL)
SW;
NEUTRAL
SW;IDLE
CONT
(UP/
DOWN)
SW;
BRAKE
EXH
BRAKE
LAMP
STOP
LAMP
UP DOWN
M/V:
EXH.
BRAKE
R/L;
STARTER
27
10
29
33
26
Engi ne C o n t ro l Mo d u l e ( E C M)
LFW36ELF000301
INTAKE
AIR
TEMP
SENSOR
SIG
53
PTO
ENGINE ACCELEFUEL
COOLANT RATOR
TEMP
TEMP POSITION BOOST
SENSOR SENSOR SENSOR SENSOR
SIG
52
30
64
56
SIG
72 61
COMMON RAIL
PRESSURE
SENSOR
GND VCC
55
73
CAM
CKP
SENSOR
SENSOR
(PUMP
(CRANK
POSITION) POSITION)
SIG
71 62
+
77 58 49
+
76 57 48
ACCELERATOR
PEDAL
POSITION
SENSOR
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36ELF000401
M/T
VEHICLE
SPEED SENSOR
(VSS)
R/L;
PTO
(CLUTCH)
PARKING
BRAKE
LAMP
DIAG
LAMP
(MIL)
R/L;A/T
ECU
VCC SIG GND
R/L;
PTO
(MAIN)
VSS
CONTROL UNIT
SW;
PARKING
BRAKE
SW;
CLUTCH
A/T
ECU
SW;
PTO
PTO LAMP
M/V;PTO
SIG
75
(A/T ONLY)
105
19
16
108
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36ELF000501
Flow Damper
Pressure Limiter
Common Rail Pressure Sensor
CAM sensor
(Pump Position Sensor)
ECT
53751E
01/05/07
060M200028-1
INJECTOR
CKP Sensor
Boost Sensor
Pressure hose
LFW36EMF000701
INJECTOR
Boost Sensor
CKP Sensor
Front
Pressure hose
2
LFW36ESH000301
Legend
(1) Dianostic Switch (White)
(2) Memory Clear Switch (Blue)
(3) Data Link Connector (DLC)
90
81
100
50
91
110
41
60
101
120
10
51
70
111
20
61
80
11
30
71
21
40
31
LFW36EMF000901
0.5
B
0.5
LY
0.5
RL
13
1.25
VW
21
21
22
23
24
31
32
0.5
RG
10
0.5
L
0.5
PG
16
25
26
0.5 0.5
LoB G
20
19
0.5
Lg
0.5
LB
27
29
0.5
P
0.5
PB
30
0.5
YB
33
40
LFW36ESH000101
81
41
44
0.5
Y
45
53
61
62
0.5
R
63
71
0.5
G
72
0.5
W
48
0.5
R
0.5
Gy
0.5
R
56
0.5
B
81
49
0.5
W
55
0.5
R
60
57
58
59
0.5
B
0.5
G
1.25
B
82
85
1.25 1.25
B
B
86
1.25 1.25
LR
LW
87
88
89
90
91
101
100
1.25
RW
1.25
RL
66
101
102
105
108
109
110
0.5
LB
1.25
RW
1.25
B
0.5
BrW
0.5
LW
0.5
Y
1.25
RY
64
0.5
W
0.5
R
54
0.5
LW
0.5
LR
61
46
0.5
0.5
GyG Gy
0.5
L
52
73
75
0.5
W
0.5
PL
80
76
/
S
77
/
S
111
112 113
1.25 0.5
B
RB
0.5
WR
114
118
119
0.5
LR
0.5
Y
1.25 1.25
RL
RL
120
120
LFW36ESF000301
89
88 87
98
97
86
96
85
95
84
94
83
93
92
82
81
50
91
60
110 109 108 107 106 105 104 103 102 101
70
80
120 119 118 117 116 115 114 113 112 111
49
59
48
58
69
79
68
78
47
57
46
56
67
77
45
55
66
76
44
54
65
75
53
64
74
43
52
63
73
72
42
41
51
62
10
20
61
71
8
18
19
30
40
29
39
7
17
28
38
37
6
16
27
26
36
5
15
4
14
25
35
3
13
24
34
2
12
23
33
32
1
11
22
21
31
LFW36ESF000201
40 pin
connector
Connector
Pin
number
Transmission Switch
Clutch Switch
10
Idling Up Switch
11
12
13
Key Switch
14
15
16
PTO Switch
17
18
19
20
21
22
23
Key Switch
24
Starter Switch
25
Diagnosis Switch
26
Brake Switch
27
28
29
30
31
32
40 pin
connector
80 pin
connector
Connector
Pin
number
33
Neutral Switch
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
Case Ground
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
80 pin
connector
Connector
Pin
number
75
76
77
78
79
80
81
Power Ground
82
Power Ground
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
Common 1
101
102
ECM Ground
103
104
105
Diagnostic Lamp
106
107
108
109
Main Relay
110
Common 1
111
ECM Ground
112
Tachometer Output
113
114
115
116
80 pin
connector
Connector
Pin
number
117
118
Main Relay
119
Common 2
120
Common 2
Operation:
When the diagnosis switch (White) mentioned below is
connected, the indicator lamp will start flashing. The selfdiagnosis code can be read from the flashing of the indicator
lamp.
As to the method to read the self-diagnosis code, please
refer to the How to Read the flashing of the indicator lamp as
mentioned later.
2
LFW36ESH000301
Legend
(1) Dianostic Switch (White)
(2) Memory Clear Switch (Blue)
(3) Data Link Connector (DLC)
Diagnostic Indication
Contents of diagnostic indication
In accordance with the conditions of Diagnostic switch, the diagnostic lamp indications are changed over as follows:
Control mode
User Mode
ON
Condition
Dealer Mode 1
Dealer Mode 2
Mode changeover between User mode, Dealer mode 1 and Dealer mode 2 is made immediately.
Mode changeover between Dealer mode 1 and Dealer mode 2 is made after a round of DTC output.
Priority of indications
Lamp control by user mode, Dealer mode 1 and 2 > Lamp check control.
Figure of 100
0.3
0.6
Figure of 10
1.2
0.6
Figure of 1
0.3
0.6
Code intervals
2.4
056MV024
Note: Tolerance of difference between light on and light out time is +0.3 to 0.1.
056MV025
1.2
0.6
1.2
2.4
ON
OFF
Figure of ten
Figure of one
F06MV045
1.2
2.4
ON
OFF
Figure of hundred
1.2
2.4
1.2
2.4
ON
OFF
Figure of ten
Figure of one
F06MV047
Condition 2
056MV028
Condition 1:
Check the memory clear switch (Blue) OFF
2
LFW36ESH000301
Legend
(1) Dianostic Switch (White)
(2) Memory Clear Switch (Blue)
(3) Data Link Connector (DLC)
Condition 2:
EEPROM data does not match its mirror data.
Data List
Units Displayed
System Voltage
Engine
27.5 ~ 28.5
Vehicle Speed
Engine
km/h
Engine
RPM
630 15 (1)
Engine Speed
Engine
RPM
630 15 (1)
Engine
0.85 ~ 1.15
Engine
Engine
0.85 ~ 1.15
Engine
Engine
Actual ATM 5
Engine
Less than 90
Fuel Temperature
Engine
36 ~ 43
Engine
kPa
98 ~ 92
Engine
kPa
2 ~ 2
Engine
MPa
25 ~ 26
Engine
MPa
25 ~ 26
Engine
mm3
5.5 ~ 1
Engine
mm3
1.4 ~ 2
Engine
mm3
5 ~ 5
Engine
mm3
5 ~ 5
Engine
mm3
5 ~ 5
Engine
mm3
5 ~ 5
Engine
mm3
5 ~ 5
Engine
mm3
5 ~ 5
Engine
CA
3 ~ 2
Engine
CA
3.5 ~ 2.5
Engine
CA
120 ~ 180
Engine
CA
14 ~ 11
Engine
0~2
Engine
0.3 ~ 0.5
Starter Switch
Engine
On/Off
Off
Key Switch
Engine
On/Off
On
Clutch Switch
Engine
On/Off
On
Neutral Switch
Engine
On/Off
On
Brake 2 Switch
Engine
On/Off
Off
Parking Switch
Engine
On/Off
On
Units Displayed
Engine
Manual/Auto
Manual (Short)
Idle Up Switch
Engine
On/Off
Off
Engine
On/Off
Off
SLD Enable
Engine
On/Off
Off
PTO Enable
Engine
On/Off
Off
PTO Switch
Engine
On/Off
Off
Engine
On/Off
Off
Diagnostic Switch
Engine
On/Off
Off
Engine
On/Off
Off
AT Relay
Engine
On/Off
Off
Transmission Switch
Engine
On/Off
Off
Engine
Active/Inactive
Inactive
Flow Damper 1
Engine
Flow Damper 2
Engine
Flow Damper 3
Engine
Flow Damper 4
Engine
Flow Damper 5
Engine
Flow Damper 6
Engine
Engine
11
Engine
Engine
Engine
Yes/No
Yes
Engine
Yes/No
Yes
Engine
Engine
Engine
CA
3.5
Engine
NOTE:
(1) Make sure the desired idle speed and actual idle speed in the data list on the Tech2.
When the engine is at idle, the desired idle speed is applied lower creation by ECM, the result is displayed 615 rpm.
When the actual idle speed is displayed about 614 rpm, the result is normal at idle.
Definitions
System Voltage
This represents the system voltage measure by the ECM at ignition feed.
Vehicle Speed
Vehicle speed is computed by the ECM from the Vehicle speed sensor.
The desired idle speed that the ECM is commanding. The ECM will compensate
for various engine loads based on engine coolant temperature, to keep the engine
at the desired speed.
Engine Speed
Engine speed is computed by the ECM from the CKP sensor. It should remain
closed to desired idle under various engine loads with engine idling.
The voltage being monitored by the ECM on the APP sensor signal circuit.
APP angle is computed by the ECM from APP sensor voltages. This should display
0% at idle and 100% at wide open throttle.
Final Accelerator opening is computed by the ECM from APP sensor voltages. This
should display 0% at idle and 100% at wide open throttle.
The atmospheric air temperature is displayed intake air temperature. The ECM
applies 5 volts to the intake air temperature sensor circuit. The sensor is a
thermistor which changes internal resistance as temperature changes.
The ECT is displayed engine coolant temperature. The ECM applies 5 volts to the
ECT circuit. The sensor is a thermistor which changes internal resistance as
temperature changes. When the sensor is cold (high resistance), the ECM
monitors a high signal voltage and interprets that as a cold engine.
Fuel Temperature
The fuel temperature is displayed fuel temperature. The ECM applies 5 volts to the
fuel temperature sensor circuit. The sensor is a thermistor which changes internal
resistance as temperature changes.
The relative boost pressure is computed by the ECM from the boost sensor. The
boost sensor measures the change in intake manifold pressure from the engine
load.
The desired rail pressure that the ECM is commanding. The ECM will compensate
for rail pressure on APP angle.
This is displayed current rail pressure. The ECM will compensate for rail pressure
to desired rail pressure.
This is displayed fuel rate for the pilot injection at engine idling. The ECM will
compensate for the amount of goal pilot injection by various sensor signals.
Fuel Rate
This is displayed current fuel rate that the ECM is commanding. The ECM will
compute for the fuel rate by various sensor signal.
This is displayed fuel rate at engine idling. The ECM will compensate for cylinder
balancing fuel rate by various sensor signals.
This is displayed fuel rate at engine idling. The ECM will compensate for cylinder
balancing fuel rate by various sensor signals.
This is displayed fuel rate at engine idling. The ECM will compensate for cylinder
balancing fuel rate by various sensor signals.
Definitions
This is displayed fuel rate at engine idling. The ECM will compensate for cylinder
balancing fuel rate by various sensor signals.
This is displayed fuel rate at engine idling. The ECM will compensate for cylinder
balancing fuel rate by various sensor signals.
This is displayed fuel rate at engine idling. The ECM will compensate for cylinder
balancing fuel rate by various sensor signals.
The main injection timing that the ECM is commanding. The ECM will compensate
for main injection timing by APP angle and various sensor.
The basic injection timing that the ECM is commanding. The ECM will compensate
for basic injection timing by various sensor signals.
This is displayed PCV operation interval. The ECM will compute for the PCV
operation by various sensor signals.
This is displayed PCV control timing. The ECM will compute for rail pressure feed
back control timing by rail pressure and various sensor.
PTO accelerator opening is computed by the ECM from PTO accelerator position
sensor voltage. This should display 0% at idle and 100% at full position.
The voltage being monitored by the ECM on the PTO accelerator position sensor
signal circuit.
Starter Switch
Key Switch
Clutch Switch
This is displayed operating status for clutch switch. (Manual transmission only)
Neutral Switch
Brake 2 Switch
Parking Switch
Idle Up Switch
SLD Enable
PTO Enable
PTO Switch
Diagnostic Switch
AT Relay
Transmission Switch
Flow Damper 1
This is displayed operation times for the flow damper. The ECM will operate the
flow damper by various sensor signals.
Definitions
Flow Damper 2
This is displayed operation times for the flow damper. The ECM will operate the
flow damper by various sensor signals.
Flow Damper 3
This is displayed operation times for the flow damper. The ECM will operate the
flow damper by various sensor signals.
Flow Damper 4
This is displayed operation times for the flow damper. The ECM will operate the
flow damper by various sensor signals.
Flow Damper 5
This is displayed operation times for the flow damper. The ECM will operate the
flow damper by various sensor signals.
Flow Damper 6
This is displayed operation times for the flow damper. The ECM will operate the
flow damper by various sensor signals.
This is displayed the fuel delay rate data. The ECM will compensate for fuel delay
rate by various sensor signals.
This is displayed the fuel delay rate data. The ECM will compensate for fuel delay
rate by various sensor signals.
This is displayed the fuel delay rate data. The ECM will compensate for fuel delay
rate by various sensor signals.
G (Pump) Sensor Installation Error Correction This is displayed CAM sensor installation error correction.
Highest Fuel Temperature
The ECM applies 5 volts to the fuel temperature sensor circuit. The sensor is a
thermistor which changes internal resistance as temperature changes.
The highest fuel temperature which immobirized is displayed.
VISUAL CHECK
Several of the symptom procedures call for a careful visual
check. This can lead to correcting a problem without further
checks and can save valuable time. This check should
include the following items:
ECM grounds for cleanliness, tightness and proper
location.
Vacuum hoses for splits, kinks, and proper connections,
as shown on the Vehicle Emission Control Information
label. Check thoroughly for any type of leak or restriction.
Air intake ducts for collapsed or damaged areas.
Ignition component for cracking, hardness, and carbon
tracking.
Wiring for proper connections, pinches and cuts.
INTERMITTENTS
An intermittent problem may or may not turn on the
malfunction indicator lamp (MIL) or store a Diagnostic Trouble
Code. DO NOT use the Diagnostic Trouble Code (DTC)
charts for intermittent problems. The fault must be present to
locate the problem.
Most intermittent problems are caused by faulty electrical
connections or wiring. Perform a careful visual/physical check
for the following conditions:
Poor mating of the connector halves or a terminal not
fully seated in the connector (backed out).
Improperly formed or damaged terminal.
All connector terminals in the problem circuit should be
carefully checked for proper contact tension.
Poor terminal-to-wire connection. This requires
removing the terminal from the connector body to check.
Road test the vehicle with a 5-8840-0366-0 Digital
Multimeter connected to a suspected circuit. An abnormal
voltage when the malfunction occurs is a good indication that
there is a fault in the circuit being monitors.
Use a scan tool to help detect intermittent conditions.
DTC(s)
Engine hunting
Surging, Hesitation
416, 421
Excessive White or
Blue Smoke
Lack of Power
Tachometer
Output Error
15
SLD Error
25
ACTION
VALUE
YES
NO
DEFINITION:
Engine cranks, but does not start for a long time. Does eventually run, or may start but immediately stalls.
1
10
Go to step 2
Go to OBD
System Check
Verify repair
Go to step 3
Go to step 4
Go to
Visual/Physical
Check
Go to
applicable
DTC table
Go to step 5
Verify repair
Go to step 6
Verify repair
Go to step 7
Verify repair
Go to step 8
Verify repair
Go to step 9
Verify repair
Go to step 10
Verify repair
Contact
Technical
Assistance
ACTION
VALUE
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 4
Go to step 3
Go to step 4
Repair/replace
problem part
Go to
applicable
DTC table
Go to step 5
Go to step 6
Replace fuel
with
recommend
specification
DEFINITION:
Engine cranks, but does not start.
1
See owners
manual
Replace fuel
Go to step 7
Did you find any leakage on the fuel pump, injection pipe etc.?
Repair problem
part
Go to step 8
Go to step 9
Repair/replace
problem part
Go to step 10
Repair/replace
problem part
Go to step 11
Go to step 12
Replace fuel
filter element
10
11
12
Clean gauze
filter or replace
it.
System OK
ACTION
Was the On-Board Diagnostic (OBD) system check
performed?
VALUE
YES
NO
Go to step 2
Go to OBD
System
Check
Go to step 3
Replace
engine oil
Replace engine
oil and repair
cause of dilution.
Go to step 4
Go to setp 5
Replace fuel
with recommend
specification.
See owners
manual
See owners
manual
Replace fuel
Go to step 6
Did you find any breakage on the fuel pump, injection pipe
etc.?
Repair/replace
problem part.
Go to step 7
Are fuel filters (prefilter, gauze filter and fuel main filter)
normal condition?
(The gauze filter is fixed in suction eye bolt on the supply
pump.)
Go to step 8
Clean/replace
problem fuel
filter
Go to step 9
Repair/replace
problem part
Go to step 10
Bleed air
from fuel
line
Go to
applicable
DTC table
Go to step 11
Go to step 12
Go to PTO
error check
System OK
Go to step 13
Replace
problem part.
Replace
supply pump
assembly.
10
11
12
13
ACTION
Was the On-Board Diagnostic (OBD) system check
performed?
VALUE
YES
NO
Go to step 2
Go to OBD
System
Check
Go to step 3
Replace
engine oil
Replace engine
oil and repair
cause of
dilution.
Go to step 4
Go to step 5
Replace fuel
with
recommend
specification
See owners
manual
See owners
manual
Replace fuel
Go to step 6
Did you find any damage on the fuel pump, injection pipe
etc.?
Repair/replace
problem part.
Go to step 7
Are fuel filters (prefilter, gauze filter and fuel main filter)
normal condition?
(The gauze filter is fixed in suction eye bolt on the supply
pump)
Go to step 8
Clean/replace
problem fuel
filter
Go to step 9
Repair/replace
problem part
Go to step 10
Bleed air
from fuel line
Go to
applicable
DTC table
Go to step 11
Go to step 12
Go to PTO
error check
Verify repair
Contact
Technical
Assistance
10
11
12
ACTION
Was the On-Board Diagnostic (OBD) system check
performed?
VALUE
YES
NO
Go to step 2
Go to OBD
System
Check
Go to
applicable
DTC table
Go to step 3
Repair or
Replace
Go to step 1
Go to step 4
Repair or
Replace
Go to step 1
Replace ECM
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
ACTION
VALUE
Replace fuel
Go to step 4
Go to step 5
Go to
applicable
DTC table
Go to step 6
Repair to
fuel injection
timing
Go to step 7
Go to step 8
Go to Check
Injectors
(engine
running)
Diagnosis chart
Go to step 9
Repair/replace
problem portion
(Piston ring,
valve stem seal
etc.)
Repair/replace
turbocharger
Go to step 10
Replace
piston ring
Go to step 11
Contact
Technical
Assistance
More than
2157 kPa
(313 psi)
11
Go to step 3
Replace fuel
with
recommend
specification
(Blue smoke)
10
Go to step 2
Replace or
supplies
engine oil.
See owners
manual
NO
See owners
manual
YES
(Blue smoke)
10
11
ACTION
Was engine oil used within specified viscosity?
VALUE
YES
NO
See owners
manual
Go to step 2
Replace
engine oil
Go to step 3
Replace fuel
with
recommend
specification
Go to
applicable
DTC table
Go to step4
Repair/replace
problem portion
(Filter, Air duct,
Pipe,
Intercooler,
etc.)
Go to step 5
Repair/replace
problem portion
Go to step 6
Repair to
fuel injection
timing
Go to step 7
Go to step 8
Repair/replace
problem portion
(Piston ring,
value stem
seal etc.)
Repair/replace
problem
portion.
Go to step 9
Go to step 10
Repair/replace
turbocharger
Replace
injector
assembly
Go to step 11
Repair/replace
problem
portion.
System OK
See owners
manual
More than
2157 kpa
(313 psi)
ACTION
VALUE
YES
NO
DEFINITION:
Engine delivers less than expected power. Little or no increase in speed when accelerator pedal is pushed down part-way.
10
11
12
Go to step 3
Go to step 4
Go to step 5
Go to step 5
Go to step 6
Readjust
oil level
Go to step 7
Replace
engine oil
Clean or
replace filter
element
Go to step 8
Take out
foreign
material
Go to step 9
Repair or
replace
problem part
Go to step 10
Go to step 11
Repair or
replace
problem part
Go to step12
Repair or
replace
problem part
System OK
Readjust
correct timing
Go to
applicable
DTC table
No Load
More than
40 MPa
Full Load
More than
100 MPa
Go to step 2
Go to OBD
System
Check
CAM SENSOR
(PUMP
POSITION)
+
77 58 49
CKP SENSOR
(CRANK
POSITION)
+
76 57 48
METER
TACHO
OUT
112
Engi ne C o n t ro l Mo d u l e ( E C M)
LFW36EMF000501
Circuit Description
When CKP sensor and CAM sensor instable (DTC not
indicated),
tachometer
output
becomes
abnormal.
If vehicle running performance is adversely affected, repair
the abnormality first.
Unless CKP sensor and CAM sensor signal both normal,
tachometer output not produced.
ECM delivers shortwave of 4 pulse (0 5V) per a
rotation to tachometer.
Tachometer do not produce output at 230 rpm or less.
If checking by voltage, digital multimeter reads around
2.5V under engine idling, and 5V or 0V for output
abnormality.
ACTION
VALUE
YES
NO
Go to step 2
While engine
running,
CKP sensor
NG: Indication
abnormal.
After key
OFF, it either
CKP sensor
damaged,
indication
became
abnormal.
Replace
tachometer
Go to step 3
Replace
tachometer
Replace ECM
184Hz
184Hz
A/T
ST
ON
KEY SW
M/T
SW;
SUB
STARTER
R/L;
EXH
BRAKE
SW;EXH.
BRAKE
R/L;
NEUTRAL
R/L;
STOP LAMP
METER
SW;IDLE
CONT
(AUTO/
MNL)
SW;
NEUTRAL
SW;IDLE
CONT
(UP/
DOWN)
SW;
BRAKE
EXH
BRAKE
LAMP
STOP
LAMP
UP DOWN
M/V:
EXH.
BRAKE
R/L;
STARTER
27
10
29
33
26
Eng i n e C o n t ro l Mo d u l e ( E C M)
LFW36ELF000301
ACTION
1. Using a scan tool output tests (Function tests), select
exhaust brake control.
2. Push Active and Inactive soft key.
3. Check the M/V Exhaust Brake display.
Was the display changed?
Measure the voltage between pin number 8 and pin number
111 during key switch ON, exhaust brake switch ON at
ECM side connector.
Was voltage within value?
VALUE
Go to step 7
Go to step 2
Go to step 4
Go to step 3
Repair wire
harness or
replace exhaust
brake switch.
Go to step 4
Repair wire
harness or
replace exhaust
brake switch.
Go to step 5
Repair wire
harness or
replace exhaust
brake magnetic
valve.
Go to step 6
Verify repair
Go to step 7
Repair/replace
exhaust brake
valve
Go to step 8
Verify repair
24V
NO
YES
34 ~ 40
(between
each terminal)
(between
terminal and
valve body)
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
M/T
VEHICLE
SPEED SENSOR
(VSS)
R/L;
PTO
(CLUTCH)
PARKING
BRAKE
LAMP
DIAG
LAMP
(MIL)
R/L;A/T
ECU
VCC SIG GND
R/L;
PTO
(MAIN)
VSS
CONTROL UNIT
SW;
PARKING
BRAKE
SW;
CLUTCH
A/T
ECU
SW;
PTO
PTO LAMP
M/V;PTO
SIG
75
(A/T ONLY)
105
19
16
108
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36ELF000501
ACTION
VALUE
YES
NO
Go to step 2
Did you find DTCs 14, 15, 24, 25, 35, 115, 118, 151, 158, 159,
217, 218, 226, 227, 245, 247, 248, 271 to 276?
Repair
DTCs table first
Go to step 3
10
11
12
Go to step 4
Go to step 5
Go to step 6
24V
24V
Go to step 7
Replace PTO
switch or repair
wire harness.
Go to step 8
Replace
parking brake
switch or repair
wire harness.
Go to step 9
Go to step 12
Go to step 10
Repair wire
harness.
Go step 11
Replace PTO
magnetic valve
and/or PTO
relay
Replace ECM
System OK
Repair/
Replace
Automatic
transmission
system
Go to step 7
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
VEHICLE
SPEED SENSOR
(VSS)
SIG
75
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000601
10
11
12
ACTION
VALUE
YES
NO
Go to step 2
Go to OBD
System check
Go to step 3
Go to
DTC table
Go to step 4
Go to step 5
(Automatic
transmission)
Repair/Replace
switch or circuit
Go to step 6
(Manual
transmission)
Repair/Replace
circuit
Go to step 6
Go to step 7
Go to step 8
Go to step 9
Go to step 9
Verify repair
Go to step 10
Go to step 12
Go to step 11
Go to step 13
Go to step 13
14
ACTION
VALUE
YES
NO
Verify repair
Go to step 14
Verify repair
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
Possible Conditions
DTC261 to 266, (226, 227), 33, 35, Scan tool
(Air bleed, Flow damper, Common rail)
No MIL
DTC 421, 217, 218, 247, 248, 226, 227 (PCV, Relay)
ECM
Charging
Circuit
BARO Sensor
(Inside ECM)
Boost Sensor
Accelerator Pedal
Position Sensor
Fuel Temp.
Sensor
Pressure Limiter
Fuel Leak off Pipe
Common Rail
Pressure Sensor
Starter Signal
Flow Damper
Supply Pump
Air
Cleaner
CKP Sensor
CAM. Sensor
(Pump Position)
Fuel Filter
Fuel Tank
LFW36ELF000601
Circuit Description
Diagnostic Aids
2.
5.
7.
9.
STEP
1
ACTION
VALUE
Engine "ON"
Was "Check system operation check" performed?
YES
NO
Go to step 2
Go to No MIL
Diagnosis chart
Go to step 3
Go to Will Not
Flash
Diagnosis chart
Go to step 4
Go to Engine
will not start
Diagnosis chart
Go to step 5
Go to System
operation
check
Diagnosis chart
Go to step 6
Go to Check
the Fuel
system
Diagnosis chart
Go to step 7
Go to step 11
Verify repair
Go to step 8
Go to step 10
Verify repair
Go to step 1
Go to step 9
More 2 stored:
Go to Multiple
DTCs stored
One stored:
Go to
Applicable
DTC table
System OK
1. Ignition "OFF".
2. Connect the scan tool.
3. Ignition "ON".
Was the power supply "ON" and engine data indicated
on the Scan tool ?
1. Engine "ON"
2. Check DTCs stored and record .
Was DTC stored?
ACTION
VALUE
10
Replace ECM.
11
12
13
YES
NO
Verify repair
Go to step 6
Intermittent
Problem, Verify
Customer
problem
analysis check
Go to step 6
Verify repair
Go to step 6
Go to step 12
Verify repair
Go to step 6
Go to step 13
Go to step 6
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
KEY SW
B1
OFF
ACC
ON
HEAT
START
M1 M2
B2
P2
P1
R/L;
MAIN
R/L;
P.C.V.
Diag
Lamp
(MIL)
GENERATOR
B
R
L
E
START MAIN
R/L
BP+
PUMP
CONT.
VALVE1
PUMP
CONT.
VALVE2
R/L;
STARTER
BATTERY
Key
24
118
109
91 101 22
21 32
31 23
13
105
33
NEUTRAL
(A/T ONLY)
M/T
81
R
GND
82
PGND
111
102
ECMECMGND
GND
59
CASE
GND
SW;SUB
STARTER
R/L;
NEUTRAL
A/T
SW;
NEUTRAL
LFW36ELF000801
Circuit Description
Diagnostic Aids
ACTION
VALUE
1. Ignition OFF.
2. Disconnect following fuses.
(Main, PCV, Warning lamp, meter)
3. Probe circuits for an open or short.
If a problem was found, repair as necessary.
Was a problem found ?
1. Ignition ON .
2. Check voltage at fuse.
If a problem was found, repair as necessary.
Was a problem found ?
1. Ignition OFF.
2. Check main relay.
If a problem was found, replace a relay.
Was a problem found ?
1. Ignition OFF.
2. Disconnect main relay.
3. Disconnect following fuses.
Main, PCV, Warning lamp, meter
4. Probe following point for an open to ground and short to
voltage.
Between fuse and main relay
Between main relay and ECM
If a problem was found, repair as necessary.
Was a problem found?
YES
NO
Go to step 2
Go to
Diagnostic Aids
Verify repair
Go to step 3
Verify repair
Go to OBD
system check
Diagnosis chart
Go to step 4
Go to OBD
system check
Diagnosis chart
Go to step 5
Go to OBD
system check
Diagnosis chart
Verify repair
Go to step 6
Verify repair
Go to OBD
system check
Diagnosis chart
Go to step 7
Verify repair
Go to OBD
system check
Diagnosis chart
Go to step 8
Verify repair
Go to OBD
system check
Diagnosis chart
Go to step 9
Verify repair
Go to OBD
system check
Diagnosis chart
Go to step 10
11
12
13
ACTION
1. Probe for an open or short between meter and ECM.
If a problem was found, repair as necessary
Was a problem found ?
1. Ignition OFF
2. Repair or replace meter assembly.
Was the meter repaired/replaced?
VALUE
YES
NO
Verify repair
Go to OBD
system check
Diagnosis chart
Go to step 11
Verify repair
Go to OBD
system check
Diagnosis chart
Go to step 12
Verify repair
Go to OBD
system check
Diagnosis chart
Go to step 13
Verify repair
Go to OBD
system check
Diagnosis chart
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
KEY SW
B1
OFF
ACC
ON
HEAT
START
M1 M2
B2
P2
P1
R/L;
MAIN
R/L;
P.C.V.
Diag
Lamp
(MIL)
GENERATOR
B
R
L
E
START MAIN
R/L
BP+
PUMP
CONT.
VALVE1
PUMP
CONT.
VALVE2
R/L;
STARTER
BATTERY
Key
24
118
109
91 101 22
21 32
31 23
13
105
33
NEUTRAL
(A/T ONLY)
M/T
81
R
GND
82
PGND
111
102
ECMECMGND
GND
59
CASE
GND
SW;SUB
STARTER
R/L;
NEUTRAL
A/T
SW;
NEUTRAL
LFW36ELF000801
Circuit Description
It comprises diagnosis switch, ECM, fuses, relays, bulb,
battery and etc.
There is the MIL on the instrument panel. Diagnosis switch
is located under the inner part of instrument panel (the left of
steering column).
This is check, when self diagnosis isnt operation.
Diagnosis switch connect. If the MIL isnt turned on, Excite
this checking circuit.
Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbedthrough wire insulation or a wire broken inside the
insulation. Check for poor connections or a damaged
harness. Inspect the ECM harness and connector for
improper mating, broken locks, improperly formed or
damaged terminals, poor terminal-to-wire connection, and
damaged harness.
Test Description
1
3
5
ACTION
VALUE
1. Ignition OFF.
2. Disconnect ECM.
3. Probe lamp circuit between lamp and ECM for an open or
short.
If a problem was found, repair as necessary.
Was a problem found ?
1. Ignition ON.
2. If NO lamp, check meter and fuse.
If a problem was found, repair as necessary.
Was a problem found?
1. Ignition OFF.
2. Connect ECM.
3. Ignition ON.
4. Diag switch ON.
5. Check to see if MIL lamp is flashing.
Is the MIL flashing?
1. Ignition OFF.
2. Check following circuit for open or short.
Between ECM and diag switch
Between diag switch and GND
If a problem was found, repair diag switch circuit.
Was a problem found?
1. Ignition ON.
2. Diag switch ON.
3. Check to see if MIL lamp is flashing.
Is the MIL lamp flashing?
1. Check DTCs
Was a DTC displayed?
YES
NO
Go to step 2
Go to
Diagnostic Aids
Verify repair
Go to OBD
System check
Go to step 3
Verify repair
Go to OBD
System check
Go to step 4
Go to step 7
Go to step 5
Verify repair
Go to OBD
System check
Go to step 6
Go to step 7
Replace ECM
Verify repair
Go to OBD
System check
Go to specific
DTC Diagnosis
chart
Go to OBD
System check
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
ECM
Charging
Circuit
BARO Sensor
(Inside ECM)
Boost Sensor
Accelerator Pedal
Position Sensor
Fuel Temp.
Sensor
Pressure Limiter
Fuel Leak off Pipe
Common Rail
Pressure Sensor
Starter Signal
Flow Damper
Supply Pump
Air
Cleaner
CKP Sensor
Fuel Filter
Fuel Tank
LFW36ELF000601
Circuit Description
Fuel system comprises fuel, fuel filter, starter switch,
injectors, supply pump, sensors, ECM and etc.
There are many causes. It is fuel quality, fuel filter, and
other. Refer to any section.
Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbedthrough wire insulation or a wire broken inside the
insulation. Check for poor connections or a damaged
harness. Inspect the ECM harness and connector for
improper mating, broken locks, improperly formed or
damaged terminals, poor terminal-to-wire connection, and
damaged harness.
Test Description
5.
6.
7.
8.
Check
Check
Check
Check
the
the
the
the
ACTION
VALUE
Was the Fuel injection and timing relation (engine off) check
performed?
Was the Check the fuel pressure in common rail (engine off)
check performed?
YES
NO
Verify repair
Go to OBD
System check
Go to step 2
Verify repair
Go to OBD
System check
Go to step 3
Verify repair
Go to OBD
System check
Go to step 4
Verify repair
Go to OBD
System check
Go to step 5
Go to step 6
Go to Fuel
Injection and
Timing Relation
(engine off)
Diagnosis chart
Go to step 7
Go to Check
supply pump
(engine off)
Diagnosis chart
Go to step 8
Go to Check
Injectors
(engine off)
Diagnosis chart
Go to step 9
Go to Check
the fuel
pressure
(engine off)
Diagnosis chart
Verify repair
Go to OBD
System check
Go to step 4
CAM SENSOR
(PUMP
POSITION)
CKP SENSOR
(CRANK
POSITION)
77 58 49
76 57 48
En g i n e C o n t ro l Mo d u l e ( E C M)
060MY00035
Circuit Description
Test Description
Diagnostic Aids
ACTION
VALUE
CKP sensor
109 143
(about 20C)
CAM sensor
1850 2450
(about 20C)
YES
NO
Verify repair
Go to OBD
System check
Go to step 2
Verify repair
Go to OBD
System check
Go to step 3
Verify repair
Go to OBD
System check
Go to step 4
Verify repair
Go to OBD
System check
Go to step 5
Verify repair
Go to OBD
System check
Go to step 6
Verify repair
Go to OBD
System check
Return to
Engine Will
Not Start
Diagnosis chart
R/L; PUMP
CONT. VALVE
PUMP
CONT.
VALVE1
R/L; MAIN
MAIN
R/L
24 91
+BP
PUMP
CONT.
VALVE2
MAIN
R/L
KEY
22
21
32
31
23
13
En g i n e C o n t ro l Mo d u l e ( E C M)
LFW36ELF000701
Circuit Description
It comprises fuses, relays, supply pump, gauzefilter and
etc.
This test confirms that the supply pump is operating. If the
pump is not operating, fuel will not be supplied to the injectors
and the engine will not start.
Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbedthrough wire insulation or a wire broken inside the
insulation. Check for poor connections or a damaged
harness. Inspect the ECM harness and connector for
improper mating, broken locks, improperly formed or
damaged terminals, poor terminal-to-wire connection, and
damaged harness.
Test Description
10 This check is mechanical check.
11 Do not intercharge the PCV1 and PCV2 harnesses.
Doing so will charge the injection timing of PCVs.
10
ACTION
VALUE
Probe a circuit between the pump relay and PCV for an open
or short to ground and short to voltage.
If a problem was found, repair as necessary.
Was a problem found ?
0.9 1.3
YES
NO
Verify repair
Go to OBD
System check
Go to step 2
Verify repair
Go to OBD
System check
Go to step 3
1. Remove the pipe between the fuel filter and the supply
pump.
2. Check the gauze filter
If a problem was found, clean up the filter.
Was a problem found ?
Verify repair
Go to OBD
System check
Go to step 4
Verify repair
Go to OBD
System check
Go to step 5
Verify repair
Go to OBD
System check
Go to step 6
Verify repair
Go to OBD
System check
Go to step 7
Verify repair
Go to OBD
System check
Go to step 8
Verify repair
Go to OBD
System check
Go to step 9
Verify repair
Go to OBD
System check
Go to step 10
Verify repair
Go to OBD
System check
Go to step 11
12
ACTION
VALUE
YES
NO
Verify repair
Go to OBD
System check
Go to step 12
Verify repair
Go to OBD
System check
Go to Engine
Will Not Start
and Run
Diagnosis chart
COM2
COM1
120 119
110 100
CYL.1
CYL.5
CYL.3
CYL.6
CYL.2
CYL.4
INJ.1
INJ.2
INJ.3
INJ.4
INJ.5
INJ.6
90
89
88
87
86
85
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000401
Circuit Description
It comprises circuit of injector, injector, ECM and etc.
There are two way valves (TWV) in injector. TWVs control
fuel supply at injectors.
A faulty circuit or air in the system may stop fuel being
injected into the engine.
Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbedthrough wire insulation or a wire broken inside the
insulation. Check for poor connections or a damaged
harness. Inspect the ECM harness and connector for
improper mating, broken locks, improperly formed or
damaged terminals, poor terminal-to-wire connection, and
damaged harness.
Test Description
3
4.
This test will check the resistance of the injectors and the
harnesses.
Air bleeding will check for air in the injector circuits.
ACTION
1. Disconnect following:
The harnesses of ECM
The injector connector of the cylinder head.
2. Probe the circuit for an open or short.
If a problem was found, repair as necessary.
Was a problem found ?
1. Probe the Injector circuit at the connector of engine head.
2. Probe the common circuit and injector circuit for an open
or short. (Refer to circuit diagram)
If a problem was found, repair as necessary.
Was a problem repair ?
1.
2.
3.
4.
5.
VALUE
YES
NO
Verify repair
Go to OBD
System check
Go to step 2
Go to step 3
Go to step 4
Verify repair
Go to OBD
System check
Go to step 4
Verify repair
Go to OBD
System check
Go to step 5
Verify repair
Go to OBD
System check
Go to Engine
Will Not Start
Diagnosis chart
Resistance
0.3 1.3
(about 20C)
0.3 1.3
(between each
terminal)
(between
terminal and
injector body)
1.
2.
3.
Did
1.
2.
3.
Did
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
PRESSURE SENSOR
COMMON RAIL
GND VCC
55
73
71
SIG
62
Eng i n e C o n t r o l M o d u l e ( E C M )
056MX022
Circuit Description
It comprises common rail pressure sensor, priming pump
on the supply pump, ECM and etc.
The common rail pressure sensor is sensing fuel pressure
in common rail. It send signal to ECM.
This case, supply pump is working but fuel pressure is
poorer than usual. According to Fuel supply isnt enough.
Common rail pressure sensor is gauged pressure in common
rail.
Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbedthrough wire insulation or a wire broken inside the
insulation. Check for poor connections or a damaged
harness. Inspect the ECM harness and connector for
improper mating, broken locks, improperly formed or
damaged terminals, poor terminal-to-wire connection, and
damaged harness.
Test Description
2
4
6
ACTION
VALUE
5V
1. Ignition OFF.
2. Reconnect the harness at the pressure sensor.
3. Connect the scan tool.
4. Ignition ON.
Check Actual Rail Pressure in Section ENGINE DATA,
using the scan tool.
NOTE: When Engine stopped, there is residual pressure.
Is the pressure in the specified range?
1. Replace the fuel pressure sensor.
2. Bleed fuel system.
Was the action complete ?
Replace ECM.
Was the action complete ?
NO
Verify repair
Go to OBD
System check
Go to step 2
Go to step 3
Go to step 7
Go to step 5
Go to step 4
Go to step 3
Go to step 6
Go to step 4
Verify repair
Go to OBD
System check
Go to Engine
Will Not Start
and Run
Diagnosis chart
Verify repair
0 1.5 MPa
YES
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
ECM
Charging
Circuit
BARO Sensor
(Inside ECM)
Boost Sensor
Accelerator Pedal
Position Sensor
Fuel Temp.
Sensor
Pressure Limiter
Fuel Leak off Pipe
Common Rail
Pressure Sensor
Starter Signal
Flow Damper
Supply Pump
Air
Cleaner
CKP Sensor
Fuel Filter
Fuel Tank
LFW36ELF000601
Circuit Description
Test Description
Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbedthrough wire insulation or a wire broken inside the
insulation. Check for poor connections or a damaged
harness. Inspect the ECM harness and connector for
improper mating, broken locks, improperly formed or
damaged terminals, poor terminal-to-wire connection, and
damaged harness.
Check
Check
Check
Check
the
the
the
the
ACTION
VALUE
YES
NO
Clean or
Replace
Go to OBD
System check
Go to step 2
Change Oil.
Go to OBD
System check
Go to step 3
Go to step 4
Check
Appropriate
Diagnosis chart
Repair or
Replace.
Go to OBD
System check
Go to step 5
Repair or
Replace.
Go to OBD
System check
Go to step 6
Verify repair
Go to OBD
System check
Bleed the
Fuel system
CAM SENSOR
(PUMP
POSITION)
CKP SENSOR
(CRANK
POSITION)
+
77 58 49
+
76 57 48
Engi n e C o n t ro l Mo d u l e ( E C M)
060MY00035
Circuit Description
It comprises crank position sensor (CKP sensor), Pump
position sensor (CAM sensor), supply pump and etc.
CKP sensor is sensing speed of engine crank. CAM
sensor is sensing speed of 3-lobe cam (It is in the priming
pump). It send each signal to ECM.
An engine idling is abnormal sometimes. One of causes,
there is bad condition of sensors.
Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbedthrough wire insulation or a wire broken inside the
insulation. Check for poor connections or a damaged
harness. Inspect the ECM harness and connector for
improper mating, broken locks, improperly formed or
damaged terminals, poor terminal-to-wire connection, and
damaged harness.
Test Description
1
2
4
ACTION
VALUE
CKP sensor
109 143
(about 20C)
CAM sensor
1850 2450
(about 20C)
CKP Sensor
1. Check flywheel condition.
(Distortion, scratch, etc.)
2. Clean up
3. If a problem was found, repair or replace as necessary.
YES
NO
Go to step 7
Go to step 2
Verify Repair
Go to step 7
Go to step 3
Verify Repair
Go to step 7
Go to step 5
Verify repair
Go to step 7
Go to step 5
Go to step 7
Go to step 6
Go to step 7
Check the
CKP and CAM
sensors
Verify repair
Go to System
operation check
Diagnosis chart
CAM Sensor
1. Replace supply pump.
Did you check the CKP and CAM sensors ?
7
R/L; PUMP
CONT. VALVE
PUMP
CONT.
VALVE1
R/L; MAIN
MAIN
R/L
24 91
+BP
PUMP
CONT.
VALVE2
MAIN
R/L
KEY
22
21
32
31
23
13
Eng i n e C o n t ro l Mo d u l e ( E C M)
LFW36ELF000701
Circuit Description
It comprises fuses, relays, supply pump, gauzefilter and
etc.This case, It conform stopped supply pump. There are two
PCV. When One PCV is stopped, Engine will run steady.
Because another one is working. To supply fuel to the injector.
If both PCV stop the engine will not run.
Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbedthrough wire insulation or a wire broken inside the
insulation. Check for poor connections or a damaged
harness. Inspect the ECM harness and connector for
improper mating, broken locks, improperly formed or
damaged terminals, poor terminal-to-wire connection, and
damaged harness.
Test Description
1
ACTION
VALUE
YES
NO
Verify Repair
Go to OBD
System check
Go to step 2
Verify Repair
Go to OBD
System check
Go to step 3
Go to OBD
System check
Go to System
Operation check
Diagnosis chart
PRESSURE SENSOR
COMMON RAIL
GND VCC
55
73
SIG
71
62
Engin e C o n t r o l M o d u l e ( E C M )
056MX022
Circuit Description
The common rail pressure sensor is sensing pressure of
common rail. It send signal to ECM.
This case, supply pump is working but fuel pressure is
poorer than usual. According to Fuel supply isnt enough.
Common rail pressure sensor is gauged pressure in common
rail.
Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbedthrough wire insulation or a wire broken inside the
insulation. Check for poor connections or a damaged
harness. Inspect the ECM harness and connector for
improper mating, broken locks, improperly formed or
damaged terminals, poor terminal-to-wire connection,and
damaged harness.
Test Description
1
ACTION
VALUE
YES
NO
Go to step 2
Go to step 3
Verify Repair
Go to OBD
System check
Go to step 3
Verify Repair
Go to OBD
System check
Go to System
Operation check
Diagnosis chart
COM2
COM1
120 119
110 100
CYL.1
CYL.5
CYL.3
CYL.6
CYL.2
CYL.4
INJ.1
INJ.2
INJ.3
INJ.4
INJ.5
INJ.6
90
89
88
87
86
85
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000401
Circuit Description
Test Description
Diagnostic Aids
ACTION
VALUE
1. Engine OFF.
2. Replace a injector of a cylinder with no change in the
working noize and RPM drop.
3. Engine ON
Was the action completed?
YES
NO
Go to step 3
Go to step 2
Go to step 1
Complete action
Go to step 4
Complete action
Verify repair
Go to OBD
system check
Go to System
operation check
Diagnosis chart
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
Fuel Filter
Injector
Common Rail
Flow
Damper
Common Rail
Pressure Sensor
Pressure Limiter
PCV
Over Flow Valve
Gauze Filter
Feed Pump
Supply Pump
Fuel Tank
060MY00052
Circuit Description
It confirm leak of fuel. Accelerating of Engine raise fuel
pressure and it will be leaks more. Overlook it.
It comprises following pipes and etc.
Between injectors to common rail.
Between common rail to supply pump.
Between supply pump to fuel filter.
Between fuel filter to fuel tank.
Between pressure limiter to fuel tank.
Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbedthrough wire insulation or a wire broken inside the
insulation. Check for poor connections or a damaged
harness. Inspect the ECM harness and connector for
improper mating, broken locks, improperly formed or
damaged terminals, poor terminal-to-wire connection, and
damaged harness.
Test Description
1
ACTION
VALUE
1. Engine ON.
2. Acclerate the engine revolution until 3,000 rpm is reached.
NOTE: Dont over-rev. the engine.
3. Ignition OFF, engine OFF and listen for flow damper to
reset (click) sound. This may take 120 seconds.
NOTE: If this test is performed, it may operate also
with a normal flow damper, and if engine is stopped,
there may be flow damper working sound.
Was click sound heard?
1. Ignition OFF.
2. Check the fuel high pressure pipe with operated flow
damper.
3. Check for leak at injector piping.
If the pipe has a leak, repair as necessary.
Did you the problem repair?
Check the balancing fuel rate Engine data with the scan tool.
If a problem was found, repair as necessary.
Was a problem found?
Replace the injection parts.
Was a action complete?
Injector Side
5 5
Ball
060MY00039
YES
NO
Go to step 2
System OK
Go to step 3
Repair or
Replace
Verify repair
Go to OBD
system check
Go to step 4
Verify repair
Go to OBD
system check
R/L; PUMP
CONT.
VALVE
R/L; MAIN
START
PUMP
MAIN R/L PUMP
KEY
CONT. VALVE1
CONT. VALVE2
22
91 101 118 109
21 32
31 23
13
BP+
24
BI S G MI M2 B2 P2 P1
KEY SW
E n g i n e C o n t ro l Mo d u l e ( E C M)
81
82
111
102
59
R
PECM- ECM- CASE
GND GND GND GND GND
OFF
ACC
ON
HEAT
START
R/L;
STARTER
B
R
L
E
STARTER
GENERATOR
BATTERY
LFW36ELF000901
INTAKE
AIR
TEMP
SENSOR
SIG
53
PTO
ENGINE ACCELEFUEL
COOLANT RATOR
TEMP
TEMP POSITION BOOST
SENSOR SENSOR SENSOR SENSOR
SIG
52
30
64
56
SIG
72 61
COMMON RAIL
PRESSURE
SENSOR
GND VCC
55
73
CAM
CKP
SENSOR
SENSOR
(PUMP
(CRANK
POSITION) POSITION)
SIG
71 62
+
77 58 49
+
76 57 48
ACCELERATOR
PEDAL
POSITION
SENSOR
Engi ne C o n t ro l Mo d u l e ( E C M)
LFW36ELF000401
COM2
COM1
120 119
110 100
CYL.1
CYL.5
CYL.3
CYL.6
CYL.2
CYL.4
INJ.1
INJ.2
INJ.3
INJ.4
INJ.5
INJ.6
90
89
88
87
86
85
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000401
D Group
060MX113
Test Description
Diagnostic Aids
An intermittent may be caused by a poor connection,
rubbedthrough wire insulation or a wire broken inside the
insulation. Check for poor connections or a damaged
harness. Inspect the ECM harness and connector for
improper mating, broken locks, improperly formed or
damaged terminals, poor terminal-to-wire connection, and
damaged harness.
STEP
1
ACTION
Was the On-Board Diagnostic (OBD) system Check
performed?
VALUE
YES
NO
Go to step 2
Go to OBD
system check
Verify repair
Go to OBD
system check
Go to step 3
Verify repair
Go to OBD
system check
Go to step 4
Verify repair
Go to OBD
system check
Go to step 5
Verify repair
Go to OBD
system check
Replace ECM
1.
2.
3.
4.
5.
6.
Replace ECM
Was ECM replaced?
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
24
1, 3
23
25
22
15
DTC table
DTC table
Refer to
Illuminate
MIL
Description
14
DTC
The following table lists the diagnosis trouble codes supported by this vehicle
application. If any DTCs not listed here are displayed by a scan tool, the scan tool data
Remarks
Fail safe
may be faulty; notify the scan tool manufacture of any DTCs displayed that are not
included in the following table.
1
1
1
CPU Monitoring IC
Error (ECM inside trouble)
32
33
34
35
118
151
158
115
DTC table
71
DTC table
65
DTC table
Lack of power,
PTO abnormal (common used power source)
Lack of power,
PTO abnormal (common used power source)
Lack of power,
PTO abnormal (common used power source)
Lack of power.
Engine hunting.
Remarks
Fail safe
42
DTC table
Refer to
28
Illuminate
MIL
Description
DTC
Check fuel pressure in a common Limits are set to common rail pressure
Lack of power, Black smoke, Both of fuel
rail, DTC table
open loop control, common rail pressure pressure and engine hunting,
and injection amount.
PTO engage impossible
Common rail pressure: 60 MPa
Injection amount: 50 mm3/st
Common rail pressure is limited to 60
MPa or less.
1
1
3
3
217
218
226
227
245
247
248
261
262
211
Remarks
Fail safe
Refer to
159
Illuminate
MIL
Description
DTC
3
3
3
1
1
1
1
1
1
2
3
264
265
266
271
272
273
274
275
276
416
417
421
543
DTC table
Remarks
Fail safe
Refer to
Illuminate MIL
1 Turn on lamp is starter switch ON.
2 Turn on lamp after engine is running more than 20 second.(at idle)
3 Not turn on lamp.
263
Illuminate
MIL
Description
DTC
CAM SENSOR
(PUMP
POSITION)
- +
77 58 49
Engi n e C o n t r o l M o d u l e ( E C M )
060MY00028
Circuit Description
CAM sensor is installed at the side of the supply pump,
serving to distinguish the cylinders of the engine and back up
the detection of engine speed (in case of CKP sensor
trouble).
This CAM sensor comprises the same parts as in CKP
sensor, but the number of turns of its coil is different from that
of CKP sensor and installed to the supply pump.
With the engine started, the pulser notches in the middle of
the supply pump camshaft cut off intermittently the magnetic
field made by the sensor magnet, thereby generating
alternating current.
The pulser notches are made every 60 of camshaft (every
120 of crank angle) and there is a surplus tooth.
Therefore, seven pulses are outputted per one rotation of
camshaft (2 rotations of the engine). The pulse outputted by
the surplus tooth is recognized as engine number 1 cylinder
reference pulse.
Diagnostic Aids
Check for the following conditions:
Poor connection at ECM Inspect harness connectors
for backed-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
Damaged harness Inspect the wiring harness for
damage, shorts to ground, shorts to battery and open
circuits. If the harness appears to be OK, observe the
injection pump signal present display on the scan tool
while moving connectors and wiring harnesses related to
the CAM sensor. A change in the display will indicate the
location of the fault.
White smoke in case of racing.
Poor output of tachometer (CAM failure during drive is
outputted till engine stop).
ACTION
Was the On-Board Diagnostic (OBD) System Check
performed?
VALUE
1850
to
2450
(about 20C)
1850
to
2450
(about 20C)
Go to step 2
Go to OBD
System
Check
Go to step 3
Go to
Diagnostic Aids
Go to step 7
Go to step 4
Go to step 5
Repair harness
then
Go to step 9
Go to step 6
Replace CAM
sensor then
Go to step 9
Go to step 9
Replace CAM
sensor then
Go to step 9
Go to step 8
Replace
supply pump
assembly then
Go to step 8
Replace ECM
then
Go to step 9
Go back step 3
System OK
Less than
2
NO
YES
More than
10M
More than
0.4V/260 rpm
More than
3.4V/2600 rpm
Note:
As compared with CAM sensor, CKP sensor is difficult
to detect trouble because its influence is smaller.
An Intermittent condition can be caused by the
following
Poor connections
Rubbed through wire insulation
There are two countermeasure for CAM sensor error,
one is CAM sensor replacement and the other is
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
B
View B
1
90
41
120
71
A
E
C
M
View A
Measuring method 1
Measuring method 3
Measurement
Measurement
CAM SENSOR
E
C
M
CAM SENSOR
Harness
E
C
M
Harness
Measuring method 2
Measuring method 4
Measurement
Measurement
CAM SENSOR
E
C
M
CAM SENSOR
E
C
M
Harness
Harness
Measuring method 5
Measurement
CAM SENSOR
E
C
M
Harness
Measuring method 6
Measurement
CAM SENSOR
E
C
M
Harness
ECM
CAM SENSOR
(PUMP POSITION)
49
58
77
LFW36EXF000201
CKP SENSOR
(CRANK
POSITION)
- +
76 57 48
Eng i n e C o n t r o l M o d u l e ( E C M )
060MY00029
Circuit Description
This sensor comprises a permanent magnet, coil, and iron
core and is installed to the flywheel housing. With the engine
started, the signal holes made on the outer periphery of the
flywheel cut off intermittently the magnetic field made by the
magnet, thereby generating AC in the coil.
The signal holes on the flywheel are provided every 7.5,
but 3 point is holeless. Therefore, the signal holes total 45.
90 pulses are outputted per 2 rotations of the engine. By this
signal, engine speed and 7.5-based crank angle can be
detected.
Diagnostic Trouble Code 15 will set when the ECM detects
a no signal for open circuit or sensor damage on the CKP
sensor signal circuit.
10
ACTION
Was the On-Board Diagnostic (OBD) System Check
performed?
VALUE
NO
Go to step 2
Go to OBD
System
Check
Go to step 3
Go to
Diagnostic Aids
Go to step 7
Go to step 4
Go to step 5
Repair CKP
sensor harness
then
Go to step 10
Go to step 6
Replace CKP
sensor then
Go to step 10
Go to step 10
Replace CKP
sensor then
Go to step 10
Go to step 8
Adjustment then
Go to step 10
Replace
CKP sensor
Go to step 9
Replace ECM
Go to step 10
Go back step 3
System OK
109
to
143
(about 20C)
Less than
2
109
to
143
(about 20C)
YES
10M
or more
Note:
1. If scan tool is used, intermittent trouble can be
detected by CKP sensor active flag(Crank signal
Present).
2. If CKP sensor signal is completely lost, tachometer
output is not produced (When NG in the midway, use
CAM sensor to produce output).
3. Under CAM sensor operation, diesel knocking and/or
white smoke may often occur due to racing.
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
NOTE: Air gap value is 0.9 to 1.2 mm between CKP sensor and flywheel. (Not adjustable)
B
View B
1
90
41
120
71
A
E
C
M
View A
Measuring method 1
Measuring method 3
Measurement
Measurement
CKP SENSOR
E
C
M
CKP SENSOR
Harness
E
C
M
Harness
Measuring method 2
Measurement
Measuring method 4
Measurement
CKP SENSOR
E
C
M
CKP SENSOR
E
C
M
Harness
Harness
Measuring method 5
Measurement
CKP SENSOR
E
C
M
Harness
Measuring method 6
Measurement
CKP SENSOR
E
C
M
Harness
ECM
CKP SENSOR
(CRANK POSITION)
48
57
76
FLW36EXF000301
SENSOR
INTAKE
AIR
TEMP
SENSOR
FUEL TEMP
SIG
53
SIG
52
SENSOR
ENGINE
COOLANT
TEMP
GND SIG
66
30
Eng i n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000301
Circuit Description
The Intake Air Temperature (IAT) Sensor is located inside
of cab front panel.
The IAT is changed into a resistance change signal and
sent to ECM for optimization of fuel injection control.
Diagnostic Trouble Code 22 will set when the ECM detects
abnormal signal for open circuit or sensor damage on the
sensor signal circuit.
ACTION
VALUE
0.1V
to
4.95V
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 5
Go to step 4
Repair IAT
sensor harness
Go to step 6
Go to step 10
Go to step 6
Go to step 7
Repair
disconnect
IAT sensor
harness.
Go to step 8
Repair/replace
IAT sensor
harness.
Then go to
step 10
Go to step 9
Replace IAT
sensor
assembly.
Then go to
step 10
Replace ECM
assembly then
Go to step 10
System OK
Go back to
step 3
System OK
Fixed
20C (68F)
2 or less
10M or more
10
Resistance (k)
20
40
1.6 (1.9V)
60
0.8 (1.1V)
80
0.4 (0.7V)
Clear DTC.
Is display DTC 22?
View A
90
41
120
71
View B
1
66P
53P
A
E
C
M
Measuring method 1
Measuring method 3
Measurement
Measurement
SENSOR
INTAKE AIR TEMP
SENSOR
INTAKE AIR TEMP
E
C
M
Harness
Harness
Measuring method 2
SENSOR
INTAKE AIR TEMP
E
C
M
Measuring method 4
Measurement
E
C
M
SENSOR
Measurement
INTAKE AIR TEMP
E
C
M
Harness
Harness
ECM
SENSOR
ENGINE COOLANT TEMP
30
66
SENSOR
FUEL TEMP
SENSOR
INTAKE AIR TEMP
53
FLW36EXF000401
SENSOR
INTAKE
AIR
TEMP
SENSOR
FUEL TEMP
SIG
53
SIG
52
SENSOR
ENGINE
COOLANT
TEMP
GND SIG
66
30
Eng i n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000301
Circuit Description
The engine control module (ECM) applies a voltage (about
5 volts) through a pull-up resistor to the ECT signal circuit.
When the engine coolant is cold, the sensor (thermistor)
resistance is high, therefore the ECM will measure a high
signal voltage. As the engine coolant warms, the sensor
resistance becomes less, and the ECT signal voltage
measured at the ECM drops. With a fully warmed up engine,
the ECT signal voltage should measure about 1.5 to 2.0 volts.
If the ECM detect a continuous open in the ECT sensor or
circit, then a code 23 will set.
ACTION
VALUE
0.1V to 4.8V
2 or less
10M or more
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 5
Go to step 4
Go to step 5
Go to step 6
Go to step 3
Complete
Then go to
step 10
Go to step 7
Repair/replace
to ECT sensor
harness
Go to step 8
Repair/replace
to ECT sensor
harness
Go to step 9
Replace ECT
sensor
Replace ECM
assembly.
Then go to
step 10
System OK
Go back to
step 3
System OK
10
Resistance (k)
20
40
1.3 (1.6V)
60
0.6 (0.9V)
80
0.4 (0.65V)
66P
B
View A
90
41
120
71
View B
1
A
E
C
M
View A
30P
10
40
31
Measuring method 1
Measurement
SENSOR
ENGINE COOLANT TEMP
Measuring method 3
Measurement
SENSOR
ENGINE COOLANT TEMP
E
C
M
Harness
Harness
Measuring method 2
SENSOR
ENGINE COOLANT TEMP
E
C
M
Measuring method 4
Measurement
E
C
M
SENSOR
Measurement
ENGINE COOLANT TEMP
E
C
M
Harness
Harness
ECM
SENSOR
ENGINE COOLANT TEMP
30
66
SENSOR
FUEL TEMP
52
SENSOR
INTAKE AIR TEMP
53
FLW36EXF000501
ACCELERATOR SENSOR
54
63
45
44
41
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000201
Circuit Description
This sensor is an IC type substituting electric signals for
accelerator pedaling amount to be sent to ECM. It is installed
to accelerator pedal bracket assembly.
The Accelerator Position (AP) signal is used by the engine
control module (ECM) for fuel control and most of the ECM
controlled outputs. The ECM monitors accelerator position. If
the ECM detects an out-of-range condition, then a DTC code
24 will set.
Item 4. Accelerator
Sensor 2
Intermediate voltage hold trouble.
Item 1 and 2: Accelerator voltage exceeding 4.8V or lower
than 0.5V continues 1 sec. or more.
Item 3 and 4: Difference between previous value and current
value is lower than 0.05 V (stationary), difference from the
other sensor voltage exceeding 0.2V and no individual
abnormality detected by sensor 1 and 2 continues.
Diagnostic Aids
Check for the following conditions:
Poor connection at ECM Inspect harness connectors
for backed-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
Damaged harness Inspect the wiring harness for
damage, shorts to ground, shorts to battery and open
circuits. If the harness appears to be OK, observe the
APP sensor display on the scan tool while moving
connectors and wiring harnesses related to the AP
sensor. A change in the APP sensor display will indicate
the location of the fault.
Poor throttle response.
No accelerator response.
1200 rpm fixed.
056MV040
EF
.)
7.
(R
1
3
VIEW A
2
Legend
(1) Pedal Initial Position
(2) Sensor Set Position
(3) Sensor Travel (Deg.)
(4) Pedal Full Position
(5) Pedal Full Stroke Position
(6) Idling Side Sensor Set Position
056MV039
ACTION
VALUE
0%
1.
2.
3.
4.
4.5V to 5.5V
Idle Position
0.85 to 1.15V
YES
NO
Go to step 2
Go to OBD
System check
Go to step 3
Go to
Diagnostic Aids
Go to Step 4
Repair/
Replace
circuit or
brake switch
Repair/
Replace
sensor harness
Go to Step 5
Go to Step 6
Replace ECM
Go to Step 8
Go to Step 7
Go to Step 8
Go to Step 9
Replace
accelerator
position sensor
Go back to
step 6
Idle Position
0.85 to 1.15V
WOT Position
4.5V (MAX)
10
11
ACTION
VALUE
Check the APP sensor 1 output voltage (SIG) and the APP
sensor 2
output voltage (SIG)
As compared with specified value, it checks whether output
voltage is normal.
Is voltage within value?
Idle Position
0.85 to 1.15V
WOT Position
4.5V (MAX)
Idle Position
0.85 to 1.15V
WOT Position
4.5V (MAX)
YES
NO
Go to Step 10
Replace
accelerator
position sensor
Go back to
step 6
Go to Step 11
Replace ECM
Go back to
step 3
System OK
Note: After replacing the APP it is necessary to set voltage at idle position. (See page 6E-141 for procedure)
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
View A
View B
1
90
120
46 45 44
54
41
41
E
C
M
63
71
Measuring method 1
ACCELERATOR
Measurement
PEDAL POSITION
SENSOR
Harness
Measuring method 4
ACCELERATOR
Measurement
PEDAL POSITION
SENSOR
E
C
M
Measuring method 2
ACCELERATOR
PEDAL POSITION Measurement
SENSOR
Harness
Measuring method 3
ACCELERATOR
Measurement
PEDAL POSITION
SENSOR
Harness
Harness
E
C
M
E
C
M
Measuring method 5
ACCELERATOR
Measurement
PEDAL POSITION
SENSOR
Harness
E
C
M
Measuring method 6
ACCELERATOR
Measurement
PEDAL POSITION
SENSOR
Harness
E
C
M
E
C
M
ECM
41
44
ACCELERATOR
PEDAL POSITION
SENSOR
45
63
54
46
LFW36EXF000601
SIG
75
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000601
Circuit Description
Diagnostic Aids
Check the following conditions:
Poor connection at ECM Inspect harness connectors for
back-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
Damaged harness Inspect the wiring harness for
damage, shorts to battery and open circuits. If the harness
appears to be OK, observe the injection pump signal
present display on the scan tool while moving connectors
and wiring harness related to the VS sensor. A change in
the display will indicate the location of the fault.
10
ACTION
VALUE
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 4
Go to step 5
Go to step 3
Go to step 9
Go to step 6
Go to step 8
Go to step 7
Go to step 9
Go to step 6
Verify repair
Go to step 10
Go to step 9
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
View A
90
41
120
71
A
ECM
75P
View B
3P
Vehicle Speed
B
Sensor C/U
Measuring method 1
Measurement
VSS C/U
12
12P
ECM
Harness
10P
Measuring method 2
Measurement
VSS
VSS C/U
ECM
Harness
ECM
Measuring method 3
VCC
Measurement
VSS
VSS
C/U
VEHICLE
SPEED
SENSOR
SIG
GND
VSS
C/U
75
Harness
LFW36EXF000701
SIG
64
BOOST
SENSOR
GND VCC
56
SIG
72 61
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000101
Description
The PTO accelerator position sensor provides a voltage
signal that changes relative to PTO accelerator angle. The
signal voltage will vary from about 0.5 volts at PTO
accelerator idle position to about 4.5 volts at PTO accelerator
full position.
The PTO accelerator position sensor signal is used by the
ECM for fuel control and many of the ECM-controlled outputs.
The ECM monitors PTO accelerator position and
compares actual PTO accelerator position from the PTO
accerelator position sensor to a predicted PTO accelerator
position sensor value calculated from engine speed.
If the ECM detects an out-of-range condition, DTC 28 will
set.
Diagnostic Aids
Check the following conditions:
Poor connection at ECM Inspect harness connectors for
back-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
Damaged harness Inspect the wiring harness for
damage, shorts to battery and open circuits. If the harness
appears to be OK, observe the injection pump signal
present display on the scan tool while moving connectors
and wiring harness related to the PTO accelerator position
sensor. A change in the display will indicate the location of
the fault.
10
ACTION
Was the "On-Board Diagnostic (OBD) System Check"
performed?
Measure the impression voltage of PTO accelerator position
sensor.
1. Starter switch "OFF".
2. Disconnect the harness from PTO accelerator position
sensor.
3. Starter switch "ON".
4. Measure voltage between VCC and ground at PTO
accelerator position sensor side connector.
Was voltage within value?
VALUE
5V0.25
Go to step 2
Go to OBD
System Check
Go to step 6
Go to step 3
Go to step 5
Go to step 4
Go to step 3
Go to step 3
Go to step 7
Go to step 8
Go to step 11
Go to step 10
Go to step 9
Go to step 10
Go to step 7
Verify repair
Go to Step 12
Go to step 11
Sensor signal
position: 0.3 to
0.5V (Idle
position)
position: 4.2 to
4.5V (WOT)
NO
YES
Sensor signal
position: 0.3 to
0.5V
position: 4.2 to
4.5V
11
12
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
56P
64P
72P
B
View A
View B
1
90
41
120
71
A
E
C
M
Measuring method 1
Measurement
PTO
ACCELERATOR
POSITION
SENSOR
E
C
M
Harness
Measuring method 2
Measurement
PTO
ACCELERATOR
POSITION
SENSOR
E
C
M
Harness
Measuring method 3
Measurement
PTO
ACCELERATOR
POSITION
SENSOR
E
C
M
Harness
ECM
PTO
ACCELERATOR
POSITION
SENSOR
64
72
56
LFW36EXF000801
PTO
ACCELERATOR
POSITION
SENSOR
SIG
BOOST
SENSOR
GND VCC
64
56
SIG
72 61
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000101
Circuit Description
ACTION
Was the On-Board Diagnostic (OBD) System Check
performed?
About 1.3V
4.75V
to
5.25V
VALUE
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 7
Go to step 4
Go to step 6
Go to step 5
Replace boost
sensor.
Then go to
step 10
Repair boost
sensor harness.
Replace boost
sensor or
ECM assembly.
Then go to
step 10
Repair boost
sensor harness.
Go to step 8
Replace boost
sensor
Go to step 9
Go to step 10
System OK
Repair piping
and/or Replace
turbocharger
2 or less
10M or more
2 or less
10M or more
Pressure
(kPa)
0
50
162
Voltage
(V)
1.029
1.75
3.43
11
ACTION
Clear all DTCs.
Is DTC 32?
VALUE
YES
NO
Replace ECM
assembly.
Then go to
step 11
System OK
Replace ECM.
Go to step 11
System OK
Caution: The actual measuring output voltage of boost sensor will be drifted due to if power source voltage
of boost sensor comes down.
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
56P
72P
61P
B
View A
View B
1
90
41
120
A
E
C
M
71
Measuring method 1
Measurement
E
C
M
BOOST SENSOR
Harness
Measuring method 2
Measurement
BOOST SENSOR
E
C
M
Harness
Measuring method 3
Measurement
BOOST SENSOR
E
C
M
Harness
ECM
61
BOOST
SENSOR
72
56
LFW36EXF000901
060MX113
Circuit Description
The ECM supplies either 5 or 24 volts to power various
sensors or switches. The power is supplied through
resistances in the ECM which are so high in value that a test
light will not light when connected to the circuit. In some
cases, even an ordinary shop voltmeter will not give an
accurate reading because its resistance is too low. The ECM
controls output circuits such as the injectors, ISC, etc.
The input/output devices in the ECM include analog-todigital converters, signal buffers, counters, and special
drivers. The ECM controls most components with electronic
switches which complete a ground circuit when turned ON.
STEP
1
Diagnostic Aids
ACTION
VALUE
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 5
Go to step 4
Repair problem.
Then go to
step 6
System OK
Replace ECM
assembly.
Then go to
step 6
System OK
System OK
Go back to
step 3
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
060MX113
STEP
ACTION
VALUE
YES
NO
Go to step 2
Assume that fuel rate data may not be written to ECM after
replaced ECM assembly.
Is the Fuel Rate data listed on the scan tool?
Check scan
tool connection
and/or ECM
connection.
Then go to
step 4
Go to step 3
Same as step 2
System OK
Go back to
step 2
System OK
Note:
When ECM assembly replaced, scan tool is required.
Make sure that lamp is lighted when DTC 34 code is
set.
When ECM replaced, down load fuel rate number from
the old ECM, and then input it into new ECM by scan
tool.
If step 2 and/or 4 are intermittents, call ISUZU Tech
Line staff.
060MX113
Circuit Description
The ECM supplies either 5 or 24 volts to power various
sensors or switches. The power is supplied through
resistances in the ECM which are so high in value that a test
light will not light when connected to the circuit. In some
cases, even an ordinary shop voltmeter will not give an
accurate reading because its resistance is too low. The ECM
controls output circuits such as the injectors, ISC, etc.
The input/output devices in the ECM include analog-todigital converters, signal buffers, counters, and special
drivers. The ECM controls most components with electronic
switches which complete a ground circuit when turned ON.
STEP
1
Diagnostic Aids
ACTION
Charging Circuit
Error
(ECM inside
trouble)
Lack of power.
and increasing smoke.
(white smoke)
VALUE
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 5
Go to step 4
Repair problem.
Then go to
step 6
System OK
Replace ECM
assembly.
Then go to
step 6
System OK
System OK
Go back to
step 3
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
PTO
ACCELERATOR
POSITION
SENSOR
SIG
BOOST
SENSOR
GND VCC
64
56
SIG
72 61
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000101
Circuit Description
The boost sensor is fixed on the cab back frame and is
connected to rear portion of inlet manifold by vacuum hose.
The boost sensor generates voltage according to air
aspiration pressure and the generated voltage is input to ECM
for boost sensor signal.
If the ECM detects a boost sensor signal voltage that is
excessively high, Diagnostic Trouble Codes 42, 32 will be set.
ACTION
VALUE
Normal value
see table left
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 4
Replace boost
sensor and/or
repair piping
Repair or
replace
abnormal
portion.
Go to step 5
Go to step 6
Repair/replace
turbocharger
and/or
wastegate
piping.
Refer to
Section 6J in
this manual.
Then go to
step 6
Replace ECM.
Then go to
step 7
System OK
Go back to
step 3
System OK
Boost
Sensor voltage
80 kPa
About 0.7V
(Negative pressure)
Atmospheric release
1.0V
169 kPa
2.0V
Guide line
value see table
at left
Voltage
3.4 V or more
Boost
CKP
Acceleration
100%
Caution: The actual measuring output voltage of boost sensor will be drifted due to if power source voltage
of boost sensor comes down.
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
56P
72P
61P
B
View A
View B
1
90
41
120
A
E
C
M
71
Measuring method 1
Measurement
E
C
M
BOOST SENSOR
Harness
Measuring method 2
Measurement
BOOST SENSOR
E
C
M
Harness
Measuring method 3
Measurement
BOOST SENSOR
E
C
M
Harness
ECM
61
BOOST
SENSOR
72
56
LFW36EXF000901
PTO
ACCELERATOR
POSITION
SENSOR
SIG
BOOST
SENSOR
GND VCC
64
56
SIG
72 61
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000101
Circuit Description
ACTION
VALUE
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 4
Replace boost
sensor or
repair/replace
boost sensor
harness.
Repair or replace
abnormal portion.
Go to step 5
Go to step 6
Replace boost
sensor and/or
repair
turbocharger.
Refer to section
6J in this
manual
then go to
step 6
Replace ECM
assembly.
Then go to
step 7
System OK
Go back to
step 3
System OK
Normal value
see table left
Boost
Sensor voltage
80 kPa
About 0.7V
(Negative pressure)
Atmospheric release
1.0V
169 kPa
2.0V
Guide line
value see
table left
Voltage
2.0 V or less
Boost
70 kPa or less
CKP
2,000 rpm
Acceleration
100%
Caution: The actual measuring output voltage of boost sensor will be drifted due to if power source
voltage of boost sensor comes down.
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
56P
72P
61P
B
View A
View B
1
90
41
120
71
A
E
C
M
Measuring method 1
Measurement
E
C
M
BOOST SENSOR
Harness
Measuring method 2
Measurement
BOOST SENSOR
E
C
M
Harness
Measuring method 3
Measurement
BOOST SENSOR
E
C
M
Harness
ECM
61
BOOST
SENSOR
72
56
LFW36EXF000901
060MX113
Circuit Description
The BARO sensor is installed in the ECM.
If the ECM detects a signal voltage that is excessively low
or high, Diagnostic Trouble Code 71 will be set.
STEP
1
ACTION
VALUE
YES
NO
Go to step 2
Go to
Diagnostic Aids
Replace ECM
assembly.
Then go to
step 3.
Erroneous
diagnosis due to
electrical noise
or
intermittent
problem.
Go back to
step 2
System OK
PRESSURE SENSOR
COMMON RAIL
GND VCC
55
73
SIG
71
62
Engine C o n t r o l M o d u l e ( E C M )
056MX022
Circuit Description
The common rail is installed to intake manifold, equipped
with flow damper, pressure limiter, and common rail pressure
sensor.
The common rail unit has a common fuel passage, fuel
passage holes, and installing threaded holes. The common
fuel passage is a through hole made in the common rail unit.
The common rail pressure sensor is installed at the left end of
the hole.
The ECM monitors the Rail Pressure signals for voltage
outside the normal range of the Rail Pressure sensor. If the
ECM detects a Rail Pressure signal voltage that is
excessively abnormal, Diagnostic Trouble Code 115 will be
set.
Diagnostic Aids
Check for the following conditions:
Poor connection at ECM Inspect harness connectors
for backed-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
Damaged harness Inspect the wiring harness for
damage, shorts to ground, shorts to battery and open
circuits. If the harness appears to be OK, observe the
Rail pressure display on the scan tool while moving
connectors and wiring harnesses related to the Rail
pressure sensor. A change in the Rail pressure display
will indicate the location of the fault.
ACTION
VALUE
0.9V
to
1.1V
2 or less
No change
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 5
Go to step 4
Replace
common rail
pressure
sensor or ECM
assembly then
Go to step 11
Repair or
replace
common rail
pressure
sensor harness
then
Go to step 11
Go to step 7
Go to step 6
Replace ECM
assembly then
Go to step 11
Correct to
incomplete
contact of
connector then
Go to step 11
Go to step 8
Repair the
common rail
pressure
sensor harness
then
Go to step 11
2 or less
10
11
ACTION
Measure the resistance between pin number 71 and 62 at
ECM side connector and GND on common rail pressure
sensor harness. (List measurement method number)
Is resistance within value?
Clear DTC.
Does DTC 115 display?
VALUE
YES
NO
Go to step 9
Repair the
common rail
pressure
sensor harness
then
Go to step 11
Go to step 10
Correct to
incomplete
contact of
connector, then
Go to step 11
Replace
common rail
pressure
sensor or ECM
assembly then
Go to step 11
System OK
Go back to
step 3
System OK
10M or more
View A
90
View B
1
55P
73P
62P
71P
41
120
A
E
C
M
71
Measuring method 1
Measuring method 3
Measurement
COMMON RAIL
PRESSURE SENSOR
Measurement
COMMON RAIL
PRESSURE SENSOR
E
C
M
E
C
M
Harness
Harness
Measuring method 2
Measuring method 4
Measurement
COMMON RAIL
PRESSURE SENSOR
E
C
M
COMMON RAIL
PRESSURE SENSOR
Measurement
E
C
M
Harness
Harness
ECM
62
COMMON RAIL
PRESSURE
71
73
55
LFW36EXF001001
PRESSURE SENSOR
COMMON RAIL
GND VCC
55
73
71
SIG
62
Engin e C o n t r o l M o d u l e ( E C M )
056MX022
Circuit Description
The Common rail is installed to intake manifold, equipped
with flow damper, pressure limiter, and common rail pressure
sensor.
The common rail pressure sensor, installed at left end of
the common rail, serving the detect fuel pressure. It is a
semiconductor type pressure sensor utilizing silicons
property that the electric resistance of pressurized silicone is
varied.
The ECM monitors the Rail Pressure signals for voltage
outside the normal range of the Rail Pressure sensor. If the
ECM detects a Rail Pressure signal voltage that is
excessively low, Diagnostic Trouble Code 118 will be set.
Diagnostic Aids
Check for the following conditions:
Poor connection at ECM Inspect harness connectors
for backed-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
Damaged harness Inspect the wiring harness for
damage, shorts to ground, shorts to battery and open
circuits. If the harness appears to be OK, observe the
display on the scan tool while moving connectors and
wiring harnesses related to the sensor. A change in the
display will indicate the location of the fault.
ACTION
VALUE
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 5
Repair/replace
common rail
pressure
sensor harness.
Then go to
step 4
Replace ECM
assembly.
Then go to
step 5
Go to step 9
Go to step 6
Go to step 7
Repair
incomplete
connection on
the connector
Go to step 12
Replace
common rail
pressure
sensor.
Then go to
step 8
Go back to
step 6
Go to step 7
System OK
Go to step 10
Repair/replace
common rail
pressure
sensor harness.
Then go to
step 12
Replace
common rail
pressure
sensor.
Then go to
step 11
Replace
common rail
pressure
sensor harness
then
go to step 11
3.4V or more
(at 125 MPa)
3.4V or more
2 or less
10M or more
10
NO
YES
12
ACTION
Reconnect all connectors.
Does DTC 118 display?
VALUE
YES
NO
Replace ECM
assembly.
Then go to
step 12
System OK
Go back to
step 3
System OK
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
View A
View B
1
55P
73P
62P
71P
90
41
120
71
Measuring method 1
A
E
C
M
Measuring method 3
Measurement
COMMON RAIL
PRESSURE SENSOR
Measurement
COMMON RAIL
PRESSURE SENSOR
E
C
M
E
C
M
Harness
Harness
Measuring method 2
Measuring method 4
Measurement
COMMON RAIL
PRESSURE SENSOR
E
C
M
COMMON RAIL
PRESSURE SENSOR
Measurement
E
C
M
Harness
Harness
ECM
62
COMMON RAIL
PRESSURE
71
73
55
LFW36EXF001001
PRESSURE SENSOR
COMMON RAIL
GND VCC
55
73
71
SIG
62
Eng i n e C o n t r o l M o d u l e ( E C M )
056MX022
Circuit Description
The Common rail is installed on the intake manifold,
equipped with flow damper, pressure limiter, and common rail
pressure sensor.
The common rail unit has a common fuel passage and fuel
passage holes. The common fuel passage is a through hole
made in the common rail unit. The common rail pressure
sensor is installed at the left end of the unit.
The ECM monitors the Rail Pressure signals for voltage
outside the normal range of the Rail Pressure sensor. If the
ECM detects a Rail Pressure signal voltage that is
excessively high, Diagnostic Trouble Code 151 will be set.
ACTION
VALUE
Does the scan tool display DTC 151 while engine is running
or when key switch ON?
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to Fuel System
Check then
Go to step 3
Go to step 4
Go to step 7
Go to step 6
Go to step 5
System OK
Reconnect or
repair common
rail pressure
sensor harness,
then
Go to step 11
First,repair or
replace for
these problems.
Go to step 8
Go to step 8
Repair/replace
or correct
connector
contact for
common rail
pressure
sensor harness.
Then go to
step 11
Go to step 9
Repair harness
shortage or
replace
common rail
pressure
sensor harness.
Then go to
step 11
Replace
common rail
pressure
sensor.
Then go to
step 11
Repair harness
shortage or
replace common
rail pressure
sensor harness.
Then go to
step 11
YES
2 or less
10M or more
11
ACTION
Clear all DTCs then engine start.
Is DTC 151 display?
VALUE
YES
NO
Replace ECM
assembly.
Then go to
step 11
System OK
Go back to
step 3
System OK
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
View A
View B
1
55P
73P
62P
71P
90
41
120
71
Measuring method 1
A
E
C
M
Measuring method 3
Measurement
COMMON RAIL
PRESSURE SENSOR
Measurement
COMMON RAIL
PRESSURE SENSOR
E
C
M
E
C
M
Harness
Harness
Measuring method 2
Measuring method 4
Measurement
COMMON RAIL
PRESSURE SENSOR
E
C
M
COMMON RAIL
PRESSURE SENSOR
Measurement
E
C
M
Harness
Harness
ECM
62
COMMON RAIL
PRESSURE
71
73
55
LFW36EXF001001
COM2
COM1
120 119
110 100
CYL.1
CYL.5
CYL.3
CYL.6
CYL.2
CYL.4
INJ.1
INJ.2
INJ.3
INJ.4
INJ.5
INJ.6
90
89
88
87
86
85
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000401
Circuit Description
A hydraulic piston and injector have been added to the
conventional nozzle. Receiving signals from the ECM, the
injector opens and closes to change the pressure in the
pressure adjustment chamber on top of the hydraulic piston
so that the hydraulic piston operates, thereby to inject the fuel
from the nozzle.
ACTION
VALUE
Does the scan tool display DTC 158 or DTC 159 while key
switch ON or engine is running?
1V or less
1V or less
10M or more
10M or more
0.4 to 0.8
(about 20C)
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 4
Repair
common1
and/or
common2
of indicator
harness.
Then go to
step 6
Go to step 5
Repair/replace
injector
harness.
Then go to
step 7
Go to step 6
Repair/replace
injector
harness.
Then go to
step 7
Go to step 8
Repair/replace
injector
harness.
Then go to
step 9
Go to step 8
Replace
injector
assembly.
Then go to
step 8
ACTION
1. Clear DTC.
2. Start engine.
Does DTC 158 or DTC 159 display?
VALUE
YES
NO
Replace ECM
assembly.
Then go to
step 9
System OK
Go back to
step 3
System OK
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
A
E
C
M
INJECTOR 1(CYL1)
Connector1 View B
3
View A
41
120
71
110P
120
71
View A
90
41
120
71
41
110P
119P
120P
87P
90
41
120
71
INJECTOR 6(CYL4)
Connector2
100P
86P
98P
INJECTOR 4(CYL6)
Connector2
100P
88P
90
INJECTOR 5(CYL2)
Connector1
3
90
INJECTOR 3(CYL3)
Connector1
3
INJECTOR 2(CYL5)
Connector2 View B
90P
100P
119P
120P
85P
90
41
90
41
120
71
120
71
119P
120P
110P
Measuring method 1
INJECTOR
E
C
M
Harness
Measuring method 3
INJECTOR
Measuring method 2
Measurement
E
C
M
Measuring method 4
Measurement
Harness
INJECTOR
E
C
M
INJECTOR
Harness
E
C
M
ECM
100
110
CYL1
CYL2
CYL3
90
86
88
119
120
CYL4
CYL5
CYL6
85
89
87
LFW36EXF001101
COM2
COM1
120 119
110 100
CYL.1
CYL.5
CYL.3
CYL.6
CYL.2
CYL.4
INJ.1
INJ.2
INJ.3
INJ.4
INJ.5
INJ.6
90
89
88
87
86
85
Eng i n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000401
Circuit Description
A hydraulic piston and injector have been added to the
conventional nozzle. Receiving signals from ECM, the injector
opens and closes to change the pressure in the pressure
adjustment chamber on top of the hydraulic piston so that the
hydraulic piston operates, thereby to inject the fuel from the
nozzle.
ACTION
VALUE
Does the scan tool display DTC 158 or DTC 159 while key
switch ON or engine is running?
1V or less
1V or less
10M or more
10M or more
0.4 to 0.8
(about 20C)
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 4
Repair
common1
and/or
common2
of injector
harness.
Then go to
step 6
Go to step 5
Repair/replace
injector
harness.
Then go to
step 7
Go to step 6
Repair/replace
injector
harness.
Then go to
step 7
Go to step 7
Repair/replace
injector
harness.
Then go to
step 9
Go to step 8
Replace
injector
assembly.
Then go to
step 8
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
ACTION
1. Clear DTC.
2. Start engine.
Does DTC 158 or DTC 159 display?
VALUE
YES
NO
Replace ECM
assembly.
Then go to
step 9
System OK
Go back to
step 3
System OK
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
A
E
C
M
INJECTOR 1(CYL1)
Connector1 View B
3
View A
41
120
71
110P
41
120
71
View A
90
41
120
71
110P
87P
90
41
120
71
119P
120P
INJECTOR 6(CYL4)
Connector2
100P
86P
98P
INJECTOR 4(CYL6)
Connector2
100P
88P
90
INJECTOR 5(CYL2)
Connector1
3
90
INJECTOR 3(CYL3)
Connector1
3
INJECTOR 2(CYL5)
Connector2 View B
90P
100P
119P
120P
85P
90
41
90
41
120
71
120
71
119P
120P
110P
Measuring method 1
E
C
M
Harness
Measuring method 3
INJECTOR
Measuring method 2
Measurement
INJECTOR
E
C
M
Measuring method 4
Measurement
Harness
INJECTOR
E
C
M
INJECTOR
Harness
E
C
M
ECM
100
110
CYL1
CYL2
CYL3
90
86
88
119
120
CYL4
CYL5
CYL6
85
89
87
LFW36EXF001101
SENSOR
INTAKE
AIR
TEMP
SENSOR
FUEL TEMP
SIG
53
SIG
52
SENSOR
ENGINE
COOLANT
TEMP
GND SIG
66
30
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000301
Circuit Description
ACTION
VALUE
Does the scan tool display DTC 211 while key switch ON or
engine running?
0.1V
to
4.8V
More than
212F (100C)
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 5
Go to step 4
Correct to
complete
connection.
Go to step 5
Repair fuel
system
Go to step 6
Go to step 7
Repair/replace
fuel
temperature
sensor harness.
Go to step 8
Repair/replace
fuel
temperature
sensor harness
Go to step 9
Replace fuel
temperature
sensor
Replace ECM
assembly then
Go to step 10
System OK
Go back to
step 3
System OK
2 or less
10M or more
See table on
left
10
Resistance (k)
About 2.7 (3V)
40
1.3 (2.2V)
60
0.6 (1.5V)
80
0.4 (1V)
View A
90
View B
1
41
120
E
C
M
71
Measuring method 1
SENSOR
FUEL TEMP
66P
52P
Measuring method 3
Measurement
Measurement
SENSOR
FUEL TEMP
E
C
M
Harness
Harness
Measuring method 2
SENSOR
FUEL TEMP
E
C
M
Measuring method 4
Measurement
E
C
M
SENSOR
FUEL TEMP
Measurement
E
C
M
Harness
Harness
ECM
SENSOR
ENGINE COOLANT TEMP
30
66
SENSOR
FUEL TEMP
52
SENSOR
INTAKE AIR TEMP
53
LFW36EXF001201
R/L; PUMP
CONT. VALVE
PUMP
CONT.
VALVE1
R/L; MAIN
MAIN
R/L
24 91
+BP
PUMP
CONT.
VALVE2
MAIN
R/L
KEY
22
21
32
31
23
13
En g i n e C o n t ro l Mo d u l e ( E C M)
LFW36ELF000701
Circuit Description
Diagnostic Aids
Check for the following conditions:
Poor connection at ECM Inspect harness connectors
for backed-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
Damaged harness Inspect the wiring harness for
damage, shorts to ground, shorts to battery and open
circuits. If the harness appears to be OK, observe the
PCV display on the scan tool while moving connectors
and wiring harnesses related to the PCV sensor A
change in the PCV display will indicate the location of the
fault.
ACTION
VALUE
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 4
Replace PCV
assembly.
Then go to
step 8
Go to step 6
Go to step 5
Go to step 6
Repair them.
Then go to
step 6
Replace ECM.
Then go to
step 8
Go to step 7
Go to step 8
Repair/replace
PCV harness.
Then go to
step 8
Go to step 9
Repair/replace
ECM Ground
harness.
Then go to
step 9
Go back to
step 3
System OK
3.0 to 3.4
(about 20C)
1V or less
Less than 1V
Less than 1
YES
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
A
B
E
C
M
5
View C
View A
82P
PCV1
22P
21P
View A
90
41
120
71
View B
2
10
40
31
32P
31P
PCV2
82P
90
41
120
71
Measuring method 1
PCV
E
C
M
Harness
40
31
PCV
Harness
PCV
E
C
M
Harness
Measuring method 5
PCV
Measurement
R/L
C
Measuring method 6
PCV
Measurement
R/L
PCV
PCV
Harness
E
C
M
Measuring method 4
Measurement
Measuring method 2
Measurement
PCV
Measuring method 3
Measurement
Measurement
Harness
10
E
C
M
Harness
E
C
M
E
C
M
+B
ECM
PCV1
PCV2
21
22
31
32
82
LFW36EXF001301-1
R/L; PUMP
CONT. VALVE
PUMP
CONT.
VALVE1
R/L; MAIN
MAIN
R/L
24 91
+BP
PUMP
CONT.
VALVE2
MAIN
R/L
KEY
22
21
32
31
23
13
Eng i n e C o n t ro l Mo d u l e ( E C M)
LFW36ELF000701
Circuit Description
Diagnostic Aids
Check for the following conditions:
Poor connection at ECM Inspect harness connectors
for backed-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
Damaged harness Inspect the wiring harness for
damage, shorts to ground, shorts to battery and open
circuits. If the harness appears to be OK, observe the
PCV display on the scan tool while moving connectors
and wiring harnesses related to the PCV sensor A
change in the PCV display will indicate the location of the
fault.
ACTION
VALUE
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 4
Replace PCV
assembly.
Then go to
step 8
Go to step 6
Go to step 5
Go to step 6
Repair them.
Then go to
step 6
Replace ECM.
Then go to
step 8
Go to step 7
Go to step 8
Repair/replace
PCV harness.
Then go to
step 8
Go to step 9
Repair/replace
ECM Ground
harness.
Then go to
step 9
Go back to
step 3
System OK
3.0 to 3.4
(about 20C)
1V or less
Less than 1V
Less than 1
YES
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
A
B
E
C
M
5
View C
View A
82P
PCV1
22P
21P
View A
90
41
120
71
View B
2
10
40
31
32P
31P
PCV2
82P
90
41
120
71
Measuring method 1
PCV
E
C
M
Harness
40
31
PCV
Harness
PCV
E
C
M
Harness
Measuring method 5
PCV
Measurement
R/L
C
Measuring method 6
PCV
Measurement
R/L
PCV
PCV
Harness
E
C
M
Measuring method 4
Measurement
Measuring method 2
Measurement
PCV
Measuring method 3
Measurement
Measurement
Harness
10
E
C
M
Harness
E
C
M
E
C
M
+B
ECM
PCV1
PCV2
21
22
31
32
82
LFW36EXF001301-1
PRESSURE SENSOR
COMMON RAIL
GND VCC
55
73
71
SIG
62
Engi n e C o n t r o l M o d u l e ( E C M )
056MX022
Circuit Description
The pressure limiter opens when abnormally high pressure
is generated, releasing the pressure. When the common rail
pressure reaches approx. 170 MPa (1,734 kg/cm2), the
pressure limiter is actuated (opens), and when the pressure
drops to approx. 30 MPa (310 kg/cm2) later, it works to
maintain the pressure, thereby enabling continuous running.
The common rail pressure sensor, installed at left end of
the common rail, is used to detect fuel pressure. It is a
semiconductor type pressure sensor utilizing silicons
property that the electric resistance of pressurized silicone is
varied.
Further, a special gasket is used at the connection part
with the common rail body so as to seal high pressure fuel.
Diagnostic Aids
STEP
1
ACTION
VALUE
Does the scan tool display DTC 226 while Ignition ON, or
engine at idle?
Check the fuel lines from supply pump to common rail for
broken, loose, or restriction.
Also check fuel filter for restriction.
Was a problem found?
25 MPa
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 4
See Note on
Intermittent
Repair or
replace
Go back to
step 3
Go to step 5
Repair or
replace
Go back to
step 3
Go to step 6
Go to step 7
See Note on
Intermittent
Replace supply
pump.
Go back to
step 3
Go to step 8
Replace supply
pump.
Go back to
step 3
Go to step 9
Go to step 11
Replace
common rail
pressure sensor
Go back to
step 3
More than
60MPa
ACTION
VALUE
10
Using the scan tool, check the value for PCV closed interval.
1. Engine is idling.
2. Disconnect the PCV1 harness.
3. Check the value for PCV closed interval.
4. Reconnect the PCV1 harness.
5. Disconnect the PCV2 harness.
6. Check the value for PCV closed interval.
7. Reconnect the PCV2 harness.
Is PCV closed interval within value?
120CA to
180CA
11
12
YES
NO
Go to step 11
Go to system
check
(Common Rail
system check:
Fuel system)
Replace
pressure limiter
Go back to
step 3
Go to step 12
Replace ECM
Go back to
step 3
Replace ground
Go back to
step 3
PRESSURE SENSOR
COMMON RAIL
GND VCC
55
73
71
SIG
62
Engi n e C o n t r o l M o d u l e ( E C M )
056MX022
Circuit Description
The common rail pressure sensor, installed at left end of
the common rail, is used to detect fuel pressure. It is a
semiconductor type pressure sensor utilizing silicons
property that the electric resistance of pressurized silicone is
varied.
Further, a special gasket is used at the connection part
with the common rail body so as to seal high pressure fuel.
STEP
1
Diagnostic Aids
Check for the following conditions:
Poor connection at ECM Inspect harness connectors
for backed-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
Lack of power due to fuel leakage, fuel pressure and
injection amount limited.
Check Fuel Filter.
ACTION
VALUE
Does the scan tool display DTC 227 while Ignition ON, or
engine at idle?
Check the fuel lines from supply pump to common rail for
broken, loose, or restriction.
Also check fuel filter for restriction.
Was a problem found?
25 MPa
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 4
See Note on
Intermittent
Repair or
replace
Go back to
step 3
Go to step 5
Repair or
replace
Go back to
step 3
Go to step 6
Go to step 7
See Note on
Intermittent
Replace supply
pump.
Go back to
step 3
Go to step 8
Replace supply
pump.
Go back to
step 3
Go to step 9
Go to step 10
Replace
common rail
pressure
sensor
Go back to
step 3
More than
60 MPa
ACTION
VALUE
10
Using the scan tool, check the value for PCV closed interval.
1. Engine is idling.
2. Disconnect the PCV1 harness.
3. Check the value for PCV closed interval.
4. Reconnect the PCV1 harness.
5. Disconnect the PCV2 harness.
6. Check the value for PCV closed interval.
7. Reconnect the PCV2 harness.
Is PCV closed interval within value?
120CA to
180CA
11
12
YES
NO
Go to step 11
Go to system
check
(Common Rail
system check:
Fuel system)
Replace
pressure limiter
Go back to
step 3
Go to step 12
Replace ECM
Go back to
step 3
Replace ground
Go back to
step 3
PRESSURE SENSOR
COMMON RAIL
GND VCC
55
73
SIG
71
62
Engine C o n t r o l M o d u l e ( E C M )
056MX022
Circuit Description
The common rail pressure sensor, installed at left end of
the common rail, is used to the detect fuel pressure. It is a
semiconductor type pressure sensor utilizing silicons
property that the electric resistance of pressurized silicone is
varied.
Further, a special gasket is used at the connection part
with the common rail body so as to seal high pressure fuel.
If the ECM detects a rail pressure signal voltage that is
excessively low or high, Diagnostic Trouble Code 245 will be
set.
ACTION
VALUE
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 4
Go to step 5
Go to step 5
Refer to
Diagnostic Aids
Go to step 9
Go to step 6
Go to step 7
Repair or
replace the
common rail
pressure
sensor harness
then
Go to step 15
Go to step 8
Repair or replace
common rail
pressure sensor
harness then
Go to step 15
Go to step 9
Check, Repair
harness and/or
connector for
poor
connections
then
Go to step 15
0.7V
to
4.7V
4.5V
to
5.5V
2 or less
10M or more
4.5V
to
5.5V
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
ACTION
VALUE
2 or less
10
11
12
13
14
15
NO
Go to step 10
Repair/ or
replace
the common
rail pressure
sensor harness
then
go to step 16
Go to step 11
Repair or
replace
common rail
pressure
sensor harness
then
Go to step 13
Go to step 13
Go to step 12
Replace
common rail
pressure
sensor then
Go to step 15
Go to step 13
Make complete
contact then
Go to step 14
System OK
Replace ECM
assembly then
Go to step 15
System OK
Go back to
step 3
System OK
10M or more
YES
View A
View B
1
55P
73P
62P
71P
90
41
120
71
Measuring method 1
A
E
C
M
Measuring method 3
Measurement
COMMON RAIL
PRESSURE SENSOR
Measurement
COMMON RAIL
PRESSURE SENSOR
E
C
M
E
C
M
Harness
Harness
Measuring method 2
Measuring method 4
Measurement
COMMON RAIL
PRESSURE SENSOR
E
C
M
COMMON RAIL
PRESSURE SENSOR
Measurement
E
C
M
Harness
Harness
ECM
62
COMMON RAIL
PRESSURE
71
73
55
LFW36EXF001001
R/L; PUMP
CONT. VALVE
PUMP
CONT.
VALVE1
R/L; MAIN
MAIN
R/L
24 91
+BP
PUMP
CONT.
VALVE2
MAIN
R/L
KEY
22
21
32
31
23
13
Eng i n e C o n t ro l Mo d u l e ( E C M)
LFW36ELF000701
Circuit Description
The PCV is used to adjust supply pump discharge amount
so as to adjust common rail pressure. Discharge amount from
the supply pump to the common rail is determined by PCV
current timing.
If the ECM detects a PCV1 signal voltage that is
excessively high, Diagnostic Trouble Code 247 will be set.
Diagnostic Aids
Check for the following conditions:
Poor connection at ECM Inspect harness connectors
for backed-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
Damaged harness Inspect the wiring harness for
damage, shorts to ground, shorts to battery and open
circuits. If the harness appears to be OK, observe the
PCV display on the scan tool while moving connectors
and wiring harnesses related to the PCV sensor. A
change in the PCV sensor display will indicate the
location of the fault.
ACTION
VALUE
24V
10M or more
Less than
10M
2 or less
More than
10M
Less than 2
1.
2.
3.
4.
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 9
Go to step 4
Go to step 6
Repair PCV
harness
Go to step 5
Repair/replace
PCV harness.
Then go to
step 13
Go to step 6
Go to step 7
Repair PCV
harness.
Then go to
step 13
Go to step 8
Go to step 13
Go to step 9
Repair/replace
PCV harness.
Then go to
step 13
10
11
12
13
ACTION
Measure PCV coil resistance. (Measuring method 1)
Is resistance within value?
VALUE
YES
NO
Go to step 10
Replace PCV
and/or supply
pump.
Then go to
step 13
Go to step 12
Repair wire
harness in
between power
supply and
relay.
Then go to
step 11
Repair it.
Go to step 12
System OK
Replace ECM
assembly.
Go to step 13
System OK
Go back to
step 3
System OK
3.0 to 3.4
(about 20C)
24V
Clear DTCs.
Does DTC 247 display?
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
NOTE: If PCV1 and PCV2 connectors are switched, engine will not start.
A
B
E
C
M
5
View C
View A
82P
PCV1
22P
21P
View A
90
41
120
71
View B
2
10
40
31
32P
31P
PCV2
82P
90
41
120
71
Measuring method 1
PCV
E
C
M
Harness
40
31
PCV
Harness
PCV
E
C
M
Harness
Measuring method 5
PCV
Measurement
R/L
C
Measuring method 6
PCV
Measurement
R/L
PCV
PCV
Harness
E
C
M
Measuring method 4
Measurement
Measuring method 2
Measurement
PCV
Measuring method 3
Measurement
Measurement
Harness
10
E
C
M
Harness
E
C
M
E
C
M
+B
ECM
PCV1
PCV2
21
22
31
32
82
LFW36EXF001301
R/L; PUMP
CONT. VALVE
PUMP
CONT.
VALVE1
R/L; MAIN
MAIN
R/L
24 91
+BP
PUMP
CONT.
VALVE2
MAIN
R/L
KEY
22
21
32
31
23
13
Eng i n e C o n t ro l Mo d u l e ( E C M)
LFW36ELF000701
Circuit Description
The PCV is used to adjust supply pump discharge amount
so as to adjust common rail pressure. Discharge amount from
the supply pump to the common rail is determined by PCV
current timing.
If the ECM detects a PCV2 signal voltage that is
excessively high, Diagnostic Trouble Code 248 will be set.
Diagnostic Aids
Check for the following conditions:
Poor connection at ECM Inspect harness connectors
for backed-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
Damaged harness Inspect the wiring harness for
damage, shorts to ground, shorts to battery and open
circuits. If the harness appears to be OK, observe the
PCV display on the scan tool while moving connectors
and wiring harnesses related to the PCV sensor. A
change in the PCV sensor display will indicate the
location of the fault.
ACTION
VALUE
24V
10M or more
Less than
10M
2 or less
More than
10M
Less than 2
1.
2.
3.
4.
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 9
Go to step 4
Go to step 6
Repair PCV
harness
Go to step 5
Repair/replace
PCV harness.
Then go to
step 13
Go to step 6
Go to step 7
Repair PCV
harness.
Then go to
step 13
Go to step 8
Go to step 13
Go to step 9
Repair/replace
PCV harness.
Then go to
step 13
10
11
12
13
ACTION
Measure PCV coil resistance. (Measuring method 1)
Is resistance within value?
VALUE
YES
NO
Go to step 10
Replace PCV
and/or supply
pump.
Then go to
step 13
Go to step 12
Repair wire
harness in
between power
supply and
relay.
Then go to
step 11
Repair it.
Go to step 11
System OK
Replace ECM
assembly.
Go to step 13
System OK
Go back to
step 3
System OK
3.0 to 3.4
24V
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
NOTE: If PCV1 and PCV2 connectors are switched, engine will not starts.
A
B
E
C
M
5
View C
View A
82P
PCV1
22P
21P
View A
90
41
120
71
View B
2
10
40
31
32P
31P
PCV2
82P
90
41
120
71
Measuring method 1
PCV
E
C
M
Harness
40
31
PCV
Harness
PCV
E
C
M
Harness
Measuring method 5
PCV
Measurement
R/L
C
Measuring method 6
PCV
Measurement
R/L
PCV
PCV
Harness
E
C
M
Measuring method 4
Measurement
Measuring method 2
Measurement
PCV
Measuring method 3
Measurement
Measurement
Harness
10
E
C
M
Harness
E
C
M
E
C
M
+B
ECM
PCV1
PCV2
21
22
31
32
82
LFW36EXF001301
Injector
Common Rail
Flow
Damper
Common Rail
Pressure Sensor
Pressure Limiter
PCV
Over Flow Valve
Gauze Filter
Feed Pump
Supply Pump
Fuel Tank
060MY00052
Operation Description
The flow damper comprises a piston, ball, spring seat, and
spring.
The flow damper is used to damp the pressure pulsating in
the common rail and the injection pipe.
During driving the flow of fuel makes the piston, ball, and
spring seat move a little to the injector side and float.
Should too much fuel pass the flow damper, the ball moves
further toward the injector until the ball comes into contact
with the seat surface of the flow damper unit, thereby shutting
the fuel passages.
Injector Side
Ball
060MY00039
Cylinder No. 1
No DTC 271 to DTC 276, DTC 158 and DTC 159.
ECT higher than 60C.
Correction of uneven injection amount exceeding 5
mm3/st and continues for 65535 times.
(Balancing Fuel Rate Data)
Diagnostic Aids
STEP
1
ACTION
VALUE
Does the scan tool display DTC 261 while Ignition ON, or
engine at idle?
Check for fuel leak in line between flow damper and fuel
injector.
Was fuel leak found?
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 4
See Note on
Intermittent
Go to step 5
Go to step 4
Go to step 6
Go to step 7
Repair or
replace
Go back to
step 3
Go to step 7
Go to step 8
Replace
injector
Go back to
step 3
Repair or
replace
Go back to
step 3
Go to step 9
Go to step 2
System OK
NOTE: Use scan tool Common rail pressure control to check for fuel leakage, etc.
Sometimes DTC 261 will be displayed due to engine hunting when the common rail pressure sensor fails.
Intermittents codes are activated by:
Clutch shudder
Clutch shock Disengagement
Air in Fuel Line
Injector
Common Rail
Flow
Damper
Common Rail
Pressure Sensor
Pressure Limiter
PCV
Over Flow Valve
Gauze Filter
Feed Pump
Supply Pump
Fuel Tank
060MY00052
Operation Description
The flow damper comprises a piston, ball, spring seat, and
spring.
The flow damper is used to damp the pressure pulsating in
the common rail and the injection pipe.
During driving the flow of fuel makes the piston, ball, and
spring seat move a little to the injector side and float.
Should too much fuel pass the flow damper, the ball moves
further toward the injector until the ball comes into contact
with the seat surface of the flow damper unit, thereby shutting
the fuel passages.
Injector Side
Ball
060MY00039
Cylinder No. 2
No DTC 271 to DTC 276, DTC 158 and DTC 159.
ECT higher than 60C.
Correction of uneven injection amount exceeding 5
mm3/st and continues for 65535 times.
(Balancing Fuel Rate Data)
Diagnostic Aids
STEP
1
ACTION
VALUE
Does the scan tool display DTC 262 while Ignition ON, or
engine at idle?
Check for fuel leak in line between flow damper and fuel
injector.
Was fuel leak found?
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 4
See Note on
Intermittent
Go to step 5
Go to step 4
Go to step 6
Go to step 7
Repair or
replace
Go back to
step 3
Go to step 7
Go to step 8
Replace
injector
Go back to
step 3
Repair or
replace
Go back to
step 3
Go to step 9
Go to step 2
System OK
NOTE: Use scan tool Common rail pressure control to check for fuel leakage, etc.
Sometimes DTC 262 will be displayed due to engine hunting when the common rail pressure sensor fails.
Intermittents codes are activated by:
Clutch shudder
Clutch shock Disengagement
Air in Fuel Line
Injector
Common Rail
Flow
Damper
Common Rail
Pressure Sensor
Pressure Limiter
PCV
Over Flow Valve
Gauze Filter
Feed Pump
Supply Pump
Fuel Tank
060MY00052
Operation Description
The flow damper comprises a piston, ball, spring seat, and
spring.
The flow damper is used to damp the pressure pulsating in
the common rail and the injection pipe.
During driving the flow of fuel makes the piston, ball, and
spring seat move a little to the injector side and float.
Should too much fuel pass the flow damper, the ball moves
further toward the injector until the ball comes into contact
with the seat surface of the flow damper unit, thereby shutting
the fuel passages.
Injector Side
Ball
060MY00039
Cylinder No. 3
No DTC 271 to DTC 276, DTC 158 and DTC 159.
ECT higher than 60C.
Correction of uneven injection amount exceeding 5
mm3/st and continues for 65535 times.
(Balancing Fuel Rate Data)
Diagnostic Aids
STEP
1
ACTION
VALUE
Does the scan tool display DTC 263 while Ignition ON, or
engine at idle?
Check for fuel leak in line between flow damper and fuel
injector.
Was fuel leak found?
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 4
See Note on
Intermittent
Go to step 5
Go to step 4
Go to step 6
Go to step 7
Repair or
replace
Go back to
step 3
Go to step 7
Go to step 8
Replace
injector
Go back to
step 3
Repair or
replace
Go back to
step 3
Go to step 9
Go to step 2
System OK
NOTE: Use scan tool Common rail pressure control to check for fuel leakage, etc.
Sometimes DTC 263 will be displayed due to engine hunting when the common rail pressure sensor fails.
Intermittents codes are activated by:
Clutch shudder
Clutch shock Disengagement
Air in Fuel Line
Injector
Common Rail
Flow
Damper
Common Rail
Pressure Sensor
Pressure Limiter
PCV
Over Flow Valve
Gauze Filter
Feed Pump
Supply Pump
Fuel Tank
060MY00052
Operation Description
The flow damper comprises a piston, ball, spring seat, and
spring.
The flow damper is used to damp the pressure pulsating in
the common rail and the injection pipe.
During driving the flow of fuel makes the piston, ball, and
spring seat move a little to the injector side and float.
Should too much fuel pass the flow damper, the ball moves
further toward the injector until the ball comes into contact
with the seat surface of the flow damper unit, thereby shutting
the fuel passages.
Injector Side
Ball
060MY00039
Cylinder No. 4
No DTC 271 to DTC 276, DTC 158 and DTC 159.
ECT higher than 60C.
Correction of uneven injection amount exceeding 5
mm3/st and continues for 65535 times.
(Balancing Fuel Rate Data)
Diagnostic Aids
STEP
1
ACTION
VALUE
Does the scan tool display DTC 264 while Ignition ON, or
engine at idle?
Check for fuel leak in line between flow damper and fuel
injector.
Was fuel leak found?
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 4
See Note on
Intermittent
Go to step 5
Go to step 4
Go to step 6
Go to step 7
Repair or
replace
Go back to
step 3
Go to step 7
Go to step 8
Replace
injector
Go back to
step 3
Repair or
replace
Go back to
step 3
Go to step 9
Go to step 2
System OK
NOTE: Use scan tool Common rail pressure control to check for fuel leakage, etc.
Sometimes DTC 264 will be displayed due to engine hunting when the common rail pressure sensor fails.
Intermittents codes are activated by:
Clutch shudder
Clutch shock Disengagement
Air in Fuel Line
Injector
Common Rail
Flow
Damper
Common Rail
Pressure Sensor
Pressure Limiter
PCV
Over Flow Valve
Gauze Filter
Feed Pump
Supply Pump
Fuel Tank
060MY00052
Operation Description
The flow damper comprises a piston, ball, spring seat, and
spring.
The flow damper is used to damp the pressure pulsating in
the common rail and the injection pipe.
During driving the flow of fuel makes the piston, ball, and
spring seat move a little to the injector side and float.
Should too much fuel pass the flow damper, the ball moves
further toward the injector until the ball comes into contact
with the seat surface of the flow damper unit, thereby shutting
the fuel passages.
Injector Side
Ball
060MY00039
Cylinder No. 5
No DTC 271 to DTC 276, DTC 158 and DTC 159.
ECT higher than 60C.
Correction of uneven injection amount exceeding 5
mm3/st and continues for 65535 times.
(Balancing Fuel Rate Data)
Diagnostic Aids
STEP
1
ACTION
VALUE
Does the scan tool display DTC 265 while Ignition ON, or
engine at idle?
Check for fuel leak in line between flow damper and fuel
injector.
Was fuel leak found?
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 4
See Note on
Intermittent
Go to step 5
Go to step 4
Go to step 6
Go to step 7
Repair or
replace
Go back to
step 3
Go to step 7
Go to step 8
Replace
injector
Go back to
step 3
Repair or
replace
Go back to
step 3
Go to step 9
Go to step 2
System OK
NOTE: Use scan tool Common rail pressure control to check for fuel leakage, etc.
Sometimes DTC 265 will be displayed due to engine hunting when the common rail pressure sensor fails.
Intermittents codes are activated by:
Clutch shudder
Clutch shock Disengagement
Air in Fuel Line
Injector
Common Rail
Flow
Damper
Common Rail
Pressure Sensor
Pressure Limiter
PCV
Over Flow Valve
Gauze Filter
Feed Pump
Supply Pump
Fuel Tank
060MY00052
Operation Description
The flow damper comprises a piston, ball, spring seat, and
spring.
The flow damper is used to damp the pressure pulsating in
the common rail and the injection pipe.
During driving the flow of fuel makes the piston, ball, and
spring seat move a little to the injector side and float.
Should too much fuel pass the flow damper, the ball moves
further toward the injector until the ball comes into contact
with the seat surface of the flow damper unit, thereby shutting
the fuel passages.
Injector Side
Ball
060MY00039
Cylinder No. 6
No DTC 271 to DTC 276, DTC 158 and DTC 159.
ECT higher than 60C.
Correction of uneven injection amount exceeding 5
mm3/st and continues for 65535 times.
(Balancing Fuel Rate Data)
Diagnostic Aids
STEP
1
ACTION
VALUE
Does the scan tool display DTC 266 while Ignition ON, or
engine at idle?
Check for fuel leak in line between flow damper and fuel
injector.
Was fuel leak found?
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 4
See Note on
Intermittent
Go to step 5
Go to step 4
Go to step 6
Go to step 7
Repair or
replace
Go back to
step 3
Go to step 7
Go to step 8
Replace
injector
Go back to
step 3
Repair or
replace
Go back to
step 3
Go to step 9
Go to step 2
System OK
NOTE: Use scan tool Common rail pressure control to check for fuel leakage, etc.
Sometimes DTC 266 will be displayed due to engine hunting when the common rail pressure sensor fails.
Intermittents codes are activated by:
Clutch shudder
Clutch shock Disengagement
Air in Fuel Line
COM2
COM1
120 119
110 100
CYL.1
CYL.5
CYL.3
CYL.6
CYL.2
CYL.4
INJ.1
INJ.2
INJ.3
INJ.4
INJ.5
INJ.6
90
89
88
87
86
85
Engi n e C o n t ro l Mo d u l e ( E C M)
LFW36EMF000401
Circuit Description
Diagnostic Aids
Check for the following conditions:
Poor connection at ECM Inspect harness connectors
for backed-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
No smooth rotation.
Lack of engine power.
ACTION
VALUE
Does the scan tool display any DTC from DTC 271 while key
switch is ON or engine is running?
2.0 or less
for injector
harness
resistance.
0.9 to 1.3
for injector coil
resistance.
Thus minimum
resistance is
0.9 to 1.3.
(If harness
resistance 0)
2 or less
0.4
to
0.8
(about 20C)
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 8
Before going to
step 8, recheck
incomplete
connection on
harness
connector.
Go to step 4
Go to step 5
Repair/replace
injector
harness.
Go to step 7
Go to step 6
Repair problem
portion.
Then go to
step 7
Go to step 7
Replace ECM
assembly.
Then go to
step8
Go to step 8
Go back to
step 3
System OK
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
A
E
C
M
INJECTOR 1(CYL1)
Connector1 View B
3
View A
41
120
71
110P
41
120
71
View A
90
41
120
71
110P
87P
90
41
120
71
119P
120P
INJECTOR 6(CYL4)
Connector2
100P
86P
98P
INJECTOR 4(CYL6)
Connector2
100P
88P
90
INJECTOR 5(CYL2)
Connector1
3
90
INJECTOR 3(CYL3)
Connector1
3
INJECTOR 2(CYL5)
Connector2 View B
90P
100P
119P
120P
85P
90
41
90
41
120
71
120
71
119P
120P
110P
Measuring method 1
E
C
M
Harness
Measuring method 3
INJECTOR
Measuring method 2
Measurement
INJECTOR
E
C
M
Measuring method 4
Measurement
Harness
INJECTOR
E
C
M
INJECTOR
Harness
E
C
M
ECM
100
110
CYL1
CYL2
CYL3
90
86
88
119
120
CYL4
CYL5
CYL6
85
89
87
LFW36EXF001101
COM2
COM1
120 119
110 100
CYL.1
CYL.5
CYL.3
CYL.6
CYL.2
CYL.4
INJ.1
INJ.2
INJ.3
INJ.4
INJ.5
INJ.6
90
89
88
87
86
85
Engi ne C o n t ro l Mo d u l e ( E C M)
LFW36EMF000401
Circuit Description
Diagnostic Aids
Check for the following conditions:
Poor connection at ECM Inspect harness connectors
for backed-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
No smooth rotation.
Lack of engine power.
ACTION
VALUE
Does the scan tool display any DTC from DTC 272 while key
switch is ON or engine is running?
2.0 or less
for injector
harness
resistance.
0.9 to 1.3
for injector coil
resistance.
Thus minimum
resistance is
0.9 to 1.3.
(If harness
resistance 0)
2 or less
0.4
to
0.8
(about 20C)
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 8
Before going to
step 8, recheck
incomplete
connection on
harness
connector.
Go to step 4
Go to step 5
Repair/replace
injector
harness.
Go to step 7
Go to step 6
Repair problem
portion.
Then go to
step 7
Go to step 7
Replace ECM
assembly.
Then go to
step 8
Go to step 8
Go back to
step 3
System OK
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
A
E
C
M
INJECTOR 1(CYL1)
Connector1 View B
3
View A
41
120
71
110P
120
71
View A
90
41
120
71
41
110P
119P
120P
87P
90
41
120
71
INJECTOR 6(CYL4)
Connector2
100P
86P
98P
INJECTOR 4(CYL6)
Connector2
100P
88P
90
INJECTOR 5(CYL2)
Connector1
3
90
INJECTOR 3(CYL3)
Connector1
3
INJECTOR 2(CYL5)
Connector2 View B
90P
100P
119P
120P
85P
90
41
90
41
120
71
120
71
119P
120P
110P
Measuring method 1
INJECTOR
E
C
M
Harness
Measuring method 3
INJECTOR
Measuring method 2
Measurement
E
C
M
Measuring method 4
Measurement
Harness
INJECTOR
E
C
M
INJECTOR
Harness
E
C
M
ECM
100
110
CYL1
CYL2
CYL3
90
86
88
119
120
CYL4
CYL5
CYL6
85
89
87
LFW36EXF001101
COM2
COM1
120 119
110 100
CYL.1
CYL.5
CYL.3
CYL.6
CYL.2
CYL.4
INJ.1
INJ.2
INJ.3
INJ.4
INJ.5
INJ.6
90
89
88
87
86
85
Engi ne C o n t ro l Mo d u l e ( E C M)
LFW36EMF000401
Circuit Description
Diagnostic Aids
Check for the following conditions:
Poor connection at ECM Inspect harness connectors
for backed-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
No smooth rotation.
Lack of engine power.
ACTION
VALUE
Does the scan tool display any DTC from DTC 0273 while key
switch is ON or engine is running?
2.0 or less
for injector
harness
resistance.
0.9 to 1.3
for injector coil
resistance.
Thus minimum
resistance is
0.9 to 1.3.
(If harness
resistance 0)
2 or less
0.4
to
0.8
(about 20C)
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 8
Before going to
step 8, recheck
incomplete
connection on
harness
connector.
Go to step 4
Go to step 5
Repair/replace
injector
harness.
Go to step 7
Go to step 6
Repair problem
portion.
Then go to
step 7
Go to step 7
Replace ECM
assembly.
Then go to
step 8
Go to step 8
Go back to
step 3
System OK
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
A
E
C
M
INJECTOR 1(CYL1)
Connector1 View B
3
View A
41
120
71
110P
120
71
View A
90
41
120
71
41
110P
119P
120P
87P
90
41
120
71
INJECTOR 6(CYL4)
Connector2
100P
86P
98P
INJECTOR 4(CYL6)
Connector2
100P
88P
90
INJECTOR 5(CYL2)
Connector1
3
90
INJECTOR 3(CYL3)
Connector1
3
INJECTOR 2(CYL5)
Connector2 View B
90P
100P
119P
120P
85P
90
41
90
41
120
71
120
71
119P
120P
110P
Measuring method 1
INJECTOR
E
C
M
Harness
Measuring method 3
INJECTOR
Measuring method 2
Measurement
E
C
M
Measuring method 4
Measurement
Harness
INJECTOR
E
C
M
INJECTOR
Harness
E
C
M
ECM
100
110
CYL1
CYL2
CYL3
90
86
88
119
120
CYL4
CYL5
CYL6
85
89
87
LFW36EXF001101
COM2
COM1
120 119
110 100
CYL.1
CYL.5
CYL.3
CYL.6
CYL.2
CYL.4
INJ.1
INJ.2
INJ.3
INJ.4
INJ.5
INJ.6
90
89
88
87
86
85
Engi ne C o n t ro l Mo d u l e ( E C M)
LFW36EMF000401
Circuit Description
Diagnostic Aids
Check for the following conditions:
Poor connection at ECM Inspect harness connectors
for backed-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
No smooth rotation.
Lack of engine power.
ACTION
VALUE
Does the scan tool display any DTC from DTC 274 while key
switch is ON or engine is running?
2.0 or less
for injector
harness
resistance.
0.9 to 1.3
for injector coil
resistance.
Thus minimum
resistance is
0.9 to 1.3.
(If harness
resistance 0)
2 or less
0.4
to
0.8
(about 20C)
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 8
Before going to
step 8, recheck
incomplete
connection on
harness
connector.
Go to step 4
Go to step 5
Repair/replace
injector
harness.
Go to step 7
Go to step 6
Repair problem
portion.
Then go to
step 7
Go to step 7
Replace ECM
assembly.
Then go to
step 8
Go to step 8
Go back to
step 3
System OK
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
A
E
C
M
INJECTOR 1(CYL1)
Connector1 View B
3
View A
41
120
71
110P
120
71
View A
90
41
120
71
41
110P
119P
120P
87P
90
41
120
71
INJECTOR 6(CYL4)
Connector2
100P
86P
98P
INJECTOR 4(CYL6)
Connector2
100P
88P
90
INJECTOR 5(CYL2)
Connector1
3
90
INJECTOR 3(CYL3)
Connector1
3
INJECTOR 2(CYL5)
Connector2 View B
90P
100P
119P
120P
85P
90
41
90
41
120
71
120
71
119P
120P
110P
Measuring method 1
INJECTOR
E
C
M
Harness
Measuring method 3
INJECTOR
Measuring method 2
Measurement
E
C
M
Measuring method 4
Measurement
Harness
INJECTOR
E
C
M
INJECTOR
Harness
E
C
M
ECM
100
110
CYL1
CYL2
CYL3
90
86
88
119
120
CYL4
CYL5
CYL6
85
89
87
LFW36EXF001101
COM2
COM1
120 119
110 100
CYL.1
CYL.5
CYL.3
CYL.6
CYL.2
CYL.4
INJ.1
INJ.2
INJ.3
INJ.4
INJ.5
INJ.6
90
89
88
87
86
85
Engi ne C o n t ro l Mo d u l e ( E C M)
LFW36EMF000401
Circuit Description
Diagnostic Aids
Check for the following conditions:
Poor connection at ECM Inspect harness connectors
for backed-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
No smooth rotation.
Lack of engine power.
ACTION
VALUE
Does the scan tool display any DTC from DTC 275 while key
switch is ON or engine is running?
2.0 or less
for injector
harness
resistance.
0.9 to 1.3
for injector coil
resistance.
Thus minimum
resistance is
0.9 to 1.3.
(If harness
resistance 0)
2 or less
0.4
to
0.8
(about 20C)
YES
NO
Go to step 2
Go to OBD
Ssytem Check
Go to step 3
Go to
Diagnostic Aids
Go to step 8
Before going to
step 8, recheck
incomplete
connection on
harness
connector.
Go to step 4
Go to step 5
Repair/replace
injector
harness.
Go to step 7
Go to step 6
Repair problem
portion.
Then go to
step 7
Go to step 7
Replace ECM
assembly.
Then go to
step 8
Go to step 8
Go back to
step 3
System OK
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
A
E
C
M
INJECTOR 1(CYL1)
Connector1 View B
3
View A
41
120
71
110P
120
71
View A
90
41
120
71
41
110P
119P
120P
87P
90
41
120
71
INJECTOR 6(CYL4)
Connector2
100P
86P
98P
INJECTOR 4(CYL6)
Connector2
100P
88P
90
INJECTOR 5(CYL2)
Connector1
3
90
INJECTOR 3(CYL3)
Connector1
3
INJECTOR 2(CYL5)
Connector2 View B
90P
100P
119P
120P
85P
90
41
90
41
120
71
120
71
119P
120P
110P
Measuring method 1
INJECTOR
E
C
M
Harness
Measuring method 3
INJECTOR
Measuring method 2
Measurement
E
C
M
Measuring method 4
Measurement
Harness
INJECTOR
E
C
M
INJECTOR
Harness
E
C
M
ECM
100
110
CYL1
CYL2
CYL3
90
86
88
119
120
CYL4
CYL5
CYL6
85
89
87
LFW36EXF001101
COM2
COM1
120 119
110 100
CYL.1
CYL.5
CYL.3
CYL.6
CYL.2
CYL.4
INJ.1
INJ.2
INJ.3
INJ.4
INJ.5
INJ.6
90
89
88
87
86
85
Engi ne C o n t ro l Mo d u l e ( E C M)
LFW36EMF000401
Circuit Description
Diagnostic Aids
Check for the following conditions:
Poor connection at ECM Inspect harness connectors
for backed-out terminals, improper mating, broken locks,
improperly formed or damaged terminals, and poor
terminal-to-wire connection.
No smooth rotation.
Lack of engine power.
ACTION
VALUE
Does the scan tool display any DTC from DTC 0276 while key
switch is ON or engine is running?
2.0 or less
for injector
harness
resistance.
0.9 to 1.3
for injector coil
resistance.
Thus minimum
resistance is
0.9 to 1.3.
(If harness
resistance 0)
2 or less
0.4
to
0.8
(about 20C)
YES
NO
Go to step 2
Go to OBD
System Chekc
Go to step 3
Go to
Diagnostic Aids
Go to step 8
Before going to
step 8, recheck
incomplete
connection on
harness
connector.
Go to step 4
Go to step 5
Repair/replace
injector
harness.
Go to step 7
Go to step 6
Repair problem
portion.
Then go to
step 7
Go to step 7
Replace ECM
assembly.
Then go to
step 8
Go to step 8
Go back to
step 3
System OK
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
A
E
C
M
INJECTOR 1(CYL1)
Connector1 View B
3
View A
41
120
71
110P
120
71
View A
90
41
120
71
41
110P
119P
120P
87P
90
41
120
71
INJECTOR 6(CYL4)
Connector2
100P
86P
98P
INJECTOR 4(CYL6)
Connector2
100P
88P
90
INJECTOR 5(CYL2)
Connector1
3
90
INJECTOR 3(CYL3)
Connector1
3
INJECTOR 2(CYL5)
Connector2 View B
90P
100P
119P
120P
85P
90
41
90
41
120
71
120
71
119P
120P
110P
Measuring method 1
INJECTOR
E
C
M
Harness
Measuring method 3
INJECTOR
Measuring method 2
Measurement
E
C
M
Measuring method 4
Measurement
Harness
INJECTOR
E
C
M
INJECTOR
Harness
E
C
M
ECM
100
110
CYL1
CYL2
CYL3
90
86
88
119
120
CYL4
CYL5
CYL6
85
89
87
LFW36EXF001101
KEY SW
B1
OFF
ACC
ON
HEAT
START
M1 M2
B2
P2
P1
R/L;
MAIN
R/L;
P.C.V.
Diag
Lamp
(MIL)
GENERATOR
B
R
L
E
START MAIN
R/L
BP+
PUMP
CONT.
VALVE1
PUMP
CONT.
VALVE2
R/L;
STARTER
BATTERY
Key
24
118
109
91 101 22
21 32
31 23
13
105
33
NEUTRAL
(A/T ONLY)
M/T
81
R
GND
82
PGND
111
102
ECMECMGND
GND
59
CASE
GND
SW;SUB
STARTER
R/L;
NEUTRAL
A/T
SW;
NEUTRAL
LFW36ELF000801
Circuit Description
Diagnostic Aids
ACTION
VALUE
YES
NO
Go to step 2
Go to OBD
System Check
13P
23P
View A
90
41 10
120
71 40
31
A
E
C
M
91P
101P
111P
102P
109P
118P
Measuring method 1
Measurement
Measuring method 2
Measurement
E
C
M
Harness
E
C
M
Harness
+
Battery
KEY SWITCH
ECM
OFF
ACC
23
ON
13
ST
91
101
118
MAIN RELAY
109
81
82
102
111
LFW36EXF001401
R/L; PUMP
CONT.
VALVE
R/L; MAIN
START
PUMP
MAIN R/L PUMP
KEY
CONT. VALVE1
CONT. VALVE2
91 101 118 109
22
21 32
31 23
13
BP+
24
BI S G MI M2 B2 P2 P1
KEY SW
E n g i n e C o n t ro l Mo d u l e ( E C M)
81
82
111
102
59
R
PECM- ECM- CASE
GND GND GND GND GND
OFF
ACC
ON
HEAT
START
R/L;
STARTER
B
R
L
E
STARTER
GENERATOR
BATTERY
LFW36ELF000901
Diagnostic Aids
Action Taken When the DTC Sets
ACTION
VALUE
YES
NO
Go to Step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 4
Go to step 5
Repair/replace
wire harness
starter switch
Then go to
step 5
Go to step 5
Replace ECM
assembly.
Then go to
step 6
System OK
Go back to
step 3
System OK
24V always
applied
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
13P
23P
View A
90
41 10
120
71 40
31
A
E
C
M
91P
101P
111P
102P
109P
118P
Measuring method 1
Measurement
Measuring method 2
Measurement
E
C
M
Harness
E
C
M
Harness
+
Battery
KEY SWITCH
ECM
OFF
ACC
23
ON
13
ST
91
101
118
MAIN RELAY
109
81
82
102
111
LFW36EXF001401
R/L; PUMP
CONT.
VALVE
R/L; MAIN
START
PUMP
MAIN R/L PUMP
KEY
CONT. VALVE1
CONT. VALVE2
91 101 118 109
22
21 32
31 23
13
BP+
24
BI S G MI M2 B2 P2 P1
KEY SW
E n g i n e C o n t ro l Mo d u l e ( E C M)
81
82
111
102
59
R
PECM- ECM- CASE
GND GND GND GND GND
OFF
ACC
ON
HEAT
START
R/L;
STARTER
B
R
L
E
STARTER
GENERATOR
BATTERY
LFW36ELF000901
Circuit Description
Diagnostic Aids
Check for the following conditions:
Poor connection at PCV Relay Inspect harness
connectors for backed-out terminals, improper mating,
broken locks, improperly formed or damaged terminals,
and poor terminal-to-wire connection.
Poor condition for starter switch and key on signal circuit
(Key ON Relay, harness open).
ACTION
VALUE
Battery voltage
10M or more
Less than 1V
YES
NO
Go to step 2
Go to OBD
System Check
Go to step 3
Go to
Diagnostic Aids
Go to step 6
Go to step 4
Go to step 5
Repair/replace
PCV harness or
PCV relay.
Replace ECM.
System OK
Go to step 7
Replace PCV
relay
Go to step 8
Repair/replace
PCV harness.
Then go to
step 8
Go back to
step 3
System OK
IMPORTANT: The replacement ECM must be restored the capture fuel rate data by Tech 2.
Refer to Programming of Tech 2 Scan Tool in this manual.
1
3
2
5
060HY00471
060HY00472
A
B
E
C
M
5
View C
View A
82P
PCV1
22P
21P
View A
90
41
120
71
View B
2
10
40
31
32P
31P
PCV2
82P
90
41
120
71
Measuring method 1
PCV
E
C
M
Harness
40
31
PCV
Harness
PCV
E
C
M
Harness
Measuring method 5
PCV
Measurement
R/L
C
Measuring method 6
PCV
Measurement
R/L
PCV
PCV
Harness
E
C
M
Measuring method 4
Measurement
Measuring method 2
Measurement
PCV
Measuring method 3
Measurement
Measurement
Harness
10
E
C
M
Harness
E
C
M
E
C
M
+B
ECM
PCV1
PCV2
21
22
31
32
82
LFW36EXF001301-1
060MX113
Circuit Description
STEP
VALUE
YES
NO
Go to step 2
Ask driver if over speed condition was caused by gear slipout, shift error, etc.
Misusage by
owner or
operator.
See Intermittent
chart
ECM Function
The ECM supplies either 5 or 24 volts to power various
sensors or switches. The power is supplied through
resistances in the ECM which are so high in value that a test
light will not light when connected to the circuit. In some
cases, even an ordinary shop voltmeter will not give an
accurate reading because its resistance is too low. Therefore,
a digital voltmeter with at least 10 megohms input impedance
is required to ensure accurate voltage readings. Tool 5-88400366-0 meets this requirement. The ECM controls output
circuits such as the injectors, etc.
TS23793
Removal Procedure
1.
2.
3.
4.
Tighten
3.
060MX075
060MX075
5.
6.
Inspection Procedure
1.
2.
3.
4.
4.
5.
6.
Removal Procedure
1.
2.
Removal Procedure
1.
2.
3.
CKP Sensor
060MX076
3.
4.
Installation Procedure
1.
2.
Tighten
CKP Sensor
ECT
Front
4.
060MX076
3.
4.
Inspection Procedure
1.
2.
Removal Procedure
1.
2.
Installation Procedure
1.
2.
Tighten
3.
060M200032
3.
060MX077
CKP Sensor
Installation Procedure
1.
2.
4.
Common Rail
Grease Point
LFW36ESH001701
LFW36ESH001501
ECM
key.
7. Select F0: Engine and push ENTER key.
8. Select 6HK1 (Common Rail) by operating
or
No
Yes
LFW36ESH001801
Programming
Upload successful!
Confirm
LFW36ESH001901
LFW36ESH002001
ECM Bracket
No
LFW36ESH002101
LFW36ESH001601
Yes
Download successful!
Confirm
LFW36ESH002201
In this manual, such electrical device is classified by system. For major parts shown on the circuit based on the circuit diagram
for each system, inspection and removal and installation procedures are detailed.
1
2
Connecting Handling
Disconnecting The Connectors
Some connectors have a tang lock to hold the
connectors together during vehicle operation.
Some tang locks are released by pulling them towards
you 1.
Other tang locks are released by pressing them forward
2.
Determine which type of tang lock is on the connector
being handled.
Firmly grasp both sides (male and female) of the
connector.
Release the tang lock and carefully pull the two halves of
the connector apart.
NO
Test probe
NO
OK
Connector Inspection
Use a circuit tester to check the connector for continuity.
Insert the test probes from the connector wire side.
OK
Test probe
Test probe
Tang lock
Wire
Slender shaft
Tang lock
Pin
Pin
Parts Handling
Be careful when handling electrical parts. They should
not be dropped or thrown, because short circuit or other
damage may result.
Wire
Slender shaft
Tang lock
Wire
Pin
Cable Harness
When installing the parts, be careful not to pinch or
wedge the wiring harness.
All electrical connections must be kept clean and tight.
2.
3.
4.
Wings of clip
touching former
Back of clip
centered on anvil
Splice clip
Splice clip
5.
Open the crimping tool to its full width and rest one
handle on a firm flat surface.
Center the back of the splice clip on the proper anvil
and close the crimping tool to the point where the
back of the splice clip touches the wings of the clip.
Make sure that the clip and wires are still in the
correct position. Then, apply steady pressure until
the crimping tool closes.
Solder
Apply 60/40 rosin core colder to the opening in the back
of the clip. Follow the manufacturers instructions for the
solder equipment you are using.
6.
Good (Rolled)
Bad (Flagged)
ILLUSTRATION
5-8840-0366-0
High Impedance Multimeter
(Digital Voltmeter DVM)
TS22900
1
5
2
3
901RW181
6SD1-WE-0115HK
No.6HKEED-WE-0325AR
PRINTED IN JAPAN