SECTION 6E

EMISSION AND ELECTRICAL DIAGNOSIS

6HKED-WE-0225HK
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-1

SECTION 6E
EMISSION AND ELECTRICAL DIAGNOSIS
CAUTION:
When fasteners are removed, always reinstall them at the same location from which they were removed. If a
fastener needs to be replaced, use the correct part number fastener for that application. If the correct part
number fastener is not available, a fastener of equal size and strength for (stronger) may be used. Fasteners
that are not reused, and those requiring thread locking compound, will be caned out.
The correct torque values must be used when installing fasteners that require it. If the above conditions are not
followed, part or system damage could result.

CONTENTS
ELECTRICAL CONTROL GOVERNOR

PAGE
GENERAL DESCRIPTION................................................................................................ 6E- 4
NOTES FOR WORKING ON ELECTRICAL ITEMS....................................................... 6E- 4
SYMBOLS AND ABBREVIATIONS ............................................................................... 6E- 10
PARTS FOR ELECTRICAL CIRCUIT............................................................................. 6E- 12
BRIEF EXPLANATION OF EMISSION AND ELECTRICAL CONTROL SYSTEM ........ 6E- 14
1. EC GOVERNOR (ELECTRICAL CONTROL GOVERNOR) ................................... 6E- 14
2. TICS (TIMING AND INJECTION CONTROL SYSTEM) ......................................... 6E- 15
3. EGR (EXHAUST GAS RECIRCULATION) ............................................................. 6E- 16
4. ECU SYSTEM WIRING DIAGRAM......................................................................... 6E- 17
5. LOCATION OF SENSOR AND SWITCH................................................................ 6E- 19
6. HARNESS LOCATION ........................................................................................... 6E- 21
7. ENGINE CONTROL UNIT (ECU)............................................................................ 6E- 22
8. CHART OF ECU INPUT/OUTPUT.......................................................................... 6E- 23
9. LIMP HOME CONTROL ......................................................................................... 6E- 25
10. CONFIRMATION RETURN CONDITION FOR EMERGENCY ENGINE STOP
LEVER .................................................................................................................... 6E- 26
11. CAUTION TAKEN IN REPLACING ENGINE CONTROL UNIT (ECU)................... 6E- 27
12. TROUBLESHOOTING............................................................................................ 6E- 28
13. DIAGNOSTIC TROUBLE CODE LIST ................................................................... 6E- 34
6E-2 EMISSION AND ELECTRICAL DIAGNOSIS

CONNECTOR INSPECTING PROCEDURE ................................................................ 6E- 39

1. SERVICE ENGINE SOON INDICATOR LIGHT DOES NOT TURN ON ........... 6E- 40
2. SERVICE ENGINE SOON INDICATOR LIGHT DOES NOT FLASH................ 6E- 45
3. ENGINE DOES NOT STOP .............................................................................. 6E- 50
4. ENGINE DOES NOT START ............................................................................ 6E- 51
5. ENGINE STALLING .......................................................................................... 6E- 53
6. ENGINE HUNTING............................................................................................ 6E- 56
7. ENGINE HESITATION, POOR ASPIRATION, AND LOW POWER OUTPUT.. 6E- 58
8. WHITE EXHAUST SMOKE (LARGE QUANTITY) ............................................ 6E- 62
9. BLACK EXHAUST SMOKE (LARGE QUANTITY) ........................................... 6E- 64
10. IDLE SPEED CANNOT BE ADJUSTED ........................................................... 6E- 65
11. IDLE SPEED CANNOT BE ADJUSTED DOWN............................................... 6E- 67
12. POWER SUPPLY CIRCUIT INSPECTION ....................................................... 6E- 70
13. ENGINE CONTROL UNIT (ECU) GROUND CIRCUIT INSPECTION............... 6E- 75
14. STARTING CIRCUIT INSPECTION .................................................................. 6E- 77
15. FUEL SYSTEM INSPECTION........................................................................... 6E- 80
16. INTAKE SYSTEM INSPECTION....................................................................... 6E- 81
17. EXHAUST SYSTEM INSPECTION ................................................................... 6E- 82
18. EGR INSPECTION ............................................................................................ 6E- 85
19. POWER TAKE OFF (PTO) INSPECTION......................................................... 6E- 87
20. POWER TAKE OFF (PTO) SWITCH INSPECTION.......................................... 6E- 89
21. EXTERNAL ACCELERATOR INSPECTION .................................................... 6E- 93
22. PARKING SWITCH INSPECTION .................................................................... 6E- 96
DTC-10 RACK SENSOR ERROR ....................................................................... 6E- 99
DTC-11 GOVERNOR SERVO SYSTEM ERROR ............................................... 6E- 104
DTC-14 BACKUP N SENSOR ERROR .............................................................. 6E- 109
DTC-15 N-TDC SENSOR ERROR ...................................................................... 6E- 116
DTC-211 FUEL TEMPERATURE SENSOR ERROR............................................ 6E- 124
DTC-22 ATMOSPHERIC TEMPERATURE SENSOR ERROR........................... 6E- 129
DTC-23 ENGINE COOLANT TEMPERATURE SENSOR ERROR..................... 6E- 135
DTC-24 ACCELERATOR PEDAL POSITION SENSOR ERROR ....................... 6E- 142
DTC-241 ACCELERATOR POSITION SWITCH OFF ERROR............................. 6E- 148
DTC-242 ACCELERATOR POSITION SWITCH ON ERROR............................... 6E- 154
DTC-25 VEHICLE SPEED SENSOR ERROR..................................................... 6E- 159
DTC-29 PRESTROKE SERVO SYSTEM ERROR.............................................. 6E- 166
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-3

DTC-291 PRESTROKE SENSOR ERROR ........................................................... 6E- 173

DTC-292 PRESTROKE LEARNING ERROR........................................................ 6E- 179
DTC-32 BOOST PRESSURE SENSOR ERROR................................................ 6E- 185
DTC-33 MEMORY CIRCUIT (RAM) ERROR ...................................................... 6E- 194
DTC-413 MAGNETIC VALVE D ERROR .............................................................. 6E- 195
DTC-444 MAGNETIC VALVE E ERROR .............................................................. 6E- 200
DTC-421 MAGNETIC VALVE POWER SUPPLY FUSE BLOWN......................... 6E- 205
DTC-423 PRESTROKE POWER SUPPLY FUSE BLOWN .................................. 6E- 210
DTC-518 EOL (END OF LINE) DATA ERROR ..................................................... 6E- 216
DTC-543 ENGINE OVER RUN.............................................................................. 6E- 217
DTC-571 ENGINE REVERSING ERROR.............................................................. 6E- 219
DTC-71 ATMOSPHERIC PRESSURE SENSOR ERROR .................................. 6E- 221
6E-4 EMISSION AND ELECTRICAL DIAGNOSIS

GENERAL DESCRIPTION
The emission and electrical control system operate on The harness use a split corrugated tube to protect the
a twenty four volt power supply with negative ground wires from the elements. Each circuit consists
polarity. Each wire in the vehicle is of a specific size of the following:
and has an identifying colored insulation. · Power source ¾ The battery and the alternator.
These colors are indicated in wiring diagrams and will · Wires ¾ To carry electrical current through the
help in tracing circuits and making proper connections. circuit.
Wire size is determined by load capacity and circuit · Fuses ¾ To prevent the circuit against current
length. Some wires are grouped together and taped. overload.
Such a grouping of wires is called a harness. · Relays ¾ To protect voltage drop between the
battery and the circuit parts and to protect the switch
points against burning.
· Switches ¾ To open and close the circuit.
· Load ¾ Any device, such as a light or a motor, which
converts the electrical current into useful work.
· Ground ¾ To allow the current to flow back to the
power source.

In this manual, each electrical device is classified by system. For major parts shown on the circuit based on the
circuit diagram for each system, inspection, removal and installation procedures are detailed.

NOTES FOR WORKING ON ELECTRICAL ITEMS

BATTERY CABLE
Disconnecting the Battery Cable
1) All switches should be in the "OFF" position.
2) Disconnect the battery ground cable.
3) Disconnect the battery positive cable
4) Disconnect the battery cable 3 .
CAUTION:
It is important that the battery ground cable be
disconnected first.
Disconnecting the battery positive cable first can result
in a short circuit.

Connecting the Battery Cable

Follow the disconnecting procedure in the reverse order.
CAUTION:
Clean the battery terminals and apply a light coat of
grease to prevent terminal corrosion.
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-5

Connector 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.

Never pull on the wires to separate the connectors.

This will result in wire breakage.

Connecting the Connector

Firmly grasp both sides (male and female) of the connector.
Be sure that the connector pins and pin holes match. Be
sure that both sides of the connector are aligned with each
other. Firmly but carefully push the two sides of the
connector together until a distinct click is heard.

Connector Inspection
Use a circuit tester to check the connector for continuity.
Insert the test probes from the connector wire side.
6E-6 EMISSION AND ELECTRICAL DIAGNOSIS

Never insert the circuit tester test probes into the connector
open end to test the continuity. Broken or open connector
terminals will result.

Waterproof Connector Inspection

It is not possible to insert the test probes into the connector
wire side of a waterproof connector. Use one side of a
connector (1) with its wires cut to make the test. Connect
the test connector (2) to the connector to be tested.
Connect the test probes to the cut wires to check the
connector continuity.

Connector Pin Removal

Connector Housing Tang Lock Type
1) Insert a slender shaft into the connector housing open
end.
2) Push the tang lock up (in the direction of the arrow in the
illustration). Pull the wire with pin free from the wire side
of the connector.

Pin Tang Lock Type

1) Insert a slender shaft into the connector housing open
end.
2) Push the tang lock flat (toward the wire side of the
connector). Pull the wire with pin free from the wire side
of the connector.

Connector Pin Insertion

1) Check that the tang lock is fully up.
2) Insert the pin from the connector wire side.
Push the pin in until the tang lock closes firmly.
3) Gently pull on the wires to make sure that the connector
pin is firmly set in place.
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-7

Parts Handling
Be careful when handling electrical parts. They should not
be dropped or thrown, because short circuit or other
damage may result.

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.
6E-8 EMISSION AND ELECTRICAL DIAGNOSIS

SPLICING WIRE
1. Open the Harness
If the harness is taped, remove the tape. To avoid wire
insulation damage, use a sewing "seam ripper" (available
from sewing supply stores) to cut open the harness.
If the harness has a block plastic conduit, simply pull out the
desired wire.
2. Cut the wire
Begin by cutting as little wire off the harness as possible.
You may need the extra length of wire later if you decide to
cut more wire off to change the location of a splice. You
may have to adjust splice locations to make certain that
each splice is at least 1-1/2in (40 mm) away from other
splices, harness branches, or connectors.
3. Strip the insulation
When replacing a wire, use a wire of the same size as the
original wire. Check the stripped wire for nicks or cut
stands. If the wire is damaged, repeat the procedure on a
new section of wire. The two stripped wire ends should be
equal in length.

4. Crimp the Wires

Select the proper clip to secure the splice. To determine the
Lap over bare wires proper clip size for the wire being spliced, follow the
directions included with your clips. Select the correct anvil
on the crimper. (On most crimpers your choice is limited to
either a small or large anvil.) Overlap the two stripped wire
ends and hold them between your thumb and forefinger.
Then, center the splice clip under the stripped wires and
hold it in place.

Wings of clip · Open the crimping tool to its full width and rest one
touching 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.

Before crimping the ends of the clip, be sure that:

· The wires extend beyond the clip in each direction.
· No stands of wire are cut loose, and
· No insulation is caught under the clip.
Crimp the splice again, once on each end. Do not let the
crimping tool extend beyond the edge of the clip or you may
damage or nick the wires.
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-9

5. Solder
Apply 60/40 rosin core colder to the opening in the back of
the clip. Follow the manufacturer's instructions for the
solder equipment you are using.

6. Tape the Splice

Center and roll the splicing tape. The tape should cover the
entire splice. Roll on enough tape to duplicate the thickness
of the insulation on the existing wires. Do not flag the tape.
Flagged tape may not provide enough insulation, and the
flagged ends will tangle with the other wires in the harness.

If the wire does not belong in a conduit or other harness

covering, tape the wire again. Use a winding motion to
cover the first piece of tape.
6E-10 EMISSION AND ELECTRICAL DIAGNOSIS

SYMBOLS AND ABBREVIATIONS

Symbols

Fuse Single filament light

Fusible link Double filament light

Fusible link wire Motor

Switch Buzzer

Ground Meter

Condenser Consent

Resistor Battery

Variable resistance Connected portion

Coil

Diode Crossed portion

Zener diode
Relay

NPN type transistor

Circuit breaker

PNP type transistor

 EMISSION AND ELECTRICAL DIAGNOSIS 6E-11

Abbreviations
ABBREVIATION MEANING ABBREVIATION MEANING
A/C AIR CONDITIONER N -TDC NUMBERS TOP DEAD
ACC ACCESSORY CENTER
ACT ACTUATOR OFF TURN OFF (SWITCH/LAMP)
ASSIT ASSISTANT ON TURN ON (SWITCH/LAMP)
OPT OPTION
BATT BATTERY
P/BRAKE PARKING BRAKE
CAS CAB AIR SUSPENSION PGND POWER GROUND (TO BODY
CAS C/U CAB AIR SUSPENSION EARTH)
CONTROL UNIT PIN PIN or TERMINAL
CONN CONNECTOR P/L PILOT (WARNING) LAMP
C/U CONTROL UNIT PRESS PRESSURE
PS PRESTROKE
DC DIRECT CURRENT P/T POWER TRAIN
D/CONN DIAGNOSIS CONNECTOR PTO POWER TAKE OFF
DIAG DIAGNOSIS
DTC DIAGNOSIS TROUBLE CODE Q ADJ USTMENT INJECTION OUANTITY
ADJUSTMENT
EC ELECTRICAL CONTROL
GOVERNOR RH RIGHT HAND (SIDE)
ECU ENGINE CONTROL UNIT RHD RIGHT HAND DRIVE
EGR EXHAUST GAS R/L RELAY
RECIRCULATION RR REAR
EXH EXHAUST
S/ASB SHOCK ABSORBER
FRT FRONT SIG SIGNAL
VSS VEHICLE SPEED SENSOR
GND GROUND (BODY EARTH) VSS C/U VEHICLE SPEED SENSOR
CONTROL UNIT
IN INLET, INTAKE STD STANDARD
SUSP SUSPENSION
LH LEFT HAND (SIDE) SW SWITCH
LHD LEFT HAND DRIVE
TCV TRAILER COCK VALVE
MAG MAGNETIC TICS TIMING AND INJECTION RATE
MDL (Middle) PRE STROKE LEVER DRIVE CONTROL SYSTEM
ME/CONN MEMORY ERASER
CONNECTOR VGS VARIABLE GEOMETRY
M/V MAGNETIC VALVE TURBOCHARGING SYSTEM

N NEUTRAL (TRANSMISSION W/L WARNING LAMP

GEAR)
6E-12 EMISSION AND ELECTRICAL DIAGNOSIS

PARTS FOR ELECTRICAL CIRCUIT

Wiring
Wire Color
All wires have color-coded insulation.
Wires belonging to a system's main harness will have a
single color. Wires belonging to a system's sub circuits will
have a colored stripe. Striped wires use the following code
to show wire size and colors.
Example: 0.5 G R

Red (Stripe color)

Green (Base color)

Wire size (0.5 mm)

Abbreviations are used to indicate wire color within a circuit
diagram.
Refer to the following table.

Wire Color Coding

Color-coding Meaning Color-coding Meaning
B Black Br Brown
W White Lg Light green
R Red Gr Gray
G Green P Pink
Y YeIIow Sb Sky blue
L Blue V Violet
O Orange
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-13

Stripe Color Coding

Color code 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
WV Violet White
YB Yellow Black
YG 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 JIS (Japanese
Industrial Standard) (Nominal size means approximate
cross sectional area).

Nominal size Cross sectional area Outside diameter Allowable current (A)
2
(mm ) (mm)
0.3 0.372 1.8 9
0.5 0.563 2.0 12
0.85 0.849 2.2 15
1.25 1.287 2.5 21
2 2.091 2.9 27
3 3.291 3.6 37
5 5.228 4.4 50
8 7.952 5.5 66
15 13.36 7.0 92
20 20.61 8.2 121
6E-14 EMISSION AND ELECTRICAL DIAGNOSIS

BRIEF EXPLANATION OF EMISSION AND

ELECTRlCAL CONTROL SYSTEM
1. EC GOVERNOR (ELECTRICAL CONTROL GOVERNOR)
The basic injection volume (rack position) is sought from acceleration opening angle and engine revolution, and the
target injection volume is determined after adjustment reflecting the information from each sensor input.
A rack sensor detects actual injection volume (actual rack position), and moves the governor actuator to the target
rack position, so that the injection volume will be controlled.
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-15

2. TICS (Timing and Injection Control System)

Basic prestroke is sought from loaded engine condition (rack position) and engine revolution, and the target
prestroke is determined after adjustment reflecting information from each sensor input.
Prestroke sensor detects the actual prestroke, and moves a prestroke actuator to the target prestroke so that the
prestroke will be controlled.
6E-16 EMISSION AND ELECTRICAL DIAGNOSIS

3. EGR (Exhaust Gas Recirculation)

The EGR system returns a portion of the exhaust gas to the intake manifold. The exhaust gas circulates in the
intake manifold where it mixes with the fresh air entering the engine. The burned exhaust gases reduce the
combustion temperature. When combustion temperature is reduced, fewer nitrogen oxides (NOx) are produced.
The EGR valve is between the intake manifold and the exhaust manifold. The valve opens and closes to control the
volume of exhaust gas being returned to the intake manifold.
A cooler installed to the EGR passage cools the EGR gases. The cooled gases mixing with the fresh air entering
the engine further lower the combustion temperature. This system (called a cooled EGR) provides significantly
greater NOx reduction than an uncooled EGR system.
A check valve prevents EGR gas backflow. Because the EGR gas is allowed to flow in only one direction, the
volume of the gas delivered to the intake manifold is increased.

6W engine EGR control: EGR valve operation (One-way, cooled EGR)
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-17

4. ECU SYSTEM WIRING DIAGRAM

6E-18 EMISSION AND ELECTRICAL DIAGNOSIS
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-19

5. LOCATION OF SENSOR AND SWITCH

6E-20 EMISSION AND ELECTRICAL DIAGNOSIS
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-21

6. HARNESS LOCATION
Vehicle Harness
6E-22 EMISSION AND ELECTRICAL DIAGNOSIS

7. ENGINE CONTROL UNIT (ECU)

Name plate
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-23

8. CHART OF ECU INPUT/OUTPUT

PIN
NAME NOTE
No.
1 POWER SUPPLY; CONTROL UNIT
2 POWER SUPPLY; CONTROL UNIT
3 SERVICE ENGINE SOON INDICATOR LIGHT
4  
5 SCAN TOOL SIGNAL
FROM ECU TO SCAN TOOLTXD
6 ECU; GND
7 ECU; GND
8  
9 LIMP HOME SWITCH
10 PWM LINE
FROM ABS ECU
11 TACHO OUT
12 SCAN TOOL SIGNAL
FROM SCAN TOOL TO ECURXD
13  
14  
15 EXHAUST BRAKE SIGNAL OUT; MAGNETIC VALVE
16  
17 ACCELERATOR SWITCH
18  
19 STARTER SWITCH
20 CLUTCH SWITCH
21 ACCELERATOR SENSOR POWER SUPPLY (VB 5V-2)
22 ACCELERATOR SENSOR POWER SUPPLY (VB 5V-1)
23 IDLE CONTROL SWITCH
Auto/Manual
24  
25 EXHAUST BRAKE SIGNAL
MAGNETIC VALVE
26 PARKING BRAKE SWITCH
27  
28  
29 VEHICLE SPEED SENSOR SIGNAL
30 PRESTROKE; POWER SUPPLY CUT RELAY
31 ATMOSPHERE SENSOR SIGNAL
32 ACCELERATOR SENSOR SIGNAL 2
33 ACCELERATOR SENSOR SIGNAL 1
34  
35 DIAG SWITCH
36 IDLE UP SWITCH
37  
38 AIR PRESSURE SWITCH(LOW PRESSURE)
39 BRAKE SWITCH 2
40 ECU CASE GND
41 STARTER SWITCH [H] POSITION SIGNAL
42 POWER SUPPLY RELAY; MAGNETIC VALVE
43 ACCELERATOR SENSOR GND 2
44 ACCELERATOR SENSOR GND 1
6E-24 EMISSION AND ELECTRICAL DIAGNOSIS

PIN
NAME NOTE
No.
45 MEMORY CLEAR SWITCH
46 IDLE DOWN SWITCH
47 PTO SWITCH
48 GLOW LAMP
49  
50  
51 Q – ADJUST SIG 1
52 ELECTRONIC GOVERNOR POWER SUPPLY(VB 5V)
53 ELECTRONIC PWM
SOLENOID
54 ELECTRONIC GOVERNOR POWER SUPPLY 2
55 ELECTRONIC GOVERNOR POWER SUPPLY 1
56  
57  
58  
59 Q – ADJUST SIG 2
60 Q – ADJUST GND
61 ELECTRONIC GOVERNOR POWER SUPPLY(VB 5V)
62 ELECTRONIC GOVERNOR PWM
SOLENOID
63 ELECTRONIC GOVERNOR RACK SENSOR SIGNAL
VIST
64 MAGNETIC VALVE GND
65  
66 NEUTRAL SWITCH
67  
68 Q – ADJUST SIG 3
69 ELECTRONIC GOVERNOR SHIELD
70 ELECTRONIC GOVERNOR SENSOR GND
71 ELECTRONIC GOVERNOR GND 2
72 ELECTRONIC GOVERNOR GND 1
73 PRESTROKE POWER SUPPLY
74 MAGNETIC VALVE POWER SUPPLY
75 ELECTRONIC GOVERNOR PULL DOWN SIGNAL
76 PRESTROKE SENSOR SIGNAL
77 ALL SPEED ACCELERATOR SENSOR POWER SUPPLY
78 BOOST PRESSURE SENSOR VB 5V
79 BACK UP N SENSOR SIGNAL
80 N-TDC(NE)SENSOR SIGNAL
81  
82  
83  
84 PRESTROKE ACTUATOR; +
85 PRESTROKE ACTUATOR; -
86 ELECTRONIC GOVERNOR LIMP HOME SIGNAL
87 PRESTROKE SENSOR GND
88 FUEL TEMPERATURE SENSOR SIGNAL
89 ALL SPEED ACCELERATOR SENSOR SIGNAL
90 BOOST PRESSURE SENSOR SIGNAL
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-25

PIN
NAME NOTE
No.
91 BACK UP N SENSOR GND
92 ENGINE COOLANT TEMPERATURE SENSOR GND
93 N-TDC(NE)SENSOR GND
94  
95 MAGNETIC VALVE D

96  
97 PRESTROKE SENSOR GND
98 PRESTROKE SENSOR
REFERENCE
99 PRESTROKE SENSOR(SHIELD)
100 ALL SPEED ACCELERATOR SENSOR GND
101 BOOST PRESSURE SENSOR GND
102 TEMPERATURE SENSOR GND
103  
104  
Note: The meaning of symbol marks are:
: NORMAL
: OPTION

9. LIMP HOME CONTROL

9-1. Switch over to the limp home mode
When governer servo system error (DTC N0.11 ) or rack
sensor error (DTC N0.10) is diagnosed, engine will be stopped.
Before restarting engine, make sure that DTC N0.11 or DTC
N0.10 is diagnosed by self-diagnosis.
· Turn engine starter for 10 seconds.
· Don't turn ignition switch off.
· Connect the limp home switch.
· Start engine.
Note: the engine will emit excessive black exhaust gas
when in limp home control.
Move the vehicle to a safe place. Fit a spacer to the
adjusting screw to adjust the position to full stroke.

Adjusting screw (Normal running)

Adjusting screw
6E-26 EMISSION AND ELECTRICAL DIAGNOSIS

10. CONFIRMATION RETURN CONDITION FOR EMERGENCY ENGINE STOP

LEVER
10-1. Emergency engine stop button in the cabin

10-2. Adjustment procedure of emergency engine stop cable

 EMISSION AND ELECTRICAL DIAGNOSIS 6E-27

11. CAUTION TAKEN IN REPLACING ENGINE CONTROL UNIT (ECU)

The quantity adjusting resistance number. is described on the seal attached to the vehicle.
Please set the Quantity adjusting resistance in accordance with the information described on the seal.

1. ECU operation correct before replacement

Use TECH II to read the data from the old ECU before
replacement. Write this data into the new ECU.
· Programming
Set up the accelerator learning. Communicate with Tech II and control unit and write the set values into the
control unit.

Menu F3: Programming on the menu and press the ENTER

F0: Diagnostic Trouble Codes
key.
F1: Data Display
F2: Snap Shot
F3: Programming
F4: Special Functions

Programming Programming items are displayed.

Menu F0: Upload fuel delivery rate data and press the enter
F0: Upload Fuel Delivery Rate Data
key.
F1: Download Fuel Delivery Rate Data
F2: Accelerator Leaming Data

2. ECU operation incorrect before replacement

Notify your local distributor of the Q-adjustment values
(position shown in the illustration). The distributor will send
you the back-up data for the old ECM. This data can be
written to the new ECM.
6E-28 EMISSION AND ELECTRICAL DIAGNOSIS

12. TROUBLESHOOTING
12-1. Vehicle diagnostic procedure

Step Procedure Result Yes No

1 Begin the diagnostic procedure.  Go to Step 2 
 Go to Step 3 Go to
Check the SERVICE ENGINE SOON indicator
“SERVICE
light (ON/OFF)
ENGINE
2 SOON
1. Turn the starter switch to the ON position (do
indicator light
not start the engine).
does not turn
Does the indicator light turn on?
on”
Check the SERVICE ENGINE SOON indicator  Go to Step 4 Go to
light (flash). “SERVICE
ENGINE
3 1. Turn the starter switch to the ON position (do SOON
not start the engine). indicator light
2. Connect the diagnostic connector. does not flash”
Did the indicator light flash?
Check that the engine stops when the starter  Go to “Engine Go to Step 5
switch is moved to the OFF position. does not stop”
Caution: If the engine continues to run after the
4 starter switch is moved to the OFF position, wait
until it stops. Do not restart the engine until the
problem has been corrected. Serious engine
damage can result.
Start the engine.  Go to step 6 Go to “Engine
5
Does the engine start? does not start”
Install the scan tool.  Go to Step 7 Refer to the
scan tool
1. Turn the starter switch to the OFF position. manual
2. Connect the checker connector to the
checker.
6 3. Turn the starter switch to the ON position.
4. Turn the scan tool on.
5. Check that the scan tool is communicating
with the ECU (the scan tool should recognize
the ECU as soon as its power is turned on).
Was a problem found?
Use the scan tool to read and record the DTC  Go to step 8 
with the engine off.
7 Previous and current codes are stored in MEMO-
No.1.
Is the action complete?
Use the scan tool to read and record the self-  Go to step 9 
diagnosis codes with the engine on.
8 Previous and current codes are stored in MEMO-
No.2.
Is the action complete?
Compare the contents of MEMO-No.1 and  Go to Go to step 10
MEMO-No.2. Confirm DTC details. “Applicable
DTC (Separate
Ÿ Current code diagnostic
9
Ÿ Previous code methods).
If conditions are normal, DTC [1] is displayed.
Does the current code displayed?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-29

Step Procedure Result Yes No

 1. Go to Go to step 11
“Applicable
DTC
(Separate
diagnostic
Check that previous code exists (Step 9 DTC
methods).”
10 confirmation).
2. Refer to
Is the previous code displayed?
scan tool
engine
data when
making
repairs.
 Go to step 12 Go to
Refer to the diagnostic information (user
“Applicable
information) and the engine data. Inspect
problem
11 applicable areas and make repairs where
indications
necessary.
(Separate
Is the action complete?
inspection)”
Clear the ECU memory.  Verify repair 
12
Is the action complete?
6E-30 EMISSION AND ELECTRICAL DIAGNOSIS

12-2. DTC functions

(1) Memorization of self-diagnosis code
The DTC indicated will be memorized in EEPROM within the ECU.
Accordingly even if the starter switch turns off or the ECU is removed from the vehicle, the memorized DTC
will not be eliminated.
* Unless an elimination procedure is taken, the DTC will remain in memory.
(The memory will be eliminated only by a memory clear connector.)
Method to confirm the DTC (dealer mode)
The DTC can be read from the flashing of the service engine soon indicator light.
Reading DTC from the service engine soon indicator light.

To Display DTCs:
When the diagnosis connector mentioned below is connected, the indicator light will start flashing.
The DTC can be read from the flashing of the indicator light.

Operation:
· Starter switch ON.
· Connect diagnosis connector.
· Read DTC code.
· Disconnect diagnosis connector.
· Starter switch OFF.
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-31

Contents of indication:
Engine revolution = 0 DTC now being framed and DTC framed in the past will be indicated simultaneously.
Engine revolution ¹ 0 Only the DTC now being framed will be indicated.
Note: If no problem (or nothing memorized), the service engine soon indicator light will flash on and off to
indicate '01'.

How to read flashing of the service engine soon indicator light:

The three-digit DTC flashes starting from hundred's place, while the two-digit DTC flashes starting from ten's place
to indicate the DTC.
Please read the DTC from the flashing.
If the plural DTC's are indicated, the same DTC is flashes repeatedly in steps of three times. Please read it
correctly.

(For example) In case of indicate two digits figure '42' Unit ; s

(For example) In case of indicate three digits figure '242' Unit ; s

Method to confirm the repair completion

· Start engine.
· Connect diagnosis connector.
· If DTC code "01" was flashed, it shows the repair successfully completed.
· Engine stop.
6E-32 EMISSION AND ELECTRICAL DIAGNOSIS

(2) Clear of DTC

DTC memorized in the EEPROM within the ECU can be cleared only by the operation of the memory clear
connector.

Location of the memory connector

shown in the illustration.

The clear DTC method is described below:

1. Make sure that the memory clear connector is disconnected.
2. Turn off the starter switch, first, and turn it on again.
3. Leave it as is for more than 1 second, while the starter switch "ON".
4. Connect the memory clear connector for more than 1 second, and then disconnect it.
*The DTC will be cleared in about 0.5 second after the memory clear connector is disconnected.
5. Turn off the starter switch and then turn it on again to make sure that the DTC is cleared.
*If the DTC is not cleared, please repeat the above procedure.
6. Turn off the starter switch.
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-33

12-3. Abnormal Situation detection way other than the DTC code (User Mode)
If the self-diagnosis switch is turned off, the service engine soon indicator light will flash on and off to indicate a
problem in the engine control system.
The light-on way is classified depending upon the nature of the DTC (determined according to the degree of impact
on vehicles), as follows:
Light not switched on: [¾] (sign indicated in the DTC list)
Even if a DTC is framed or memorized, the indicator lamp will not turn on.
Light conditionally switched on: [ ] (sign indicated in the DTC list)
If the DTC is framed, the service engine soon indicator light will turn on if the situation of Ne£600rpm lasts for 20
seconds, and turn off if Ne > 600rpm.
Light constantly switched on: [ ] (sign indicated in the DTC list)
When the DTC is framed the service engine soon indicator light will unconditionally turn on.
(Note) When the engine control system is functions normally, the service engine soon indicator light will
indicate.
Ne = 0 ® Turns on
Ne ¹ 0 ® Turn off

12-4. Restorability to normal control

The control system is designed in such a way that backup control will be operated when the DTC is framed.
Depending upon the nature of the DTC, some specifications are designed in such a way that when abnormal
section is restored to normal conditions during backup control, the backup control automatically returns to normal
control. This system is called "Restorable System." On the contrary, some specification are designed in such a way
that when the DTC is framed, the backup control continues and does not make normal judgment until ECU is reset.
This is called 'Unrestorable system.'
The "Restorable system" DTC is used to indicate trouble that does not adversely affect driving nor damages engine.
The "Unrestorable system" DTC is used to indicate trouble that affects driving adversely or damages engine.
 6E-34 EMISSION AND ELECTRICAL DIAGNOSIS
13. Diagnostic Trouble Codes List
Code Back-up control
No. Item Details Decision time TICS Other
Data EC governor EGR
(Pre-stroke) information
1 Normal


Normal control Normal control No control

Ÿ Open or short More injection volume than
10 RACK SENSOR
ERROR Ÿ Sensor voltage more than 4.5 or less 160m second required for engine speed Pull-down or limp- Normal control
and other conditions during home
Control off during
limp-home


than 0.4 limp-home
Ÿ Engine running
GOVERNOR Ÿ Difference between target value (Rsol) 1 second More injection volume than Control off

SERVO and actual value (Rist) more than 2 mm required for engine speed Pull-down or limp- Normal control
11
SYSTEM Ÿ Engine start and other conditions during home
ERROR Ÿ Starter switch on 10 seconds limp-home Control off during


Ÿ Above conditions if heater is on
limp-home
BACKUP N Ÿ
Engine speed more than 350 rpm


14 SENSOR
ERROR Ÿ
Pulse signal abnormal or absent
1 second Engine speed required Normal control Normal control Normal control

N-DTC SENSOR Ÿ
Engine speed more than 350 rpm



15
ERROR Ÿ
Pulse signal abnormal or absent
Engine speed required Normal control Normal control Normal control
N-TDC SENSOR 2.5 seconds
14/15 & BACKUP N No signal from N-TDC sensor and back-up (abnormal) or
Pull-down Control off Control off

SENSOR N-sensor 1 second
ERROR (back-up)
FUEL Temperature
TEMPERATURE Sensor voltage more than 4.92 volts or compensation
211 SENSOR less than 0.1 volt 3 seconds Fuel temperature = 20 control only - Normal control Normal control

ERROR other controls
inoperative
ATMOSPHERIC Temperature Shift to back-up
TEMPERATURE Sensor voltage more than 4.8 volts or less Atmospheric temperature = compensation map in response
22 SENSOR than 0.1 volt 1 seconds 25 control only - to coolant and air No control

ERROR other controls temperature fixed
inoperative values
ENGINE Shift to back-up
COOLANT Sensor voltage more than 4.92 volts or Coolant temperature = map in response
23 TEMPERATURE less than 0.1 volt 3 seconds 55 Normal control to coolant and air No control

SENSOR temperature fixed
ERROR values
ACCELERATOR
PEDAL Sensor voltage more than 4.8 or less than Engine speed measured Control by
24 POSITION 0.1 1 second as accelerator switch is shifting to Control off Control off

SENSOR turned on and off all-speed map
ERROR
ACCELERATOR Ÿ Accelerator position switch off
241 POSITION
SWITCH OFF Ÿ Accelerator sensor voltage less than 1 second Accelerator opening angle
= 80%
Normal control Normal control Normal control

ERROR 0.65 volts
ACCELERATOR Ÿ Accelerator position switch on
242 POSITION
SWITCH ON Ÿ Accelerator sensor voltage more than 0.5 second Accelerator opening angle
= 30%
Shift control to all
speed map
Normal control No control

ERROR 3.06 volts
VEHICLE
SPEED
Ÿ Sensor circuit open or shorted to
25 ground 1 second
Normal control Normal control Normal control

SENSOR
ERROR Ÿ Terminal voltage less than 0.5 volts
PRESTROKE Control by
29 SERVO Difference between target value (PSsol) 20 seconds
shifting to shunt Control off Control off

SYSTEM and actual value (PSist) more than 0.6 mm injection map
ERROR
Code Control Service engine soon indicator light indication
return Control return conditions Diagnostic switch open Diagnostic switch shorted
No. Remarks
(User) (Diagnostic mode)
1

 Continuous 0 – 1 (Long – short) Normal control after engine is started (No abnormalities)
Ÿ No malfunction indicated when limp-home and pull-down are operative
Ÿ Trouble code appearance indicates possibility of limp-home control
10 No
 Continuous 1 – 0 (Long – short) shift
Ÿ Error may occur in governor and/or rack server as result of limp-home
conditions when the limp-home switch is on and the engine is running
Ÿ Sensing occurs (Not related to engine speed)
Ÿ No malfunction indicated when limp-home and pull-down are operative

 Continuous
Ÿ Limp-home control can be switched when limp-home switch is on
11 No 1 – 1 (Long – short)
Ÿ Limp-home control can be switched when limp-home switch is on
Ÿ Error may occur in governor and/or rack server as result of limp-home
conditions when the limp-home switch is on and the engine is running
0 (On when engine speed is
14 Yes Correct pulse signal less than 800 rpm for more than 1 – 4 (Long – short) Ÿ Error not detected when battery voltage is less than 18 volts
20 seconds)
0 (On when engine speed is Ÿ Error not detected when battery voltage is less than 18 volts
15 Yes Correct pulse signal less than 800 rpm for more than 1 – 5 (Long – short) Ÿ During malfunction, back-up N-sensor signal is used for back-up
20 seconds) control
Input signal (pulse) from N-
 Continuous
1 – 5 (Long – short) Ÿ Error not detected when battery voltage is less than 18 volts
14/15 Yes TDC sensor and back-up N-
sensor
1 – 4 (Long – short) Ÿ Trouble code not stored in memory
Input signal from sensor more Ÿ Error not detected when battery voltage is less than 18 volts
211 Yes than 0.1 volt but less than 4.92 X Not lit 2 – 1 – 1 (Short – long – short) Ÿ When ground circuit is open, coolant temperature sensor and
volts for more than 3 seconds atmospheric pressure sensor error is simultaneously detected
Input signal from sensor more Ÿ Error not detected when battery voltage is less than 18 volts
22 Yes than 0.1 volt but less than 4.8  Continuous 2 – 2 (Long – short) Ÿ When ground circuit is open, coolant temperature sensor and fuel
volts for more than 3 seconds temperature sensor error is simultaneously detected
Input signal from sensor more 0 (On when engine speed is Ÿ Error not detected when battery voltage is less than 18 volts

EMISSION AND ELECTRICAL DIAGNOSIS 6E-35

23 Yes than 0.1 volt but less than 4.92 less than 800 rpm for more than 2 – 3 (Long – short) Ÿ When ground circuit is open, atmospheric pressure sensor and fuel
volts 20 seconds) temperature sensor error is simultaneously detected
Ÿ When DTC 241 and DTC 242 are active, switching to the back-up
24 No
 Continuous 2 – 4 (Long – short) mode is not possible
Ÿ Error not detected when battery voltage is less than 18 volts
Ÿ No shift to back-up mode when DTC24 is active
241 No
 Continuous 2 – 4 – 1 (Short – long – short) Ÿ Error not detected when battery voltage is less than 18 volts
Ÿ Accelerator opening angle limited to 80%
Ÿ No shift to back-up mode when DTC24 is active
242 No
 Continuous 2 – 4 – 2 (Short – long – short) Ÿ Error not detected when battery voltage is less than 18 volts
Ÿ Accelerator opening angle limited to 20%
25 Yes Input signal (pulse) from X Not lit 2 – 5 (Long – short) Error not detected when battery voltage is less than 18 volts
sensor
Ÿ  Continuous (Actual value

large when slippage is
Ÿ Error not detected when DTC 291 and DTC 292 are active
29 No
Ÿ
toward positive side)
X Not lit (Slippage is toward
2 – 9 (Long – short)
Ÿ Error not detected when battery voltage is less than 18 volts
negative side)
 6E-36 EMISSION AND ELECTRICAL DIAGNOSIS
Code Back-up control
No. Item Details Decision time TICS Other
Data EC governor EGR
(Pre-stroke) information
PRESTROKE SENSOR Pre-stroke value (Psist) more than Control by
291 2 seconds shifting to shunt Control off Control off

ERROR 6.05 mm or less than 1.11 mm
injection map
PRESTROKE LEARNING Pre-stroke value (Psist) more than Control by
292 ERROR 6.05 mm or less than 1.11 mm

shifting to shunt Control off Control off

injection map
When engine stop, sensor voltage
more than 1.3
1.3 (V) = 120 (kPa) {900 [mmHg] Control by
32 BOOST PRESSURE (abs)} 1 seconds Boost pressure = shifting to shunt Control off Normal control

SENSOR ERROR When engine running, sensor voltage 101.3 [kPa] injection map
less than 0.5
0.5 (V) = 66.7 (kPa) {500 [mmHg]
(abs)}
Ÿ Control off
33 MEMORY CIRCUIT (RAM) ECU malfunction


Pull-down or
power supply Control off
Ÿ Fail-safe Exhaust brake
ERROR cut relay on
operative
Ÿ Magnetic valve not operating
Ÿ Weak signal from magnetic valve
413 MAGNETIC VALVE D,E (ECU input circuit problem)
1.5 seconds
Normal control Normal control No control

444 ERROR Ÿ Magnetic valve operating
Ÿ Strong signal from magnetic valve
(ECU input circuit problem)
Ÿ Low relay valve drive voltage
(Impressed ECU voltage)
421
MAGNETIC VALVE POWER
SUPPLY FUSE BLOWN Ÿ No drive force to magnetic valve 1 second
Normal control Normal control No control

(Abnormally low voltage being
delivered to ECU)
PRESTROKE POWER Pre-stroke power supply less than 3 Control by Pre-stroke
423 SUPPLY FUSE BLOWN (V) 1 second
shifting to shunt actuator No control

injection map
Ÿ Q-adjustment data
abnormal but back-up
data present (No. 4)
518
EOL (END OF LINE) DATA
ERROR
Q-adjustment data bad or no
accelerator learning Instantaneous Ÿ Accelerator learning Normal control Normal control Normal control

idle position and full
position back-up data
function (0.5 – 3.75V)


Pull-down Normal control Normal control Exhaust brake
ENGINE OVER RUN Engine speed more than 3,380 rpm 0.5 second on
543
Normal control Normal control Normal control

Ÿ 300 rpm < Engine speed < 800
rpm
ENGINE REVERSING Ÿ Vehicle speed less than 10 km/h



571
ERROR Ÿ Starter switch off
1 second Pull-down Normal control Normal control
Ÿ Signal input of N-TDC sensor
(back-up N-sensor) reversed
71 ATMOSPHERIC PRESSURE Sensor voltage less than 1.63 volts 3 seconds Atmospheric pressure = Normal control Normal control No control

SENSOR ERROR 101.3 kPa
Code Back-up control
No. Item Details Decision time TICS Other
Data EC governor EGR
(Pre-stroke) information
Error occurs
during idle
Ÿ Sensor not operating period – no
No control –
Ÿ Sensor voltage more than 4.8 volts

operational Normal control
normal control
except during

or less than 0.1 volts map shift – procedure
ALL SPEED other normal

ACCELERATOR SENSOR control
ERROR Error occurs
Ÿ Sensor operating during No control –
Ÿ Sensor voltage more than 4.8 volts 1 second All speed accelerator
opening angle = 0%
operation –
shift to back-up
Normal control normal control
except during


or less than 0.1 volts operational procedure
map

ENGINE CONTROL UNIT
(Lamp) (ECU) MAIN POWER Power not being delivered to the ECU

Control load Control load Control load

SUPPLY FUSE BLOWN

EMISSION AND ELECTRICAL DIAGNOSIS 6E-37

 6E-38 EMISSION AND ELECTRICAL DIAGNOSIS
Code Control Service engine soon indicator indication
No. return Control return conditions Diagnostic switch shorted
Diagnostic switch open (User) Remarks
(Diagnostic mode)
Pre-stroke actual value (Psist) 0 (On when engine speed is less
291 Yes within specified range of 1.11 than 800 rpm for more than 20 2 – 9 – 1 (Short – long – short) Error not detected when battery voltage is less than 18 volts
mm to 6.05 mm seconds)
Ÿ Error not detected when DTC 291 is active


0 (On when engine speed is less Ÿ Error not detected when battery voltage is less than 18 volts
292 No than 800 rpm for more than 20
seconds)
2 – 9 – 2 (Short – long – short)
Ÿ Decision is made when the starter switch is moved from the
OFF position to the ON position
When engine stop, sensor
voltage less than 1.3
1.3 (V) = 120 (kPa) {900 0 (On when engine speed is less
32 Yes [mmHg] (abs)} than 600 rpm for more than 20 3 – 2 (Long – short) Error not detected when battery voltage is less than 18 volts
When engine running, sensor seconds)
voltage more than 0.5
0.5 (V) = 66.7 (kPa) {500
[mmHg] (abs)}
33 No Power supply reset  Continuous 3 – 3 (Long – short)

0 (On when engine speed is less
Ÿ 4 – 4 – 4 (Short – long – short)
Ÿ Error not detected when battery voltage is less than 18 volts
413 No
than 800 rpm for more than 20
Ÿ
magnetic valve C
Ÿ Magnetic valve E – EGR-2
444 seconds) 4 – 1 – 3 (Short – long – short)
magnetic valve D
Ÿ Magnetic valve D – EGR-1
Ÿ Magnetic pulse not driven 0 (On when engine speed is less Ÿ
421 Yes Ÿ High voltage at ECU for than 800 rpm for more than 20 Ÿ 4 – 2 – 1 (Short – long – short)
Ÿ
Error not detected when battery voltage is less than 18 volts
Error not detected when magnetic pulse is on (Open)
more than 1 second seconds)

 Continuous Ÿ Ÿ Error not detected when battery voltage is less than 18 volts
423 No 4 – 2 – 3 (Short – long – short)
Ÿ Error not detected when pre-stroke cut relay is active (On)
Ÿ Q-adjustment data correct
Ÿ Recovery occurs in all areas after back-up treatment is
 Continuous
518 Yes
Ÿ Accelerator learning occurs
5 – 1 – 8 (Short – long – short)
Ÿ
complete
Error not detected when battery voltage is less than 18 volts
Ÿ Only the trouble code stored in memory.
543 No
Engine speed more than 3,180
X Not lit 5 – 4 – 3 (Short – long – short) Ÿ Error not detected when DTC 14 and DTC 15 are active
rpm
Ÿ Error not detected when battery voltage is less than 18 volts
Starter switch on (System
Ÿ Service engine soon indicator light on when engine is
571 Yes X Not lit 5 – 7 – 1 (Short – long – short) stopped
reset) Ÿ Limp-home control does not operate when pull-down is active
0 (On when engine speed is less
71 No than 800 rpm for more than 20 7 – 1 (Long – short) Error not detected when battery voltage is less than 18 volts
seconds)
ALL Yes Normal sensor signal X Not lit 0 – 1 (Long – short)
 Continuous (Only during

SPEED No
Normal signal
operation)



 Continuous
System down – Engine cannot be started – No control –
Warning lamps continuously on
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-39

CONNECTOR INSPECTING PROCEDURE

Connector inspecting procedure
6E-40 EMISSION AND ELECTRICAL DIAGNOSIS

1. SERVICE ENGINE SOON INDICATOR LIGHT DOES NOT TURN ON

· Open meter power supply circuit (Between fuse
Circuit Description
(No. 11) and upper instrument panel connectors
The service engine soon indicator light is part of the and/or meter and instrument lower harness
display on the vehicle dashboard. connectors)
Power is delivered to the lamp through the No. 11 · Open lamp drive circuit (Between meter and lower
fuse. instrument panel connectors and/or instrument
The lamp is turned on and off by a lamp control switch upper harness connectors and ECU)
inside the engine control unit (ECU). The switch is · ECU malfunction
between the power supply and ground. · ECU power supply malfunction (Between fuse (No.
Possible Problems 20) and ECU)
· ECU ground circuit malfunction (Between ECU and
· Meter cluster malfunction (Display circuit or
front frame harness connectors, ECU and lower
communication circuit)
instrument panel connectors, instrument lower
· Control unit malfunction (May involve meter
harness and front frame harness connectors,
assembly)
and/or front frame harness and ground)
· Burned out bulb
· Meter malfunction (Circuit)
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-41

Troubleshooting (Inspection and repair procedures)

Step Action Value(s) Yes No
1. Starter switch ON.
Go to Step 3 Go to Step 2
2. Check that the meter display is operational
1 (lights other than the service engine soon
indicator light turn on).
Was a problem found?
Check that the meter power supply has the same
Go to Step 3 Go to Power
voltage level as the battery. supply circuit
inspection
2 1. Remove the No. 11 fuse.
2. Starter switch ON.
3. Measure the voltage across the fuse
installation point.
Check that the ECU supply has the same voltage
Go to Step 4 Go to Power
level as the battery supply circuit
inspection
3 1. Remove the No. 20 fuse.
2. Starter switch ON.
3. Measure the voltage across the fuse
installation point.
Measure the resistance (continuity) between the Less than 0.5W Go to Step 6 Go to Step 5
4
No. 20 fuse and the ECU connectors.
1. Repair or replace the ECU power supply
Verify repair Go to Step 6
circuit.
2. Connect the diagnostic switch and check the
5
service engine soon indicator light operation
again.
Was a problem found?
Inspect the ECU ground circuit. Less than 1W/0V Go to Step 7 Go to Power
supply circuit
1. Starter switch OFF. inspection
2. Remove the ECU.
3. Measure the resistance and voltage drop
6
between Terminals 6, 7, 64, and 97 and
battery ground.
4. Measure the resistance and voltage drop
between Terminal 40 (cab ground) and the
circuit.
Inspect the indicator light circuit. Less than 0.5W Go to Step 9 Go to Step 8
7
Measure the resistance (continuity) between the
instrument upper harness and the connectors.
6E-42 EMISSION AND ELECTRICAL DIAGNOSIS

Troubleshooting (Inspection and repair procedures) (Cont'd)

Step Action Value(s) Yes No
1. Repair or replace the ECU/ instrument upper Light on Verify repair Go to Step 9
harness circuit and/or the ECU/ instrument (Operational)
lower harness circuit.
8 2. Connect the diagnostic switch and check the
service engine soon indicator light operation
again.
Was a problem found?
Inspect the indicator light circuit. It must not be Less than 0.5W Go to Step 11 Go to Step 10
open.

9 1. Remove the meter assembly.

2. Measure the resistance (continuity) between
the meter and the instrument lower harness
connector.
1. Repair or replace the meter/ instrument Light on Verify repair Go to Step 11
lower harness and/or the meter/ instrument (Operational)
upper harness.
10 2. Reconnect the diagnostic switch. Check the
service engine soon indicator light operation
again.
Was a problem found?
Check for burned out bulbs in the meter. Operational Go to Step 14 Go to Step 13
11
Was a problem found?
1. Replace the burned out bulb(s). Operational Verify repair Go to Step 16
2. Reconnect the diagnostic switch. Check the
12 service engine soon indicator light operation
again.
Was a problem found?
Inspect the meter power supply circuit. Less than 0.5W Go to Step 16 Go to Step 15

1. Remove the No. 11 fuse.

13
2. Measure the resistance (continuity) between
the meter and the instrument lower harness
connector.
1. Repair or replace the meter/ instrument Light on Verify repair Go to Step 16
lower harness and/or the meter/ instrument (Operational)
upper harness.
14 2. Reconnect the diagnostic switch. Check the
service engine soon indicator light operation
again.
Was a problem found?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-43

Troubleshooting (Inspection and repair procedures) (Cont'd)

Step Action Value(s) Yes No
Inspect the meter power supply circuit. Less than 0.5W Go to Step 18 Go to Step 17
Measure the resistance (continuity) between the
15
No. 11 fuse and the instrument upper harness
connector.
1. Repair or replace the No. 11 fuse/ instrument
Verify repair Go to Step 18
upper harness and/or the No. 11 fuse/
instrument lower harness.
16 2. Connect the diagnostic switch and check the
service engine soon indicator light operation
again.
Was a problem found?
Measure the resistance (continuity) of the Less than 1W Go to Step 20 Go to Step 19
diagnostic switch connector circuit.

1. Measure between the diagnostic switch

17 connector and the instrument upper
connector at the instrument lower harness.
2. Measure between the diagnostic switch
connector and the ECU connector at the
instrument lower harness.
1. Repair or replace the diagnostic switch
Verify repair Go to Step 20
connector/ instrument upper harness circuit
and/or the ECU/ instrument lower harness.
18 2. Connect the diagnostic switch and check the
service engine soon indicator light operation
again.
Was a problem found?
Check the meter assembly (lamp circuits).
Go to Step 22 Go to Step 21
1. Install the meter to the harness.
2. Connect the instrument lower harness and
the instrument upper harness.
3. Remove the ECU.
19 4. Joint the ECU No.3 pin to Gnd.
5. Starter switch ON.
6. Operate the No. 14 frame diagnostic
confirmation switch of the checker to confirm
lamp operation.
Was a problem found?
Replace the meter assembly.
Verify repair

20
Is the action complete?
Replace the ECU.
Verify repair

21
Is the action complete?
6E-44 EMISSION AND ELECTRICAL DIAGNOSIS

(Meter connections)
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-45

2. SERVICE ENGINE SOON INDICATOR LIGHT DOES NOT FLASH

Circuit Description Possible Problems
The service engine soon indicator light is part of the · Warning lamp/meter cluster malfunction (Display
display on the vehicle dashboard. circuit or communication circuit)
Power is delivered to the light through the No. 11 fuse. · ECU malfunction (May involve meter assembly)
The light is turned on and off by a light control switch · Meter malfunction (Circuit)
inside the engine control unit (ECU). The switch is · Open lamp drive circuit (Between meter and
between the power supply and ground. instrument lower connectors and/or instrument
A diagnostic connector is attached to the ECU to upper connectors and ECU)
permit DTC. The light flashes on and off to indicate · ECU malfunction
the appropriate DTC. · ECU power supply malfunction (Between fuse No.
20 and ECU)
· Diagnostic switch circuit malfunction (Between
ECU, diagnostic connector, joint connector, and
front frame harness connector or front frame
harness, instrument lower harness connector, and
ground)
6E-46 EMISSION AND ELECTRICAL DIAGNOSIS

Troubleshooting (Inspection and repair procedures)

Step Action Value(s) Yes No
Ÿ White Go to Step 7 Go to Step 2
diagnosis
Check the diagnostic connector circuit. connector
connected =
1 1. Starter switch "OFF". less than 3W
2. Remove the engine control unit (ECU). Ÿ Black
3. Measure the circuit resistance. diagnosis
connector
connected = ¥
Check the diagnosis connector circuit (front Less than 0.5W Go to Step 4 Go to Step 3
frame harness).

1. Starter switch ON.

2. Disconnect the instrument lower harness
2
and the front frame harness.
3. Measure the resistance (continuity) between
the instrument lower harness connector and
the frame ground.
Was a problem found?
1. Repair or replace the diagnostic connector
Go to Step 4 Go to Step 4
circuit.
2. Connect the diagnostic switch and check the
3
service engine soon indicator light operation
again.
Was a problem found?
Check the diagnosis connector circuit. Less than 0.5W Go to Step 7 Go to Step 5

1. Starter switch ON.

2. Remove the ECU.
3. Measure the resistance (continuity) of the
following circuits. An open circuit is
4 unacceptable.

Ÿ ECU « black diagnostic connector

Ÿ White diagnostic connector « joint
connector
Ÿ Joint connector « front frame harness
connector
1. Repair or replace the diagnostic connector
Go to Step 5 Go to Step 6
circuit (front frame harness).
2. Connect the diagnostic switch and check the
5
service engine soon indicator light operation
again.
Was a problem found?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-47

Troubleshooting (Inspection and repair procedures) (Cont'd)

Step Action Value(s) Yes No
Check the joint connector. If a problem is found,
Go to Step 7

repair or replace as necessary.

Ÿ There must be continuity between each

6
connector pin.
Ÿ The connector must be undamaged. The
terminals must be tight.
Is the action complete?
Check the meter circuit. Does not short by Go to Step 8 Go to Step 9
other circuit
1. Starter switch OFF.
2. Remove the Engine Control Unit (ECU).
7 3. Remove the meter.
4. Check for a short circuit between the ECU
connector (harness side) and the meter
connector (harness side).
Was a problem found?
Repair or replace the meter circuit (separated
Verify repair Go to Step 9
from the harnesses).

1. Disconnect the instrument upper and lower

harnesses.
2. Check between the ECU connector (harness
8
side) and the instrument upper installation
connector.
3. Connect the diagnostic switch and check the
service engine soon indicator light operation
again.
Was a problem found?
Check the meter operation.
Go to Step 11 Go to Step 13

1. Connect all harnesses, except for meter.

9
2. Starter switch ON.
Does the service engine soon indicator light
turns on?
1. Replace the meter assembly.
Verify repair Go to Step 13
2. Connect the diagnostic switch and check the
10 service engine soon indicator light operation
again.
Was a problem found?
Check the meter operation.
Go to Step 11 Go to Step 13

1. Connect all harnesses.

11
2. Starter switch ON.
Is the service engine soon indicator light turns
on?
Replace the ECU.
Verify repair

12
Is the action complete?
6E-48 EMISSION AND ELECTRICAL DIAGNOSIS

Diagnostic Connector
Connect the diagnostic connectors, engine connector,
and common GND connector.
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-49

(Meter Connections)
6E-50 EMISSION AND ELECTRICAL DIAGNOSIS

3. ENGINE DOES NOT STOP

Possible Problems Inspection Cautions
· Power supply circuit malfunction (ECU shorted to If the engine continues to run after the starter switch
power supply or starter switch circuit harness has been moved to the OFF position, wait until it
shorted to power supply) eventually stops. Do not restart the engine until the
· Battery relay malfunction (Internal short or sticking) problem is rectified. Serious engine damage can
· Injection pump malfunction (Governor damage) result.
· Starter switch malfunction

Troubleshooting (Inspection and repair procedures)

Step Action Value(s) Yes No
Check the engine control and service engine
Go to Step 2 Go to Step 3
soon indicator light operation.
1
Starter switch ON and OFF several times.
The service engine soon indicator light should
turn off.
Replace the injection pump.
Verify repair

2
Is the action complete?
Check the power supply circuit. Refer to “Power
Verify repair Go to power
supply check.” supply check

Make repairs or replacements as required.

3
Ÿ Battery relay and/or starter switch sticking
Ÿ Battery relay, starter switch, and/or harness
shorting
Is the action complete?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-51

4. ENGINE DOES NOT START

· Fuel system malfunction (No fuel, supply system
Possible Problems
malfunction, clogged fuel or air filter, frozen fuel,
· Starter system malfunction (Starter motor, starter etc.)
relay, starter circuit, battery, etc.) · Intake system malfunction (Damaged of clogged
· Engine control system inoperative (Engine control filter and/or intake shutter)
unit malfunction, power supply problem, short to · Problem somewhere else in the engine
ground, etc.)
· Injection pump malfunction (Damage to unit or feed
pipes)

Troubleshooting (Inspection and repair procedures)

Step Action Value(s) Yes No
Check the starter motor operation.
Go to Step 2 Go to Starter
1
Was a problem found? circuit check
Check the fuel system. Refer to the item on fuel
Go to Step 3 Go to Fuel
2 system checking. system check
Was a problem found?
Check the intake system operation. Refer to the
Go to Step 4 Go to Intake
3 item on intake system checking. system check
Was a problem found?
Check the DTC.
Perform the Go to Step 5
appropriate
1. Crank the engine for more than 10 seconds. inspection
2. Confirm that the DTC appears. procedure for
4 the displayed
DTC's 10, 11, and 33 appear separately (one at code
a time). DTC's 14 and 15 may appear
simultaneously.
Do the DTC codes appear?
Start the engine.
Verify repair Go to Step 6
5
Could the engine be started?
Check the ECU.
Go to Step 8 Go to Step 7

1. Starter switch OFF.

6
2. Replace the ECU.
3. Start the engine.
Could the engine be started?
Replace the ECU.
Verify repair Go to Step 8
7
Could the engine be started?
Check the injection pump (feed pump) operation.
Go to Step 10 Go to Step 9
8
Use the priming pump to confirm that fuel is
being delivered under pressure.
6E-52 EMISSION AND ELECTRICAL DIAGNOSIS

Troubleshooting (Inspection and repair procedures) (Cont'd)

Step Action Value(s) Yes No
1. Replace the injection pump (feed pump).
Verify repair

9 2. Start the engine.
Could the engine be started?
Check the mechanical parts of the engine. If a
Verify repair

problem is found, repair as necessary.

Ÿ Valve train
Ÿ Injection nozzles
10
Ÿ Compression
Ÿ Timing gear
Ÿ Piston, connecting rod, and crankshaft
connections
Is the action complete?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-53

5. ENGINE STALLING
Possible Problems
· Engine control system inoperative (ECU
malfunction, power supply problem, short to ground,
etc.)
· Injection pump malfunction (Damage to unit or feed
pipes)
· Fuel system malfunction (No fuel, supply system
malfunction, clogged fuel or air filter, frozen fuel,
etc.)
· Intake system malfunction (Damaged of clogged
filter)
· Problem somewhere else in the engine
· Alternating current generator (ACG) malfunction
· Problem with radio or other electrical accessories
installed after vehicle manufacture (Faulty
equipment or installation error)
· Chassis part malfunction (Clutch, transmission,
etc.)
6E-54 EMISSION AND ELECTRICAL DIAGNOSIS

Troubleshooting (Inspection and repair procedures)

Step Action Value(s) Yes No
Check the engine control or service engine soon
Go to Step 2 Go to Service
indicator light operation. engine soon
1 indicator light
Starter switch ON, Engine OFF. does not turn
Is the service engine soon indicator light turn on? on
Check the engine control and service engine
Go to Step 3 Go to Service
soon indicator light operation. engine soon
2 indicator light
Starter switch ON, Engine OFF.
does not turn
Is the service engine soon indicator light
on
flashing?
Check the DTC. Code appears Perform the Go to Step 4
appropriate
1. Crank the engine for more than 10 seconds.
inspection
2. Confirm that the DTC appears.
procedure for
3
DTC's 10, 11, and 33 appear separately (one at the displayed
a time). DTC's 14 and 15 may appear DTC
simultaneously.
Do the DTC codes appear?
Start the engine.
Go to Step 5 Go to Engine
4
Could the engine be started? does not start
Check the fuel system.
Go to Step 6 Go to Fuel
5
Was a problem found? system check
Check the intake system.
Go to Step 7 Go to Intake
6
Was a problem found? system check
Check the exhaust system.
Go to Step 8 Go to Exhaust
7
Was a problem found? system check
Check the ACG.
Go to Step 10 Go to Step 9

8 Check the charging lamp (meter cluster). It

should be on when the engine is running.
Was the charging lamp off?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-55

Troubleshooting (Inspection and repair procedures) (Cont'd)

Step Action Value(s) Yes No
Replace the ACG.
Go to Step 10

9
Is the action complete?
Check the any electrical accessories installed to
Go to Step 12 Go to Step 11
the vehicle after manufacture.
10
1. Remove power from the accessory.
2. Check to see if the engine continues to stall.
1. Install the additional equipment correctly or
Verify repair Go to Step 12
11 remove it from the vehicle.
2. Start the engine.
Check the ECU.
Verify repair Go to Step 13

1. Starter switch OFF.

12
2. Replace the ECU.
3. Start the engine.
Did the engine stall?
Check the injection pump (feed pump). Fuel delivery Go to Step 15 Go to Step 14
13
Use the priming pump to confirm that fuel is
being delivered under pressure.
1. Replace the injection pump (feed pump).
Verify repair Go to Step 15
14 2. Start the engine.
Could the engine be started?
Check the mechanical parts of the engine. If a
Go to Step 16

problem is found, repair as necessary.

Ÿ Valve train
Ÿ Injection nozzles
15
Ÿ Compression
Ÿ Timing gear
Ÿ Piston, connecting rod, and crankshaft, etc.
connections
Was a problem found?
Check the chassis parts (transmission and
Verify repair

16 clutch). If a problem found, repair as necessary.
Is the action complete?
6E-56 EMISSION AND ELECTRICAL DIAGNOSIS

6. ENGINE HUNTING
· Input circuit malfunction (Switch or harness
Possible Problems
damage)
· Fuel quality (Wrong fuel) · Accelerator position sensor, N-TDC sensor, and/or
· Air in the fuel system all-speed accelerator sensor malfunction (Switch or
· Clogged fuel filter harness damage)
· Problem with radio or other electrical accessories · Engine malfunction (Injection nozzles, fuel pump,
(special tail lamps, etc.) installed after vehicle flywheel, crankshaft damper, etc.)
manufacture (Faulty equipment or installation error) · ECU malfunction
· Switch malfunction (Reverse, neutral, air
conditioner, etc.)

Troubleshooting (Inspection and repair procedures)

Step Action Value(s) Yes No
Drain the fuel tank and fuel lines. Replace the
Verify repair Go to Step 2
1 discarded fuel with the specified fuel.
Does the engine hunt?
Bleed the air from the fuel system.
Verify repair Go to Step 3
2
Does the engine hunt?
Check the fuel filter for foreign material.
Go to Step 4 Go to Step 5
3
Is the fuel filter clogged?
Replace the fuel filter.
Verify repair Go to Step 5
4
Does the engine hunt?
Check any electrical accessories installed to the
Go to Step 6 Go to Step 7
vehicle after manufacture.
5
1. Remove power from the accessory.
2. Check to see if hunting continues.
Does the engine hunt?
Install the additional equipment correctly or
Verify repair Go to Step 7
6 remove it from the vehicle.
Does the engine hunt?
Check tail lamps and other equipment installed
Go to Step 9 Go to Step 8
to the vehicle after manufacture.
7
Ÿ Harness malfunction (Short circuit or direct
grounding to frame)
Repair tail lamps and other equipment installed
Verify repair Go to Step 9
8 to the vehicle after manufacture.
Does the engine hunt?
Check the reverse switch input circuit. Normal (Lamp Go to Step 11 Go to Step 10
turns on when
1. Place the gearshift lever in the neutral lever is in reverse
9
position. and off when lever
2. Starter switch ON. is in neutral)
3. Gearshift lever reverse.
Replace or repair the reverse switch (refer to
Go to Step 15

10 “Reverse circuit” in this Manual).
Does the engine hunt?
Normal (Lamp Go to Step 13 Go to Step 12
Check the neutral switch input circuit.
turns on when
lever is in neutral
11 1. Gearshift lever NEUTRAL.
and off when lever
2. Starter switch ON.
is in some other
3. Gearshift lever to some other position.
position)
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-57

Troubleshooting (Inspection and repair procedures) (Cont'd)

Step Action Value(s) Yes No
Replace or repair the neutral switch (refer to
Verify repair Go to Step 13.
“Neutral switch” manual or automatic
12
transmission) in this Manual).
Does the engine hunt?
Check the installation condition of the N-TDC
Go to Step 15 Go to Step 14
13 sensor.
Was a problem found?
Position the N-TDC sensor so that it is snug.
Verify repair Go to Step 15
14
Does the engine hunt?
Check the N-TDC sensor function.
Go to Step 16 Go to Step 17

1. Start the engine.

15
2. Remove the harness form the N-TDC
sensor.
Does the engine hunt?
Check the flywheel and injection pump timer for Normal (No Verify repair Go to Step 17
16 damage, corrosion, and dirt. Clean, repair, or hunting)
replace as required.
Check the accelerator sensor function (Refer to
Verify repair Go to Step 18
DTC 24).
17 If a problem is found, repair or replace as
necessary.
Does the engine hunt?
Check the all-speed accelerator sensor function. Normal (No Verify repair Go to Step 19
18
Does the engine hunt? hunting)
Check the mechanical parts of the engine. If a No hunting Verify repair Go to Step 20
problem is found, repair as necessary.

Ÿ Valve train (Valve clearance)

19
Ÿ Injection nozzles
Ÿ Compression
Ÿ Crankshaft damper
Does the engine hunt?
Change the engine control unit (ECU).
Go to Step 21 Go to Step 22

1. Starter switch OFF.

20
2. Replace the existing ECU.
3. Start the engine.
Does the engine hunt?
Replace the ECU.
Verify repair

21
Is the action complete?
Replace the injection pump.
Verify repair

22
Is the action complete?
6E-58 EMISSION AND ELECTRICAL DIAGNOSIS

7. ENGINE HESITATION, POOR ASPIRATION, AND LOW POWEROUTPUT

· ECU malfunction
Possible Problems
· Engine malfunction (Injection nozzles, fuel pump,
· Fuel quality (Wrong fuel) valve clearance, turbocharger, etc.)
· Intake system malfunction · Problem with radio or other electrical accessories
· Fuel system malfunction (special tail lamps, etc.) installed after vehicle
· Clogged fuel filter manufacture (Faulty equipment or installation error)
· Sensor malfunction (All-speed accelerator sensor, · Chassis part malfunction (Clutch, transmission,
N-TDC sensor, boost pressure sensor, vehicle brakes, etc.)
speed sensor, etc.) · Exhaust brake switch input circuit malfunction
· Power-take-off (PTO) malfunction (Switch or harness damage)
· Exhaust gas recirculation (EGR) malfunction · Mechanical timing malfunction (Slippage)
· Exhaust brake malfunction
· Exhaust pipe damage

Troubleshooting (Inspection and repair procedures)

Step Action Value(s) Yes No
Drain the fuel tank and fuel lines. Replace the
Verify repair Go to Step 2
1 discarded fuel with the specified fuel.
Was a problem found?

Go to Step 3 Go to Intake
Check the intake system.
2 system
Was a problem found?
procedures
Check the engine mechanical timing (Slippage) 2 degrees BTDC Go to Step 5 Go to Step 4
3
Was a problem found?
Adjust the mechanical timing.
Verify repair Go to Step 5
4
Was a problem found?

Go to Step 6 Go to Fuel
Check the fuel system.
5 system
Was a problem found?
procedures
Check the injection pump (feed pump) operation.
Go to Step 8 Go to Step 7

6 Use the priming pump to confirm that fuel is

being delivered under pressure.
Was a problem found?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-59

Troubleshooting (Inspection and repair procedures) (Cont'd)

Step Action Value(s) Yes No
Replace the injection pump.
Verify repair Go to Step 8
7
Was a problem found?
Inspect the exhaust brake input circuit. Normal (Lamp Go to Step 10 Go to Step 9
turns on when
1. Gearshift lever NEUTRAL. switch is in ON
8
2. Starter switch ON. position and off
3. Operate the exhaust brake switch. when switch is in
Was a problem found? OFF position)

Go to Step 6 Go to Exhaust
Check the exhaust system.
9 system
Was a problem found?
procedures
Check the boost pressure sensor hose for
Go to Step 13 Go to Step 12
damage, clogging, and holes.
10
Was a problem found?
Repair or replace the boost pressure sensor.
Verify repair Go to Step 13
11
Was a problem found?
Check the intake pipes.
Go to Step 15 Go to Step 14

Ÿ Leakage between the turbocharger,

12
intercooler and intake manifold
Ÿ Looseness, damage, and/or gaps
Was a problem found?
Repair or replace the intake pipes. Normal Verify repair Go to Step 15
13
Was a problem found?
Check the function of individual boost pressure
Go to Step 15 Refer to DTC
sensor parts. 32
Refer to DTC 32.
14 If a problem is found, repair or replace as
necessary.

Was a problem found?

6E-60 EMISSION AND ELECTRICAL DIAGNOSIS

Troubleshooting (Inspection and repair procedures) (Cont'd)

Step Action Value(s) Yes No
Check the accelerator pedal full open position. Normal (12 mm) Go to Step 17 Go to Step 16

1. Starter switch OFF.

15 2. Press the accelerator pedal top the
floorboard.
3. Measure the floor stopper bolt gap.
Was a problem found?
Adjust the floor stop bolt.
Go to Step 18

16
Is the action complete?
Check accelerator learning.
Go to Step 19

17
Is the action complete?
Check the function of individual accelerator
Go to Step 20 Refer to DTC
sensor parts. 24

18 Refer to DTC 24.

If a problem found, repair or replace as
necessary.
Was a problem found?
Check any electrical accessories installed to the Normal Go to Step 21 Go to Step 22
vehicle after manufacture.
19
1. Remove power from the accessory.
2. Check to see if the problem continues.
Was a problem found?
Install the additional equipment correctly or
Verify repair Go to Step 22
20 remove it from the vehicle.
Was a problem found?
Check the vehicle speed sensor and pulse
Go to Step 20 Refer to DTC
matching parts. Repair or replace as required. 25

21 Refer to DTC 25.

If a problem is found, repair or replace as
necessary.
Is the action complete?
Check the PTO. If a problem is found, repair or
Go to Step 24 Go to PTO
22 replace as necessary. check
Is the action complete?
Check the injection pump pre-stroke response.
Go to Step 25 Refer to DTC
Replace the pump if necessary. 29
23
Refer to DTC 29.
Is the action complete?
Check for exhaust pipe crushed area or other
Go to Step 26 Go to Step 25
24 constriction.
Was a problem found?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-61

Troubleshooting (Inspection and repair procedures) (Cont'd)

Step Action Value(s) Yes No
Repair or replace the exhaust pipes.
Verify repair Go to Step 26
25
Was a problem found?
Check the intercooler exterior for crushed areas
Go to Step 28 Go to Step 27
26 and holes.
Was a problem found?
Repair or replace the intercooler.
Verify repair Go to Step 29
27
Was a problem found?
Check the EGR. Repair or replace as required.
Go to Step 29 Go to EGR
28
Was a problem found? procedures
Check the Engine Control Unit (ECU).
Go to Step 30 Go to Step 31

1. Starter switch OFF.

29
2. Replace the existing ECU.
3. Start the engine.
Was a problem found?
Replace the ECU.
Go to Step 31

30
Is the action complete?
Check the mechanical parts of the engine. If a
Verify repair Go to Step 32
problem is found, repair as necessary.

Ÿ Valve train (Valve clearance)

31
Ÿ Injection nozzles
Ÿ Compression
Ÿ Crankshaft damper
Was a problem found?
Check chassis parts (clutch, transmission, and Done Verify repair

32 brakes). Repair if required.
Is the action complete?
6E-62 EMISSION AND ELECTRICAL DIAGNOSIS

8. WHITE EXHAUST SMOKE (LARGE QUANTITY)

· Injection pump malfunction (Pre-stroke)
Possible Problems
· Clogged air breather pipe
· Fuel quality (Wrong fuel) · ECU malfunction
· Air in fuel system · Exhaust pipe damage
· Mechanical timing malfunction (Slippage) · Engine malfunction (Injection nozzles, pistons,
· Sensor malfunction (Engine coolant sensor, turbocharger, oil circulation between top and bottom
atmospheric temperature sensor, and/or boost of engine, etc.)
pressure sensor)

Troubleshooting (Inspection and repair procedures)

Step Action Value(s) Yes No
Drain the fuel tank and fuel lines. Replace the
Verify repair Go to Step 2
1 discarded fuel with the specified fuel.
Was a problem found?
Bleed the air from the fuel system.
Verify repair Go to Step 3
2
Was a problem found?
Check the engine mechanical timing (slippage) 2 degrees BTDC Go to Step 5 Go to Step 4
3
Was a problem found?
Adjust the mechanical timing. Normal Verify repair Go to Step 5
4
Was a problem found?
Check the engine coolant temperature sensor. Normal Go to Step 6 Refer to DTC
Refer to DTC 23. 23
5 If a problem is found, repair or replace as
necessary.
Was a problem found?
Check the atmospheric temperature sensor. Normal Go to Step 7 Refer to DTC
Refer to DTC 22. 22
6 If a problem is found, repair or replace as
necesssary.
Was a problem found?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-63

Troubleshooting (Inspection and repair procedures) (Cont'd)

Step Action Value(s) Yes No
Check the boost pressure sensor. Repair or
Go to Step 8 Refer to DTC
replace the sensor if required. 32

7 Refer to DTC 32.

If a problem is found, repair or replace as
necessary.
Was a problem found?
Check the injection pump pre-stroke response.
Go to Step 9 Refer to DTC
Replace the pump if necessary. 29
8
Refer to DTC 29.
Was a problem found?
Check the ECU.
Verify repair Go to Step 10

1. Starter switch OFF.

9
2. Replace the existing ECU.
3. Start the engine.
Was a problem found?
Check the mechanical parts of the engine. If a Normal Verify repair

problem is found, repair as necessary.

Ÿ Compression
10 Ÿ Pistons (Ring wear)
Ÿ Clogged air breather pipe
Ÿ Turbocharger
Ÿ Oil circulation
Is the action complete?
6E-64 EMISSION AND ELECTRICAL DIAGNOSIS

9. BLACK EXHAUST SMOKE (LARGE QUANTITY)

· EGR magnetic valve malfunction (Body, air pipes,
Possible Problems
or harness arrangement wrong)
· Clogged air filter · EGR valve malfunction
· Exhaust brake function impaired (Poor return · Engine malfunction (Injection nozzles, valve
action) clearance, injection pump, turbocharger, etc.)
· Boost pressure sensor malfunction · ECU malfunction
· Mechanical timing wrong

Troubleshooting (Inspection and repair procedures)

Step Action Value(s) Yes No
Check the intake system. Repair or replace as
Go to Step 2 Go to intake
1 required. system
Was a problem found? procedure
Check the engine mechanical timing (slippage).
Go to Step 4 Go to Step 3
2
Ÿ 2 degrees BTDC
Was a problem found?
Adjust the mechanical timing.
Verify repair Go to Step 4
3
Was a problem found?
Check the exhaust system. Repair or replace as
Go to Step 5 Go to exhaust
4 required. system
Was a problem found? procedure
Check the EGR. Repair or replace as required.
Go to Step 6 Go to EGR
5
Was a problem found? procedure
Check the boost pressure sensor. Repair or
Go to Step 7 Refer to DTC
6 replace as required. 32 (Chapter 3)
Was a problem found?
Check the injection nozzles.
Go to Step 9 Go to Step 8
7
Was a problem found?
Adjust or replace the injection nozzles.
Verify repair Go to Step 9
8
Was a problem found?
Check the mechanical parts of the engine.
Go to Step 11 Go to Step 10
Repair or replace the parts if required.
9
Ÿ Valve clearance
Ÿ Valve lift
Was a problem found?
Check the engine control unit (ECU) (use check
Verify repair Go to Step 11
ECU).

10 1. Starter switch OFF.

2. Replace the existing ECU.
3. Start the engine.
Was a problem found?
Check the mechanical parts of the engine. If a
Verify repair

problem is found, repair as necessary.
11 Ÿ Compression
Ÿ Turbocharger
Is the action complete?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-65

10. IDLE SPEED CANNOT BE ADJUSTE

· Switch input circuit malfunction (Idle control switch
Possible Problems
or idle control changeover switch)
· Idle control switch malfunction (Operation, position, · Sensor or sensor circuit malfunction (Accelerator
up/down action) position sensor, all-speed accelerator sensor, etc.)
· Idle control changeover switch malfunction · PTO malfunction
· ECU malfunction

Troubleshooting (Inspection and repair procedures)

Step Action Value(s) Yes No
Check the idle control changeover switch
Go to Step 3 Go to Step 2
1 position.
Is the switch position AUTO?
Check the idle control switch function. Idle speed Verify repair Go to Step 3
adjustment
1. Move the idle control changeover switch to possible
2 the MANU position.
2. Operate the idle control switch (up or down)
to adjust the idle speed.
Was a problem found?
Check the Engine Control Unit (ECU) and each Display shows ON Go to Step 5 Go to Step 4
of the switch input circuits. or OFF as the
switches are
1. Gearshift lever NEUTRAL. operated
3 2. Starter switch ON.
3. Check the function of the following switches.

Ÿ Idle control switch (Idle up and idle down)

Ÿ Idle control changeover switch
Repair or replace the switch circuits (refer to Idle speed Verify repair Go to Step 5
Circuit checks). adjustment
possible
4 Ÿ Idle control switch
Ÿ Idle control changeover switch
Ÿ Limp-home switch
Was a problem found?

Go to Step 6 Go to PTO
Check the PTO. Repair or replace if required.
5 maintenance
Was a problem found?
procedure
Check the ECU.
Verify repair

1. Starter switch OFF.

6
2. Replace the ECU.
3. Start the engine.
Is the action complete?
6E-66 EMISSION AND ELECTRICAL DIAGNOSIS

Idle Control Switch (External appearance and operation)

(Appearance)

(Operation)

Part Measuring points Switch position Resistance (W) Remarks

(3) ßà (1) Neutral (Contacts separated) ¥
Idle UP circuit
Up Less than 0.5
control (2) ßà (3)
Neutral (Contacts separated) ¥
switch DOWN circuit
(2) ßà (1) Down Less than 0.5
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-67

11. IDLE SPEED CANNOT BE ADJUSTED DOWN

· Sensor or sensor circuit malfunction (Accelerator
Possible Problems
position sensor, all-speed accelerator sensor,
· Idle control switch malfunction (Operation, position, engine coolant temperature sensor, etc.)
up/down action) · PTO malfunction
· Idle control changeover switch malfunction · Engine Control Unit (ECU) malfunction
· Switch input circuit malfunction (Idle control switch · Injection nozzle malfunction
or idle control changeover switch)
· Air conditioner switch malfunction

Troubleshooting (Inspection and repair procedures)

Step Action Value(s) Yes No
Check the idle control changeover switch
Go to Step 3 Go to Step 2
1 position.
Is the switch position AUTO?
Check the idle control switch function. Idle speed Go to Step 8 Go to Step 3
adjustment
1. Idle control changeover switch "MANU". possible
2
2. Operate the idle control switch (up or down)
to adjust the idle speed.
Was a problem found?
Check the ECU and each of the switch input Display shows ON Go to Step 5 Go to Step 4
circuits. or OFF as the
switches are
1. Gearshift lever NEUTRAL. operated
2. Starter switch ON.
3
3. Check the function of the following switches.

Ÿ Idle control switch (Idle up and idle down)

Ÿ Idle control changeover switch
Was a problem found?
Repair or replace the switch circuits (refer to Idle speed Go to Step 5

Circuit checks). adjustment
possible
4 Ÿ Idle control switch
Ÿ Idle control changeover switch
Ÿ Limp-home switch
Was a problem found?
6E-68 EMISSION AND ELECTRICAL DIAGNOSIS

Troubleshooting (Inspection and repair procedures) (Cont'd)

Step Action Value(s) Yes No
Check the air conditioner switch input circuit. Display shows ON Go to Step 8 Go to Step 7
or OFF as the
1. Gearshift lever NEUTRAL. switch is operated
5
2. Starter switch ON.
3. Check the function of the air conditioner
switch.
Repair or replace the air conditioner switch Idle speed Go to Step 8

6 circuit (refer to Circuit checks). adjustment
Is the action complete? possible
Check the PTO. If a problem is found, repair or
Go to Step 9 Go to PTO
7 replace as necessary. maintenance
Was a problem found? procedure
Check the engine coolant temperature sensor.
Go to Step 10 Refer to DTC
Refer to DTC 23. 23
8 If a problem is found, repair or replace as
necessary.
Was a problem found?
Check the injection nozzle operation (injection
Go to Step 12 Go to Step 11
9 condition).
Was a problem found?
Idle speed Verify repair Go to Step 12
Adjust or replace the injection nozzles.
10 adjustment
Was a problem found?
possible
Check the ECU.
Verify repair

1. Starter switch OFF.

11
2. Replace the ECU.
3. Start the engine.
Is the action complete?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-69

Idle Control Switch (External appearance and operation)

(Appearance)

(Operation)

Part Measuring points Switch position Resistance (W) Remarks

(3) ßà (1) Neutral (Contacts separated) ¥
Idle UP circuit
Up Less than 0.5
control (2) ßà (3)
Neutral (Contacts separated) ¥
switch DOWN circuit
(2) ßà (1) Down Less than 0.5
6E-70 EMISSION AND ELECTRICAL DIAGNOSIS

12. POWER SUPPLY CIRCUIT INSPECTION

Circuit Description Possible Problems
The circuit is divided into 2 major sections. · Battery weak (Fluid lever, specific gravity, etc.)
· SBF blown
The first section delivers electrical power from the · Individual equipment fuse(s) blown
battery to the ECU, the meters, and individual · Battery relay malfunction (Internal wiring open,
equipment units when the starter switch is in the ON stuck in position, etc.)
position. The power is routed through the Slow-Blow- · Starter switch malfunction
Fuse (SBF No. 1) and the battery relay. · Loose battery cable
· Harness malfunction (Open or short circuit)
The second section delivers power directly to the Between SBF (SBF box harness) and front frame
starter motor and the power tilt device. harness, starter switch fuse box, and instrument
lower harness
Between battery relay (SBF box harness), ground
point, and front frame harness

Troubleshooting (Inspection and repair procedures)

Step Action Value(s) Yes No
Check the No. 1 and No. 4 SBF.
Go to Step 3 Go to Step 2

1. Starter switch OFF.

1
Remove the SBF box cover.
Check the SBF.
Was a problem found?
Replace the SBF.
Go to Step 3

2
Is the action complete?
Check the No. 20 and No. 28 fuses.
Go to Step 5 Go to Step 4
3
Was a problem found?
Replace the No. 20 and No. 28 fuses.
Go to Step 5

4
Is the action complete?
Battery voltage (At Go to Step 6 Go to Step 13
5 Measure the voltage across the No. 1 SBF.
least 24 volts)
Measure the voltage across the No. 28 fuse. Battery voltage (At Go to Step 7 Go to Step 14
least 24 volts)
6 1. Remove the No. 28 fuse.
2. Measure between the opposite sides of the
No. 28 fuse holder.
Ÿ Starter switch Go to Step 8 Go to Step 20
OFF = 0 volts
Measure the voltage between the front frame
7 harness connector and Pin 1 (instrument lower
Ÿ Starter switch
ON = battery
harness) with the starter switch OFF and ON.
voltage (At
least 24 volts)
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-71

Troubleshooting (Inspection and repair procedures) (Cont'd)

Step Action Value(s) Yes No
Ÿ Starter switch Go to Step 9 Go to Step 23
OFF = 0 volts
Measure the voltage at the battery relay
8 connector (front frame harness) with the starter
Ÿ Starter switch
ON = battery
switch OFF and ON.
voltage (At
least 24 volts)
Ÿ Starter switch Go to Step 10 Go to Step 25
OFF = 0 volts
9
Measure the voltage at the No. 4 SBF with the Ÿ Starter switch
starter switch OFF and ON. ON = battery
voltage (At
least 24 volts)
Ÿ Starter switch Go to Step 11 Go to Step 26
OFF = 0 volts
Measure the voltage at the front frame harness
10 connector (SBF box harness) with the starter
Ÿ Starter switch
ON = battery
switch OFF and ON.
voltage (At
least 24 volts)
Ÿ Starter switch Go to Step 12 Go to Step 28
OFF = 0 volts
Measure the voltage between the instrument
11 lower harness connector and Pin 37 (front frame
Ÿ Starter switch
ON = battery
harness) with the starter switch OFF and ON.
voltage (At
least 24 volts)
Ÿ Starter switch Go to Step 31 Go to Step 30
OFF = 0 volts
Measure the voltage at the No. 20 fuse and each
12 of the individual equipment fuses with the starter
Ÿ Starter switch
ON = battery
switch OFF and ON.
voltage (At
least 24 volts)
Check the battery.
Go to Step 6

1. Measure the battery voltage at the battery.

2. Check the cable connections for looseness
13
or severe corrosion.
If a problem is found, repair or replace as
necessary.
was a problem found?
Check the No. 28 fuse circuit for continuity. Less than 1 W Go to Step 16 Go to Step 5

1. Disconnect the cable at the battery negative

terminal.
14
2. Measure between the fuse and the voltage
supply terminal (to the left of the fuse).
3. Measure between the fuse and the front
frame harness connector.
Repair or replace damaged circuits.
Go to Step 16

15
Is the action complete?
Measure the resistance (continuity) between the Less than 1 W Go to Step 18 Go to Step 17
16 instrument lower connector and the SBF box
harness connector.
6E-72 EMISSION AND ELECTRICAL DIAGNOSIS

Troubleshooting (Inspection and repair procedures) (Cont'd)

Step Action Value(s) Yes No
Repair or replace the circuit between the
Go to Step 18

instrument lower connector and the SBF box
17
harness connector (front frame harness).
Is the action complete?
Check the SBF box harness. Less than 1 W Go to Step 7 Go to Step 25

1. Remove the No. 1 SBF.

18
2. Measure the resistance (continuity) between
the No. 1 SBF terminal and the front frame
harness connector.
Repair or replace the circuit between the No. 1
Go to Step 7

SBF terminal and the front frame harness
19
connector.
Is the action complete?
Measure the resistance (continuity) between the
Go to Step 22 Go to Step 21
starter switch connector and the following points.

Ÿ Front frame harness connector

20
Ÿ No. 28 fuse
Ÿ No. 20 fuse (Power supply side)
Ÿ No. 45 fuse (Power supply side)
Was a problem found?
Repair or replace the starter switch circuit
Go to Step 8

21 (instrument lower harness).
Is the action complete?
Replace the starter switch.
Go to Step 8

22
Is the action complete?
Measure the resistance (continuity) between the Less than 0.5 W Go to Step 9 Go to Step 24
battery relay connector (front frame harness) and
the following points.
23
Ÿ Instrument lower harness connector
Ÿ Ground
Repair or replace damaged front frame harness
Go to Step 9

24 circuits.
Is the action complete?
Replace the battery relay.
Go to Step 10

25
Is the action complete?
Measure the resistance (continuity) between the Less than 0.5 W Go to Step 11 Go to Step 27
26 No. 4 SBF and the front frame harness
connector (SBF box harness).
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-73

Troubleshooting (Inspection and repair procedures) (Cont'd)

Step Action Value(s) Yes No
Repair or replace damaged circuits SBF box
Go to Step 11

27 harness).
Is the action complete?
Measure the resistance (continuity) between the Less than 0.5 W Go to Step 12 Go to Step 29
28 instrument lower connector and the SBF box
harness connector.
Repair or replace the circuit between the
Go to Step 12

instrument lower connector and the SBF box
29
harness connector.
Is the action complete?
Measure the resistance (continuity) between the Less than 0.5 W Go to Step 31

30 No. 20 fuse power supply terminal and the frame
harness connector (left of the fuse).
Measure the resistance (continuity) between the Less than 0.5 W Verify repair Go to Step 21
31
No. 20 fuse and the ECU power supply circuit.
Repair or replace the ECU power supply circuit.
Verify repair

32 (instrument lower harness)
Is the action complete?
6E-74 EMISSION AND ELECTRICAL DIAGNOSIS

Fuse Arrangement

SBF Arrangement

Legend
1. Battery key (40A) 3. Starter (60A)
2. Lamp (40A) 4. A/C (40A)
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-75

13. ENGINE CONTROL UNIT (ECU) GROUND CIRCUIT INSPECTION

Circuit Description Possible Problems
The ECU ground circuit is divided into 2 sections. One · Poor ground point connections (Looseness or
section is grounded to the case (cab ground) and the separation)
other section is grounded to the battery (front frame · Individual harness malfunction (Open or short
harness). circuit between the ECU (instrument lower harness)
The pre-stroke ground circuit and the magnetic valve and harness ground or joint connector/front frame
ground circuit are grounded to the battery (front frame harness/ground point).
harness). · Joint connector malfunction (Open or short circuit)

Troubleshooting (Inspection and repair procedures)

Step Action Value(s) Yes No
Check the ECU ground circuit. Less than 0.5 W Go to Step 5 Go to Step 2

1. Measure the resistance (continuity) between

the ECU connector (harness side) and the
1
front frame harness connector (instrument
lower harness).
2. Measure the voltage to detect a short
between the ECU and other circuits.
Measure the resistance (continuity) of the Less than 0.5 W Go to Step 4 Go to Step 3
following ground circuits.

2 Ÿ ECU connector (harness side) to joint

connector
Ÿ Joint connector to front frame panel
connector (instrument lower harness)
Repair or replace any defective ground circuits.
Go to Step 4

3
Is the action complete?
Check the joint connector for the following.
Go to Step 5

Ÿ Continuity between connector and individual

4 pins
Ÿ Connector damage
Ÿ Terminal looseness
Was a problem found?
Measure the resistance (continuity) between the Less than 0.5 W Go to Step 7 Go to Step 6
5 instrument lower harness and the battery ground
(front frame harness).
Repair or replace any defective ground circuits.
Go to Step 9

6
Is the action complete?
6E-76 EMISSION AND ELECTRICAL DIAGNOSIS

Troubleshooting (Inspection and repair procedures) (Cont'd)

Step Action Value(s) Yes No
Check the ground point installation.
Go to Step 8

If a problem is found, repair as necessary.
7
Ÿ Looseness
Ÿ Floating
Is the action complete?
Check the case ground circuit. Less than 0.5 W Verify repair Go to Step 9

1. Starter switch OFF.

8 2. Remove the ECU.
3. Measure the resistance (continuity) between
the ECU connector (harness side) and the
cab panel.
Repair or replace the case ground circuit
Verify repair

9 (instrument lower harness).
Is the action complete?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-77

14. STARTING CIRCUIT INSPECTION

starter circuit activates the starter relay when the
Circuit description
neutral relay is active and the starter switch ON.
The starter circuit is activated by the starter relay to
provide electrical power to the starter motor. Possible Problems
In vehicles equipped with a manual transmission, · Starter system or circuit malfunction (Starter motor,
turning the starter switch to the S position activates starter relay, battery, etc.)
the starter relay. · Starter switch malfunction
In vehicles equipped with an automatic transmission, · Neutral relay malfunction
turning the starter switch to the S position activates · Control unit malfunction (Automatic transmission)
the starter relay only when the neutral relay is active. · Neutral switch malfunction
In vehicles equipped either with a manual
transmission or an automatic transmission, the sub-

Troubleshooting (Inspection and repair procedures)

Step Action Value(s) Yes No
Inspect the resistance (continuity) following Less than 0.5 W Go to Step 3 Go to Step 2
circuits.

Ÿ Starter relay « No. 4 SBF (SBF box)

1
Ÿ Starter relay « Starter motor (Terminal C)
Ÿ Starter relay « Frame (Ground)
Ÿ Starter motor « Battery
Ÿ Starter motor « Frame (Starter ground)
1. Repair or replace the starter relay (front Engine starts Verify repair Go to Step 3
2 frame harness).
2. Start the engine.
Inspect the starter relay circuit. Ÿ Starter switch Go to Step 10 Go to Step 4
in OFF position
1. Starter switch OFF. = 0 volts
2. Disconnect the harness from the starter Ÿ Starter switch
relay (2 connector terminals at the relay coil in S position =
3 side). battery voltage
3. Measure the voltage at the starter relay (At least 24
connector (harness side). volts)
4. Starter switch S.
5. Measure the voltage at the starter relay
connector (harness side).
6E-78 EMISSION AND ELECTRICAL DIAGNOSIS

Troubleshooting (Inspection and repair procedures) (Cont'd)

Step Action Value(s) Yes No
1. Disconnect the instrument lower harness Ÿ Starter switch Go to Step 5 Go to Step 6
and the front frame harness. in OFF position
2. Starter switch OFF. = 0 volts
3. Measure the voltage at the front frame Ÿ Starter switch
harness connector (lower instrument panel in S position =
4
harness).
battery voltage
4. Starter switch S.
(24 volts)
5. Measure the voltage at the front frame
harness connector (lower instrument panel
harness).
1. Repair or replace the circuit between the Engine starts Verify repair Go to Step 8
instrument lower harness and the front
5 frame harness.
2. Start the engine.
Was a problem found?
Measure the resistance (continuity) between the Less than 0.5 W Go to Step 8 Go to Step 7
6 starter switch and the front frame harness
connector.
1. Repair or replace the circuit between the Engine starts Verify repair Go to Step 8
starter switch and the front frame harness
7
connector.
2. Start the engine.
1. Inspect the starter switch. Less than 0.5 W Go to Step 10 Go to Step 9
2. Measure the resistance (continuity) between
8
the starter harness connector pins 2 and 3
when the starter switch is in the S position.
1. Replace the starter switch. Engine starts Verify repair Go to Step 10
9
2. Start the engine.
Inspect the starter switch. Ÿ Starter switch Go to Step 11 Go to Step 12
in OFF position
1. Disconnect the harness from the starter. = 0 volts
2. Starter switch OFF. Ÿ Starter switch
10 3. Measure the voltage at the starter harness in S position =
connector (front frame harness). battery voltage
4. Starter switch S. (At least 24
5. Measure the voltage at the starter harness volts)
connector (front frame harness).
Replace the starter.
Verify repair

11
Is the action complete?
Replace the starter relay.
Verify repair

12
Is the action complete?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-79

Starter Relay

Legend
1. Battery key (40A) 3. Starter (60A)
2. Lamp (40A) 4. A/C (40A)
6E-80 EMISSION AND ELECTRICAL DIAGNOSIS

15. FUEL SYSTEM INSPECTION

· Fuel pipe malfunction (Crushing, breakage,
Possible Problems
clogging, disconnection, etc.)
· No fuel · Fuel tank malfunction (Foreign material, bent
· Air in the fuel line piping, cracks, etc.)
· Clogged fuel filter · Emergency engine stop knob (inside the vehicle)
not returned to its normal (off) position

Troubleshooting (Inspection and repair procedures)

Step Action Value(s) Yes No
Check fuel volume.
Go to Step 2 Add fuel and
1
Was a problem found? go to Step 2
Bleed the air from the fuel system.
Go to Step 3 Bleed air and
2
Is the action complete? go to Step 3
Make sure that the emergency engine stop knob
Go to Step 4

is returned to its normal position (pushed in – not
3
pulled out).
Is the action complete?
Check the main fuel filter and the pre-fuel filter
Go to Step 5

4 for clogging. Clean or replace as required.
Is the action complete?
Check the fuel line for damage and leakage.
Go to Step 6

Clean, repairor replace as required.

Ÿ Crushed areas
5 Ÿ Breakage
Ÿ Cracks
Ÿ Loose connections
Ÿ Foreign material in the overflow valve
Is the action complete?
Check the inside of the fuel tank.
Verify repair

If a problem is found, clean, repair or replace as
necessary.

Ÿ Foreign material (Clogged suction port)

6 Ÿ Bent or cracked suction pipe
Ÿ Fuel tank distortion
Ÿ Fuel tank improper installation
Ÿ Clogged fuel cap hole (Air breather)
Ÿ Water
Is the action complete?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-81

16. INTAKE SYSTEM INSPECTION

· Fuel pipe malfunction (Crushing, breakage,
Possible Problems
clogging, disconnection, etc.)
· No fuel · Fuel tank malfunction (Foreign material, bent
· Air in the fuel line piping, cracks, etc.)
· Clogged fuel filter · Emergency engine stop knob (inside the vehicle)
not returned to its normal (off) position

Troubleshooting (Inspection and repair procedures)

Step Action Value(s) Yes No
Check the air cleaner warning lamp (instrument
Go to Step 3 Go to Step 2
1 panel).
Was a lamp turn off?
Clean or replace the air cleaner element.
Go to Step 3

2
Is the action complete?
Check the inside of the air cleaner case for water Present Go to Step 4 Go to Step 5
3 and foreign material.
Was a problem found?
1. Clean the air cleaner case.
Go to Step 5 Verify repair
2. Check the water bleed valve for clogging.
4
Clean or replace the valve if required.
Is the action complete?
Check the intake pipes for crushed areas and Normal Verify repair Go to Step 6
5 other damage.
Was a problem found?
Repair or replace the intake pipes.
Verify repair

6
Is the action complete?
6E-82 EMISSION AND ELECTRICAL DIAGNOSIS

17. EXHAUST SYSTEM INSPECTION

valve. This signal is also delivered to the engine
Circuit description
control unit (ECU).
Power is delivered to the exhaust brake circuit through
the No. 13 fuse. Possible Problems
When the exhaust brake switch (combination switch) · Exhaust brake malfunction (Exhaust brake remains
is moved to the ON position, a signal is simultaneously closed, no air cylinder return, etc.)
sent to the brake aggregate control unit and the · Exhaust brake magnetic valve malfunction
engine control unit. The brake aggregate control unit · Brake aggregate control unit malfunction
sends a signal to activate the exhaust brake magnetic · Exhaust brake switch malfunction

Troubleshooting (Inspection and repair procedures)

Step Action Value(s) Yes No
Check the exhaust brake operation.
Verify repair Go to Step 2

1. Starter switch ON.

2. Start the engine and allow it to idle.
1 3. Open the inspection cover.
4. Disconnect the connector from the PA1
terminal (green).
5. Exhaust brake switch ON.
Does the exhaust break operate?
1. Check the following circuits for continuity.
Verify repair Go to Step 3
Repair or replace the circuits as required.

Ÿ Exhaust brake switch « combination switch

Ÿ Combination switch « No. 13 fuse
Ÿ Combination switch « base harness
connector
Ÿ Base harness connector « ECU
2 Ÿ Combination switch « floor harness
connector (left side)
Ÿ Floor harness connector (left side) « seat
harness connector
Ÿ Floor harness connector (left side) « brake
aggregate control unit connector (A)

2. Check the exhaust brake operation (refer to

Step 1).
Does the exhaust brake operate?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-83

Troubleshooting (Inspection and repair procedures) (Cont'd)

Step Action Value(s) Yes No
Ÿ Between the Go to Step 5 Go to Step 4
magnetic valve
terminals =
Use a circuit tester to measure exhaust brake
3 34~40 W
magnetic valve resistances.
Ÿ Between each
terminal and
the body = ¥
1. Replace the exhaust brake magnetic valve. Exhaust brake Verify repair Go to Step 6
2. Check the exhaust brake operation (refer to operates
4
Step 1).
Does the exhaust brake operate?
1. Check the exhaust brake magnetic valve Exhaust brake Verify repair Go to Step 7
circuit for continuity between the areas listed operates
below. Repair or replace the circuits as
required.

Ÿ Brake aggregate control unit connector A «

floor harness connector (left side)
Ÿ Seat harness connector « lower instrument
panel harness connector
Ÿ Floor harness connector (left side) « front
5 frame harness connector
Ÿ Floor harness connector (left side) « ECU
Ÿ Lower instrument panel harness connector
« member harness connector
Ÿ Front frame harness connector « exhaust
brake magnetic valve
Ÿ Member harness connector « ground

2. Check the exhaust brake operation (refer to

Step 1).
Does the exhaust brake operate?
Replace the exhaust brake valve.
Verify repair

6
Is the action complete?
1. Replace the brake aggregate control unit.
Verify repair

2. Check the brake aggregate control unit
circuits (power supply and ground).
7
If a problem is found, repair or replace as
necessary.
Is the action complete?
6E-84 EMISSION AND ELECTRICAL DIAGNOSIS

Magnetic Valve External Appearance, Terminal Nomenclature, And Resistances

External appearance

Terminal nomenclature
Terminal No. Signal
1
Magnetic valve (Coil)
2

Connector Inspection point W)

Resistance (W Remarks
Z-type (1) « (2) 34~40 Between magnetic valve coils
Gray (1) « body
¥ Between magnetic valve coil and body
2 terminals (1) « body
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-85

18. EGR INSPECTION

· Magnetic valve malfunction
Possible Problems
· ECU malfunction
· EGR valve malfunction
· Air pipe malfunction (Crushed areas, breakage,
looseness, gas leakage, etc.)

Troubleshooting (Inspection and repair procedures)

Step Action Value(s) Yes No
Check the engine coolant level and replenish if
Go to Step 2

1 required.
Is the action complete?
Check the installation of the air pipes (leading to
Go to Step 3

the magnetic valve, EGR) and the harnesses.
2
Reinstall the parts if there is a problem.
Is the action complete?
Displayed Go to Chapter Go to Step 4
3 (DTC's) for
3 Check for DTC 413, 444 and 421. separate
inspection
procedure
1. Starter switch ON (do not start the engine). Magnetic valve Go to Step 6 Go to Step 5
4 2. Remove the air pipes from the EGR valve air operation
cylinder.
Repair or replace the magnetic valve.
Go to Step 6

5
Is the action complete?
6 Check the air cylinder operation. Normal Go to Step 8 Go to Step 7
Repair or replace the magnetic valve.
Go to Step 6

7
Is the action complete?
Check EGR valve operation. EGR operates Verify repair Go to Step 9

8 1. Disconnect the EGR valve from the engine.

2. Connect the air pipes to the EGR.
Does the EGR operates?
Repair or replace the EGR valve.
Verify repair

9
Is the action complete?
6E-86 EMISSION AND ELECTRICAL DIAGNOSIS

Magnetic Valve Arrangement

Cab rear member
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-87

19. POWER TAKE OFF (PTO) INSPECTION

· ECU malfunction
Possible Problems
· PTO relay malfunction
· Failure to follow PTO operation procedure · PTO idle switch malfunction (Optional auxiliary
· All-speed accelerator sensor malfunction (Device, equipment circuits for concrete pumper)
bad installation, poor adjustment, etc.
· Parking switch malfunction Pre-Inspection Checks
· PTO switch malfunction · Connector installation (Looseness and damage)
· Sensor and/or switch circuit malfunction (Open or · Harness condition (Fraying, twisting, breakage, etc.)
short circuit) · Battery voltage (At least 24 volts)
· PTO magnetic valve malfunction

Troubleshooting (Inspection and repair procedures)

Step Action Value(s) Yes No
The PTO will not operate unless the following Correct Go to Step 2 Go to Step 3
conditions are met. procedure/
conditions met
Ÿ Parking brake on (Lever pulled up)
Ÿ Gearshift lever in neutral position
Ÿ Engine at idle
Ÿ Clutch pedal depressed (Manual
1 transmission only)

To turn the PTO off –

1. Run the engine at idle.

2. Gearshift lever NEUTRAL.
3. PTO switch OFF.
4. Release the parking brake.
2 Follow the correct operating procedure. PTO operation Go to Step 3 Go to Step 1
Check the accelerator pedal and external Pedal and lever at Go to Step 5 Go to Step 4
3 accelerator lever positions when the PTO is not original positions –
in use. Engine at idle
Return the accelerator pedal and external
Go to Step 5 Go to Step 3
4 accelerator lever to their original positions.
Was a problem found?
6E-88 EMISSION AND ELECTRICAL DIAGNOSIS

Troubleshooting (Inspection and repair procedures) (Cont'd)

Step Action Value(s) Yes No
Confirm that the PTO operation is correct and Ÿ PTO operation Go to Step 7 Go to Step 6
that the governor characteristics change when – Idle speed
the vehicle is switched from on-road operation to does not
PTO operation. change
Ÿ On-road
Refer to Chapter 1 (Engine control system operation – Idle
overview – PTO control) for governor speed changes
characteristics during on-road and PTO
operation.
5
Ÿ Idle speed does not change during PTO
operation even when the idle control switch is
moved.
Ÿ Idle speed changes during on-road operation
when the idle control switch is moved. If it
does not change refer to ‘Idle speed cannot
be adjusted’ (inspection and repair are
required).
Check the PTO switch circuit. Display shows ON Go to Step 7 Go to PTO
when the switch is switch
6 1. Gearshift lever NEUTRAL. on and OFF when maintenance
2. Starter switch ON. the switch is off. procedure
3. PTO idle switch ON and OFF.
Ÿ 0.3~0.5 volts Go to Step 8 Go to External
Check the external accelerator (all-speed
(Accelerator at accelerator
accelerator sensor) adjustment.
idle position) procedure
7
1. Remove the harness from the ECU.
Ÿ 4.2~4.5 volts
(Accelerator at
2. Measure the all-speed sensor output
full-open
voltage.
position)
Check the parking switch. Display shows ON Go to Step 9 Go to Parking
when the switch is switch
8 1. Gearshift lever NEUTRAL. on and OFF when procedure
2. Starter switch ON. the switch is off.
3. Parking switch OFF.
Done (Engine Verify repair Go to Step 10
Check the PTO operation (correct change
speed changes
9 between on-road accelerator and external
with the accelerator
accelerator).
being used)
Replace the ECU.
Verify repair

10
Is the action complete?

All-speed accelerator sensor output voltages

Measuring point Accelerator pedal position Output (V)

Terminal 2 (red/5V) « Terminal 2 (black/ground) No depression 4.6~4.9
Idle 0.3~0.5
Terminal 2 (yellow/SIG) « Terminal 2 (black/ground)
Full 4.2~4.5
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-89

20. POWER TAKE OFF (PTO) SWITCH INSPECTION

Possible Problems
Circuit Description
· PTO switch malfunction
The PTO switch turns the magnetic valve on and off. · PTO magnetic valve malfunction
The ECU senses PTO magnetic valve power to · ECU malfunction
control PTO operation. · PTO relay malfunction
PTO on and off operation (switching) depends on PTO · Switching circuit malfunction (Open or shorted)
switch position, sensor data (all-speed accelerator · PTO idle switch malfunction
sensor and others), and the parking brake operation
signal.

Troubleshooting (Inspection and repair procedures)

Step Action Value(s) Yes No
Ÿ Starter switch Go to Step 3 Go to Step 2
Measure the voltage at the No. 13 fuse (PTO OFF = 0 volts
1
magnetic valve power supply). Ÿ Starter switch
1. Starter switch OFF. ON = battery
2. Measure the voltage at the No. 13 fuse. voltage (at
least 24 volts)
Ÿ Starter switch


3. Repair or replace the No. 13 fuse circuit OFF = 0 volts
2
(refer to the schematic in Chapter 5. Ÿ Starter switch
4. Measure the voltage at the No. 13 fuse (refer ON = battery
to Step 1). voltage (at
least 24 volts)
Measure the resistance (continuity) of the closed Less than 0.5 W Go to Step 5 Go to Step 4
3 (on) PTO switch.
Was a problem found?
Replace the PTO switch.
Go to Step 5

4
Is the action complete?
6E-90 EMISSION AND ELECTRICAL DIAGNOSIS

Troubleshooting (Inspection and repair procedures) (Cont'd)

Step Action Value(s) Yes No
Measure the resistance (continuity) of the PTO Less than 1 W Go to Step 7 Go to Step 6
switch circuits at the points specified below.

Dump lever PTO switch

Ÿ No. 13 fuse « right-side floor harness

connector
Ÿ Instrument lower harness connector « PTO
switch
5
Ÿ Right-side floor harness connector « ECU

Instrument panel PTO switch

Ÿ No. 13 fuse « Instrument upper harness

connector
Ÿ Instrument lower harness connector « PTO
switch
Ÿ Instrument upper harness connector « ECU
Repair or replace the PTO switch circuit.
Go to Step 7

6
Is the action complete?
Measure the resistance (continuity) of the PTO Less than 1 W Go to Step 9 Go to Step 8
magnetic valve circuits at the points specified
below.

Dump lever PTO switch

Ÿ Right-side floor harness connector « frame

harness connector
Ÿ Instrument lower harness connector « PTO
7 magnetic valve
Ÿ PTO magnetic valve « frame (ground)

Instrument panel PTO switch

Ÿ Instrument upper harness connector « front

frame harness connector
Ÿ Instrument lower harness connector « PTO
magnetic valve
Ÿ PTO magnetic valve « frame (ground)
Repair or replace the PTO magnetic valve.
Go to Step 9

8
Is the action complete?
Measure the resistance between the PTO 27~33 W Go to Step 18 Go to Step 10
9
magnetic valve terminals.
Replace the PTO magnetic valve.
Go to Step 18 Go to Step 11
10
Is the action complete?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-91

Troubleshooting (Inspection and repair procedures) (Cont'd)

Step Action Value(s) Yes No
Repair or replace the PTO switch.
Go to Step 12

11
Is the action complete?
Measure the resistance (continuity) of the PTO Less than 1 W Go to Step 14 Go to Step 13
magnetic circuit at the points specified below.

12 Ÿ PTO relay « front frame harness connector

Ÿ Instrument lower harness connector « PTO
magnetic valve
Ÿ PTO magnetic valve « frame (ground)
Repair or replace the PTO switch.
Go to Step 14

13
Is the action complete?
Measure the resistance between the PTO 27~33 W Go to Step 16 Go to Step 15
14
magnetic valve terminals.
Replace the PTO magnetic valve.
Go to Step 16

15
Is the action complete?
Check the control unit. Battery voltage (At Go to Step 18 Go to Step 17
least 24 volts)
1. Disconnect all harnesses.
2. Gearshift lever NEUTRAL.
3. Remove the PTO relay.
4. Starter switch ON.
16
5. Turn the PTO ON.
6. Measure the voltage at terminal 3 of the PTO
relay.
7. Repeat Steps 5 and 6 for the PTO
instrument panel switch and the PTO dump
lever switch.
Replace the control unit.
Go to Step 18

17
Is the action complete?
Check the ECU (PTO switch circuit). Display shows ON Verify repair Go to Step 19
when the switch is
1. Gearshift lever NEUTRAL. on and OFF when
18
2. Starter switch ON. the switch is off.
3. Operate the PTO switch.
Was a problem found?
Replace the ECU.
Verify repair

19
Is the action complete?
6E-92 EMISSION AND ELECTRICAL DIAGNOSIS

Instrument Panel PTO Switch General Appearance and Circuit Resistances

Measuring point Resistance (WW)

Terminal 1 « Terminal 2 Less than 0.5

Dump Lever PTO Switch

Measuring point Resistance (WW) Switch position

Less than 0.5 ON
Terminal 1 « Terminal 2 ¥ OFF
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-93

21. EXTERNAL ACCELERATOR INSPECTION

Whenever the all-speed sensor is repaired or
Circuit Description
replaced, adjustment is required.
The external accelerator and all-speed accelerator
sensor control engine speed during PTO operation.
The external accelerator performs the same function Possible Problems
as the accelerator pedal inside the vehicle. · Incorrect PTO operating sequence
The all-speed accelerator sensor receives power from · All-speed accelerator sensor wrongly installed or
the ECU. When the PTO lever is operated, the output poorly adjusted
voltage changes. This results in a data signal being · ECU malfunction
returned to the ECU. Based on this data, the ECU · Sensor circuit malfunction (Open or shorted)
calculates the all-speed accelerator opening angle to
control the accelerator.

Troubleshooting (Inspection and repair procedures)

Step Action Value(s) Yes No
Measure the resistance (conductivity) between Less than 1 W Go to Step 3 Go to Step 2
the ECU and the all-speed accelerator sensor at
the measuring points specified below.
1
Ÿ ECU « member harness connector
Ÿ Member harness connector « all-speed
accelerator sensor
Repair or replace the circuitry between the ECU
Go to Step 3

2 and the all-speed accelerator sensor.
Is the action complete?
Measure the all-speed accelerator sensor output · Idle = Verify repair Go to Step 4
voltage. 0.3~0.5
volts
3 1. Remove the harness from the ECU. · Full-open =
2. Starter switch ON. 4.2~4.5
3. Measure the output voltage at the idle volts
position and the full-open position.
Check the ECU. 5 volts Go to Step 6 Go to Step 5

1. Remove all harnesses except the all-speed

4 accelerator sensor harness.
2. Starter switch ON.
3. Measure the power supply voltage at the all-
speed accelerator sensor connector.
Replace the ECU.
Go to Step 7

5
Is the action complete?
Replace the all-speed accelerator sensor.
Go to Step 7

6
Is the action complete?
Adjust the external accelerator (all-speed
Verify repair

7 accelerator sensor).
Is the action complete?
6E-94 EMISSION AND ELECTRICAL DIAGNOSIS

All-speed accelerator sensor output voltages

Measuring point Accelerator pedal position Output (V)

Terminal 2 (red/5V) « Terminal 2 (black/ground) No depression 4.6~4.9
Idle 0.3~0.5
Terminal 2 (yellow/SIG) « Terminal 2 (black/ground)
Full 4.2~4.5

accelerator sensor harness. Refer to the

Output Voltage Measurement Using The
illustration below.
Voltage Check Harness 2. Use a circuit tester to measure the output
1. Connect the voltage check harness between voltage at the special 3-terminal female
the vehicle harness and the all-speed connector.

Output voltage

Terminal Voltage
A 5
B SIG
C GND

All-Speed Accelerator Sensor Connector

 EMISSION AND ELECTRICAL DIAGNOSIS 6E-95

All-Speed Accelerator Sensor Connector (External View)

All-speed accelerator sensor harness voltages and wire color

Terminal Voltage Wire color

1 5 Black
2 SIG Green
3 GND Red

All-speed accelerator sensor harness voltages (Between terminals)

Measuring point (Voltage check connector) Accelerator pedal position Output (V)
A—C No depression 4.6~4.9
Idle 0.3~0.5
B—C
Full 4.2~4.5
6E-96 EMISSION AND ELECTRICAL DIAGNOSIS

22. PARKING SWITCH INSPECTION

Circuit Description Possible Problems
The parking switch is installed to the wheel pack (front · Parking switch mechanical malfunction
frame harness). · Parking switch circuit malfunction
When the parking brake handle is pulled up (no air in · Meter mechanical malfunction
the wheel pack chamber), the parking switch turns on. · Meter circuit malfunction
The parking switch receives power from the parking · ECU malfunction
lamp on the instrument panel. The circuit is grounded
to the front frame.

Troubleshooting (Inspection and repair procedures)

Step Action Value(s) Yes No
Measure the voltage at the parking switch.
Go to Step 7 Go to Step 2

1. Disconnect the harness from the parking

switch.
1
2. Starter switch ON.
3. Ground the parking switch connector (power
supply side).
Did the lamp turn on?
Check the parking lamp bulb (burn-out).
Go to Step 4 Go to Step 3
2
Is the action complete?
Replace the parking lamp bulb.
Go to Step 5 Go to Step 4
3
Is the action complete?
Check the parking lamp power supply. Battery voltage (At Go to Step 5 Check the
least 24 volts) power supply
4
1. Starter switch ON. circuit
2. Measure the voltage at the meter connector.
Check the resistance (conductivity) between the Less than 1 W Go to Step 7 Go to Step 6
parking lamp (instrument panel) and the parking
switch at the points specified below.

Ÿ Parking lamp « instrument lower harness

connector
Ÿ Instrument upper harness connector « front
frame harness connector
5
Ÿ Instrument upper harness connector « ECU
connector
Ÿ Instrument lower connector « parking
switch
Ÿ Instrument lower connector « rear frame
harness connector
Ÿ Front frame harness connector « parking
switch
1. Repair or replace the parking lamp circuit.
Verify repair Go to Step 7
2. Check that the lamp turns on when the
6
parking switch is operated.
Did the lamp turn on?
Check the parking switch ground circuit.
Go to Step 9 Go to Step 8
7
Did the problem found?
1. Repair or replace the parking switch ground
Verify repair Go to Step 9
circuit.
8 2. Check that the lamp turns on when the
parking switch is operated.
Did the lamp turn on?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-97

Troubleshooting (Inspection and repair procedures) (Cont'd)

Step Action Value(s) Yes No
Measure the voltage at the parking switch.
Go to Step 11 Go to Step 10

1. Disconnect the harness from the parking

switch.
9
2. Starter switch ON.
3. Ground the parking switch connector (power
supply side).
Did the lamp turn on?
1. Repair or replace the meter.
Verify repair Go to Step 11
2. Check that the lamp turns on when the
10
parking switch is operated.
Did the lamp turn on?
Check the parking brake switch operation. Lamp is on when Go to Step 13 Go to Step 12
lever is up and off
1. Confirm that the air pressure is correct. when lever is down
11 2. Check that the parking lamp turns on when
the parking brake lever is pulled up.
3. Check that the parking lamp turns off when
the parking brake lever is released.
1. Replace the parking switch.
Verify repair Go to Step 13
2. Check that the lamp turns on when the
12
parking switch is operated.
Did the lamp turn on?
Check the parking switch. Display shows ON Verify repair Go to Step 14
when lever is up
1. Move the gearshift lever to the neutral and OFF when
13
position. lever is down
2. Starter switch ON.
3. Operate the parking brake lever (switch).
Replace the ECU.
Verify repair

14
Is the action complete?
6E-98 EMISSION AND ELECTRICAL DIAGNOSIS

Parking Switch External Appearance and Operation

Wheel pack air pressure 1 2 Switch position
2
Less than 460 kPa (4.7 kg/cm ) O O On
2
More than 460 kPa (4.7 kg/cm ) Off
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-99

DTC-10 RACK SENSOR ERROR

Electronic governor circuit (Including N-TDC sensor circuit and N sensor circuit)
6E-100 EMISSION AND ELECTRICAL DIAGNOSIS

If the ECU detects more than 4.5 volts (open circuit) or

Circuit description
less than 0.4 volts (short to ground) for more than 0.16
The rack sensor is inside the injection pump. It detects second, it will indicate rack sensor malfunction (DTC
rack position (fuel injection condition). 10).
Rack sensor position data (rack position voltage) is
delivered to the engine control unit (ECU). The data is Possible causes of rack sensor malfunction
converted to provide rack position DTC. 1. Loose connections
The rack sensor circuit and the servo circuit (used to · ECU and governor harness connectors
drive the governor) both operate on a 5-volt power · Injection pump and governor harness connectors
supply from the engine control unit. If the power is Rack sensor circuit open or shorted (Rack position
suspended, (open power supply circuit), there will be voltage = 5 volts)
no rack sensor position data output. · Between governor harness and vehicle harness
· Between injection pump harness and vehicle
Rack sensor malfunction effects
harness
3. Engine stops (Stall) Injection pump malfunction
4. Engine cannot be started · Injection pump harness
Diagnostic conditions · Injection pump internal circuitry
ECU malfunction
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-101

DTC 10 Rack sensor error

Step Action Value(s) Yes No
Confirmation (Rack Go to Step 2 Go to Step 10
Use the TECH 2 to confirm DTC 10 (indicates
1 sensor error) (Existing (Previous
existing malfunction).
malfunction) malfunction)
If there is a rack Go to Step 6 Go to Step 3
1. Starter switch ON.
sensor error (pull-
2. Use a circuit tester to measure rack sensor
2 down), the voltage
output voltage at the vehicle harness and
will be 3.3
3.6
the sensor body.
volts
If there is a rack Go to Step 4 Go to Step 5
1. Starter switch ON. sensor error (pull-
3 2. Use a circuit tester to measure rack sensor down), the voltage
output voltage at the sensor body. will be 3.3
3.6
volts
Replace the governor harness and/or repair  Go to Step 17 
4 damaged circuit areas.
Is the action complete ?
Replace injection pump.  Go to Step 17 
5
Is the action complete ?
1. Inspect the electronic governor circuit and Normal Go to Step 8 Go to Step 7
connections (refer to the schematic). Check
for loose and/or damaged connectors, open
wiring, and corroded terminals.
6 2. Check the harness for open wires, VB/GND
shorting, and layer shorting.
If there are no abnormal conditions, once again
check the harness and measure the rack
position voltage (5V).
Replace the governor harness and/or repair  Go to Step 17 
7 damaged circuit areas.
Is the action complete ?
Ÿ Existing Go to Step 9 Go to Step 18
1. Clear memory. malfunction
8
2. Use the TECH 2 to confirm DTC 10. Ÿ Previous
malfunction
Replace the engine control unit (ECU).  Go to Step 17 
9
Is the action complete ?
1. Start the engine. Rack position Go to Step 15 Go to Step 11
2. Set Tech 2 for data display. values change
10 3. Display rack position.
4. Press the accelerator pedal and confirm
that the rack position values change.
If there is a rack Go to Step 15 Go to Step 12
1. Starter switch ON.
sensor error (pull-
2. Use a circuit tester to measure rack sensor
11 down), the voltage
output voltage at the vehicle harness and
will be 3.3
3.6
the sensor body.
volts
If there is a rack Go to Step 13 Go to Step 14
1. Starter switch ON. sensor error (pull-
12 2. Use a circuit tester to measure rack sensor down), the voltage
output voltage at the sensor body. will be 3.3
3.6
volts
Replace the governor harness and/or repair  Go to Step 17 
13 damaged circuit areas.
Is the action complete ?
6E-102 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 10 Rack sensor error (Cont'd)

Step Action Value(s) Yes No
Replace injection pump.  Go to Step 17 
14
Is the action complete ?
1. Inspect the electronic governor circuit and Normal Go to Step 17 Go to Step 16
connections (refer to the schematic).
Check for loose and/or damaged
connectors, open wiring, and corroded
terminals.
15 2. Check the harness for open wires,
VB/GND shorting, and layer shorting.
If there are no abnormal conditions, once again
check the harness and measure the rack
position voltage (5V).
Replace the governor harness and/or repair  Go to Step 17 
16 damaged circuit areas.
Is the action complete ?
Ÿ Existing Go to Step 1 Verify repair
1. Clear memory. malfunction
17
2. Use the TECH 2 to confirm DTC 10. Ÿ Previous
malfunction
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-103

Injection pump external appearance and nomenclature

1. External appearance

2. Nomenclature

Terminal Wire color/diameter

Connector Signal
No. (Injection pump harness)
1 Governor actuator drive voltage – 1 R/1.2
2 Governor circuit GND-1 W/1.2
3 Target rack position – 1 L/1.2
SWP
4 Rack position voltage G/1.2
8-terminals
5 Governor circuit 5V-1 Y/1.2
Black
6 Backup N sensor (GND) BR/1.2
7 Backup N sensor (SIG) O/1.2
8 Pull-down B/1.2
9 Governor actuator drive voltage – 2 R/1.2
SWP 10 Target rack position – 2 L/1.2
6-terminals 11 Governor circuit GND-2 W/1.2
Black 12 Governor circuit SIG GND BR/1.2
13 Governor circuit 5V-2 Y/1.2
SWP 14 Limp home V/1.2
3-terminals
Black 15 Sub-coil (Not used) BY/1.2
6E-104 EMISSION AND ELECTRICAL DIAGNOSIS

DTC-11 GOVERNOR SERVO SYSTEM ERROR

Electronic governor circuit (Including N-TDC sensor circuit and N sensor circuit)
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-105

Circuit description Possible causes of governor malfunction

The rack sensor and governor actuator drive circuit are 1. Engine emergency stop knob not fully returned or
built-in to the injection pump. The Engine Control Unit emergency stop knob cable damaged
(ECU) sends the target rack position signal (PVM) to Clogged injection nozzle(s)
the injection pump. Upon receiving this signal, the This condition can result in either a governor
injection pump activates the governor actuator to malfunction indication (DTC 11) or a pre-stroke
control the rack position. malfunction indication (DTC 29).
The ECU receives rack position voltage data from the 2. Loose connections
injection pump. The control unit checks that rack · Between ECU and governor harness
position control precision is adequate. · Between governor harness and injection pump
Also connected to the ECU are the rack sensor circuit Governor circuit (Governor actuator drive power supply
(inside the injection pump), the governor actuator drive voltage (SIG-GND/GND) open or shorted
circuit and 5-volt power supply, the governor ground Damaged vehicle harness, governor harness, or
circuit, and the governor signal-ground circuit. Pull- injection pump harness
down signals and limp home signals are received from Injection pump malfunction
these circuits. · Rack mechanical movement (Stiffness)
· Harness defect
Governor malfunction effects
· Internal circuit problem
2. Engine stops (Stall) ECU malfunction
3. Engine cannot be started
Diagnostic conditions
· Engine running (More than 10 seconds from the
time the engine was started)
If the target rack position and the actual rack position
are more than 2 mm apart for more than 1 second,
governor malfunction will be diagnosed (DTC 11).
· Immediately after engine start
If the target rack position and the actual rack position
are more than 2 mm apart for more than 10 seconds,
governor malfunction will be diagnosed (DTC 11).
6E-106 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 11 Governor servo system error

Step Action
Value(s) Yes No
No.
Perform inspection procedures related to engine  Go to Step 4 Go to Step 2
trouble (Inspection
procedure
1
based on
previous
malfunction)
Check engine emergency stop knob (red) Recent use Go to Step 3 Go to Step 4
2 operation (Ask driver if it has been used
recently).
Advise driver not to use emergency stop knob  Go to Step 20 
3
unless there is an emergency.
1. Check the emergency stop knob. Ÿ Knob fully Go to Step 6 Go to Step 5
2. Check for gap between the emergency returned
engine stop lever and injection pump Ÿ Cable tension
governor. Ÿ Lever returned
3. Check the cable condition and adjustment. to original
4 position (No
gap between
emergency
stop engine
lever and
injection pump
lever)
1. Return emergency engine stop knob to its  Go to Step 20 
5 original position.
2. Adjust cable.
Check TECH 2 display for other DTC (11 or 29 is Ÿ Existing Go to Step 10 Go to Step 7
possible). malfunction
6 Ÿ Previous
malfunction
(DTC 11 or 29)
Inspect the injection nozzles (check for Clogging Go to Step 9 Go to Step 8
7
clogging).
8 Perform troubleshooting procedure for DTC 29.   
9 Repair or replace the injection nozzles  Go to Step 20 
1. Starter switch ON. If there is a rack Go to Step 14 Go to Step 11
2. Use a circuit tester to measure rack sensor sensor error (pull-
10 output voltage at the vehicle harness and down), the voltage
the sensor body. will be 3.3
3.6
volts
1. Starter switch ON. If there is a rack Go to Step 12 Go to Step 13
2. Use a circuit tester to measure rack sensor sensor error (pull-
11 output voltage at the sensor body. down), the voltage
will be 3.3
3.6
volts
Replace the governor harness and/or repair  Go to Step 20 
12 damaged circuit areas.
Is the action complete ?
Replace injection pump.  Go to Step 20 
13
Is the action complete ?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-107

DTC 11 Governor servo system error (Cont'd)

Step
Action Value(s) Yes No
No.
Confirm inspection objectives (Engine trouble or Engine trouble Go to Step 15 Go to Step 20
14 previous appearance of malfunction). Engine trouble Previous
malfunction
1. Inspect the electronic governor circuit and Normal Go to Step 17 Go to Step 16
connections (refer to the schematic). Check
for loose and/or damaged connectors, open
wiring, and corroded terminals.
2. Check the harness for open wires, VB/GND
15
shorting, and layer shorting.
If there are no abnormal conditions, once again
check the harness and measure the governor
actuator drive power supply voltage, the SIG-
GND voltage, and the GND voltage.
Replace the governor harness and/or repair  Go to Step 20 
16 damaged circuit areas.
Is the action complete ?
1. Clear the memory. Ÿ Engine stalls Go to Step 18 Go to Step 16
2. Start the engine and allow it to idle. and DTC 11
3. Check the governor harness for vibration appears
17 and looseness (pay particular attention to the Ÿ Existing
moving area around the torsion bar). malfunction: 11
4. Check for reoccurrence of problem. Ÿ Previous
5. Confirm the TECH 2 DTC 11. malfunction
Replace the governor harness and/or repair  Go to Step 20 
18 damaged circuit areas.
Is the action complete ?
Replace Engine Control Unit (ECU).  Go to Step 20 
19
Is the action complete ?
Ÿ Engine trouble Go to Step 1 Verify repair
Ÿ DTC
1. Clear the memory.
20 2. Start the engine and allow it to idle.
Ÿ Existing
malfunction
3. Use the TECH 2 to confirm DTC 11.
Ÿ Previous
malfunction
6E-108 EMISSION AND ELECTRICAL DIAGNOSIS

Electronic governor external appearance and nomenclature

1. External appearance

Nomenclature

Terminal Wire color/diameter

Connector Signal
No. (Injection pump harness)
1 Governor actuator drive voltage – 1 R/1.2
2 Governor circuit GND-1 W/1.2
3 Target rack position – 1 L/1.2
SWP
4 Rack position voltage G/1.2
8-terminals
5 Governor circuit 5V-1 Y/1.2
Black
6 Backup N sensor (GND) BR/1.2
7 Backup N sensor (SIG) O/1.2
8 Pull-down B/1.2
9 Governor actuator drive voltage – 2 R/1.2
SWP 6- 10 Target rack position - 2 L/1.2
terminals 11 Governor circuit GND-2 W/1.2
Black 12 Governor circuit SIG-GND BR/1.2
13 Governor circuit 5V-2 Y/1.2
SWP 3- 14 Limp home V/1.2
terminals
Black 15 Sub-coil (Not used) BY/1.2
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-109

DTC-14 BACKUP N SENSOR ERROR

N-TDC sensor circuit and backup N sensor circuit (Including electronic governor circuit)
6E-110 EMISSION AND ELECTRICAL DIAGNOSIS

Circuit description Possible causes of backup N sensor

malfunction
The backup N sensor monitors engine speed when the
N-TDC sensor is disabled. 1. Loose connections
The backup N sensor is built-in to the injection pump · Between ECU and governor harness
electronic governor. · Between governor harness and injection pump
The sensing plate moves rapidly across the tip of the 2. Backup N sensor SIG circuit open or shorted
sensor to generate a voltage pulse. This pulse is · Between ECU and governor harness
detected by the engine control unit (ECU). The control · Between governor harness and injection pump
unit calculates the time between pulses to determine 3. Backup N sensor GND circuit open or shorted
engine speed. · Between ECU and governor harness
· Between governor harness and injection pump
Backup sensor N malfunction effects 4. Injection pump malfunction
The failure of the backup sensor has no effect on the · Harness defect
vehicle. However, the engine control lamp will turn on · Sensor defect
at idle speed. · Bent sensing plate
5. N-TDC sensor signal problem
Diagnostic conditions
Increased signal due to loose connections or injection
When engine speed exceeds 350 rpm, there should be nozzle malfunction
pulse input from the N-TDC sensor but no pulse input 6. ECU malfunction
from the backup N sensor. If there is no pulse input
from either sensor, troubleshooting is required.
Under the above conditions, backup N sensor
malfunction is indicated by a DTC 14. Decision time
increases with a decrease in engine speed.
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-111

DTC 14 Backup N sensor error

Step
Action Value(s) Yes No
No.
Ÿ Existing Go to Step 2 Go to Step 22
1. Start the engine and allow it to idle.
malfunction: 14 Existing Previous
1 2. Confirm that DTC 14 appears on the TECH
2 display (existing malfunction).
Ÿ Backup sensor malfunction malfunction
error
1. Use a circuit tester to measure the backup Ÿ SIG – GND = Go to Step 6 Go to Step 3
N sensor resistance between the vehicle 2.1~2.5 k
2
harness and the sensor (injection pump Ÿ All terminals –
side). body = 
2. Measure the resistance between each
terminal and the sensor body.
Ÿ Terminal 7 Go to Step 5 Go to Step 4
(SIG) –
Terminal 6
Use a circuit tester to measure the backup N
3 (GND) =
sensor resistance (injection pump side).
2.1~2.5 kΩ
Ÿ Terminal 6 and
7 – body = 
Replace the injection pump.  Go to Step 26 
4
Is the action complete ?
Replace the governor harness and/or repair  Go to Step 26 
5 damaged circuit areas.
Is the action complete ?
1. Remove the N-TDC sensor connector. Engine stable (No Go to Step 7 Go to Step 18
2. Start the engine and allow it to idle. hunting)
6
3. Use the TECH 2 to check the engine speed
(stability).
Ÿ SIG – GND = Go to Step 11 Go to Step 8
Use a circuit tester to measure the N-TDC
2.1~2.5 kΩ
7 sensor resistance between the vehicle harness
and the sensor.
Ÿ All terminals –
body = 
Ÿ Terminal 2 Go to Step 10 Go to Step 9
(SIG) –
Terminal 1
(GND) =
2.1~2.5 kΩ
Ÿ Terminal 2
Use a circuit tester to measure the N-TDC (SIG) –
8 sensor resistance between the specified Terminal 3
terminals. (shield) = 
Ÿ Terminal 1
(SIG) –
Terminal 3
(shield) = 
Ÿ All terminals –
body = 
Replace the N-TDC sensor  Go to Step 26 
9
Is the action complete ?
Replace the governor harness and/or repair  Go to Step 26 
10
damaged circuit areas.
Check the connections of any accessory wiring Proper connections Go to Step 12 Go to Step 13
11
(radio, etc.) attached to the governor harness.
6E-112 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 14 Backup N sensor error (Cont'd)

Step
Action Value(s) Yes No
No.
Rearrange accessory wiring (Disconnect wires  Go to Step 26 
12 from harness first).
Is the action complete ?
1 mm (Turn in Go to Step 15 Go to Step 14
13 Check the N-TDC sensor gap. once and allow
return)
Adjust the N-TDC sensor gap.  Go to Step 26 
14
Is the action complete ?
15 Check the sensing plate for bending. Bending Go to Step 17 Go to Step 16
Replace the injection pump.  Go to Step 26 
16
Is the action complete ?
Replace the N-TDC sensor  Go to Step 26 
17
Is the action complete ?
1. Inspect the backup N sensor circuit and Normal Go to Step 20 Go to Step 19
connections (refer to the schematic). Check
for loose and/or damaged connectors, open
wiring, and corroded terminals.
18
2. Check the harness for open wires, VB/GND
shorting, and layer shorting.
If there are no abnormal conditions, once again
check the backup N sensor harness.
Replace the governor harness and/or repair  Go to Step 26 
19 damaged circuit areas.
Is the action complete ?
Ÿ Existing Go to Step 21 Go to Step 27
1. Clear the memory.
malfunction
20 2. Start the engine and allow it to idle.
3. Use the TECH 2 to confirm DTC 14.
Ÿ Previous
malfunction
Replace Engine Control Unit (ECU).  Go to Step 26 
21
Is the action complete ?
Ÿ Terminal 7 Go to Step 24 Go to Step 23
(SIG) –
Terminal 6
Use a circuit tester to measure the backup N (GND) =
22
sensor resistance (injection pump side). 2.1~2.5 kΩ
Ÿ Terminals 6
and 7 – body =

Replace the injection pump.  Go to Step 26 
23
Is the action complete ?
1. Inspect the backup N sensor circuit and Normal Go to Step 26 Go to Step 25
connections (refer to the schematic). Check
for loose and/or damaged connectors, open
wiring, and corroded terminals.
24
2. Check the harness for open wires, VB/GND
shorting, and layer shorting.
If there are no abnormal conditions, once again
check the backup N sensor harness.
Replace the governor harness and/or repair  Go to Step 26 
25 damaged circuit areas.
Is the action complete ?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-113

DTC 14 Backup N sensor error (Cont'd)

Step
Action Value(s) Yes No
No.
Ÿ Existing Verify repair Go to Step 1
1. Clear the memory.
malfunction
26 2. Start the engine and allow it to idle.
3. Use the TECH 2 to confirm DTC 14.
Ÿ Previous
malfunction
6E-114 EMISSION AND ELECTRICAL DIAGNOSIS

Backup N sensor (inside the injection pump) external appearance and nomenclature
1. External appearance

2. Nomenclature

Terminal Wire color/diameter

Connector Signal
No. (Injection pump harness)
1~5 Omitted (Governor circuit) 
SWP 6 Backup N sensor (GND) BR/1.2
8-terminals
Black 7 Backup N sensor (SIG) O/1.2
8 Omitted (Governor circuit) 

SWP
6-terminals 9~13 Omitted (Governor circuit) 
Black

SWP
3-terminals 14~15 Omitted (Governor circuit) 
Black

3. Backup sensor resistance values

Measuring points Resistance Remarks

SWP connector Terminal 7 ßà Terminal 8 2.1~2.5 kΩ SIG~GND
Green Terminal 7 ßà Body  SIG~Body
3-terminals Terminal 8 ßà Body  GND~Body
Note: Resistances will change as the engine warms up.
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-115

N-TDC sensor external appearance and nomenclature

1. External appearance

2. Nomenclature

Terminal No. Signal Wire color/diameter

1 GND B/0.5
2 SIG Y/0.5
3 Shield G/0.5

3. N-TDC sensor resistance values

Measuring points Resistance Remarks

Terminal 2 ßà Terminal 1 2.1~2.5 kΩ SIG~GND
Terminal 2 ßà Terminal 3  SIG~Shield
SWP connector Terminal 2 ßà Body  SIG~Body
Green
Terminal 1 ßà Terminal 3  GND~Shield
3-terminals
Terminal 1 ßà Body  GND~Body
Terminal 3 ßà Body  Shield~Body

N-TDC sensor gap adjustment

Gap Adjustment procedure

1. Loosen the lock nut.
2. Turn in the sensor until it contacts the sensing plate.
1 mm
3. Back off the sensor 1 turn.
4. Tighten the lock nut.
6E-116 EMISSION AND ELECTRICAL DIAGNOSIS

DTC-15 N-TDC SENSOR ERROR

N-TDC sensor circuit and backup N sensor circuit (Including electronic governor circuit)
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-117

Under the above conditions, N-TDC sensor

Circuit description
malfunction is indicated by a DTC 15. Decision time
The N-TDC sensor monitors engine speed. increases with a decrease in engine speed.
The sensing plate is attached to the injection pump.
The plate moves quickly across the tip of the sensor to Possible causes of backup N sensor
generate a voltage pulse. This pulse is detected by the malfunction
engine control unit (ECU). The ECU calculates the 1. Loose connections
time between pulses to determine engine speed. · Between ECU and governor harness
If the N-TDC sensor fails, the backup N sensor (built-in · Between governor harness and injection pump
to the injection pump) operates to determine engine 2. N-TDC sensor SIG circuit open or shorted
speed. · Between ECU and governor harness
N-TDC sensor N malfunction effects · Between governor harness and injection pump
3. N-TDC sensor GND circuit open or shorted
Measured engine speed drops to 0 rpm for an instant · Between ECU and governor harness
until the backup sensor begins to operate. · Between governor harness and injection pump
Diagnostic conditions 4. Sensor damage (Harness or internal circuitry)
When engine speed exceeds 350 rpm, there should be 5. Bent sensing plate
pulse input from the backup N sensor but no pulse 6. Backup N sensor signal problem
input from the N-TDC sensor. If there is no pulse input Increased signal due to loose connections or injection
from either sensor, troubleshooting is required. nozzle malfunction
7. ECU malfunction
6E-118 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 15 N-TDC sensor error

Step Action Value(s) Yes No
Ÿ Existing Go to Step 2 Go to Step 22
1. Start the engine and allow it to idle.
malfunction: 15 Existing Previous
1 2. Confirm that DTC 15 appears on the TECH
2 display (existing malfunction).
Ÿ N-TDC sensor malfunction malfunction
error
1. Use a circuit tester to measure the N-TDC Ÿ SIG – GND = Go to Step 3 Go to Step 6
sensor resistance between the vehicle 2.1~2.5 kΩ
2
harness and the sensor (injection pump Ÿ All terminals –
side). body = 
2. Measure the resistance between each
terminal and the sensor body.
Ÿ Terminal 2 Go to Step 5 Go to Step 4
(SIG) –
Terminal 1
(GND) =
2.1~2.5 k
Ÿ Terminal 2
Use a circuit tester to measure the N-TDC (SIG) –
3 sensor resistance between the specified Terminal 3
terminals. (shield) = 
Ÿ Terminal 1
(SIG) –
Terminal 3
(shield) = 
Ÿ All terminals –
body = 
Replace the N-TDC sensor.  Go to Step 26 
4
Is the action complete ?
Replace the governor harness and/or repair  Go to Step 26 
5 damaged circuit areas.
Is the action complete ?
1. Remove the N-TDC sensor connector. Engine stable (No Go to Step 14 Go to Step 7
2. Start the engine and allow it to idle. hunting)
6
3. Use the TECH 2 to check the engine speed
(stability).
Ÿ SIG – GND = Go to Step 11 Go to Step 8
Use a circuit tester to measure the N-TDC
2.1~2.5 k
7 sensor resistance between the vehicle harness
and the sensor.
Ÿ All terminals –
body = 
Ÿ Terminal 7 Go to Step 10 Go to Step 9
(SIG) –
Terminal 6
Use a circuit tester to measure the backup N (GND) =
8 sensor resistance between the specified
2.1~2.5 k
terminals.
Ÿ Terminals 6
and 7 – body =

Replace the injection pump.  Go to Step 26 
9
Is the action complete?
Replace the governor harness and/or repair  Go to Step 26 
10 damaged circuit areas.
Is the action complete ?
Check the connections of any accessory wiring Proper connections Go to Step 12 Go to Step 13
11
(radio, etc.) attached to the governor harness.
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-119

DTC 15 N-TDC sensor error (Cont'd)

Step Action Value(s) Yes No
Rearrange accessory wiring (Disconnect wires  Go to Step 26 
12 from harness first).
Is the action complete ?
Replace the injection pump.  Go to Step 26 
13
Is the action complete?
1 mm (Turn in Go to Step 16 Go to Step 15
14 Check the N-TDC sensor gap. once and allow
return)
Adjust the N-TDC sensor gap.  Go to Step 26 
15
Is the action complete ?
16 Check the sensing plate for bending. Bending Go to Step 17 Go to Step 18
Replace the injection pump.  Go to Step 26 
17
Is the action complete ?
1. Inspect the N-TDC sensor circuit and Normal Go to Step 20 Go to Step 19
connections (refer to the schematic). Check
for loose and/or damaged connectors, open
wiring, and corroded terminals.
18 2. Check the harness for open wires, VB/GND
shorting, and layer shorting.
If there are no abnormal conditions, once again
check the N-TDC sensor harness.
Replace the governor harness and/or repair  Go to Step 26 
19
damaged circuit areas.
Ÿ Existing Go to Step 21 Go to Step 27
1. Clear the memory.
malfunction
20 2. Start the engine and allow it to idle.
3. Use the TECH 2 to confirm DTC 15.
Ÿ Previous
malfunction
Replace the Engine Control Unit (ECU).  Go to Step 26 
21
Is the action complete ?
Ÿ Terminal 2 Go to Step 24 Go to Step 23
(SIG) –
Terminal 1
(GND) =
2.1~2.5 k
Ÿ Terminal 2
Use a circuit tester to measure the N-TDC (SIG) –
22 sensor resistance between the specified Terminal 3
terminals. (shield) = 
Ÿ Terminal 1
(SIG) –
Terminal 3
(shield) = 
Ÿ All terminals –
body = 
Replace the N-TDC sensor.  Go to Step 26 
23
Is the action complete ?
6E-120 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 15 N-TDC sensor error (Cont'd)

Step Action Value(s) Yes No
1. Inspect the N-TDC sensor circuit and Normal Go to Step 26 Go to Step 25
connections (refer to the schematic). Check
for loose and/or damaged connectors, open
wiring, and corroded terminals.
24 2. Check the harness for open wires, VB/GND
shorting, and layer shorting.
If there are no abnormal conditons, once again
check the N-TDC sensor harness.
Replace the governor harness and/or repair  Go to Step 26 
25 damaged circuit areas.
Is the action complete ?
Ÿ Existing Go to Step 1 Verify repair
1. Clear the memory.
malfunction
26 2. Start the engine and allow it to idle.
3. Use the TECH 2 to confirm DTC 14.
Ÿ Previous
malfunction
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-121

N-TDC sensor gap adjustment

Gap Adjustment procedure

1. Loosen the lock nut.
2. Turn in the sensor until it contacts the sensing plate.
3 mm
3. Back off the sensor 3 turns.
4. Tighten the lock nut.

N-TDC sensor external appearance, nomenclature, and resistance values

1. External appearance

(8-2) Nomenclature

Terminal No. Signal Wire color/diameter

1 GND B/0.5
2 SIG Y/0.5
3 Shield G/0.5

2. N-TDC sensor resistance values

Measuring points Resistance Remarks

Terminal 2 ßà Terminal 1 2.1~2.5 k SIG~GND
Terminal 2 ßà Terminal 3  SIG~Shield
SWP connector
Terminal 2 ßà Body  SIG~Body
Green
Terminal 1 ßà Terminal 3  GND~Shield
3-terminals
Terminal 1 ßà Body  GND~Body
Terminal 3 ßà Body  Shield~Body

Note: Resistance values will change as the engine warms up.

6E-122 EMISSION AND ELECTRICAL DIAGNOSIS

N-TDC sensor (inside injection pump) external appearance, terminal nomenclature, and
resistance values

1. Backup N sensor external appearance

 EMISSION AND ELECTRICAL DIAGNOSIS 6E-123

2. Nomenclature

Terminal Wire color/diameter

Connector Signal
No. (Injection pump harness)
1~5 Omitted (Governor circuit) 
SWP 6 Backup N sensor (GND) BR/1.2
8-terminals
Black 7 Backup N sensor (SIG) O/1.2
8 Omitted (Governor circuit) 

SWP
6-terminals 9~13 Omitted (Governor circuit) 
Black

SWP
3-terminals 14~15 Omitted (Governor circuit) 
Black

3. Backup N sensor resistance values

Resistance Remarks
Measuring points
SWP connector Terminal 7 ßà Terminal 8 2.1~2.5 k SIG~GND
Green Terminal 7 ßà Body  SIG~Body
3-terminals Terminal 8 ßà Body  GND~Body

Note: Resistance values will change as the engine warms up.

6E-124 EMISSION AND ELECTRICAL DIAGNOSIS

DTC-211 FUEL TEMPERATURE SENSOR ERROR

Fuel temperature sensor circuit (Includes Engine coolant temperature sensor and atmospheric
temperature sensor circuits)
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-125

Circuit description
The fuel temperature sensor monitors the temperature
of the fuel being delivered to the engine from the fuel
tank.
Changes in the fuel temperature cause changes in
sensor resistance. Changing resistance causes a
change in voltage level. The engine control unit (ECU)
detects the voltage level and calculates the fuel
temperature. This data is used to make engine control
decisions.
A 5-volt potential (power supply) is delivered to the
sensor from the ECU through the load.
Other sensors (engine coolant temperature and
atmospheric temperature) share a common path to
ground with the fuel temperature sensor.
Sensor malfunction effects
Power loss when climbing in hot weather
Diagnostic conditions
If the ECU detects a voltage of more than 4.92 volts
(open circuit to ground) or less than 0.1 volt (short
circuit to ground) for 1 second, it will declare an
accelerator position sensor malfunction (DTC 211).
Possible causes of sensor malfunction
1. Loose connections
· Between ECU and governor harness
· Between governor harness and sensor
2. Fuel temperature sensor SIG circuit open or shorted
Between vehicle harness, sensor harness, and
governor harness
3. Fuel temperature sensor GND circuit open
Between vehicle harness, sensor harness, and
governor harness
4. Other temperature sensor open circuit (common
ground/governor harness)
Other malfunction indications may appear (coolant
temperature sensor/DTC 23 or atmospheric
temperature sensor/DTC 22).
5. Sensor damage (Harness or internal area)
Increased signal due to loose connections or injection
nozzle malfunction
6. ECU malfunction
6E-126 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 211 Fuel temperature sensor error

Step Action Value(s) Yes No
Ÿ Existing malfunction: 211 Go to Step 2 Go to Step 13
1 Use the TECH 2 to confirm DTC 211 Ÿ Fuel temperature sensor Existing Previous
error malfunction malfunction
Use the TECH 2 to check for Ÿ DTC 22 and 23 Go to Step 3 Go to Step 5
2 simultaneous appearance of other Ÿ DTC 22 and 211
DTC’s (existing malfunctions). Ÿ DTC's 22, 23, and 211
Between SIG (+) and GND (-) Go to Step 9 Go to Step 4
Ÿ Coolant temperature
sensor = 350W (80°C)
and 1.25k (40°C)
Use a circuit tester to measure the fuel Ÿ Atmospheric temperature
temperature sensor, atmospheric sensor = 3.74k(20°C)
temperature sensor, and fuel
3 and 9.77k(0°C C)
temperature sensor resistance between
the vehicle harness and the individual Ÿ Fuel temperature sensor
sensors. = 1.21k(40°C) and
3.45k(10°C)
Ÿ Between each terminal
and body, all sensor
resistances = 
Replace the governor harness and/or  Go to Step 17 
4 repair damaged circuit areas.
Is the action complete ?
Ÿ Between sensor Go to Step 7 Go to Step 6
terminals = 1.21k
Use a circuit tester to measure the fuel (40°C) and 3.45k(10°C)
5
temperature sensor resistance. Ÿ Between each terminal
and body, all sensor
resistances = 
Replace the governor harness and/or  Go to Step 17 
6 repair damaged circuit areas.
Is the action complete ?
Ÿ Between SIG (+) and Go to Step 9 Go to Step 8
GND (-) = 1.21k
Use a circuit tester to measure the fuel Ÿ (40°C) and 3.45k
7 temperature sensor resistance between (10°C)
the governor harness and the sensor. Ÿ Between each terminal
and body, all sensor
resistances = 
Replace the governor harness and/or  Go to Step 17 
8 repair damaged circuit areas.
Is the action complete ?
1. Inspect the fuel temperature sensor Normal Go to Step 11 Go to Step 10
circuit and connections (refer to the
schematic). Check for loose and/or
damaged connectors, open wiring,
and corroded terminals.
9 2. Check the harness for open wires,
VB/GND shorting, and layer
shorting.
If there are no abnormal conditions,
once again check the fuel temperature
sensor harness.
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-127

DTC 211 Fuel temperature sensor error (Cont'd)

Step
Action Value(s) Yes No
No.
Replace any damaged harnesses  Go to Step 17 
10 and/or repair damaged circuits
Is the action complete ?
1. Clear the memory. Ÿ Existing malfunction Go to Step 12 Verify repair
11 2. Use the TECH 2 to confirm DTC Ÿ Previous malfunction
211 appearance.
Replace the Engine Control Unit (ECU).  Go to Step 17 
12
Is the action complete ?
Ÿ Between sensor Go to Step 15 Go to Step 14
terminals = 1.21k
Use a circuit tester to measure the fuel (40°C) and 3.45k(10°C)
13
temperature sensor resistance. Ÿ Between each terminal
and body, all sensor
resistances = 
Replace the fuel temperature sensor.  Go to Step 17 
14
Is the action complete ?
1. Inspect the fuel temperature sensor Normal Go to Step 17 Go to Step 16
circuit and connections (refer to the
schematic). Check for loose and/or
damaged connectors, open wiring,
and corroded terminals.
15 2. Check the harness for open wires,
VB/GND shorting, and layer
shorting.
If there are no abnormal conditions,
once again check the fuel temperature
sensor harness.
Replace any damaged harnesses  Go to Step 17 
16 and/or repair damaged circuits
Is the action complete ?
1. Clear the memory. Ÿ Existing malfunction Go to Step 1 Verify repair
17 2. Use the TECH 2 to confirm DTC Ÿ Previous malfunction
211 appearance.
6E-128 EMISSION AND ELECTRICAL DIAGNOSIS

Fuel temperature sensor external appearance,

2. Terminal nomenclature
terminal nomenclature, and resistance
1. External appearance Terminal No. Signal
1
Engine control thermister
2

3. Fuel temperature sensor resistance values

Resistance
Connector Measuring points Temperature  Remarks
(k

)
1.21 40
Terminal 1 ßà Terminal 2 Engine control thermister
SWP 3.45 10
Black
2 terminals Terminal 1 ßà Body Between engine control
 
Terminal 2 ßà Body thermister and body

Note: Resistance values vary with changes in engine temperature

 EMISSION AND ELECTRICAL DIAGNOSIS 6E-129

DTC-22 ATMOSPHERIC TEMPERATURE SENSOR ERROR

Atmospheric temperature sensor circuit (Including engine coolant temperature sensor circuit and
fuel temperature sensor circuit)
6E-130 EMISSION AND ELECTRICAL DIAGNOSIS

Circuit description
The atmospheric temperature sensor monitors outside
air temperature.
Temperature changes in the sensing area cause
changes in circuit resistance. The engine control unit
(ECU) detects circuit resistance change and calculates
the existing voltage. The voltage level is converted into
a temperature reading. The ECU dictates certain
engine control changes in response to changing
temperature.
A 5-volt power supply voltage is delivered to the
sensor from the ECU and through the load.
The ground circuit is shared with other sensors
(coolant temperature sensor and fuel temperature
sensor).
1. Atmospheric temperature sensor malfunction effects
· Exhaust gas deterioration (EGR control stops)
· Reduced power output when climbing in hot
weather
Diagnostic conditions
If the ECU detects a voltage of more than 5 volts (open
circuit) or less than 0.1 volt (short circuit) for 1 second,
it will declare an atmospheric temperature sensor
malfunction (DTC 22).
Possible causes of atmospheric temperature
sensor malfunction
1. Loose connections
· Between engine control unit and governor
harness
· Between fascia harness and sensors
· Between fascia harness and governor harness
2. Atmospheric temperature sensor SIG circuit open or
shorted
Fascia harness problem
3. Atmospheric temperature sensor GND circuit open
or shorted
Fascia harness problem
4. Engine coolant temperature sensor circuit open
(Common ground)
In addition to DTC 22 (atmospheric temperature
sensor), DTC 23 (Engine coolant temperature sensor)
or DTC 211 (fuel temperature sensor) may also
appear.
5. Sensor damage (Internal circuitry)
6. ECU malfunction
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-131

DTC 22 Atmospheric temperature sensor error

Step Action Value(s) Yes No

Ÿ Existing Go to Step 2 Go to Step 15
malfunction: 22 Existing Previous
1 Use the TECH 2 to confirm DTC 22 Ÿ Atmospheric malfunction malfunction
temperature
sensor error
Ÿ DTC 22 and 23 Go to Step 3 Go to Step 5
Use the TECH 2 to check for simultaneous
Ÿ DTC 22 and
2 211
appearance of other DTC.
Ÿ DTC 22, 23,
and 211
Between SIG (+) Go to Step 11 Go to Step 4
and GND (-)
Ÿ Engine
Coolant
temperature
sensor = 350
(80°C) and
1.25kΩ (40°C)
Ÿ Atmospheric
temperature
sensor =
Use a circuit tester to measure the atmospheric
3.74kΩ (20°C)
temperature sensor, engine coolant temperature
and 9.77kΩ
3 sensor, and fuel temperature sensor resistance
(0°C)
between the vehicle harness and the individual
sensors.
Ÿ Fuel
temperature
sensor =
1.21kΩ (40°C)
and 3.45kΩ
(10°C)
Ÿ Between each
terminal and
body, all
sensor
resistances =

Replace the governor harness and/or repair  Go to Step 19 
4 damaged circuit areas.
Is the action complete ?
Ÿ Between Go to Step 7 Go to Step 6
sensor
terminals =
Use a circuit tester to measure the atmospheric 3.74 kΩ (20°C)
5
temperature sensor resistance. and 9.77kΩ
(0°C)
Ÿ All terminals –
body = 
Replace the atmospheric temperature sensor.  Go to Step 19 
6
Is the action complete ?
6E-132 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 22 Atmospheric temperature sensor error (Cont'd)

Step Action Value(s) Yes No
Ÿ Between SIG Go to Step 11 Go to Step 8
(+) and GND (-
) = 3.74 kΩ
(20ºC) and
Use a circuit tester to measure the atmospheric 9.77kΩ (0ºC)
7 temperature sensor resistance between the Ÿ Between each
vehicle harness and the sensor. terminal and
body, all
sensor
resistances =

Ÿ Between SIG Go to Step 9 Go to Step 10
(+) and SDL
Pin 15 = 3.74
kΩ (20ºC) and
Use a circuit tester to measure the atmospheric 9.77 kΩ (0ºC)
8 temperature sensor resistance between the Ÿ Between each
fascia harness and the sensor. terminal and
body, all
sensor
resistances =

Replace the governor harness and/or repair  Go to Step 19 
9 damaged circuit areas.
Is the action complete ?
Replace the fascia harness and/or repair  Go to Step 19 
10 damaged circuit areas.
Is the action complete ?
1. Inspect the atmospheric temperature sensor Normal Go to Step 13 Go to Step 12
circuit and connections (refer to the
schematic). Check for loose and/or damaged
connectors, open wiring, and corroded
terminals.
11 2. Check the harness for open wires, VB/GND
shorting, and layer shorting.
If there are no abnormal conditions, once again
check the atmospheric temperature sensor
harness.
Replace defective harness parts and repair  Go to Step 19 
12 atmospheric temperature circuit.
Is the action complete ?
Ÿ Existing Go to Step 14 Go to Step 20
1. Clear the memory.
malfunction
13 2. Use the TECH 2 to confirm DTC 22
appearance.
Ÿ Previous
malfunction
Replace the Engine Control Unit (ECU).  Go to Step 19 
14
Is the action complete ?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-133

DTC 22 Atmospheric temperature sensor error (Cont'd)

Step Action Value(s) Yes No
Ÿ Between Go to Step 17 Go to Step 16
sensor
terminals =
3.74 kΩ (20°C)
and 9.77kΩ
Use a circuit tester to measure the atmospheric (0°C)
15
temperature sensor resistance. Ÿ Between each
terminal and
body, all
sensor
resistances =

Replace the atmospheric temperature sensor.  Go to Step 19 
16
Is the action complete ?
1. Inspect the atmospheric temperature sensor Normal Go to Step 19 Go to Step 18
circuit and connections (refer to the
schematic). Check for loose and/or damaged
connectors, open wiring, and corroded
terminals.
17 2. Check the harness for open wires, VB/GND
shorting, and layer shorting.
If there are no abnormal conditions, once again
check the atmospheric temperature sensor
harness.
Replace defective harness parts and repair  Go to Step 19 
18 atmospheric temperature circuit.
Is the action complete ?
Ÿ Existing Go to Step 1 Verify repair
1. Clear the memory.
malfunction
19 2. Use the TECH 2 to confirm DTC 22
appearance.
Ÿ Previous
malfunction
6E-134 EMISSION AND ELECTRICAL DIAGNOSIS

Atmospheric temperature sensor external appearance, terminal nomenclature, and resistance

values
1. Installation position

1: Atmospheric temperature sensor

Terminal No. Signal

1
Engine control thermister
2

2. Resistance values (Reference)

Measuring points Resistance Temperature Remarks

3.74 kΩ 20°C Between Engine control
Terminal 1 ßà Terminal 2
Connector 9.77 kΩ 0°C thermisters
Black Terminal 1 ßà Body   Between each Engine
2 terminals  control thermister and
Terminal 2 ßà Body 
body

Note: Resistance values will change as the engine warms up.

 EMISSION AND ELECTRICAL DIAGNOSIS 6E-135

DTC-23 ENGINE COOLANT TEMPERATURE SENSOR ERROR

Engine coolant temperature sensor circuit (Including atmospheric temperature sensor and fuel
temperature sensor circuits)
6E-136 EMISSION AND ELECTRICAL DIAGNOSIS

ground) for 1 second, it will declare an engine coolant

Circuit description
temperature sensor malfunction (DTC 23).
The engine coolant temperature sensor monitors
engine coolant temperature. Possible causes of engine coolant
Temperature changes in the sensing area cause temperature sensor malfunction
changes in circuit resistance. The engine control unit 1. Loose connections
(ECU) detects circuit resistance change and calculates · Between ECU and governor harness
the existing voltage. The voltage level is converted into · Between fascia harness and governor harness
a temperature reading. The ECU dictates certain · Between fascia harness and frame harness
engine control changes in response to changing · Between frame harness and sensor
temperature. 2. Engine coolant temperature sensor SIG circuit open
A 5-volt power supply voltage is delivered to the or shorted
sensor from the ECU and through the load. Governor harness, fascia harness, and/or frame
The ground circuit is shared with other sensors harness problem
(atmospheric temperature sensor and fuel temperature 3. Engine coolant temperature sensor GND circuit
sensor). open or shorted
Engine coolant temperature sensor Governor harness, fascia harness, and/or frame
malfunction effects harness problem
4. Engine coolant temperature sensor circuit open
· Difficult cold weather starting
(Common ground) (Vehicle harness defect)
· Black or white exhaust emissions when engine is
In addition to DTC 23 (Engine coolant temperature
cold
sensor), DTC 22 (atmospheric temperature sensor) or
· Exhaust gas deterioration (EGR control stops)
DTC 211 (fuel temperature sensor) may also appear.
Diagnostic conditions 5. Sensor damage (Internal circuitry)
If the ECU detects a voltage of more than 4.92 volts 6. ECU malfunction
(open circuit) or less than 0.1 volt (short circuit to
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-137

DTC 23 Engine coolant temperature sensor error

Step Action Value(s) Yes No
Use the TECH 2 to confirm DTC 23 Ÿ Existing Go to Step 2 Go to Step 15
malfunction: 23 Existing Previous
1 Ÿ Engine coolant malfunction malfunction
temperature
sensor error
Use the TECH 2 to check for simultaneous Ÿ DTC 22 and 23 Go to Step 3 Go to Step 5
appearance of other DTC. Ÿ DTC 22 and
2 211
Ÿ DTC 22, 23,
and 211
Use a circuit tester to measure the engine Between SIG (+) Go to Step 13 Go to Step 4
coolant temperature sensor, atmospheric and GND (-)
temperature sensor, and fuel temperature Ÿ Engine coolant
sensor resistance between the vehicle harness temperature
and the individual sensors. sensor = 350
(80°C) and
1.25kΩ (40°C)
Ÿ Atmospheric
temperature
sensor = 3.74k
Ω (20°C) and
9.77kΩ (0°C)
3
Ÿ Fuel
temperature
sensor =
1.21kΩ(40°C)
and 3.45kΩ
(10°C)
Ÿ Between each
terminal and
body, all
sensor
resistances =

Replace the governor harness and/or repair  Go to Step 21 
4 damaged circuit areas.
Is the action complete?
Use a circuit tester to measure the engine Ÿ Between Go to Step 7 Go to Step 6
coolant temperature sensor resistance. Engine control
terminals = 350
 (80°C) and
1.25kΩ (40°C)
Ÿ Between each
terminal and
body, all
sensor
5
resistances =

Ÿ Between
Engine control
terminals and
body = 
Ÿ Between meter
terminal and
body = 
6E-138 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 23 Engine coolant temperature sensor error (Cont'd)

Step Action Value(s) Yes No
Replace the engine coolant temperature sensor.  Go to Step 21 
6
Is the action complete ?
Use a circuit tester to measure the engine Ÿ Between SIG Go to Step 13 Go to Step 8
coolant temperature sensor resistance between (+) and GND (-
the vehicle harness and the sensor. ) = 350
(80°C) and
1.25kΩ (40°C)
7 Ÿ Between each
terminal and
body, all
sensor
resistances =

Use a circuit tester to measure the engine Ÿ Between SDL Go to Step 9 Go to Step 10
coolant temperature sensor resistance between Pin 17 and Pin
the fascia harness, the frame harness, and the 18 = 350
sensor. (80°C) and
1.25 kΩ (40°C)
8 Ÿ Between each
terminal and
body, all
sensor
resistances =

Replace the governor harness and/or repair  Go to Step 21 
9 damaged circuit areas.
Is the action complete ?
Use a circuit tester to measure the engine Ÿ Between SMJ Go to Step 11 Go to Step 12
coolant temperature sensor resistance between Pin 35 and Pin
the frame harness and the sensor. 36 = 350
(80°C) and
1.25 kΩ (40°C)
10 Ÿ Between each
terminal and
body, all
sensor
resistances =

Replace the fascia harness and/or repair  Go to Step 21 
11 damaged circuit areas.
Is the action complete ?
Replace the frame harness and repair engine  Go to Step 21 
12
coolant temperature circuit.
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-139

DTC 23 Engine coolant temperature sensor error (Cont'd)

Step Action Value(s) Yes No
1. Inspect the coolant temperature sensor Normal Go to Step 15 Go to Step 14
circuit and connections (refer to the
schematic). Check for loose and/or damaged
connectors, open wiring, and corroded
13 terminals.
2. Check the harness for open wires, VB/GND
shorting, and layer shorting.
If there are no abnormal conditions, once again
check the coolant temperature sensor harness.
Replace defective harness parts and repair  Go to Step 21 
14 engine coolant temperature circuit.
Is the action complete ?
1. Clear the memory. Ÿ Existing Go to Step 16 Go to Step 22
2. Use the TECH 2 to confirm DTC 23 malfunction
15
appearance. Ÿ Previous
malfunction
Replace the engine control unit (ECU).  Go to Step 21 
16
Is the action complete ?
Use a circuit tester to measure the engine Ÿ Between Go to Step 19 Go to Step 18
coolant temperature sensor resistance. Engine control
terminals = 350
 (80°C) and
1.25 kΩ (40°C)
Ÿ Between each
terminal and
body, all
sensor
17
resistances =

Ÿ Between
Engine control
terminals and
body = 
Ÿ Between meter
terminal and
body = 
Replace the engine coolant temperature sensor.  Go to Step 21 
18
Is the action complete ?
1. Inspect the engine coolant temperature Normal Go to Step 21 Go to Step 20
sensor circuit and connections (refer to the
schematic). Check for loose and/or damaged
connectors, open wiring, and corroded
terminals.
19 2. Check the harness for open wires, VB/GND
shorting, and layer shorting.
If there are no abnormal conditions, once again
check engine coolant temperature sensor
harness.
Replace defective harness parts and repair  Go to Step 21 
20 engine coolant temperature circuit.
Is the action complete ?
6E-140 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 23 Engine coolant temperature sensor error (Cont'd)

Step Action Value(s) Yes No
1. Clear the memory. Ÿ Existing
2. Use the TECH 2 to confirm DTC 23 malfunction
21 Go to Step 1 Verify repair
appearance. Ÿ Previous
malfunction
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-141

Engine coolant temperature sensor external appearance, terminal nomenclature, and resistance
values
1. External appearance

(7-2) Terminal nomenclature

Terminal No. Signal

1 Engine control thermister
2 Meter thermister (Body ground)
3 Engine control thermister

2. Resistance values

Measuring points Resistance Temperature Remarks

Between engine control
Terminal 1 ßà Terminal 2   thermister and meter
thermister
350 80°C Between each engine
Terminal 1 ßà Terminal 3
1.25 kΩ 40°C control thermister
Between each engine
Terminal 1 ßà Body   control thermister and
RV connector
body
Blue
3 terminals Between engine control
Terminal 2 ßà Terminal 3   thermister and meter
thermister
Between meter
Terminal 2 ßà Body 52 80°C
thermister and body
Between each engine
Terminal 3 ßà Body   control thermister and
body

Note: Resistance values will change as the engine warms up.

6E-142 EMISSION AND ELECTRICAL DIAGNOSIS

DTC-24 ACCELERATOR PEDAL POSITION SENSOR ERROR

Accelerator position sensor circuit (Including accelerator switch circuit)
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-143

Circuit description
The accelerator position sensor monitors the
accelerator pedal opening angle.
The sensor is installed to the engine control unit
(ECU).
When the accelerator pedal is depressed, the
accelerator sensor lever is rotated by the system lever.
This changes the output voltage (voltage is high when
the pedal is depressed and low when the pedal is
released). The ECU reads the voltage change and
converts it into accelerator opening angle data that is
used for engine control.
Sensor power supply voltage is 5 volts. SIG and GND
circuits are used only by the accelerator position
sensor. Duplicate connections to the ECU are used.
Accelerator pedal position is monitored at the
accelerator switch. This function is also diagnosed by
the accelerator position sensor.
Accelerator position sensor malfunction
effects
· Poor engine aspiration
· Power loss
· Engine response to accelerator pedal movement
slow
Diagnostic conditions
If the ECU detects a voltage of more than 4.8 volts
(open circuit to ground) or less than 0.1 volt (short
circuit to ground) for 1 second, it will declare an
accelerator position sensor malfunction (DTC 24).
Possible causes of accelerator position
sensor malfunction
1. Loose connections
· Between ECU and fascia harness
· Between fascia harness and sensor
· Between fascia harness and frame harness
· Between frame harness and sensor
2. Accelerator position sensor SIG/GND circuit open or
shorted
Fascia harness problem
3. Sensor damage (Internal circuitry)
4. ECU malfunction
6E-144 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 24 Accelerator pedal position sensor error

Step Action Result Yes No
Use the TECH 2 to confirm DTC 24. Ÿ Existing Go to Step 2 Go to Step 10
malfunction: 24 Existing Previous
1 Ÿ Accelerator malfunction malfunction
position sensor
error
Use a circuit tester to measure the accelerator Ÿ Between SV Go to Step 6 Go to Step 3
position sensor output voltage between the and GND =
vehicle harness and the sensor. 4.95~5.05 volts
Ÿ Between SIG
and GND with
pedal at idle
position =
2 0.35~0.65 volts
Ÿ Between SIG
and GND with
pedal at fully
depressed
position = idle
voltage +
3.5~4.8 volts
Use a circuit tester to measure the accelerator Ÿ Between SV Go to Step 5 Go to Step 4
position sensor output voltage. and GND =
4.95~5.05 volts
Ÿ Between SIG
and GND with
pedal at idle
position =
0.35~0.65 volts
(New engine)
3 or 0.31~0.69
volts (Used
engine)
Ÿ Between SIG
and GND with
pedal at fully
depressed
position = idle
voltage +
3.5~4.8 volts
Replace the bracket assembly and/or  Go to Step 14 
accelerator position sensor.
4
When the bracket assembly and/or accelerator
sensor is replaced, adjustment is required.
Adjust the bracket assembly before the sensor.
Replace the fascia harness and/or repair  Go to Step 14 
5 damaged circuit areas.
Is the action complete ?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-145

DTC 24 Accelerator pedal position sensor error (Cont'd)

Step Action Result Yes No
1. Inspect the accelerator position sensor Normal Go to Step 8 Go to Step 7
circuit and connections (refer to the
schematic). Check for loose and/or damaged
connectors, open wiring, and corroded
6 terminals.
2. Check the harness for open wires, VB/GND
shorting, and layer shorting.
If there are no abnormal conditions, once again
check the accelerator position sensor harness.
Repair damaged circuit areas at the fascia  Go to Step 14 
7
harness.
1. Clear the memory. Ÿ Existing Go to Step 9 Go to Step 15
2. Use the TECH 2 to confirm DTC 24 malfunction
8
appearance. Ÿ Previous
malfunction
Replace the Engine Control Unit (ECU).  Go to Step 14 
9
Is the action complete ?
1. Inspect the accelerator position sensor Normal Go to Step 12 Go to Step 11
circuit and connections (refer to the
schematic). Check for loose and/or damaged
connectors, open wiring, and corroded
10 terminals.
2. Check the harness for open wires, VB/GND
shorting, and layer shorting.
If there are no abnormal conditions, once again
check the accelerator position sensor harness.
Repair damaged circuit areas at the fascia  Go to Step 14 
11 harness.
Is the action complete ?
Use a circuit tester to measure the accelerator Ÿ Between SV Go to Step 14 Go to Step 13
position sensor output voltage. and GND =
4.95~5.05 volts
Ÿ Between SIG
and GND with
pedal at idle
position =
0.35~0.65 volts
(New engine)
12 or 0.31~0.69
volts (Used
engine)
Ÿ Between SIG
and GND with
pedal at fully
depressed
position = idle
voltage +
3.5~4.8 volts
6E-146 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 24 Accelerator pedal position sensor error (Cont'd)

Step Action Result Yes No
Replace the bracket assembly and/or  Go to Step 14 
accelerator position sensor.
13
When the bracket assembly and/or accelerator
sensor is replaced, adjustment is required.
Adjust the bracket assembly before the sensor.
1. Clear the memory. Ÿ Existing Go to Step 1 Verify repair
2. Use the TECH 2 to confirm DTC 24 malfunction
14
appearance. Ÿ Previous
malfunction
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-147

Accelerator position sensor external appearance, terminal nomenclature, and output voltage

1. External appearance

(7-2) Terminal nomenclature

Terminal No. Signal Wire color/diameter

1 5 volts (Main) L/0.5
2 GND (Main) G/0.5
3 5 volts (Sub) R/0.5
4 SIG (Main) Y/0.5
5 SIG (Sub) W/0.5
6 GND (Sub) B/0.5

2. Bracket assembly (External view)

3. Output voltage (Sensor connected to engine control unit)

Accelerator
Measuring points Output voltage Remarks
pedal position
Terminal 1 & 3
ßà  5.07~5.17 
Terminal 2 & 6
SDL connector Idle 0.35~0.65 New engine
White
Terminal 4 & 5 Full open voltage must not
6 terminals
ßà exceed 4.8 volts. The difference
Idle voltage +
Terminal 2 & 6 Full-open between idle voltage and full-
3.5~4.8
open voltage must be more than
3.5 volts.
6E-148 EMISSION AND ELECTRICAL DIAGNOSIS

DTC-241 ACCELERATOR POSITION SWITCH OFF ERROR

Accelerator switch circuit (Includes accelerator position sensor circuit)
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-149

Circuit description
The accelerator switch senses the accelerator pedal
position.
The switch is installed to the engine control bracket
together with the accelerator position sensor.
When the accelerator pedal is operated, the stem lever
causes the accelerator switch push rod to move. This
opens and closes contact points inside the accelerator
switch. When the contact points are closed
(accelerator pedal fully up), battery voltage (high level)
is applied to the switch. When the contact points are
open (accelerator pedal depressed), this voltage is not
applied (low level).
When the engine control unit (ECU) detects the high
battery voltage, it interprets this as the idle position.
When the ECU detects a lower voltage, it gathers data
from the accelerator position sensor to control engine
operation.
A No. 15 fuse is installed to the primary side of the
accelerator switch circuit. The secondary side of the
circuit is connected to the ECU.
Sensor malfunction effects
· Power loss
· Idle control not effective
· Exhaust brake does not function (Manual
transmission only)
Diagnostic conditions
If the ECU detects a voltage of less than 0.65 volt, it
assumes that the accelerator switch is off (low
level/switch open). If this condition continues for 1
second, the ECU declares an accelerator switch OFF
malfunction (DTC 241).
Possible causes of accelerator switch OFF
malfunction
· Loose connections (Between ECU and fascia
harness or between fascia harness and switch)
· Accelerator switch disconnected
· Accelerator switch circuit open between vehicle
harness and fascia harness
· Internal damage to accelerator switch
· Accelerator switch poorly adjusted
· Blown fuse (Short to ground or circuit overload
caused by vehicle modification)
· ECU malfunction
6E-150 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 241 Accelerator position switch off error

Step Action Value(s) Yes No
Ÿ Existing malfunction: 241 Go to Step 2 Go to Step 18
1 Use the TECH 2 to confirm DTC 241. Ÿ Accelerator switch OFF Existing Previous
error malfunction malfunction
Determine if other areas are functioning Ÿ Other areas Go to Step 3 Go to Step 6
2 or not (exhaust brake (manual nonfunctional
transmission only) and idle control)
3 Check the fuse. Normal Go to Step 5 Go to Step 4
Replace the fuse.  Go to Step 24 
4
Is the action complete ?
Repair the fascia harness circuits.  Go to Step 24 
5
Is the action complete ?
Check the accelerator switch Normal Go to Step 8 Go to Step 7
6 connectors for looseness and
separation.
Check the position of the accelerator  Go to Step 24 
7
switch connector waterproof covers.
1. Starter switch ON. Correct voltage values Go to Step 12 Go to Step 9
2. Set the circuit tester to the voltage Ÿ Idle position = battery
display. voltage (28 volts)
8
3. Measure the accelerator switch Ÿ Full-open position =
output voltage between the vehicle ground (0 volts)
harness and the switch.
1. Remove the accelerator switch from Correct resistance values Go to Step 11 Go to Step 10
the assembly bracket. Ÿ Idle position (pressure on
2. Set the circuit tester to the rod) = less than 0.5
9
resistance display. Ÿ Full-open position (no
3. Measure the accelerator switch pressure on rod) = 
resistance.
Replace the bracket assembly and/or  Go to Step 24 
accelerator switch.
When the accelerator switch is
10
replaced, bracket and switch adjustment
is required. Perform bracket adjustment
first.
Repair the fascia harness circuits.  Go to Step 24 
11
Is the action complete ?
Use the TECH 2. Correct accelerator sensor Go to Step 14 Go to Step 13
voltage = 0.7~1.35 volts
1. Check the accelerator switch action.
2. Make sure that the control unit is
12 properly installed.
3. Slowly depress the accelerator
pedal. Measure the accelerator
sensor voltage at the instant the
accelerator switch turns off.
Replace the bracket assembly and/or  Go to Step 24 
13 accelerator switch.
Is the action complete ?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-151

DTC 241 Accelerator position switch off error (Cont'd)

Step Action Value(s) Yes No
1. Inspect the accelerator switch circuit Normal Go to Step 16 Go to Step 15
and connections (refer to the
schematic). Check for loose and/or
damaged connectors, open wiring,
and corroded terminals.
14 2. Check the harness for open wires,
VB/GND shorting, and layer
shorting.
If there are no abnormal conditions,
once again check the accelerator switch
harness.
Repair the fascia harness circuits.  Go to Step 24 
15
Is the action complete ?
1. Clear the memory. Ÿ Existing malfunction Go to Step 17 Verify repair
16 2. Use the TECH 2 to confirm DTC Ÿ Previous malfunction
241 appearance.
Replace the engine control unit (ECU)  Go to Step 24 
17
Is the action complete ?
1. Inspect the accelerator switch circuit Normal Go to Step 20 Go to Step 19
and connections (refer to the
schematic). Check for loose and/or
damaged connectors, open wiring,
and corroded terminals.
18 2. Check the harness for open wires,
VB/GND shorting, and layer
shorting.
If there are no abnormal conditions,
once again check the accelerator switch
harness.
Repair the fascia harness circuits.  Go to Step 24 
19
Is the action complete ?
1. Remove the accelerator switch from Correct resistance values Go to Step 22 Go to Step 21
the assembly bracket. Ÿ Idle position (pressure on
2. Set the circuit tester to the rod) = less than 0.5
20
resistance display. Ÿ Full-open position (no
3. Measure the accelerator switch pressure on rod) = 
resistance.
Replace the bracket assembly and/or  Go to Step 24 
accelerator switch.
When the accelerator switch is
21
replaced, bracket and switch adjustment
is required. Perform bracket adjustment
first.
Use the TECH 2. Correct accelerator sensor Go to Step 24 Go to Step 21
1. Check the accelerator switch action. voltage = 0.7~1.35 volts
2. Make sure that the control unit is
properly installed.
22
3. Slowly depress the accelerator
pedal. Measure the accelerator
sensor voltage at the instant the
accelerator switch turns off.
6E-152 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 241 Accelerator position switch off error (Cont'd)

Step Action Value(s) Yes No
Replace the bracket assembly and/or  Go to Step 24 
23
accelerator switch.
1. Clear the memory. Ÿ Existing malfunction Go to Step 1 Go to Step 25
24 2. Use the TECH 2 to confirm DTC Ÿ Previous malfunction
241 appearance.
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-153

Accelerator switch external appearance,

terminal nomenclature, and resistance values

1. Accelerator switch external appearance

2. Accelerator pedal external appearance

3. Resistance values

Accelerator pedal and

Connector Measuring points Resistance ()
accelerator switch rod position
Idle position (Pressure on rod) Less than 0.5
S-type Terminal 1 ßàTerminal 2 Full-open position (No pressure on
White rod)

2 terminals Terminal 1 ßà Body

Terminal 2 ßà Body
6E-154 EMISSION AND ELECTRICAL DIAGNOSIS

DTC-242 ACCELERATOR POSITION SWITCH ON ERROR

Accelerator switch circuit (Includes accelerator sensor circuit)
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-155

Circuit description
The accelerator switch senses the accelerator pedal
position.
The switch is installed to the engine control bracket
together with the accelerator position sensor.
When the accelerator pedal is operated, the stem lever
causes the accelerator switch push rod to move. This
opens and closes contact points inside the accelerator
switch. When the contact points are closed
(accelerator pedal fully up), battery voltage (high level)
is applied to the switch. When the contact points are
open (accelerator pedal depressed), this voltage is not
applied (low level).
When the engine control unit (ECU) detects the high
battery voltage, it interprets this as the idle position.
When the ECU detects a lower voltage, it gathers data
from the accelerator position sensor to control engine
operation.
A No. 15 fuse is installed to the primary side of the
accelerator switch circuit. The secondary side of the
circuit is connected to the ECU.
Sensor malfunction effects
Loss of accelerator pedal response when engine
speed reaches approximately 800 rpm.
Diagnostic conditions
If the ECU detects a voltage of less than 3.06 volts, it
assumes that the accelerator switch is on (high
level/switch closed). If this condition continues for 0.5
seconds, the ECU declares an accelerator switch ON
malfunction (DTC 242).
Possible causes of accelerator switch ON
malfunction
· Loose connections (Between ECU and fascia
harness or between fascia harness and switch)
· Accelerator switch circuit VB short (fascia/vehicle
harness)
· Internal damage to accelerator switch
· Restricted accelerator switch push rod operation
· Accelerator switch poorly adjusted
· ECU malfunction
6E-156 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 242 Accelerator position switch on error

Step Action Value(s) Yes No
1. Starter switch ON (do not start the Ÿ Existing malfunction: 242 Go to Step 2 Go to Step 12
engine). Ÿ Accelerator switch ON Existing Previous
1 2. Fully depress the accelerator pedal. error malfunction malfunction
3. Use the TECH 2 to confirm DTC
242.
1. Starter switch ON. Correct voltage values Go to Step 6 Go to Step 3
2. Set the circuit tester to the voltage Ÿ Idle position = battery
display. voltage (28 volts)
2
3. Measure the accelerator switch Ÿ Full-open position =
output voltage between the vehicle ground (0 volts)
harness and the switch.
1. Remove the accelerator switch from Correct resistance values Go to Step 5 Go to Step 4
the assembly bracket. Ÿ Idle position (pressure on
2. Set the circuit tester to the rod) = less than 0.5
3
resistance display. Ÿ Full-open position (no
3. Measure the accelerator switch pressure on rod) = 
resistance.
Replace the bracket assembly and/or  Go to Step 18 
accelerator switch.
When the accelerator switch is
4
replaced, bracket and switch adjustment
is required. Perform bracket adjustment
first.
Repair the fascia harness circuits.  Go to Step 18 
5
Is the action complete ?
Use the TECH 2. Correct accelerator sensor Go to Step 8 Go to Step 7
1. Check the accelerator switch action. voltage = 0.7~1.35 volts
2. Make sure that the control unit is
properly installed.
6
3. Slowly depress the accelerator
pedal. Measure the accelerator
sensor voltage at the instant the
accelerator switch turns off.
Replace the bracket assembly and/or  Go to Step 18 
7 accelerator switch.
Is the action complete ?
1. Inspect the accelerator switch circuit Normal Go to Step 10 Go to Step 9
and connections (refer to the
schematic). Check for loose and/or
damaged connectors, open wiring,
and corroded terminals.
8 2. Check the harness for open wires,
VB/GND shorting, and layer
shorting.
If there are no abnormal conditions,
once again check the accelerator switch
harness.
Repair the fascia harness circuits.  Go to Step 18 
9
Is the action complete ?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-157

DTC 242 Accelerator position switch on error (Cont'd)

Step Action Value(s) Yes No
1. Clear the memory. Ÿ Existing malfunction Go to Step 11 Verify repair
2. Starter switch ON (do not start the Ÿ Previous malfunction
engine).
10
3. Fully depress the accelerator pedal.
4. Use the TECH 2 to confirm DTC
242.
Replace the engine control unit (ECU)  Go to Step 18 
11
Is the action complete ?
1. Inspect the accelerator switch circuit Normal Go to Step 14 Go to Step 13
and connections (refer to the
schematic). Check for loose and/or
damaged connectors, open wiring,
and corroded terminals.
12 2. Check the harness for open wires,
VB/GND shorting, and layer
shorting.
If there are no abnormal conditions,
once again check the accelerator switch
harness.
Repair the fascia harness circuits.  Go to Step 18 
13
Is the action complete ?
1. Remove the accelerator switch from Correct resistance values Go to Step 16 Go to Step 15
the assembly bracket. Ÿ Idle position (pressure on
2. Set the circuit tester to the rod) = less than 0.5
14
resistance display. Ÿ Full-open position (no
3. Measure the accelerator switch pressure on rod) = 
resistance.
Replace the bracket assembly and/or  Go to Step 18 
accelerator switch.
When the accelerator switch is
15
replaced, bracket and switch adjustment
is required. Perform bracket adjustment
first.
Use the TECH 2. Correct accelerator sensor Go to Step 18 Go to Step 17
1. Check the accelerator switch action. voltage = 0.7~1.35 volts
2. Make sure that the control unit is
properly installed.
16
3. Slowly depress the accelerator
pedal. Measure the accelerator
sensor voltage at the instant the
accelerator switch turns off.
Replace the bracket assembly and/or  Go to Step 18 
17
accelerator switch.
1. Clear the memory. Ÿ Existing malfunction Go to Step 1 Verify repair
2. Starter switch ON (do not start the Ÿ Previous malfunction
engine).
18
3. Fully depress the accelerator pedal.
4. Use the TECH 2 to confirm DTC
242.
6E-158 EMISSION AND ELECTRICAL DIAGNOSIS

Accelerator switch external appearance,

terminal nomenclature, and resistance values

1. Accelerator switch external appearance

2. Accelerator pedal external appearance

3. Resistance values

Accelerator pedal and

Connector Measuring points Resistance ()
accelerator switch rod position
Idle position (Pressure on rod) Less than 0.5
S-type Terminal 1 ßàTerminal 2 Full-open position (No pressure on
White rod)

2 terminals Terminal 1 ßà Body

Terminal 2 ßà Body
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-159

DTC-25 VEHICLE SPEED SENSOR ERROR

Vehicle speed sensor circuit

6E-160 EMISSION AND ELECTRICAL DIAGNOSIS

Circuit description
The vehicle speed sensor monitors the vehicle speed.
The sensor is installed to the transmission output shaft.
The output signal is sent to the vehicle speed sensor
control unit where it is converted into pulses. These
pulses are sent to the engine control unit (ECU). The
ECU calculates the pulse width to determine vehicle
speed.
Vehicle speed sensor malfunction effects
· No Power-Take-Off (PTO) acceleration
· Poor fuel economy
Diagnostic conditions
If the ECU detects a voltage of less than 0.5 volts (SIG
open or short to ground) for 1 second, it will declare an
vehicle speed sensor malfunction
(DTC 25).
Possible causes of vehicle speed sensor
malfunction
1. Loose connections
· Between ECU and vehicle speed sensor control
unit
· Between fascia harness and vehicle speed sensor
control unit
· Between fascia harness and frame harness
· Between frame harness and sensor
2. Accelerator position sensor power supply or
SIG/GND circuit open or shorted
· Fascia harness problem
· Installation harness problem
3. Sensor damage (Harness or internal circuitry)
4. Vehicle speed sensor control unit malfunction
5. ECU malfunction
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-161

DTC 25 Vehicle speed sensor error

Step Action Result Yes No
Use the TECH 2 to confirm DTC 25. Ÿ Existing Go to Step 2 Go to Step 3
malfunction: 25 Existing Previous
1
Ÿ Vehicle speed malfunction malfunction
sensor error
1. Connect the TECH 2.  Go to Step 3 Go to Step 4
2. Set the TECH 2 to show engine speed
sensor data (engine mode display).
2 3. Drive the vehicle at a speed of more than 5
kilometers per hour.
4. Check that vehicle speed sensor data is
present.
1. Inspect the vehicle speed sensor circuit and Normal Go to Step 5 Go to Step 4
connections (refer to the schematic). Check
for loose and/or damaged connectors, open
wiring, and corroded terminals.
3
2. Check the harness for open wires, VB/GND
shorting, and layer shorting.
If there are no abnormal conditions, once again
check the vehicle speed sensor harness.
Repair any sensor circuit damage.  Go to Step 22 
4
Is the action complete ?
Check that the speedometer gives an accurate  Go to Step 16 Go to Step 6
5
indication of vehicle speed.
1. Starter switch ON. Battery voltage (28 Go to Step 7 Go to Step 10
2. Set the circuit tester to the voltmeter volts)
6 position.
3. Use the circuit tester to measure the vehicle
speed sensor power supply voltage.
1. Starter switch ON. 1~3 volts or 12~15 Go to Step 9 Go to Step 8
2. Set the circuit tester to the voltmeter volts when the
7 position. vehicle is at rest
3. Use the circuit tester to measure the vehicle
speed sensor output voltage.
Replace the vehicle speed sensor.  Go to Step 21 
8
Is the action complete ?
Use a circuit tester to measure the speed sensor 1~3 volts or 12~15 Go to Step 16 Go to Step 10
circuit output voltage across the vehicle speed volts when the
9
sensor control unit connector (harness and vehicle is at rest
sensor).
Measure the speed sensor circuit resistance Ÿ Between SIG Go to Step 11 Go to Step 12
between the sensor, the frame harness, and the and GRD = (manual
transmission harness. Note whether the vehicle 9~11 kΩ transmission)
10 is equipped with a manual transmission. Ÿ Between or Step 13
power supply (automatic
and ground = 7 transmission)
M~
Repair any sensor circuit damage around the   
11
fascia harness.
Repair any sensor circuit damage around the   
12
frame harness.
6E-162 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 25 Vehicle speed sensor error (Cont'd)

Step Action Value(s) Yes No
Measure the resistance between the Ÿ Between SIG Go to Step 15 Go to Step 14
transmission harness, the chassis, and the and GRD =
vehicle speed sensor. Note whether the vehicle 9~11 kΩ
13 is equipped with a manual transmission. Ÿ Between
power supply
and ground = 7
M~
Repair any sensor circuit damage around the  Go to Step 15 
14 transmission harness.
Is the action complete ?
1. Clear the memory. Ÿ No existing Go to Step 1 Verify repair
2. Use the TECH 2 to confirm DTC 25 malfunction
15
appearance. Ÿ Previous
malfunction
1. S switch ON. 1~3 volts Go to Step 22 Go to Step 17
2. Set the circuit tester to the voltmeter
position.
16 3. Use the circuit tester to measure the vehicle
speed sensor output voltage between the
vehicle harness and the vehicle speed
sensor control unit.
1. Starter switch ON. 1~3 volts Go to Step 18 Go to Step 19
2. Set the circuit tester to the voltmeter
17 position.
3. Use the circuit tester to measure the vehicle
speed sensor control unit output.
Repair any sensor circuit damage around the  Go to Step 22 
18 fascia harness.
Is the action complete ?
Replace the vehicle speed sensor control unit.  Go to Step 22 
19
Is the action complete ?
1. Clear the memory. Ÿ Existing Go to Step 21 Verify repair
2. Use the TECH 2 to confirm DTC 25 malfunction
20
appearance. Ÿ Previous
malfunction
Replace the Engine Control Unit (ECU).  Go to Step 22 
21
Is the action complete ?
1. Clear the memory. Ÿ Existing Go to Step 1 Verify repair
2. Use the TECH 2 to confirm DTC 25 malfunction
22
appearance. Ÿ Previous
malfunction
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-163

Vehicle speed sensor external appearance, terminal nomenclature, and output voltage
1. External appearance

2. Terminal nomenclature

Terminal No. Signal Wire color/diameter

1 GND B/0.5
2 Vehicle speed SIG W/0.5
3 Vehicle speed sensor power supply Y/0.5

3. Output voltage (Sensor connected to engine control unit (ECU) through the vehicle speed sensor control unit)

Accelerator pedal
Measuring points Output voltage Remarks
position
Terminal 1
ßà  Battery voltage (VB) 24~29 volts (Reference)
Terminal 3

Vehicle stopped (No

090 II
transmission shaft 1~3 or 12~15 
connector
rotation)
Gray Terminal 2
3 terminals ßà To test output voltage,
Terminal 1 Vehicle moving disconnect the vehicle speed
(Transmission shaft 1~3 changing to 12~15 sensor from the transmission
rotation) and rotate the transmission
shaft by hand.

4. Confirming output from the rotating shaft

Slowly rotate the shaft. The vehicle speed sensor output should shift voltage (high to low or low to high) at 7.2
degree intervals (25 pulses for each rotation).

Note: Install the vehicle speed sensor to the transmission and tighten the nuts to the specified torque. Do not apply
too much torque – the sensor will be damaged.
6E-164 EMISSION AND ELECTRICAL DIAGNOSIS

Vehicle speed sensor control unit external appearance, terminal nomenclature, and output
voltage
1. External appearance

2. Terminal nomenclature
Terminal No. Signal Wire color/diameter
1 8-pulse signal P/0.5
2 25-pulse signal PL/0.5
3 Vehicle speed sensor power supply Y/0.5
4 Power supply (VB) Y/0.5
5  
6  
7  
8  
9  
10 Vehicle speed sensor signal input W/0.5
11  
12 Ground B/0.5
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-165

3. Output voltage (Vehicle speed sensor control unit connected to engine control unit (ECU))
Vehicle
Measuring points Output voltage Remarks
condition
Terminal 4
ßà  Battery voltage (VB) 24~29 volts (Reference)
Terminal 12
Terminal 3
ßà  Battery voltage (VB) 24~29 volts (Reference)
Terminal 12
Stationary
(No shaft 0~1.5 volts
rotation)
Terminal 1
A-type Pulse signal
ßà
connector Terminal 12
Moving Ÿ Low level = 0~1.5 volts
White (Shaft Ÿ High level = (VB)~(VB-5)
12 terminals rotation) Ÿ 5,096 pulses per minute at An oscilloscope or similar
60 kilometers per hour wave-measuring instrument
Stationary is required to measure the
(No shaft 0~1.5 volts output voltage
rotation)
Terminal 2
Pulse signal
ßà
Terminal 12
Moving Ÿ Low level = 0~3.0 volts
(Shaft Ÿ High level = 12~15 volts
rotation) Ÿ 15,925 pulses per minute
at 60 kilometers per hour
6E-166 EMISSION AND ELECTRICAL DIAGNOSIS

DTC-29 PRESTROKE SERVO SYSTEM ERROR

Pre-stroke sensor and pre-stroke actuator circuit
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-167

Circuit description Possible causes of pre-stroke sensor

malfunction
The pre-stroke sensor and actuator are built-in to the
injection pump. 1. Loose connections
The pre-stroke sensor detects the actual pre-stroke · Between ECU and governor harness
position and sends this data to the engine control unit · Between governor harness and sensor
(ECU). The ECU sends target pre-stroke position data 2. Pre-stroke actuator circuits (+ or -) open
to the actuator. The actuator adjusts the pre-stroke · Governor harness problem
position to the target value. · Injection pump harness problem
Actuator operation requires both a power supply (pre- 3. Pre-stroke actuator positive circuit shorted to ground
stroke actuator positive side) and a ground (pre-stroke or body
actuator negative side). These circuits are connected · Governor harness problem
to the ECU. · Injection pump harness problem
4. Injection pump damage
Pre-stroke sensor malfunction effects · Harness or internal circuitry
· Black or white exhaust emissions · Sluggish control rod movement due to corrosion
· Power loss or dirt
· Poor engine aspiration 5. Clogged injection nozzles
This problem may be indicated by either DTC 29 (pre-
Diagnostic conditions
stroke sensor) or DTC 11 (governor).
If the difference between the actual pre-stroke position 6. ECU malfunction
and the target pre-stroke position is more than 0.6
millimeters for 20 seconds, the ECU will declare a pre-
stroke sensor malfunction (DTC 29).
6E-168 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 29 Prestroke servo system error

Step Action Result Yes No
Ÿ Existing malfunction Go to Step 2 Go to Step 4
Use the TECH 2 to determine the
1
existence of other DTCs.
Ÿ Previous malfunction: 11 DTC 11 DTC 29 only
or 29
Inspect the injection nozzles for Clogged nozzles Go to Step 3 Go to Step 4
2
clogging.
Replace the injection nozzles.  Go to Step 15 
3
Is the action complete ?
Ÿ Between MEASURE and Go to Step 8 Go to Step 5
MIDDLE = 5.5~9.1
Ÿ Between MEASURE and
REFERENCE = 11~15.2

Ÿ Between MIDDLE and
REFERENCE = 5.5~9.1
Use a circuit tester to measure the 
resistance of the pre-stroke sensor and Ÿ Between the positive and
4
actuator circuit between the vehicle negative sides of the
harness, sensor, and actuator. actuator = 2.45~5.95
Ÿ Between all of the above
points where direction is
not specified = 
Ÿ Between each terminal
and the shield = 
Ÿ Between each terminal
and the body = 
Ÿ Between terminal 6 Go to Step 7 Go to Step 6
(MEASURE) and terminal
5 (MIDDLE) = 5.5~9.1
Ÿ Between terminal 6
(MEASURE) and terminal
4 (REFERENCE) =
11~12.2
Ÿ Between terminal 5
(MIDDLE) and terminal 4
(REFERENCE) = 5.5~6.1
Use a circuit tester to measure the  Between terminal 2
resistance of the pre-stroke sensor and (positive side of the
5
actuator circuit (inside the injection actuator) and terminal 1
pump). (negative side of the
actuator) = 2.45~2.95
Ÿ Between all of the above
points where direction is
not specified (terminals
1~6) = 
Ÿ Between each terminal
and terminal 3 (shield) =

Ÿ Between each terminal
and the body = 
Replace the injection pump.  Go to Step 15 
6
Is the action complete ?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-169

DTC 29 Prestroke servo system error (Cont'd)

Step Action Result Yes No
Replace the governor harness and/or  Go to Step 15 
7 repair damaged circuit areas.
Is the action complete ?
1. Start the engine. Normal operation and Go to Step 11 Go to Step 9
2. Connect the TECH 2 and set it to response (Gap is more than
8 the engine data display. 0.6 mm for an instant before
3. Increase engine speed to falling to less than 0.6 mm)
800~2,400 rpm.
4. Confirm pre-stroke response.
Normal operation and Go to Step 15 Go to Step 10
1. Replace the injection pump. response (Gap is more than
9
2. Repeat Step 8. 0.6 mm for an instant before
falling to less than 0.6 mm)
10
Replace the engine control unit (ECU).  Go to Step 15 
Is the action complete ?
1. Inspect the pre-stroke sensor circuit Normal Go to Step 13 Go to Step 12
and connections (refer to the
schematic). Check for loose and/or
damaged connectors, open wiring,
and corroded terminals.
11 2. Check the harness for open wires,
VB/GND shorting, and layer
shorting.
If there are no abnormal conditions,
once again check the pre-stroke sensor
harness.
Replace the governor harness and/or  Go to Step 15 
12 repair damaged circuit areas.
Is the action complete ?
1. Start the engine and allow it to idle. Normal (No variation) Go to Step 15 Go to Step 14
2. Check the moving parts of the
13 governor harness (torsion bar, etc.)
for looseness and vibration.
3. Use the TECH 2 to check for pre-
stroke variation.
Replace the governor harness and/or  Go to Step 15 
14 repair damaged circuit areas.
Is the action complete ?
1. Clear the memory. Normal operation and Verify repair Go to Step 1
2. Start the engine. response (Gap is more than
3. Connect the TECH 2 and set it to 0.6 mm for an instant before
15 the engine data display. falling to less than 0.6 mm)
4. Increase engine speed to
800~2,400 rpm.
5. Confirm pre-stroke response.
6E-170 EMISSION AND ELECTRICAL DIAGNOSIS

Pre-stroke sensor and pre-stroke actuator external appearance, terminal nomenclature, and
resistance values
1. External appearance

2. Terminal nomenclature

Connector Terminal No. Signal Wire color/diameter

1 Pre-stroke actuator (Negative side) LB/1.25

2 Pre-stroke actuator (Positive side) LW/1.25

SWP 3 Pre-stroke sensor (Shield) GY/0.5

6 terminals
Gray 4 Pre-stroke sensor (REFERENCE) B/0.5

5 Pre-stroke sensor (MIDDLE) W/0.5

6 Pre-stroke sensor (MEASURE) R/0.5

3. Resistance values

Connector Measuring points Resistance () Remarks

Terminal 6 ßà Terminal 5 5.5~6.1 Between MEASURE and MIDDLE
Terminal 6 ßà Terminal 4 11~12.2 Between MEASURE and REFERENCE
Terminal 6 ßà Terminal 3  Between MEASURE and shield
Terminal 6 ßà Body  Between MEASURE and body
Terminal 5 ßà Terminal 4 5.5~6.1 Between MIDDLE and REFERENCE
Terminal 5 ßà Terminal 3  Between MIDDLE and shield
Terminal 5 ßà Body  Between MIDDLE and body
SWP
Terminal 4 ßà Terminal 3  Between REFERENCE and shield
6 terminals
Terminal 4 ßà Body  Between REFERENCE and body
Gray
Between actuator (positive side) and
Terminal 2 ßà Terminal 1 2.45~2.95 actuator (negative side)
Terminal 2 ßà Body  Between actuator (positive side) and body
Between actuator (negative side) and
Terminal 1 ßà Body 
body
Excluding 6ßà5, 6ßà4, 5ßà4, and
Between all terminals 
6ßà5

Note: Resistance values vary with changes in engine temperature.

 EMISSION AND ELECTRICAL DIAGNOSIS 6E-171

Checking the pre-stroke response and variation using TECH 2

1. General information
Connect the TECH 2 and set it to the data display.
2. Procedure
 Start the engine.
 The TECH 2 ON.
 Select FO: DIAGNOSIS and press ENTER.
 Select the model year.

 Select the vehicle type.

 Select FO: ENGINE and press ENTER.
 Select 6WF1 and press ENTER.
 Select the data display and press ENTER.
 Display pre-stroke data using the up-and-down
arrow keys.
 Check the pre-stroke response and variation.
 The TECH 2 OFF.
 Stop the engine and move the starter switch
OFF.
3. Pre-stroke display
· Units are in millimeters.
· If the value is large, it is displayed at the lag angle
side.
· If the value is small, it is displayed at the advance
angle side.
Display content changes with engine speed.

Engine speed (rpm) Display content

Less than 800 Actual pre-stroke position
Difference between target position and actual position (lag angle is negative and
800~2,400
advance angle is positive). Pre-stroke is –0.14 mm.
More than 2,400 Actual pre-stroke position
6E-172 EMISSION AND ELECTRICAL DIAGNOSIS

4. Pre-stroke response (Troubleshooting steps 8, 9, and 15)

Refer to the illustrations below when checking pre-stroke response.

5. Pre-stroke variation (Troubleshooting step 14)

Refer to the illustrations below when checking pre-stroke variation.

 EMISSION AND ELECTRICAL DIAGNOSIS 6E-173

DTC-291 PRE-STROKE SENSOR ERROR

Pre-stroke sensor and pre-stroke actuator circuit (Built-in to the injection pump)
6E-174 EMISSION AND ELECTRICAL DIAGNOSIS

Circuit description
The pre-stroke sensor is built-in to the injection pump.
The sensor monitors pre-stroke position.
The sensor has 3 signal circuits (MIDDLE, MEASURE,
and REFERENCE).
The engine control unit (ECU) sends an MEASURE
signal (sine wave) to the pre-stroke sensor. The sensor
returns an MIDDLE signal to the ECU. The ECU then
sends an additional MEASURE signal to the sensor to
stabilize any oscillation in the MIDDLE signal. In this
way, the pre-stroke position is determined.
The REFERENCE signal acts as a standard against
which MEASURE and MIDDLE signal oscillation are
compared.
Pre-stroke sensor malfunction effects
· Black or white exhaust emissions
· Power loss
· Poor engine aspiration
· White exhaust smoke à poor engine aspiration à
normal operation cycling approximately every 2
seconds
Diagnostic conditions
If the ECU senses a value of more than 6.05 mm or
less than 1.11 mm for 2 seconds, it declares a pre-
stroke sensor malfunction (DTC 291).
Possible causes of pre-stroke sensor
malfunction
1. Loose connections
· Between ECU and governor harness
· Between governor harness and sensor
2. Sensor circuit (MIDDLE, MEASURE, and/or
REFERENCE) open or shorted
· Governor/vehicle harness
· Injection pump harness
3. Pre-stroke positive side actuator circuits shorted to
ground or body (White exhaust smoke à poor
engine aspiration à normal operation cycling
approximately every 2 seconds)
· Governor/vehicle harness problem
· Injection pump harness problem
4. Injection pump damage (Harness or internal
circuitry)
5. ECU malfunction
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-175

DTC 291 Pre-stroke sensor error

Step Action Result Yes No
Ÿ Existing malfunction: 291 Go to Step 2 Go to Step 11
1 Use the TECH 2 to confirm DTC 291. Ÿ Pre-stroke sensor error Existing Previous
malfunction malfunction
Ÿ Between MEASURE and Go to Step 6 Go to Step 3
MIDDLE = 5.5~9.1
Ÿ Between MEASURE and
REFERENCE = 11~15.2

Ÿ Between MIDDLE and
REFERENCE = 5.5~9.1
Use a circuit tester to measure the 
resistance of the pre-stroke sensor and Ÿ Between the positive and
2
actuator circuit between the vehicle negative sides of the
harness, sensor, and actuator. actuator = 2.45~5.95
Ÿ Between all of the above
points where direction is
not specified = 
Ÿ Between each terminal
and the shield = 
Ÿ Between terminals 6 and
7 and the body = 
Ÿ Between terminal 6 Go to Step 5 Go to Step 4
(MEASURE) and terminal
5 (MIDDLE) = 5.5~9.1
Ÿ Between terminal 6
(MEASURE) and terminal
4 (REFERENCE) =
11~12.2
Ÿ Between terminal 5
(MIDDLE) and terminal 4
(REFERENCE) = 5.5~6.1

Use a circuit tester to measure the
Ÿ Between terminal 2
resistance of the pre-stroke sensor and
3 (positive side of the
actuator circuit (inside the injection
actuator) and terminal 1
pump).
(negative side of the
actuator) = 2.45~2.95
Ÿ Between all of the above
points where direction is
not specified (terminals
1~6) = 
Ÿ Between each terminal
and terminal 3 (shield) =

Ÿ Between each terminal
and the body = 
Replace the injection pump.  Go to Step 15 
4
Is the action complete ?
Replace the governor harness and/or  Go to Step 15 
5 repair damaged circuit areas.
Is the action complete ?
6E-176 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 291 Pre-stroke sensor error (Cont'd)

Step Action Value(s) Yes No
1. Inspect the pre-stroke sensor Normal Go to Step 8 Go to Step 7
circuit and connections (refer to the
schematic). Check for loose and/or
damaged connectors, open wiring,
and corroded terminals.
6 2. Check the harness for open wires,
VB/GND shorting, and layer
shorting.
If there are no abnormal conditions,
once again check the pre-stroke sensor
harness.
Replace the governor harness and/or  Go to Step 15 
7 repair damaged circuit areas.
Is the action complete ?
8
Ÿ Existing malfunction Go to Step 9 Verify repair
Use the TECH 2 to confirm DTC 291.
Ÿ Previous malfunction
1. Replace the engine control unit Ÿ Existing malfunction Go to Step 10 Verify repair
(ECU). Ÿ Previous malfunction
9 2. Clear the memory.
3. Use the TECH 2 to confirm DTC
291.
10
Replace the injection pump.  Go to Step 15 
Is the action complete ?
Ÿ Between terminal 6 Go to Step 13 Go to Step 12
(MEASURE) and terminal
5 (MIDDLE) = 5.5~9.1
Ÿ Between terminal 6
(MEASURE) and terminal
4 (REFERENCE) =
11~12.2
Ÿ Between terminal 5
(MIDDLE) and terminal 4
(REFERENCE) = 5.5~6.1

Use a circuit tester to measure the
Ÿ Between terminal 2
resistance of the pre-stroke sensor and
11 (positive side of the
actuator circuit (inside the injection
actuator) and terminal 1
pump).
(negative side of the
actuator) = 2.45~2.95
Ÿ Between all of the above
points where direction is
not specified (terminals
1~6) = 
Ÿ Between each terminal
and terminal 3 (shield) =

Ÿ Between each terminal
and the body = 
12
Replace the injection pump.  Go to Step 15 
Is the action complete ?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-177

DTC 291 Pre-stroke sensor error (Cont'd)

Step Action Value(s) Yes No
1. Inspect the pre-stroke sensor Normal Go to Step 15 Go to Step 14
circuit and connections (refer to the
schematic). Check for loose and/or
damaged connectors, open wiring,
and corroded terminals.
13 2. Check the harness for open wires,
VB/GND shorting, and layer
shorting.
If there are no abnormal conditions,
once again check the pre-stroke sensor
harness.
Replace the governor harness and/or  Go to Step 15 
14 repair damaged circuit areas.
Is the action complete ?
1. Clear the memory. Ÿ Existing malfunction Go to Step 1 Verify repair
15
2. Use the TECH 2 to confirm DTC Ÿ Previous malfunction
291.
Was a probrem found ?
6E-178 EMISSION AND ELECTRICAL DIAGNOSIS

Pre-stroke sensor and pre-stroke actuator external appearance, terminal nomenclature, and
resistance values

1. External appearance

2. Terminal nomenclature

Connector Terminal No. Signal Wire color/diameter

1 Pre-stroke actuator (Negative side) LB/1.25

2 Pre-stroke actuator (Positive side) LW/1.25

SWP 3 Pre-stroke sensor (Shield) GY/0.5

6 terminals
Gray 4 Pre-stroke sensor (REFERENCE) B/0.5

5 Pre-stroke sensor (MIDDLE) W/0.5

6 Pre-stroke sensor (MEASURE) R/0.5

3. Resistance values

Connector Measuring points
)

Resistance (
Remarks
Terminal 6 ßà Terminal 5 5.5~6.1 Between MEASURE and MIDDLE
Terminal 6 ßà Terminal 4 11~12.2 Between MEASURE and REFERENCE
Terminal 6 ßà Terminal 3  Between MEASURE and shield
Terminal 6 ßà Body  Between MEASURE and body
Terminal 5 ßà Terminal 4 5.5~6.1 Between MIDDLE and REFERENCE
Terminal 5 ßà Terminal 3  Between MIDDLE and shield
Terminal 5 ßà Body  Between MIDDLE and body
SWP
Terminal 4 ßà Terminal 3  Between REFERENCE and shield
6 terminals
Terminal 4 ßà Body  Between REFERENCE and body
Gray
Between actuator (positive side) and
Terminal 2 ßà Terminal 1 2.45~2.95 actuator (negative side)
Terminal 2 ßà Body  Between actuator (positive side) and body
Between actuator (negative side) and
Terminal 1 ßà Body 
body
 Excluding 6ßà5, 6ßà4, 5ßà4, and
Between all terminals
6ßà5

Note: Resistance values vary with changes in engine temperature.

 EMISSION AND ELECTRICAL DIAGNOSIS 6E-179

DTC-292 PRE-STROKE LEARNING ERROR

Pre-stroke sensor and pre-stroke actuator circuit (Built-in to the injection pump)
6E-180 EMISSION AND ELECTRICAL DIAGNOSIS

Circuit description
The pre-stroke sensor and actuator are built-in to the
injection pump.
The pre-stroke sensor detects the actual pre-stroke
position and sends this data to the engine control unit
(ECU). The ECU sends target pre-stroke position data
to the actuator. The actuator adjusts the pre-stroke
position to the target value.
To ensure precise sensing and control of the pre-
stroke position, the position initially sensed by the pre-
stroke sensor when power is first delivered to the
sensor (1-time only when the starter switch is moved
from the OFF position to the ON position) is learned.
Pre-stroke sensor malfunction effects
· Black or white exhaust emissions
· Power loss
· Poor engine aspiration
Diagnostic conditions
When power is first delivered to the sensor (ignition
switch moved from the OFF position to the ON
position), a reading of more than 6.05 mm or less than
1.11 mm causes the ECU to declare a pre-stroke
learning malfunction (DTC 292).
Possible causes of pre-stroke sensor
malfunction
1. Loose connections
· Between ECU and governor harness
· Between governor harness and sensor
2. Pre-stroke positive side actuator circuits shorted to
ground or body
· Governor/vehicle harness problem
· Injection pump harness problem
3. Injection pump damage
· Harness or internal circuitry
· Sluggish control rod movement due to corrosion
or dirt
4. ECU malfunction
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-181

DTC 292 Pre-stroke learning error

Step Action Result Yes No
Ÿ Existing malfunction: 292 Go to Step 2 Go to Step 11
1 Use the TECH 2 to confirm DTC 292. Ÿ Pre-stroke learning error Existing Previous
malfunction malfunction
Ÿ Between MEAS and MDL Go to Step 6 Go to Step 3
= 5.5~9.1
Ÿ Between MEAS and REF
= 11~15.2
Ÿ Between MDL and REF =
5.5~9.1
Use a circuit tester to measure the Ÿ Between the positive and
resistance of the pre-stroke sensor and negative sides of the
2
actuator circuit between the vehicle actuator = 2.45~5.95
harness, sensor, and actuator. Ÿ Between all of the above
points where direction is
not specified = 
Ÿ Between each terminal
and the shield = 
Ÿ Between terminals 6 and
7 and the body = 
Ÿ Between terminal 6 Go to Step 5 Go to Step 4
(MEAS) and terminal 5
(MDL) = 5.5~9.1
Ÿ Between terminal 6
(MEAS) and terminal 4
(REF) = 11~12.2
Ÿ Between terminal 5
(MDL) and terminal 4
(REF) = 5.5~6.1
Ÿ Between terminal 2
Use a circuit tester to measure the
(positive side of the
resistance of the pre-stroke sensor and
3 actuator) and terminal 1
actuator circuit (inside the injection
(negative side of the
pump).
actuator) = 2.45~2.95
Ÿ Between all of the above
points where direction is
not specified (terminals
1~6) = 
Ÿ Between each terminal
and terminal 3 (shield) =

Ÿ Between each terminal
and the body = 
Replace the injection pump.  Go to Step 15 
4
Is the action complete ?
Replace the governor harness and/or  Go to Step 15 
5 repair damaged circuit areas.
Is the action complete ?
6E-182 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 292 Pre-stroke learning error (Cont'd)

Step Action Value(s) Yes No
1. Inspect the pre-stroke sensor circuit Normal Go to Step 8 Go to Step 7
and connections (refer to the
schematic). Check for loose and/or
damaged connectors, open wiring,
and corroded terminals.
6 2. Check the harness for open wires,
VB/GND shorting, and layer
shorting.
If there are no abnormal conditions,
once again check the pre-stroke sensor
harness.
Replace the governor harness and/or  Go to Step 15 
7 repair damaged circuit areas.
Is the action complete ?
1. Clear the memory. Ÿ Existing malfunction Go to Step 9 Verify repair
8 2. Use the TECH 2 to confirm DTC Ÿ Previous malfunction
292.
1. Replace the Engine Control Unit Ÿ Existing malfunction Go to Step 10 Verify repair
(ECU). Ÿ Previous malfunction
9 2. Clear the memory.
3. Use the TECH 2 to confirm DTC
292.
10
Replace the engine control unit (ECU).  Go to Step 15 
Is the action complete ?
Ÿ Between terminal 6 Go to Step 13 Go to Step 12
(MEASURE) and terminal
5 (MIDDLE) = 5.5~9.1
Ÿ Between terminal 6
(MEASURE) and terminal
4 (REFERENCE) =
11~12.2
Ÿ Between terminal 5
(MIDDLE) and terminal 4
(REFERENCE) = 5.5~6.1

Use a circuit tester to measure the
Ÿ Between terminal 2
resistance of the pre-stroke sensor and
11 (positive side of the
actuator circuit (inside the injection
actuator) and terminal 1
pump).
(negative side of the
actuator) = 2.45~2.95
Ÿ Between all of the above
points where direction is
not specified (terminals
1~6) = 
Ÿ Between each terminal
and terminal 3 (shield) =

Ÿ Between each terminal
and the body = 
12
Replace the injection pump.  Go to Step 15 
Is the action complete ?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-183

DTC 292 Pre-stroke learning error (Cont'd)

Step Action Value(s) Yes No
1. Inspect the pre-stroke sensor Normal Go to Step 15 Go to Step 14
circuit and connections (refer to the
schematic). Check for loose and/or
damaged connectors, open wiring,
and corroded terminals.
13 2. Check the harness for open wires,
VB/GND shorting, and layer
shorting.
If there are no abnormal conditions,
once again check the pre-stroke sensor
harness.
Replace the governor harness and/or  Go to Step 15 
14 repair damaged circuit areas.
Is the action complete ?
1. Clear the memory. Ÿ Existing malfunction Go to Step 1 Verify repair
15 2. Use the TECH 2 to confirm DTC Ÿ Previous malfunction
292.
6E-184 EMISSION AND ELECTRICAL DIAGNOSIS

Pre-stroke sensor and pre-stroke actuator external appearance, terminal nomenclature, and
resistance values

1. External appearance

2. Terminal nomenclature

Connector Terminal No. Signal Wire color/diameter

1 Pre-stroke actuator (Negative side) LB/1.25

2 Pre-stroke actuator (Positive side) LW/1.25

SWP 3 Pre-stroke sensor (Shield) GY/0.5

6 terminals
Gray 4 Pre-stroke sensor (REFERENCE) B/0.5

5 Pre-stroke sensor (MIDDLE) W/0.5

6 Pre-stroke sensor (MEASURE) R/0.5

3. Resistance values

Connector Measuring points
)

Resistance (
Remarks
Terminal 6 ßà Terminal 5 5.5~6.1 Between MEASURE and MIDDLE
Terminal 6 ßà Terminal 4 11~12.2 Between MEASURE and REFERENCE
Terminal 6 ßà Terminal 3  Between MEASURE and shield
Terminal 6 ßà Body  Between MEASURE and body
Terminal 5 ßà Terminal 4 5.5~6.1 Between MIDDLE and REFERENCE
Terminal 5 ßà Terminal 3  Between MIDDLE and shield
Terminal 5 ßà Body  Between MIDDLE and body
SWP
Terminal 4 ßà Terminal 3  Between REFERENCE and shield
6 terminals
Terminal 4 ßà Body  Between REFERENCE and body
Gray
Between actuator (positive side) and
Terminal 2 ßà Terminal 1 2.45~2.95 actuator (negative side)
Terminal 2 ßà Body  Between actuator (positive side) and body
Between actuator (negative side) and
Terminal 1 ßà Body 
body
 Excluding 6ßà5, 6ßà4, 5ßà4, and
Between all terminals
6ßà5,

Note: Resistance values vary with changes in engine temperature.

 EMISSION AND ELECTRICAL DIAGNOSIS 6E-185

DTC-32 BOOST PRESSURE SENSOR ERROR

ECU harness engine and member harness connection connector

SWP 8 pin Gray

Boost pressure sensor connector.

EJ mark ll+ 3 pin Black
6E-186 EMISSION AND ELECTRICAL DIAGNOSIS

Location of diagnosis connector and memory clear connector

 EMISSION AND ELECTRICAL DIAGNOSIS 6E-187

Voltage Inspection Harness

The voltage inspection harness is an extension harness designed to inspect the function of sensors (acceleration
sensor, boost pressure sensor, all-speed acceleration sensor and vehicle speed sensor) which can not be
confirmed by resistance values.
Connect the harness between each sensor and vehicle harness, and measure output voltage using a tester.

For boost To boost pressure

pressure sensor sensor

For To
accelerator accelerator
sensor sensor
For all speed To all speed
accelerator accelerator sensor
sensor and and speed sensor
speed sensor

Tester connector details

6E-188 EMISSION AND ELECTRICAL DIAGNOSIS

Usage of voltage inspection harness

Boost pressure sensor

Accelerator position sensor

All speed accelerator

sensor
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-189

Appearance of boost sensor and connector pin assignment

Boost pressure sensor

Connector pin assignment

Connector No. Signal
1 SIG
2 GND
3 +5V

Measurement of output voltage by using voltage inspection harness

Connect the voltage inspection harness between vehicle harness and boost pressure sensor.
Turn on starter switch, and measure output voltage at the voltage inspection harness connector.

(Reference)
Performance of harness
Engine boost pressure sensor

Boost pressure sensor

Detail of connector for tester

For voltage measurement
3 pin connector (Female)
6E-190 EMISSION AND ELECTRICAL DIAGNOSIS

Output voltage value

Inspection point Output voltage Reference
Voltage 1 ¨ 3 4.95 to 5.05 (V)
inspection (+5V) (GND)
connector 2 ¨ 3 0.8 to 1.2 (V) Atmospheric
3 pin White (SIG) (GND) pressure 760 mmHg
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-191

DTC-32 Boost pressure sensor error

Step Action Yes No
1 1. Starter switch OFF. Go to step 16 Go to step 2
2. Disconnect the boost pressure sensor connector, and
connect voltage inspection harness between boost
pressure sensor and member harness.
3. Starter switch ON.
4. Check output voltage at the measuring connector for
the voltage inspection connector.
* Check at the measuring connector terminals 2 and 3.
5. Is the output voltage in the range of 0.8 to 1.2V when
engine stops?
Mentioned above voltage in condition atmospheric
pressure is 760 mmHg(abs), the value will differ
according to weather condition.
2 1. Starter switch OFF. Go to step 3 Go to step 9
2. Disconnect 104-pin connectorof engine control unit
(ECU).
3. Disconnect boost pressure sensor connector.
4. Check for continuity in boost pressure sensor circuit
(+5V).
* Check at ECU connector terminal 78 and boost
pressure sensor connector terminal 3.
5. Is resistance value 1W or less?
3 1. Check for short circuit in boost pressure sensor circuit Go to step 4 Go to step 10
(+5V).
* Check for short circuit in ECU connector terminal 78
and body.
2. Is resistance value ¥ W?
4 1. Check for continuity in boost pressure sensor circuit Go to step 5 Go to step 11
(SIG).
* Check at ECU connector terminal 90 and boost
pressure sensor connector terminal 1 .
2. Is resistance value 1W or less?
5 1. Check for short circuit in boost pressure sensor circuit Go to step 6 Go to step 12
(SIG).
* Check for short circuit in ECU connector terminal 90
and body.
2. Is reslstance value ¥ W?
6 1. Check for continuity in boost pressure sensor circuit Go to step 7 Go to step 13
(GND).
* Check at ECU connector terminal 125 and boost
pressure sensor connector terminal 2.
2. Is resistance value 1W or less?
7 1. Check for short circuit in boost pressure sensor circuit Go to step 8 Go to step 14
(GND).
* Check for short circuit in ECU connector terminal 101
and body.
2. Is resistance value ¥ W?
6E-192 EMISSION AND ELECTRICAL DIAGNOSIS

DTC-32 Boost pressure sensor error (Cont'd)

Step Action Yes No
8 1. Check for short circuit in boost pressure sensor circuit Go to step 19 Go to step 15
(between each terminal).
* Check for short circuit between each terminal at ECU
connector terminal 78, 90, 101.
2. Is resistance value ¥ W?
9 1. Disconnect connector (8-pin) connecting engine control Repair/replace Repair/replace
unit (ECU) harness engine and member harness. member harness. ECU harness
2. Check for continuity in boost pressure sensor circuit engine.
(+5V).
* Check at ECU harness engine connector terminal 78
and member harness connector (8-pin) terminal 5.
3. Is resistance value 1W or less?
10 1. Disconnect connector (8-pin) connecting ECU harness Repair/replace Repair/replace
engine and member harness. member harness. ECU harness
2. Check for short circuit in boost pressure sensor circuit engine.
(+5V).
* Check for short circuit in ECU connector terminal 78
and body.
3. Is resistance value ¥ W?
11 1. Disconnect connector (8-pin) connecting ECU harness Repair/replace Repair/replace
engine and member harness. member harness. ECU harness
2. Check for continuity in boost pressure sensor circuit engine.
(SIG).
* Check at ECU harness engine connector terminal 90
and member harness connector (8-pin) terminal 6.
3. Is resistance value 1W or less?
12 1. Disconnect connector (8-pin) connecting ECU harness Repair/replace Repair/replace
engine and member harness. member harness. ECU harness
2. Check for short circuit in boost pressure sensor circuit engine.
(SIG).
* Check for short circuit in ECU connector terminal 90
and body.
3. Is resistance value ¥ W?
13 1. Disconnect connector (8-pin) connecting ECU harness Repair/replace Repair/replace
engine and member harness. member harness. ECU harness
2. Check for continuity in boost pressure sensor circuit engine.
(GND).
* Check at ECU harness engine connector terminal
101 and member harness connector (8-pin) terminal
7.
3. Is resistance value 1W or less?
14 1. Disconnect connector (8-pin) connecting ECU harness Repair/replace Repair/replace
engine and member harness. member harness. ECU harness
2. Check for short circuit in boost pressure sensor circuit engine.
(GND).
* Check for short circuit in ECU connector terminal 101
and body.
3. Is resistance value ¥ W?
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-193

DTC-32 Boost pressure sensor error (Cont'd)

Step Action Yes No
15 1. Disconnect connector (8-pin) connecting ECU harness Repair/replace Repair/replace
engine and member harness. member harness. ECU harness
2. Check for short circuit in boost pressure sensor circuit engine.
(between each terminal).
* Check for short circuit between each terminal at ECU
connector terminal 78, 90, 101.
3. Is resistance value ¥ W?
16 1. Starter switch OFF. Go to step 18 Go to step 17
2. Disconnect 104-pin connector of engine control unit
(ECU).
3. Disconnect boost pressure sensor connector.
4. Check for continuity in boost pressure sensor circuit
(SIG).
* Check at ECU connector terminal 90 and boost
pressure sensor connector terminal 1.
5. Is resistance value 1W or less?
17 1. Disconnect connector (8-pin) connecting ECU harness Repair/replace Repair/replace
engine and member harness. member harness. ECU harness
2. Check for continuity in boost pressure sensor circuit engine.
(SIG).
* Check at ECU connector terminal 90 and member
harness connector terminal (8-pin) terminal 6.
3. Is resistance value 1W or less?
18 1. Starter switch OFF. Go to step 19 Go to step 20
2. Disconnect voltage inspection harness and connect
boost pressure sensor connector.
3. Starter switch ON.
4. Start engine.
5. Connect diagnosis connector and read IE Warning lamp
flashing.
6. Is DTC 32 indicated?
19 1. Starter switch OFF. Replace ECU. Go to step 20
2. Replace the boost pressure sensor.
3. Starter switch ON.
4. Start engine.
5. Connect diagnosis connector and read IE Warning lamp
flashing.
6. Is DTC 32 indicated?
20 1. Stop engine. Solved Go back to step 1
2. Make sure that memory clear connector is
disconnected.
3. Starter switch ON.
4. Connect memory clear connector for more than 1
second, and disconnect it.
5. Connect diagnosis connector, and read IE warning lamp
flashing.
6. Is DTC eliminated?
6E-194 EMISSION AND ELECTRICAL DIAGNOSIS

DTC-33 MEMORY CIRCUIT (RAM) ERROR

Circuit description Diagnostic conditions
The central processing unit (CPU) and memory circuits When the power supply turns on, the ECU performs a
(RAM and ROM) are built-in to the ECU. CPU, RAM, system check. If this check is not successfully
and ROM malfunctions are displayed. completed, a malfunction is indicated (DTC 33).
ECU malfunction effects Possible causes of ECU malfunction
· Engine stalls ECU damage
· Engine is difficult to start

Step Action Value(s) Yes No

Go to Step 2 Go to Step 2
Ÿ Existing malfunction: 33
1 Use the TECH 2 to confirm DTC 33. Existing Previous
Ÿ ECU error
malfunction malfunction
Replace the engine control unilt (ECU).
Whenever the DTC 33 appears, there is
2  Go to Step 3 
a possibility of serious internal problems
(even when there is a previous code).
1. Clear the memory. Ÿ Existing malfunction
3 Go to Step 1 Verify repair
2. Use the TECH 2 to confirm DTC 33. Ÿ Previous malfunction
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-195

DTC-413 MAGNETIC VALVE D ERROR

Magnetic valve-D circuit (Includes magnetic valve-E, magnetic valve power supply cut relay, and
magnetic valve ground circuits)
6E-196 EMISSION AND ELECTRICAL DIAGNOSIS

Circuit description
The magnetic valve-D is an exhaust gas recirculation
(EGR) control valve.
Magnetic valve movement forces air cylinder
operation. The air cylinder opens and closes the EGR
valve to control EGR volume.
Power is supplied to the magnetic valve through the
power supply cut relay (suspends power to the
magnetic valve when the valve malfunctions) and the
fuse. One side of the magnetic valve is connected to
the engine control unit (ECU). Current flow during
magnetic valve operation passes thorough the ECU
and is returned to the battery through the magnetic
valve ground.
Magnetic valve malfunction effects
None that are obvious to the vehicle operator
Diagnostic conditions
Diagnostic conditions vary with magnetic valve drive
conditions.
· If the valve is not driven and the ECU detects a
low voltage level for 1.5 seconds (open circuit or
short to ground), the unit declares a magnetic
valve-D malfunction (DTC 413).
· If the valve is driven and the ECU detects a high
voltage level for 1.5 seconds (open ground
circuit), the unit declares a magnetic valve-D
malfunction (DTC 413).
Possible causes of magnetic valve
malfunction
1. Loose connections
· Between ECU and governor harness
· Between governor harness and fascia harness
· Between fascia harness and frame harness
· Between frame harness and cab back member
harness
· Between cab back member harness and each
magnetic valve connector
2. Magnetic valve circuit open or shorted
Governor harness, fascia harness, frame harness,
and/or cab back member harness/vehicle harness
problem
3. Magnetic valve common ground circuit open
Governor harness, fascia harness, and/or frame
harness problem
4. Magnetic valve internal damage
5. ECU malfunction
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-197

DTC 413 Magnetic valve D error

Step Action Result Yes No
Use the TECH 2 to confirm DTC 413 Ÿ Existing malfunction: 413 Go to Step 10 Go to Step 2
1
(magnetic valve-D). Check for the Ÿ Magnetic valve-D error when only when multiple
appearance of other magnetic valve 413 DTC DTC appear
DTC (415). appears
Check the magnetic valve ground Normal Go to Step 4 Go to Step 3
2 connectors for corrosion and looseness.
Refer to the schematic.
3 Repair damaged circuits.  Go to Step 25 
Check the wiring between the ECU Normal Go to Step 10 Go to Step 5
magnetic valve terminal (64-pin) and
4 battery ground (open harness, VB short,
and/or layer short). Refer to the
schematic.
Check the wiring between the magnetic Normal Go to Step 6 Go to Step 7
valve ground circuit and fascia/frame
5 harness (open harness, VB short,
and/or layer short). Refer to the
schematic.
Replace the governor harness and/or  Go to Step 25 
6
repair damaged circuit areas.
Check the magnetic valve ground circuit Normal Go to Step 8 Go to Step 9
on the frame harness (open harness,
7
VB short, and/or layer short). Refer to
the schematic.
8 Repair the fascia harness circuits.  Go to Step 25 
9 Repair the frame harness circuits.  Go to Step 25 
Normal values Go to Step 12 Go to Step 11

Use a circuit tester to check the Ÿ Between magnetic valve

10
magnetic valve resistance. terminals = 27~33
Ÿ Between all terminals
and the body = 
11 Replace the magnetic valve  Go to Step 25 
Check the magnetic valve ground Normal Go to Step 14 Go to Step 13
12 connectors for corrosion and looseness.
Refer to the schematic.
13 Repair damaged circuits.  Go to Step 25 
Check the wiring between the ECU Normal Go to Step 22 Go to Step 15
magnetic valve terminal (64-pin) and
14 battery ground (open harness, VB short,
and/or layer short). Refer to the
schematic.
Check the wiring between the magnetic Normal Go to Step 16 Go to Step 17
valve ground and fascia/frame harness
15
(open harness, VB short, and/or layer
short). Refer to the schematic.
Replace the governor harness and/or  Go to Step 25 
16
repair damaged circuit areas.
6E-198 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 413 Magnetic valve D error (Cont'd)

Step Action Value(s) Yes No
Check the magnetic valve-D circuit and Normal Go to Step 18 Go to Step 19
frame/cab back member harness (open
17
harness, VB short, and/or layer short).
Refer to the schematic.
18 Repair the fascia harness circuits.  Go to Step 25 
Check the magnetic valve-D circuit and Normal Go to Step 20 Go to Step 21
cab back member harness (open
19
harness, VB short, and/or layer short).
Refer to the schematic.
20 Repair the frame harness circuits.  Go to Step 25 
21
Repair the cab back member harness  Go to Step 25 
circuits.
22
Ÿ Existing malfunction Go to Step 24 Go to Step 23
Replace the check control unit.
Ÿ Previous malfunction
23 Replace the engine control unit (ECU).  Go to Step 25 
24 Replace the magnetic valve.  Go to Step 25 
25
1. Clear the memory. Ÿ Existing malfunction Go to Step 1 Verify repair
2. Use the TECH 2 to confirm DTC. Ÿ Previous malfunction
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-199

Magnetic valve external appearance, terminal nomenclature, and resistance values

1. External appearance 2. Terminal nomenclature

Terminal No. Signal

1 Magnetic valve
2

3. Resistance values

Connector Measuring points
)

Resistance (
Remarks
Z-type Terminal 6 ßà Terminal 5 27~33 Between magnetic valve terminals
2 terminals Terminal 1 ßà Body
 Between magnetic valve and body
Black Terminal 2 ßà Body
6E-200 EMISSION AND ELECTRICAL DIAGNOSIS

DTC-444 MAGNETIC VALVE E ERROR

Magnetic valve-E circuit (Includes magnetic valve-D, magnetic valve power supply cut relay, and
magnetic valve ground circuits
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-201

Circuit description
The magnetic valve-E is used to control exhaust gas
recirculation (EGR).
The magnetic valve is installed to one of the three
intake shutter valves. Magnetic valve movement
operates an air cylinder to open and close the intake
shutter valve and regulate EGR volume.
Power is supplied to the magnetic valve through the
power supply cut relay (suspends power to the
magnetic valve when the valve malfunctions) and the
fuse. One side of the magnetic valve is connected to
the engine control unit (ECU). Current flow during
magnetic valve operation passes thorough the ECU
and is returned to the battery through the magnetic
valve ground.
Magnetic valve malfunction effects
Blow-back noise during exhaust braking
Diagnostic conditions
Diagnostic conditions vary with magnetic valve drive
conditions.
• If the valve is not driven and the ECU detects a
low voltage level for 1.5 seconds (open circuit or
short to ground), the unit declares a magnetic
valve-E malfunction (DTC 444).
• If the valve is driven and the ECU detects a high
voltage level for 1.5 seconds (open ground
circuit), the unit declares a magnetic valve-E
malfunction (DTC 444).
Possible causes of magnetic valve
malfunction
1. Loose connections
• Between ECU and governor harness
• Between governor harness and fascia harness
• Between fascia harness and frame harness
• Between frame harness and cab back member
harness
• Between cab back member harness and each
magnetic valve connector
2. Magnetic valve circuit open or shorted
Governor harness, fascia harness, frame harness,
and/or cab back member harness/vehicle harness
problem
3. Magnetic valve common ground circuit open
Governor harness, fascia harness, and/or frame
harness problem
4. Magnetic valve internal damage
5. ECU malfunction
6E-202 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 444 Magnetic valve E error

Step Action Result Yes No
Use the TECH 2 to confirm DTC 444.
Ÿ Existing malfunction: 444 Go to Step 10 Go to Step 2
1 Check for the appearance of other Ÿ Magnetic valve-D error when only when multiple
415 DTC DTC appear
magnetic valve DTC (413).
appears
Check the magnetic valve ground Normal Go to Step 4 Go to Step 3
2 connectors for corrosion and looseness.
Refer to the schematic.
3 Repair damaged circuits. − Go to Step 25 −
Check the wiring between the ECU Normal Go to Step 10 Go to Step 5
magnetic valve terminal (64-pin) and
4 battery ground (open harness, VB short,
and/or layer short). Refer to the
schematic.
Check the wiring between the magnetic Normal Go to Step 6 Go to Step 7
valve ground circuit and fascia/frame
5 harness (open harness, VB short,
and/or layer short). Refer to the
schematic.
Replace the governor harness and/or − Go to Step 25 −
6
repair damaged circuit areas.
Check the magnetic valve ground circuit Normal Go to Step 8 Go to Step 9
on the frame harness (open harness,
7
VB short, and/or layer short). Refer to
the schematic.
8 Repair the fascia harness circuits. − Go to Step 25 −
9 Repair the frame harness circuits. − Go to Step 25 −
Normal values Go to Step 12 Go to Step 11

Use a circuit tester to check the Ÿ Between magnetic valve

10
magnetic valve resistance. terminals = 27~33Ω
Ÿ Between all terminals
and the body = ∞
11 Replace the magnetic valve − Go to Step 25 −
Check the magnetic valve ground Normal Go to Step 14 Go to Step 13
12 connectors for corrosion and looseness.
Refer to the schematic.
13 Repair damaged circuits. − Go to Step 25 −
Check the wiring between the ECU Normal Go to Step 22 Go to Step 15
magnetic valve terminal (64-pin) and
14 battery ground (open harness, VB short,
and/or layer short). Refer to the
schematic.
Check the wiring between the magnetic Normal Go to Step 16 Go to Step 17
valve ground and fascia/frame harness
15
(open harness, VB short, and/or layer
short). Refer to the schematic.
Replace the governor harness and/or − Go to Step 25 −
16
repair damaged circuit areas.
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-203

DTC 444 Magnetic valve E error (Cont'd)

Step Action Value(s) Yes No
Check the magnetic valve-E circuit and Normal Go to Step 18 Go to Step 19
frame/cab back member harness (open
17
harness, VB short, and/or layer short).
Refer to the schematic.
18 Repair the fascia harness circuits. − Go to Step 25 −
Check the magnetic valve-E circuit and Normal Go to Step 20 Go to Step 21
cab back member harness (open
19
harness, VB short, and/or layer short).
Refer to the schematic.
20 Repair the frame harness circuits. − Go to Step 25 −
Repair the cab back member harness − Go to Step 25 −
21
circuits.
22
Ÿ Existing malfunction Go to Step 24 Go to Step 23
Replace the check control unit.
Ÿ Previous malfunction
23 Replace the engine control unit (ECU). − Go to Step 25 −
24 Replace the magnetic valve. − Go to Step 25 −
25
1. Clear the memory. Ÿ Existing malfunction Go to Step 1 Verify repair
2. Use the TECH 2 to confirm DTC. Ÿ Previous malfunction
6E-204 EMISSION AND ELECTRICAL DIAGNOSIS

Magnetic valve external appearance, terminal nomenclature, and resistance values

1. External appearance 2. Terminal nomenclature

Terminal No. Signal

1
Magnetic valve
2

3. Resistance values

Connector Measuring points
)

Resistance (
Remarks
Z-type
2 terminals Terminal 6 ßà Terminal 5 27~33 Between magnetic valve terminals
Black
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-205

DTC-421 MAGNETIC VALVE POWER SUPPLY FUSE BLOWN

Magnetic valve power supply circuit (Includes magnetic valve-E, magnetic valve-D, magnetic
valve power supply cut relay, and magnetic valve ground circuits
6E-206 EMISSION AND ELECTRICAL DIAGNOSIS

Circuit description
Power is supplied to the magnetic valve through the
power supply cut-off relay (suspends power to the
magnetic valve when the valve malfunctions) and the
fuse. One side of the magnetic valve is connected to
the engine control unit (ECU). Current flow during
magnetic valve operation passes thorough the ECU
and is returned to the battery through the magnetic
valve ground.
Magnetic valve power supply malfunction
effects
Blow-back noise during exhaust braking
Diagnostic conditions
When magnetic valves (E, and D) are idle, the ECU
will declare a magnetic valve power supply malfunction
when the valve power supply relay voltage is low (open
circuit or short to ground). Any time the positive side of
all the magnetic valves shows a low voltage (open
circuit or short to ground) for 1 second, the ECU will
declare a magnetic valve power supply malfunction.
The DTC for both malfunctions is 421.
Possible causes of magnetic valve
malfunction
1. Loose connections
· Between magnetic valve cut-off relay parts
· Between fascia harness and frame harness
· Between cab back member harness and each
magnetic valve connector
2. Magnetic valve circuit open or shorted
Governor harness, fascia harness, frame harness,
and/or cab back member harness/vehicle harness
problem
3. Magnetic valve cut-off relay internal damage
4. Blown fuse (No. 19)
5. ECU malfunction
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-207

DTC 421 Magnetic valve power supply blown

Step Action Result Yes No
Ÿ Existing malfunction: 421 Go to Step 15 Go to Step 2
1 Use the TECH 2 to confirm DTC 421. Ÿ Magnetic valve power Previous Existing
supply error malfunction malfunction
Check the fuse (No. 19). Refer to the Normal Go to Step 4 Go to Step 3
2
caution plate.
1. Replace the fuse (be sure to use a Normal Go to Step 19 Go to Step 4
7.5 A fuse).
3 2. Start the engine and make sure that
the fuse does not immediately blow
again.
Normal values Go to Step 6 Go to Step 5
Use a circuit tester to check each of the
Ÿ Between magnetic valve
4 terminals = 27~33
magnetic valve resistances (C, and D).
Ÿ Between all terminals
and the body = 
5 Replace the magnetic valve(s)  Go to Step 19 
Normal values Go to Step 8 Go to Step 7
Ÿ Between terminal 2 and
terminal 4 (coil) =
267~287
Use a circuit tester to check the
6
magnetic valve cut relay resistance.
Ÿ Between terminal 3 and
terminal 5 (NC) = less
than 1
Ÿ Between terminal 1 and
terminal 5 = 
7 Replace the magnetic valve cut relay  Go to Step 19 
Check the conductivity between the Normal Go to Step 14 Go to Step 9
magnetic valve circuits (C, and D) and
the fascia/frame harness and the cab
8
back member harness (open harness,
ground short, and/or layer short). Refer
to the schematic.
Check the conductivity between the Normal Go to Step 10 Go to Step 11
magnetic valve circuits (C, and D) and
the frame harness and cab back
9
member harness (open harness, ground
short, and/or layer short). Refer to the
schematic.
10 Repair the fascia harness circuits.  Go to Step 19 
Check the conductivity between the Normal Go to Step 12 Go to Step 13
magnetic valves (C, and D) and the cab
11 back member harness (open harness,
ground short, and/or layer short). Refer
to the schematic.
12 Repair the frame harness circuits.  Go to Step 19 
Repair the cab back member harness  Go to Step 19 
13
circuits.
Check the magnetic valve power supply Normal Go to Step 16 Go to Step 15
14 connectors for corrosion and looseness.
Refer to the schematic.
15 Repair the circuits.
16 Replace the check control unit.
Ÿ Existing malfunction Go to Step 17 Go to Step 18
Ÿ Previous malfunction
17 Replace the engine control unit (ECU).  Go to Step 19 
6E-208 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 421 Magnetic valve power supply blown (Cont'd)

Step Action Value(s) Yes No
18 Replace the magnetic valve(s)  Go to Step 19 
19
1. Clear the memory. Ÿ Existing malfunction Go to Step 1 Verify repair
2. Use the TECH 2 to confirm DTC. Ÿ Previous malfunction
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-209

Magnetic valve external appearance, terminal nomenclature, and resistance values

1. External appearance 2. Terminal nomenclature

Terminal No. Signal

1
Magnetic valve
2

3. Resistance values

Connector Measuring points
)

Resistance (
Remarks
Z-type Terminal 1 ßà Terminal 2 27~33 Between magnetic valve terminals
2 terminals Terminal 1 ßà Body
 Between magnetic valve and body
Black Terminal 2 ßà Body

Magnetic valve cut relay external appearance, terminal nomenclature, and resistance values

4. External appearance 5. Terminal nomenclature

Terminal No. Signal

1 Output NC (Normal open)
2 Drive coil (Positive)
3 Output NO (Normal close)
4 Drive coil (Negative)
5 Input

6. Resistance values

Terminal name Terminal Nos.
)

Resistance (
Remarks
2ßà4 267~287 Between drive coil terminals
Relay 5ßà3 Less than 1 Between input and output terminals (NC)
5ßà1  Between input and output terminals (NO)
6E-210 EMISSION AND ELECTRICAL DIAGNOSIS

DTC-423 PRESTROKE POWER SUPPLY FUSE BLOWN

Pre-stroke sensor and pre-stroke actuator circuit (Built-in to the injection pump)
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-211

Circuit description
Power is supplied to the pre-stroke actuator through
the pre-stroke power supply cut-off relay (suspends
power to the actuator when the actuator malfunctions)
and the fuse. The actuator drive circuit is built-in to the
engine control unit (ECU). Current to drive the actuator
flows the ECU and returns to the battery through the
pre-stroke ground circuit.
Pre-stroke power supply malfunction effects
· Black or white exhaust emissions
· Power loss
· Poor engine aspiration
Diagnostic conditions
When the ECU senses a low voltage in the pre-stroke
power supply circuit (open or short to ground), it
declares a pre-stroke power supply malfunction (DTC
423).
Possible causes of pre-stroke sensor
malfunction
1. Loose connections
· Between magnetic valve cut-off relay parts
· Between fascia harness and governor harness
2. Pre-stroke power supply circuit shorted to ground or
body
Governor and fascia/vehicle/harness problem
3. Magnetic valve cut-off relay internal damage
4. Blown fuse (No. 20, 45)
5. ECU malfunction
6E-212 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 423 Prestroke power supply fuse blown

Step Action Result Yes No
Ÿ Existing malfunction: 423 Go to Step 10 Go to Step 2
1 Use the TECH 2 to confirm DTC 423. Ÿ Pre-stroke power supply Existing Previous
error malfunction malfunction
Check the fuse (No. 20, No. 45). Refer Normal Go to Step 4 Go to Step 3
2 to the caution plate.
1. Replace the fuse (be sure to use a Normal Go to Step 17 Go to Step 4
15 A fuse).
3 2. Start the engine and make sure that
the fuse does not immediately blow
again.
Normal values Go to Step 6 Go to Step 5

Ÿ Between terminal 2 and

terminal 4 (coil) =
Use a circuit tester to check the pre- 267~287
4
stroke power supply cut-off resistance. Ÿ Between terminal 3 and
terminal 5 (NC) = less
than 1
Ÿ Between terminal 1 and
terminal 5 = 
Replace the pre-stroke power supply  Go to Step 17 
5 cut-off relay.
Check the conductivity between the pre- Normal Go to Step 10 Go to Step 7
stroke power supply circuit and the
6 fascia harness and governor harness
(open harness, ground short, and/or
layer short). Refer to the schematic.
Check the conductivity of the governor Normal Go to Step 8 Go to Step 9
harness pre-stroke power supply circuit
7 (open harness, ground short, and/or
layer short). Refer to the schematic.
8 Repair the fascia harness circuits.  Go to Step 17 
Replace the governor harness and/or  Go to Step 17 
9 repair circuits.
Check the magnetic valve power supply Normal Go to Step 12 Go to Step 11
10 connectors for corrosion and looseness.
Refer to the schematic.
11 Repair the circuits.  Go to Step 17 
Ÿ Between terminal 2 Go to Step 14 Go to Step 13
(positive side of the
actuator) and terminal 1
(negative side of the
actuator) = 2.45~2.95
Ÿ Between all of the above
Use a circuit tester to measure the pre- points where direction is
12
stroke actuator resistances. not specified (terminals
1~6) = 
Ÿ Between each terminal
and terminal 3 (shield) =

Between each terminal and
the body = 
13 Replace the injection pump.  Go to Step 17 
Replace the check control unit.
Ÿ Existing malfunction Go to Step 15 Go to Step 16
14 Ÿ Previous malfunction
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-213

DTC 423 Prestroke power supply fuse blown (Cont'd)

Step Action Value(s) Yes No
15 Replace the engine control unit (ECU)  Go to Step 17 
16 Replace the injection pump.  Go to Step 17 
1. Clear the memory. Ÿ Existing malfunction Go to Step 1 Verify repair
17 2. Use the TECH 2 to confirm DTC Ÿ Previous malfunction
423.
6E-214 EMISSION AND ELECTRICAL DIAGNOSIS

Pre-stroke sensor and pre-stroke actuator external appearance, terminal nomenclature, and
resistance values
1. External appearance

2. Terminal nomenclature

Connector Terminal No. Signal Wire color/diameter

1 Pre-stroke actuator (Negative side) LB/1.25

2 Pre-stroke actuator (Positive side) LW/1.25

SWP 3 Pre-stroke sensor (Shield) GY/0.5

6 terminals
Gray 4 Pre-stroke sensor (REFERENCE) B/0.5

5 Pre-stroke sensor (MIDDLE) W/0.5

6 Pre-stroke sensor (MEASURE) R/0.5

3. Resistance values

Connector Measuring points
)

Resistance (
Remarks
Terminal 6 ßà Terminal 5 5.5~6.1 Between MEASURE and MIDDLE
Terminal 6 ßà Terminal 4 11~12.2 Between MEASURE and REFERENCE
Terminal 6 ßà Terminal 3  Between MEASURE and shield
Terminal 6 ßà Body  Between MEASURE and body
Terminal 5 ßà Terminal 4 5.5~6.1 Between MIDDLE and REFERENCE
Terminal 5 ßà Terminal 3  Between MIDDLE and shield
Terminal 5 ßà Body  Between MIDDLE and body
SWP
Terminal 4 ßà Terminal 3  Between REFERENCE and shield
6 terminals
Terminal 4 ßà Body  Between REFERENCE and body
Gray
Between actuator (positive side) and
Terminal 2 ßà Terminal 1 2.45~2.95 actuator (negative side)
Terminal 2 ßà Body  Between actuator (positive side) and body
Between actuator (negative side) and
Terminal 1 ßà Body 
body
Excluding 6ßà5, 6ßà4, 5ßà4, and
Between all terminals 
2ßà1
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-215

Pre-stroke power supply cut-off relay external appearance, terminal nomenclature, and
resistance values
1. External appearance 2. Terminal nomenclature

Terminal No. Signal

1 Output NC (Normal open)
2 Drive coil (Positive)
3 Output NO (Normal close)
4 Drive coil (Negative)
5 Input

3. Resistance values

Terminal name Terminal Nos.
)

Resistance (
Remarks
2ßà4 267~287 Between drive coil terminals
Relay 5ßà3 Less than 1 Between input and output terminals (NC)
5ßà1  Between input and output terminals (NO)
6E-216 EMISSION AND ELECTRICAL DIAGNOSIS

DTC-518 EOL (END OF LINE) DATA ERROR

Problem description Diagnostic conditions
The self-diagnosis error (EOL data error) is not a result If it is determined that there is no accelerator learning
of improper sensing (detection) by the engine control occurring at the engine control unit (ECU), a
system. The system is fixed to accurately track provisionary [EOL DATA ERROR] diagnosis is made.
accelerator learning conditions. DTC 518 appears.
If this problem occurs, use the Tech-2 to rectify it. Set
Diagnostic warning (Service engine soon
the Tech-2 to the [ACCELERATOR LEARNING] mode.
indicator light turns on)
Vehicle operation when the DTC appears The service engine soon indicator light turns on. It
Poor accelerator pedal feel (Small changes in remains on until the problem is fixed. Indicator light
accelerator pedal position produce large changes in operation is not affected by engine condition (on or
fuel injection volume). off).
Possible causes
· Accelerator learning is not occurring
· Defective ECU

DTC 518 EOL data error
Step Action Result Yes No
Use the Tech-2 to determine whether or Normal accelerator learning Go to Step 5 Go to Step 2
1
not accelerator learning is occurring.
Check the Tech-2 and the DLC cable Tech-2 and DLC cable Go to Step 4 Go to Step 3
(Most easily done by attaching the normal
2 Tech-2 and DLC cable to a vehicle that
is known to be normal).
3 Repair the Tech-2 and the DLC cable.  Go to Step 1 
Repair the ECU and recheck the Normal accelerator learning Go to Step 5 
4 accelerator learning.
Clear the memory. Confirm the  Verify repair Go to step 1
5 conditions that caused DTC 518 to
appear.
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-217

DTC-543 ENGINE OVER RUN

Problem description Probable causes

Engine speed exceeds the limit normally imposed by · Operator error
engine control. · Engine mechanical problem (Engine conditions
other than the engine control system are
Pre-stroke power supply malfunction effects
monitored. Therefore, the problem may not be
Existing problem related to the Engine control system. Additionally,
· Difficult starting other DTC may be displayed simultaneously with
· Poor exhaust brake function the 543 code.
Previous problem
· None that are obvious to the vehicle operator Troubleshooting (Diagnostic steps and repair
procedures)
Diagnostic conditions
When engine speed exceeds 3,380 rpm for 1/2
second, the engine control unit (ECU) declares a high
engine speed malfunction (DTC 543).

DTC 543 Engine over run

Step Action Result Yes No
Ÿ Existing malfunction: 543 Go to Step 2 Go to Step 11
1 Use the TECH 2 to confirm DTC 543. Ÿ High engine speed error Existing Previous
malfunction malfunction
Determine causes of engine overrun Operator error Go to Step 3 Go to Step 6
2 (operator error).
3 Check engine mechanical components. Normal Go to Step 5 Go to Step 4
Repair or replace defective engine  Go to Step 5 
4 parts.
Caution operator against overrunning  Go to Step 20 
5 engine.
Use the TECH 2 to confirm DTC 543. DTC 543 and 10 or 543 and Go to Step 7 Go to Step 8
6
Check also for DTC 10 or 11. 11.
Inspect the areas indicated by DTC 10  Go to Step 20 
7 (rack sensor malfunction) or 11
(governor servo malfunction.)
Use the TECH 2 to confirm DTC 543. DTC 543 and 14 or 543 and Go to Step 9 Go to Step 10
8
Check also for DTCs 14 or 15. 15.
Inspect the areas indicated by DTC 14  Go to Step 20 
9 (backup N sensor malfunction) or 15
(NTDC malfunction.)
If engine overrun due to operator error  Go to Step 20 
10
is possible, caution vehicle operator.
Check for previous engine overrun Operator error Go to Step 12 Go to Step 15
11
problems (ask vehicle operator).
12 Check engine mechanical components. Normal Go to Step 14 Go to Step 13
Repair or replace defective engine  Go to Step 14 
13
parts.
Caution operator against overrunning  Go to Step 20 
14
engine.
6E-218 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 543 Engine over run (Cont'd)

Step Action Value(s) Yes No
Use the TECH 2 to check memory for DTC 543 and 10 or 543 and Go to Step 16 Go to Step 17
15
DTC other than 543 (11 or 12). 11.
Inspect the areas indicated by DTC 10  Go to Step 20 
16 (rack sensor malfunction) or 11
(governor servo malfunction.)
Use the TECH 2 to check memory for DTC 543 and 14 or 543 and Go to Step 18 Go to Step 19
17
DTC other than 543 (14 or 15). 15.
Inspect the areas indicated by DTC 14  Go to Step 20 
18 (backup N sensor malfunction) or 15
(NTDC malfunction.)
If engine overrun due to operator error  Go to Step 20 
19
is possible, caution vehicle operator.
1. Clear the memory. Ÿ Existing malfunction Go to Step 1 Go to Step 18
20 2. Use the TECH 2 to confirm DTC Ÿ Previous malfunction
543.
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-219

DTC-571 ENGINE REVERSING ERROR

Problem description
Engine rotation opposite of normal.
Pre-stroke power supply malfunction effects
Existing problem
· Difficult starting
Previous problem
· None that are obvious to the vehicle operator
Diagnostic conditions
When engine speed is less than 800 rpm, the N-TDC
sensor signal and the backup N-TDC sensor signal
phases are reversed. If this condition continues for 1
second, an engine rotation reverse error is declared
(DTC 571).
Probable causes
· Operator error
· Other problem (Engine conditions other than the
Engine control system are monitored. Therefore,
the problem may not be related to the Engine
control system.
Troubleshooting (Diagnostic steps and repair
procedures)
6E-220 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 571 Engine reversing error

Step Action Result Yes No
Ÿ Existing malfunction: 571 Go to Step 2 Go to Step 2
1 Use the TECH 2 to confirm DTC 571. Ÿ High rotation reverse Existing Previous
error malfunction malfunction
Determine conditions and frequency of Frequent occurrence Go to Step 3 Go to Step 4
2 occurrence (ask the vehicle operator)
3 Adjust static timing.  Go to Step 5 Go to Step 4
Caution operator against reverse engine  Go to Step 9 
4 rotation
1. Clear the memory. Ÿ Existing malfunction Go to Step 1 Verify repair
5 2. Use the TECH 2 to confirm DTC Ÿ Previous malfunction
292.
 EMISSION AND ELECTRICAL DIAGNOSIS 6E-221

DTC-71 ATMOSPHERIC PRESSURE SENSOR ERROR

Sensor location
The atmospheric pressure sensor exists in ECM.
Circuit description
The atmospheric pressure sensor monitors
atmospheric pressure outside the vehicle. The sensor
responds to variations in atmospheric pressure caused
by changing weather conditions and altitude.
When atmospheric pressure is low, the sensor output
voltage is low. When atmospheric pressure is high, the
sensor output voltage is high.
The engine control unit (ECU) detects voltage level
and converts it into atmospheric pressure data. This
data is a factor in engine control decisions made by the
ECU.
Note: The ECU cannot be disassembled. If there is
atmospheric pressure sensor malfunction, the entire
ECU must be replaced.
Sensor malfunction effects
· Black or white exhaust emissions
· Power loss
Diagnostic conditions
If the sensor voltage is more than 1.63 volts for 3
seconds, the ECU will declare a sensor malfunction
(DTC 71).
Possible causes of sensor malfunction
ECU malfunction
6E-222 EMISSION AND ELECTRICAL DIAGNOSIS

DTC 71 Atmosphere pressure sensor error

Step
Action Value(s) Yes No
No.
Ÿ Existing malfunction: 71 Go to Step 3 Go to Step 2
Use the TECH 2 to confirm DTC 71 with
1
the engine both off and on.
Ÿ Atmospheric pressure Existing Previous
sensor error malfunction malfunction
1. Clear the memory. Normal Verify repair Go to Step 3
2 2. Use the TECH 2 to confirm DTC 71
(if possible, do this at high altitude).
3 Replace the engine control unit (ECU)  Go to Step 4 
1. Clear the memory. Ÿ Existing malfunction Go to Step 1 Verify repair
4 2. Use the TECH 2 to confirm DTC Ÿ Previous malfunction
with the engine both off and on.