DI−4

DIAGNOSTICS − ENGINE
DIDY2−01

PRE−CHECK
1. DIAGNOSIS SYSTEM
(a) Description
S When troubleshooting Multiplex OBD (M−OBD) ve-
hicles, the only difference from the usual trouble-
shooting procedure is that you connect the intelli-
gent tester II to the vehicle, and read off various
data output from the vehicle’s engine ECU.
FI2547
S The vehicle’s on−board computer lights up the
check engine war ning light ( CHK ENG ) on t he
instrument panel when the computer detects a mal-
function in the computer itself or in drive system
components. In addition to the CHK ENG lighting up
when a malfunction is detected, the applicable diag-
nostic trouble codes are recorded in the engine
ECU memory (see page DI−21).
If the malfunction has been repaired, the CHK ENG goes off au-
tomatically but the diagnostic trouble codes remain recorded in
the engine ECU memory.

LHD S To check the diagnostic trouble codes, connect the

Intelligent Tester II
intelligent tester II to the Data Link Connector 3
(DLC3) on the vehicle or read the number of blinks
of the CHK ENG when TC and CG terminals on the
DLC3 are connected. The intelligent tester II also
enables you to erase the diagnostic trouble codes,
activate several actuators, check freeze frame data
and various forms of engine data (for operating
DLC3 instructions, see the intelligent tester II instruction
RHD book).
Intelligent Tester II S The diagnosis system operates in normal mode
during normal vehicle use. It also has a check mode
for technicians to simulate malfunction symptoms
and perform troubleshooting. Some diagnostic
trouble codes use 2 trip detection logic* to prevent
erroneous detection and ensure thorough malfunc-
tion detection. By switching the engine ECU to
check mode using the intelligent tester II when trou-
DLC3
A23861 bleshooting, the technician can cause the CHK
ENG to light up for a malfunction that is only de-
tected once or momentarily (see page DI−21).

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DIAGNOSTICS − ENGINE

S *2 trip detection logic:

When a malfunction is first detected, the malfunc-
tion is temporarily stored in the engine ECU
memory (1st trip). If the same malfunction is de-
tected during the next subsequent drive cycle, the
CHK ENG is illuminated (2nd trip).
S Freeze frame data:
Freeze frame data records the engine conditions
(fuel system, calculated engine load, engine cool-
ant temperature, fuel trim, engine speed, vehicle
speed, etc.) when a malfunction is detected. When
troubleshooting, freeze frame data can help deter-
mine if the vehicle was running or stopped, if the en-
gine was warmed up or not, if the air−fuel ratio was
lean or rich, and other data from the time the mal-
function occurred.

(b) Check the DLC3.

The vehicle’s engine ECU uses ISO 14230 for commu-
nication. The terminal arrangement of the DLC3 complies
1 2 34 5 6 78 with ISO 15031−3 and matches the ISO 14230 format.
9 10 111213141516

DLC3

A04550

Symbols (Terminal No.) Terminal Description Condition Specified Condition

SIL (7) − SG (5) Bus ”+” line During transmission Pulse generation
CG (4) − Body ground Chassis ground Always Below 1 W
SG (5) − Body ground Signal ground Always Below 1 W
BAT (16) − Body ground Battery positive Always 9 to 14 V

HINT:
Connect the cable of the intelligent tester II to the DLC3, turn
the ignition switch ON and attempt to use the tester. If the dis-
play indicates that a communication error has occurred, there
is a problem either with the vehicle or with the tester.
S If communication is normal when the tester is connected
to another vehicle, inspect the DLC3 on the original ve-
hicle.
S If communication is still not possible when the tester is
connected to another vehicle, the problem is probably in
the tester itself. Consult the Service Department listed in
the tester’s instruction manual.

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DIAGNOSTICS − ENGINE

2. INSPECT DIAGNOSIS (Normal Mode)

(a) Check the CHK ENG.
(1) The CHK ENG lights up when the ignition switch is
turned ON and the engine is not running.
HINT:
If the CHK ENG does not light up, troubleshoot the combination
meter.
(2) When the engine is started, the CHK ENG should
FI2547 go off. If the lamp remains on, the diagnosis system
has detected a malfunction or abnormality in the
system.
(b) Check the DTC using the intelligent tester II.
NOTICE:
When the diagnosis system is changed from normal mode
to check mode, or vice versa, all the DTCs and freeze frame
data recorded in normal m ode will be erased. Before
changing modes, always check and make a note of any re-
corded DTCs and freeze frame data.
(1) Connect the intelligent tester II to the DLC3.
(2) Turn the ignition switch ON and turn the intelligent
tester II ON.
(3) Enter the following menus: Powertrain / Engine and
ECT / DTC.
(4) Check and make a note of DTCs and freeze frame
data.
(5) Confirm the details of the DTCs.

(c) Check the DTC without using the intelligent tester II.
CG (1) Turn the ignition switch ON.
(2) Using SST, connect between terminals 13 (TC) and
1 2 34 5 6 7 8 4 (CG) of the DLC3.
9 10 111213141516
SST 09843−18040

DLC3 TC

A04550

(3) Read DTCs by observing the CHK ENG. If any DTC

Normal
0.25 sec. is not detected, the CHK ENG blinks as shown in the
illustration.
ON ON ON ON HINT:
S If a diagnostic trouble code is not output, check the diag-
OFF OFF OFF nostic connector (DLC3) circuit (See page DI−146).

0.25 sec.
FI0294

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DIAGNOSTICS − ENGINE

0.5 sec. 1.5 sec. (d) Example

As an example, the blinking patterns for codes 12 and 31
4.5 sec. 4.5 sec.
are as shown on the illustration.
2.5 DTCs 12 and 31 are detected and the CHK ENG starts
ON sec. displaying the DTCs, as shown on the left. The CHK ENG
OFF
0.5 sec. blinking pattern of DTC 12 will be displayed first.
Repeat
(1) A 2.5 second pause will occur between the CHK
One Cycle ENG blinking patterns of each DTC.
Start (2) The CHK ENG blinking pattern of DTC 31 will be dis-
BR3589

played.
(3) A 4.5 second pause will occur when the CHK ENG
blinking pattern is the last of a string of multiple
DTCs.
(4) The MIL will repeat the display of the string of DTCs
again.
S Check the details of the malfunction using the diagnostic
trouble code chart on page DI−21.
S After completing the check, disconnect terminals 13 (TC)
and 4 (CG) and turn off the display.
HINT:
If 2 or more DTCs are detected, the CHK ENG will display the
smaller number DTC first.
S Confirm the details of the DTCs.

LHD 3. INSPECT DIAGNOSIS (Check Mode)

Intelligent Tester II
HINT:
Check mode has a higher sensitivity to malfunctions and can
detect malfunctions that normal mode cannot detect. Check
mode can also detect all malfunctions that normal mode can.
In check mode, the engine ECU sets DTCs using 1 trip detec-
tion logic.
NOTICE:
DLC3 All the stored DTCs and freeze frame data are erased if: 1)
RHD the engine ECU is changed from normal mode to check
Intelligent Tester II mode or vice versa; or 2) the ignition switch is turned from
ON to ACC or OFF during check mode.
Before changing modes, always check and make a note of
any stored DTCs and freeze frame data.
(a) Check mode procedure.
(1) Make sure that the vehicle is in the following condi-
tion:
S Battery positive voltage 11 V or more
DLC3
A23861 S Throttle valve fully closed
S Transmission in neutral position
S Air conditioning switch OFF
(2) Turn the ignition switch OFF.
(3) Connect the intelligent tester II to the DLC3.
(4) Turn the ignition switch ON and turn the intelligent
tester II ON.

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DIAGNOSTICS − ENGINE

(5) Enter the following menus: Powertrain / Engine and

ECT / Check Mode.

(6) Make sure that the CHK ENG flashes as shown in

the illustration.
0.13 Seconds (7) Start the engine (the CHK ENG should turn off).
ON (8) Simulate the conditions of the malfunction de-
scribed by the customer.
(9) Check the DTC(s) and freeze frame data using the
OFF intelligent tester II.
0.13 Seconds (10) After checking the DTC, inspect the appropriate cir-
A20595 cuits.
(b) Clear the DTC and freeze frame data.
(using intelligent tester II)
(1) Connect the intelligent tester II to the DLC3.
(2) Turn the ignition switch ON (do not start the engine)
and turn the intelligent tester II ON.
(3) Enter the following menus: Powertrain / Engine and
ECT / DTC / Clear.
(4) Erase DTCs and freeze frame data by pressing
YES on the tester.
(c) Clear the DTC and freeze frame data.
(not using intelligent tester II)
(1) Disconnect the cable from the negative (−) battery
terminal and wait for more than 1 minute.
(2) Remove the EFI OR ECD NO. 1 fuse from the en-
gine room J/B located inside the engine compart-
ment and wait for more than 1 minute.

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DIAGNOSTICS − ENGINE

4. FAIL−SAFE CHART
If any of the following DTCs are set, the engine ECU enters fail−safe mode to allow the vehicle to be driven
temporarily.
DTC No. Fail−Safe Operation Fail−Safe Deactivation Conditions
P0105/35 Intake air pressure is fixed at 101.3 kPa (760 mmHg, 30 in.Hg) Return to normal condition
P0110/24* Atmospheric temp. is fixed at 60˚C (140˚F) Return to normal condition
P0115/22 Engine coolant temp. is fixed at 100˚C (212˚F) Return to normal condition
P0180/39 Fuel temp. is fixed at 60˚C (140˚F) Return to normal condition
SFuel cut
P0335/13 STCV duty is fixed at 1.0% 2 of more NE signals are detected for 0.5 sec.
SClose diesel throttle valve
S TCV duty is fixed at 35.0%
P0340/12 2 of more TDC signals are detected for 4 engine revolutions
S Fuel injection volume is limited

P0500/42 Reading of speedmeter is fixed at 0 km/h (0 mph) Vehicle speed > 9 km/h (5.6 mph)
P1115/23 Intake air temp. is fixed at 20˚C (68˚F) Return to normal condition
Accelerator pedal closed position SW ON:
Accelerator pedal position is fixed at 0%
P1120/19 Ignition switch OFF
Accelerator pedal closed position SW OFF:
Accelerator pedal position is fixed at 10%

P1121/19 Accelerator pedal position below 10% Ignition switch OFF

Accelerator pedal closed position SW ON:
Accelerator pedal position is fixed at 0%
P1121/19 Ignition switch OFF
Accelerator pedal closed position SW OFF:
Accelerator pedal position is fixed at 8%

When idle SW is faulty.

Accelerator pedal closed position SW ON:
Accelerator pedal position is fixed at 0% Ignition switch OFF
Accelerator pedal closed position SW OFF:
P1122/19 Accelerator pedal position is fixed at 10%
P1123/19 When idle SW is normal.
Idle SW ON:
Accelerator pedal position is fixed at 0% Ignition switch OFF
Idle SW OFF:
Accelerator pedal position below 10%
Accelerator pedal position below 10% Ignition switch OFF
P1220/14 Fuel injection volume is limited Return to normal condition
P1222/15 Accelerator pedal opening angle is limited Ignition switch OFF
P1250/34* Variable nozzle is full opened Ignition switch OFF
Variable nozzle is full opened
P1255/34* Ignition switch OFF
Accelerator pedal opening angle is limited
P1256/34* Variable nozzle is full opened Ignition switch OFF
S Accelerator pedal opening angle is limited
P1416/58* Ignition switch OFF
S EGR cut

HINT:
*: Only for Europe

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DIAGNOSTICS − ENGINE

5. CHECK FOR INTERMITTENT PROBLEMS

HINT:
Intelligent tester II:
Inspect the vehicle’s engine ECU using check mode. Intermittent problems are easier to detect when the
engine ECU is in check mode with the intelligent tester II. In check mode, the engine ECU uses 1 trip detec-
tion logic, which has a higher sensitivity to malfunctions than normal mode (default), which uses 2 trip detec-
tion logic.
(a) Clear the DTC (see step 3).
(b) Change the engine ECU from normal mode to check mode using the intelligent tester II (see step 3).
(c) Perform a simulation test (see page IN−9).
(d) Check the connector and terminal (see page IN−19).
(e) Wiggle the harness and the connector (see page IN−19).
6. BASIC INSPECTION
When a malfunction cannot be confirmed by the DTC check, troubleshooting should be performed on all
circuits that are possible causes of the problem. However, in most cases, performing the basic engine check
shown below can help you find the problem quickly and efficiently. Always perform this check first when trou-
bleshooting the engine.

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

NO Charge or replace battery.

YES

2 Is engine cranked?

NO Proceed to problem symptoms table on page

DI−16.

YES

3 Check air filter (See Pub. No. RM617E on page EM−1).

CHECK:
Visually check that the air filter is not excessively contaminated with dirt or oil.

NG Repair or replace.

OK

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DIAGNOSTICS − ENGINE

4 Check fuel quality.

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

NG Replace fuel.

OK

5 Check fuel for air.

NG Bleed air from fuel.

OK

6 Check fuel pipes and hoses.

CHECK:
Check that the fuel pipes and fuel hoses are not blocked, damaged, disconnected or bent.

NG Repair or replace.

OK

7 Check fuel filter for blockage.

NG Clean or replace.

OK

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DIAGNOSTICS − ENGINE

8 Check engine oil (See Pub. No. RM617E on page LU−1).

NG Add or replace.

OK

9 Check coolant (See Pub. No. RM617E on page CO−1).

NG Replace coolant.

OK

10 Check injection timing (See Pub. No. RM617E on page EM−14).

NG Adjust injection timing.

OK

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DIAGNOSTICS − ENGINE

11 Check idle speed and maximum speed.

PREPARATION:
Connect the tester probe of a tachometer to terminal TAC of the
DLC3.
Start the engine.
TAC Warm up the engine.
CHECK:
Check the idle speed.
DLC3 RESULT:
A06333 Idle speed: 550 to 650 rpm
PREPARATION:
(a) Start the engine.
(b) Warm up the engine.
(c) Depress the accelerator pedal all the way.
CHECK:
(a) Check the maximum speed.
RESULT:
Maximum speed: 4300 to 4500 rpm

NG Repair or replace injection pump.

OK

12 Check diagnostic connector (DLC3) circuit (See page DI−146).

NG Repair or replace.

OK

13 Check vacuum pump.

NG Repair or replace.

OK

Proceed to problem symptoms table on page DI−16.

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DIAGNOSTICS − ENGINE

7. DATA LIST
HINT:
Using the intelligent tester II’s Data List allows switch, sensor, actuator, and other item values to be read
without removing any parts. Reading the Data List early in troubleshooting is one way to save time.
NOTICE:
In the table below, the values listed under ”Normal Condition” are reference values. Do not depend
solely on these reference values when deciding whether a part is faulty or not.
(a) Warm up the engine.
(b) Turn the ignition switch OFF.
(c) Connect the intelligent tester II to the DLC3.
(d) Turn the ignition switch ON.
(e) Turn the intelligent tester II ON.
(f) Enter the following menus: Powertrain / Engine and ECT / Data List.
(g) Read the Data List.
Measurement Item/Range
Intelligent Tester II Display Normal Conditions* Diagnostic Notes
(Display)

If value approximately 0.0 gm/s:

S Mass air flow meter power
Air flow rate from MAF meter sta- S 8 to 12 gm/s: Idling
source circuit open
MAF tus/ S 52 to 62 gm/s:
S VG circuit open or shorted
Min.: 0 gm/s, Max.: 655.35 gm/s Running without load (2,000 rpm)
If value 135 gm/s or more:
S E2G circuit open
S 90 to 110 kPa: Idling
Absolute pressure inside intake S 100 to 130 kPa:
MAP manifold/ Engine running at 2,000 rpm ¾
Min.: 0 kPa, Max.: 225 kPa S 110 to 130 kPa:
Engine running at 3,000 rpm
550 to 650 rpm: Idling
Engine speed/
Engine Speed (After warming up engine and A/C ¾
Min.: 0 rpm, Max.: 16383.75 rpm
off)
If value is −40_C (−40_F) or
Engine coolant temperature/ 80 to 95˚C (167 to 194˚F):
Coolant Temp 140_C (284_F), sensor circuit
Min.: −40_C, Max.: 140_C After warming up engine
open or shorted
If value is −40_C (−40_F) or
Intake air temperature/ Equivalent to temperature at intake
Intake Air 140_C (284_F), sensor circuit
Min.: −40_C, Max.: 140_C manifold
open or shorted
Vehicle speed/
Vehicle Speed Actual vehicle speed Speed indicated on speedometer
Min.: 0 km/h, Max.: 255 km/h

Injection volume/
Injection Volume 4 to 11 mm3: Idling ¾
Min.: 0 mm3, Max.: 1279.98 mm3
Starter signal/
Starter Signal ON: Cranking ¾
ON or OFF

Closed throttle position switch/

Closed Throttle Position SW OFF: Accelerator pedal released ¾
ON or OFF
Power steering signal/ When steering wheel is turned:
Power Steering Signal ¾
ON or OFF ON

A/C signal/
A/C Signal ON: A/C ON ¾
ON or OFF
Stop lamp switch/ S ON: Brake pedal depressed
Stop Light Switch ¾
ON or OFF S OFF: Brake pedal released

PNP switch signal/

Newtral Position SW Signal ON: P or N position ¾
ON or OFF

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DIAGNOSTICS − ENGINE

Measurement Item/Range
Intelligent Tester II Display Normal Conditions* Diagnostic Notes
(Display)
Power steering oil pressure switch S While turning steering wheel: ON
Power Steering Oil Pressure This signal is usually ON unitil igni-
signal/ S While not turning steering wheel:
Switch tion switch is turned OFF
ON or OFF OFF
EGR status for Active Test/
EGR System ¾ Active Test support date
ON or OFF
S 16 to 21˚CA: Idling
S 13 to 24˚CA:
Injection timing/
Injection Timing Engine running at 2,000 rpm ¾
Min.: 0˚CA, Max.: 51˚CA
S 18 to 31˚CA:
Engine running at 3,000 rpm
If value is −40_C (−40_F) or
Fuel temperature/
Fuel Temperature Actual fuel temperature 140_C (284_F), sensor circuit
Min.: −40_C, Max.: 140_C
open or shorted
S 0 to 10%:
Accelerator pedal released
Accelerator position status/
Accel Position S 59 to 100%: ¾
Min.: 0%, Max.: 100%
Accelerator pedal depresse-
dased
Throttle step position/
Throttle Step Position 160 to 180 step: Idling ¾
Min.: 1 step, Max.: 255 step
A/C cut status
ACT VSV ON: A/C OFF ¾
ON or OFF

HINT:
*: If no idling conditions are specified, the shift lever is in the neutral position, and the A/C switch and all ac-
cessory switches are OFF.
8. ACTIVE TEST
HINT:
Performing the intelligent tester II’s Active Test allows relay, VSV, actuator and other items to be operated
without removing any parts. Performing the Active Test early in troubleshooting is one way to save time.
The Data List can be displayed during the Active Test.
(a) Warm up the engine.
(b) Turn the ignition switch OFF.
(c) Connect the intelligent tester II to the DLC3.
(d) Turn the ignition switch ON.
(e) Turn the intelligent tester II ON.
(f) Enter the following menus: Powertrain / Engine and ECT / Active Test.
(g) Perform the Active Test.
Intelligent Tester II Display
Test Details Control Range Diagnostic Notes
(Abbreviation)
Control the EGR System
Activate E−VRV for EGR ON/OFF ¾

Control the A/C Cut Signal

Control A/C signal ON/OFF ¾

Connect the TC and TE1 Turn on TC and TE1 connection ON/OFF ¾

1HD−FTV ENGINE SUP (RM1179E)