Code Isuzu

2008-2011MY
2008-2011MY
WORKSHOP MANUAL
WORKSHOP MANUAL ENGINE CONTROL SYSTEM (6HK1 model)

ENGINE CONTROL SYSTEM
(6HK1 model)
No.MG6HKED-WE-0871
69200_MG6HKED-WE-0871_Maegaki 2011.5.9 4:01 PM ページ 1
This Workshop Manual deals only with the screen toned section(s) in the table below.
Section Sub Section
0 GENERAL INFORMATION 0A General Information
1 ENGINE 1A Engine Control System
1B Engine Mechanical
1C Engine Cooling
1D Engine Fuel
1E Engine Electrical
1F Emission Control
1G Engine Exhaust
1H Engine Lubrication
1I Engine Speed Control System
1J Induction
1K Pre-Heating System
1L Power Take-Off (PTO)
2 SUSPENSION 2A1 Air Suspension Control System
2B Front Suspension
2C Rear Suspension
2D Wheel and Tire System
3 DRIVELINE/AXLE 3A1 Front Differential
3A2 Rear Differential
3C1 Propeller Shaft
3C2 Front Axle
3C3 Rear Axle
3D Transfer Case
4 BRAKES 4A2 Brake Control System (Air Over)
4A3 Brake Control System (Full Air)
4B2 Brake (Air Over)
4B3 Brake (Full Air)
4C Anti-Lock Brake (ABS)
4C1 Anti-Lock Brake (ABS)/Anti-Slip Regulator (ASR)
4D Parking Brake
4E Hill Start Aid (HSA)
4F Speed Retarder System
4G Trailer Brake
5 TRANSMISSION/TRANSAXLE 5A Transmission Control System
5B Automatic Transmission
5C Manual Transmission
5E Clutch
5G Power Take-Off (PTO)
5G1 Side Power Take-Off
6 STEERING 6B Power Steering
7 HVAC 7A Heating and Ventilation
7B Manual Air Conditioning
7C Automatic Air Conditioning
8 RESTRAINTS 8A Seat Belt
8B Supplemental Restraint System (SRS)
8C SRS Control System
9 BODY, CAB AND ACCESSORIES 9A Lighting System
9B Wiper/Washer System
9C Entertainment
9D Wiring System
9E Instrumentation/Driver Info.
9F Body Structure
9G Cab
9H Seats
9I Security and Lock
9K Exterior/Interior Trim
9L Cab Mounting
10 CONTROL SYSTEMS 10B Vehicle Control
11 FRAME AND FRAME ACCESSORIES 11A Frame
69200_MG6HKED-WE-0871_Maegaki 2011.5.9 4:01 PM ページ 2
MG6HKED-WE-0871.book 1 ページ２０１１年５月１８日　水曜日　午後４時５８分
Engine Control System (6HK1) 1A-1
ENGINE
Engine Control System
(6HK1)
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-3 DTC P0201, P0202, P0203, P0204,
Temperature vs. Resistance. . . . . . . . . . . . . . . . 1A-3 P0205 or P0206 (Flash Code 271,
Altitude vs. Barometric Pressure . . . . . . . . . . . . 1A-4 272, 273, 274, 275 or 276) . . . . . . . . . . . . . . .1A-122
Diagnostic Trouble Code (DTC) Type DTC P0217 (Flash Code 542) . . . . . . . . . . . .1A-135
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-5 DTC P0219 (Flash Code 543) . . . . . . . . . . . .1A-137
Diagnostic Trouble Code (DTC) List . . . . . . . . . 1A-6 DTC P0234 (Flash Code 42) . . . . . . . . . . . . .1A-139
Overview Wirings . . . . . . . . . . . . . . . . . . . . . . . . . 1A-9 DTC P0299 (Flash Code 65) . . . . . . . . . . . . .1A-142
Overview Wirings . . . . . . . . . . . . . . . . . . . . . . . . 1A-9 DTC P0335 (Flash Code 15) . . . . . . . . . . . . .1A-145
Routing Diagrams . . . . . . . . . . . . . . . . . . . . . . . . 1A-11 DTC P0336 (Flash Code 15) . . . . . . . . . . . . .1A-148
Fuel System Routing Diagram . . . . . . . . . . . . . 1A-11 DTC P0340 (Flash Code 14) . . . . . . . . . . . . .1A-150
Component Locator. . . . . . . . . . . . . . . . . . . . . . . 1A-12 DTC P0341 (Flash Code 14) . . . . . . . . . . . . .1A-153
Engine Controls Component Views . . . . . . . . . 1A-12 DTC P0380 (Flash Code 66) . . . . . . . . . . . . .1A-155
Engine Control Module (ECM) DTC P0381 (Flash Code 67) . . . . . . . . . . . . .1A-157
Connector End Views. . . . . . . . . . . . . . . . . . . . 1A-18 DTC P0401 (Flash Code 93) . . . . . . . . . . . . .1A-160
Engine Control Connector End Views . . . . . . . 1A-20 DTC P0404 (Flash Code 45) . . . . . . . . . . . . .1A-162
Diagnostic Information and Procedures . . . . . . . 1A-31 DTC P0409 (Flash Code 44) . . . . . . . . . . . . .1A-165
Engine Control System Check Sheet. . . . . . . . 1A-31 DTC P0426 (Flash Code 143) . . . . . . . . . . . .1A-168
Diagnostic Starting Point - Engine Controls . . . 1A-32 DTC P0427 or P0428 (Flash Code 48) . . . . .1A-170
Diagnostic System Check - Engine Controls . . 1A-33 DTC P042B (Flash Code 145) . . . . . . . . . . . .1A-175
Scan Tool Data List . . . . . . . . . . . . . . . . . . . . . 1A-37 DTC P042C or P042D (Flash Code 49) . . . . .1A-177
Scan Tool Data Definitions . . . . . . . . . . . . . . . . 1A-41 DTC P0500 (Flash Code 25) . . . . . . . . . . . . .1A-182
Scan Tool Output Controls . . . . . . . . . . . . . . . . 1A-47 DTC P0502 or P0503 (Flash Code 25) . . . . .1A-185
Scan Tool Does Not Power Up. . . . . . . . . . . . . 1A-48 DTC P0560 (Flash Code 155) . . . . . . . . . . . .1A-193
Scan Tool Does Not Communicate with DTC P0563 (Flash Code 35) . . . . . . . . . . . . .1A-196
CAN Device (Euro 4 Specification) . . . . . . . . . 1A-49 DTC P0571 (Flash Code 26) . . . . . . . . . . . . .1A-197
Scan Tool Does Not Communicate with DTC P0601 (Flash Code 53) . . . . . . . . . . . . .1A-200
Keyword Device (Except Euro 4 Specification) 1A-52 DTC P0602 (Flash Code 154) . . . . . . . . . . . .1A-201
Lost Communication with The DTC P0604, P0606 or P060B
Engine Control Module (ECM) (Flash Code 153, 51 or 36) . . . . . . . . . . . . . .1A-203
(Except Euro 4 Specification) . . . . . . . . . . . . . . 1A-55 DTC P0633 (Flash Code 176) . . . . . . . . . . . .1A-204
Engine Cranks but Does Not Run . . . . . . . . . . 1A-58 DTC P0638 (Flash Code 61) . . . . . . . . . . . . .1A-205
DTC P0016 (Flash Code 16) . . . . . . . . . . . . . . 1A-61 DTC P0641 (Flash Code 55) . . . . . . . . . . . . .1A-208
DTC P0045 (Flash Code 33) . . . . . . . . . . . . . . 1A-63 DTC P0650 (Flash Code 77) . . . . . . . . . . . . . 1A-211
DTC P0079 or P0080 (Flash Code 38) . . . . . . 1A-65 DTC P0651 (Flash Code 56) . . . . . . . . . . . . .1A-214
DTC P0087 (Flash Code 225) . . . . . . . . . . . . . 1A-68 DTC P0685 or P0687 (Flash Code 416) . . . .1A-217
DTC P0088 (Flash Code 118) . . . . . . . . . . . . . 1A-72 DTC P0697 (Flash Code 57) . . . . . . . . . . . . .1A-220
DTC P0089 (Flash Code 151) . . . . . . . . . . . . . 1A-77 DTC P1093 (Flash Code 227) . . . . . . . . . . . .1A-223
DTC P0091 or P0092 (Flash Code 247) . . . . . 1A-80 DTC P1261 or P1262 (Flash Code 34) . . . . .1A-227
DTC P0101 (Flash Code 92) . . . . . . . . . . . . . . 1A-88 DTC P1455 (Flash Code 132) . . . . . . . . . . . .1A-230
DTC P0102 or P0103 (Flash Code 91) . . . . . . 1A-91 DTC P1471 (Flash Code 149) . . . . . . . . . . . .1A-232
DTC P0107 or P0108 (Flash Code 32) . . . . . . 1A-95 DTC P161B (Flash Code 179) . . . . . . . . . . . .1A-235
DTC P0112 or P0113 (Flash Code 22) . . . . . . 1A-99 DTC P1621 (Flash Code 54) . . . . . . . . . . . . .1A-237
DTC P0117 or P0118 (Flash Code 23) . . . . . 1A-106 DTC P1669 (Flash Code 75) . . . . . . . . . . . . .1A-241
DTC P0122 or P0123 (Flash Code 43) . . . . . 1A-110 DTC P2122 or P2123 (Flash Code 121) . . . .1A-246
DTC P0182 or P0183 (Flash Code 211) . . . . 1A-114 DTC P2127 or P2128 (Flash Code 122) . . . .1A-250
DTC P0192 or P0193 (Flash Code 245) . . . . 1A-118 DTC P2138 (Flash Code 124) . . . . . . . . . . . .1A-254
DTC P2146 or P2149
(Flash Code 158 or 159) . . . . . . . . . . . . . . . .1A-256
1A-2 Engine Control System (6HK1)

DTC P215A (Flash Code 25) . . . . . . . . . . . . . 1A-262
DTC P2227 (Flash Code 71) . . . . . . . . . . . . . 1A-264
DTC P2228 or P2229 (Flash Code 71) . . . . . 1A-267
DTC P242F (Flash Code 131) . . . . . . . . . . . . 1A-271
DTC P2452 (Flash Code 142) . . . . . . . . . . . . 1A-273
DTC P2453 (Flash Code 141) . . . . . . . . . . . . 1A-276
DTC P2454 or P2455 (Flash Code 47) . . . . . 1A-279
DTC P2456 (Flash Code 47) . . . . . . . . . . . . . 1A-284
DTC P2458 (Flash Code 139) . . . . . . . . . . . . 1A-286
DTC U0073 (Flash Code 84) . . . . . . . . . . . . . 1A-296
DTC U0101 (Flash Code 85) . . . . . . . . . . . . . 1A-300
DTC U0110 (Flash Code 87) . . . . . . . . . . . . . 1A-302
DTC U0167 (Flash Code 177) . . . . . . . . . . . . 1A-305
EGR Control System Check. . . . . . . . . . . . . . 1A-306
Glow Control System Check . . . . . . . . . . . . . 1A-310
Exhaust Brake Control System Check . . . . . . 1A-313
Cruise Control System Check . . . . . . . . . . . . 1A-319
Diesel Particulate Defuser
(DPD) Control System Check . . . . . . . . . . . . 1A-324
Symptoms - Engine Controls . . . . . . . . . . . . . . 1A-330
Symptoms - Engine Controls . . . . . . . . . . . . . 1A-330
Intermittent Conditions . . . . . . . . . . . . . . . . . . 1A-332
Hard Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-335
Rough, Unstable, or
Incorrect Idle and Stalling. . . . . . . . . . . . . . . . 1A-337
High Idle Speed . . . . . . . . . . . . . . . . . . . . . . . 1A-339
Cuts Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-340
Surges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-341
Lack of Power, Sluggishness or Sponginess . 1A-343
Hesitation, Sag or Stumble. . . . . . . . . . . . . . . 1A-345
Abnormal Combustion Noise . . . . . . . . . . . . . 1A-347
Poor Fuel Economy . . . . . . . . . . . . . . . . . . . . 1A-348
Excessive Smoke (Black Smoke) . . . . . . . . . 1A-350
Excessive Smoke (White Smoke) . . . . . . . . . 1A-352
DPD System Manual Regeneration
Frequently . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-354
DPD System Regeneration Long Time . . . . . 1A-356
Repair Instructions . . . . . . . . . . . . . . . . . . . . . . 1A-358
Engine Control Module (ECM) Replacement . 1A-358
Service Programming System (SPS)
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-360
(Remote Procedure). . . . . . . . . . . . . . . . . . . . 1A-361
(Pass-Thru Procedure). . . . . . . . . . . . . . . . . . 1A-362
Description and Operation . . . . . . . . . . . . . . . . 1A-364
Engine Control Module (ECM) Description . . 1A-364
Engine Control Component Description. . . . . 1A-367
Fuel System Description . . . . . . . . . . . . . . . . 1A-371
Fuel System Component Description. . . . . . . 1A-372
Fuel Injection System Description . . . . . . . . . 1A-376
Exhaust Gas Recirculation (EGR)
System Description . . . . . . . . . . . . . . . . . . . . 1A-377
Turbocharger Description. . . . . . . . . . . . . . . . 1A-379
Diesel Particulate Defuser (DPD)
System Description . . . . . . . . . . . . . . . . . . . . 1A-381
Special Tools and Equipment . . . . . . . . . . . . . . 1A-384
Special Tools and Equipment . . . . . . . . . . . . . 1A-384
Specifications
Temperature vs. Resistance 150 302 13900
Engine Coolant Temperature vs. Resistance 100 212 33600
°C °F Ohms 50 122 106000
Temperature vs. Resistance Value (Approximately)
Fuel Temperature vs. Resistance
120 248 115
°C °F Ohms
110 230 150
100 212 190
110 230 140
90 194 240
100 212 180
80 176 320
90 194 240
70 158 430
80 176 310
60 140 590
70 158 420
50 122 810
60 140 580
40 104 1150
50 122 810
30 86 1660
40 104 1150
20 68 2450
30 86 1660
10 50 3700
20 68 2450
0 32 5800
10 50 3700
-10 14 9300
0 32 5740
-20 -4 15480
-10 14 9160
-30 -22 26700
-20 -4 15000
Exhaust Temperature vs. Resistance -30 -22 25400
°C °F Ohms
Intake Air Temperature vs. Resistance (Euro 4
Specification)
1000 1832 120
°C °F Ohms
950 1742 135
900 1652 155
100 212 190
850 1562 180
90 194 240
800 1472 205
80 176 320
750 1382 240
70 158 430
700 1292 290
60 140 590
650 1202 345
50 122 810
600 1112 425
40 104 1150
550 1022 530
30 86 1650
500 932 675
20 68 2430
450 842 885
10 50 3660
400 752 1200
0 32 5550
350 662 1710
-10 14 8970
300 572 2580
-20 -4 14700
250 482 4300
200 392 6900

Intake Air Temperature vs. Resistance (Except Euro
4 Specification)
°C °F Ohms
100 212 190
90 194 250
80 176 330
70 158 450
60 140 610
50 122 850
40 104 1200
30 86 1730
20 68 2560
10 50 3870
0 32 6000
-10 14 9570
-20 -4 15700
Altitude vs. Barometric Pressure
Barometric
Altitude Measured Altitude Measured Pressure
in Meters (m) in Feet (ft) Measured in
Kilopascals (kPa)
Determine your altitude by contacting a local weather
station or by using another reference source.
4267 14000 56-64
3962 13000 58-66
3658 12000 61-69
3353 11000 64-72
3048 10000 66-74
2743 9000 69-77
2438 8000 71-79
2134 7000 74-82
1829 6000 77-85
1524 5000 80-88
1219 4000 83-91
914 3000 87-95
610 2000 90-98
305 1000 94-102
0 0 Sea Level 96-104
-305 -1000 101-105

Diagnostic Trouble Code (DTC) Type Definitions
Emission Related DTC • A history DTC clears after 40 consecutive warm-up
Action Taken When the DTC Sets - Type A cycles, if no failures are reported.
• Use a scan tool to clear the SVS lamp and the
• The ECM illuminates the malfunction indicator
DTC.
lamp (MIL) when the diagnostic runs and fails.
• The ECM records the operating conditions at the Action Taken When the DTC Sets - Type D
time the diagnostic fails. The ECM stores this
• The ECM will not illuminate the MIL or SVS lamp.
information in the Freeze Frame/ Failure Records.
(Euro 4 specification) • The ECM records the operating conditions at the
Action Taken When the DTC Sets - Type B information in the Failure Records. (Euro 4
specification)
• The ECM illuminates the MIL on the second
consecutive driving cycle when the diagnostic runs Conditions for Clearing the DTC - Type D
and fails.
• A current DTC clears when the diagnostic runs and
• The ECM records the operating conditions at the
passes.
time the diagnostic fails. The first time the
diagnostic fails, the ECM stores this information in • A history DTC clears after 40 consecutive warm-up
the Failure Records. If the diagnostic reports a cycles, if no failures are reported. (Euro 4
failure on the second consecutive driving cycle, the specification)
ECM records the operating conditions at the time • A history DTC clears after 40 consecutive driving
of failure and stores this information in the Freeze cycles, if no failures are reported. (Except Euro 4
Frame and updates the Failure Records. specification)
• Use a scan tool to clear the DTC.
Conditions for Clearing the MIL/ DTC - Type A or
Type B
• The ECM turns OFF the MIL after 3 consecutive
driving cycles when the diagnostic runs and does
not fail. (Euro 4 specification)
• The ECM turns OFF the MIL after 1 ignition cycle
when the diagnostic runs and does not fail. (Except
Euro 4 specification)
passes.
• A history DTC clears after 40 consecutive warm-up
cycles, if no failures are reported. (Euro 4
specification)
• A history DTC clears after 40 consecutive driving
cycles, if no failures are reported. (Except Euro 4
specification)
• Use a scan tool to clear the MIL and the DTC.
Non-Emissions Related DTCs

Action Taken When the DTC Sets - Type C
• The ECM illuminates the Service Vehicle Soon
(SVS) lamp when the diagnostic runs and fails.
• The ECM records the operating conditions at the
information in the Failure Records.
Conditions for Clearing the SVS Lamp/ DTC - Type

C
• The ECM turns OFF the SVS lamp after 1 driving
cycle when the diagnostic runs and does not fail.
passes.

Diagnostic Trouble Code (DTC) List
DTC Type
Flash Except
DTC Euro 4 DTC Descriptor
Code Euro 4
Spec.
Spec.
P0016 16 A A Crankshaft Position - Camshaft Position Correlation
P0045 33 A – Turbocharger Boost Control Solenoid Circuit
P0079 38 A – Exhaust Valve Control Solenoid Circuit Low
P0080 38 A – Exhaust Valve Control Solenoid Circuit High
P0087 225 A A Fuel Rail/ System Pressure Too Low
P0088 118 D A Fuel Rail/ System Pressure Too High (First Stage)
P0088 118 A A Fuel Rail/ System Pressure Too High (Second Stage)
P0089 151 A A Fuel Pressure Regulator Performance
P0091 247 A A Fuel Pressure Regulator Control Circuit Low
P0092 247 A A Fuel Pressure Regulator Control Circuit High
P0093 227 A A Fuel System Leak Detected
P0101 92 B – Mass Air Flow Sensor Circuit Range/ Performance
P0102 91 A – Mass Air Flow Sensor Circuit Low Input
P0103 91 A – Mass Air Flow Sensor Circuit High Input
P0107 32 A A Manifold Absolute Pressure Sensor Circuit Low Input
P0108 32 A A Manifold Absolute Pressure Sensor Circuit High Input
P0112 22 A A Intake Air Temperature Sensor Circuit Low
P0113 22 A A Intake Air Temperature Sensor Circuit High
P0116 23 B – Engine Coolant Temperature Sensor Circuit Range/ Performance
P0117 23 A A Engine Coolant Temperature Sensor Circuit Low
P0118 23 A A Engine Coolant Temperature Sensor Circuit High
P0122 43 A A Throttle Position Sensor Circuit Low
P0123 43 A A Throttle Position Sensor Circuit High
P0182 211 A A Fuel Temperature Sensor Circuit Low
P0183 211 A A Fuel Temperature Sensor Circuit High
P0192 245 A A Fuel Rail Pressure Sensor Circuit Low
P0193 245 A A Fuel Rail Pressure Sensor Circuit High
P0201 271 A A Injector Circuit Open - Cylinder 1
P0217 542 D D Engine Coolant Over Temperature Condition
P0219 543 D A Engine Overspeed Condition
P0234 42 A A Turbocharger Overboost Condition
P0299 65 B A Turbocharger Underboost
DTC Type
Flash Except
Code Euro 4
Spec.
Spec.
P0335 15 A A Crankshaft Position Sensor Circuit
P0336 15 A A Crankshaft Position Sensor Circuit Range/ Performance
P0340 14 A A Camshaft Position Sensor Circuit
P0341 14 A – Camshaft Position Sensor Circuit Range/ Performance
P0380 66 C A Glow Plug Circuit
P0381 67 C A Glow Plug Indicator Circuit
P0401 93 A – EGR Flow Insufficient Detected
P0404 45 A A EGR Control Circuit Range/ Performance
P0409 44 A A EGR Sensor Circuit
P0426 143 C – Catalyst Temperature Sensor Circuit Range/ Performance Sensor 1
P0427 48 A – Catalyst Temperature Sensor Circuit Low Sensor 1
P0428 48 A – Catalyst Temperature Sensor Circuit High Sensor 1
P042B 145 C – Catalyst Temperature Sensor Circuit Range/ Performance Sensor 2
P042C 49 C – Catalyst Temperature Sensor Circuit Low Sensor 2
P042D 49 C – Catalyst Temperature Sensor Circuit High Sensor 2
P0500 25 B A Vehicle Speed Sensor
P0502 25 A A Vehicle Speed Sensor Circuit Low Input
P0503 25 A A Vehicle Speed Sensor Circuit High Input
P0560 155 A – System Voltage
P0563 35 C A System Voltage High
P0571 26 C A Brake Switch Circuit
P0601 53 A A Internal Control Module Memory Check Sum Error
P0602 154 C A Control Module Programming Error
P0604 153 A A Internal Control Module RAM Error
P0606 51 A A ECM Processor
P060B 36 A A Internal Control Module A/D Processing Performance
P0633 176 C A Immobilizer not programmed
P0638 61 B A Throttle Actuator Control Range/ Performance
P0641 55 A A Sensor Reference Voltage 1 Circuit
P0650 77 A D Malfunction Indicator Lamp (MIL) Control Circuit
P0685 416 C A ECM Power Relay Control Circuit Open
P0687 416 C A ECM Power Relay Control Circuit High
P1093 227 A A Fuel Rail Pressure Too Low
P1261 34 A A Injector Positive Voltage Control Circuit Group 1
P1262 34 A A Injector Positive Voltage Control Circuit Group 2
P1404 45 A – EGR Position Fault (Closed Position Error)
P1404 45 A A EGR Position Fault (Learned Position Error)
DTC Type
Flash Except
Code Euro 4
Spec.
Spec.
P1455 132 A – PM Over Accumulation
P1471 149 A – DPD Insufficient Regeneration
P161B 179 C A Immobilizer wrong response
P1621 54 A A Control Module Long Term Memory Performance
P1664 76 C – Service Vehicle Soon Lamp Control Circuit
P1669 75 C – DPD Lamp Control Circuit
P2122 121 B A Pedal Position Sensor 1 Circuit Low Input
P2123 121 B A Pedal Position Sensor 1 Circuit High Input
P2127 122 B A Pedal Position Sensor 2 Circuit Low Input
P2128 122 B A Pedal Position Sensor 2 Circuit High Input
P2138 124 B A Pedal Position Sensor 1-2 Voltage Correlation
P2146 158 A A Fuel Injector Group 1 Supply Voltage Circuit
P2149 159 A A Fuel Injector Group 2 Supply Voltage Circuit
P215A 25 A – Vehicle Speed - Wheel Speed Correlation
P2227 71 B – Barometric Pressure Sensor Circuit Range/ Performance
P2228 71 A A Barometric Pressure Sensor Circuit Low
P2229 71 A A Barometric Pressure Sensor Circuit High
P242F 131 A – DPD Restriction
P2452 142 A – DPD Differential Pressure Sensor Circuit
P2453 141 A – DPD Differential Pressure Sensor Circuit Range/ Performance
P2454 47 A – DPD Differential Pressure Sensor Circuit Low
P2455 47 A – DPD Differential Pressure Sensor Circuit High
P2456 47 A – DPD Differential Pressure Sensor Learned Position
P2458 139 A – DPD Regeneration Duration
P253A 28 C A PTO Sensor Circuit
P256A 31 C A Engine Idle Speed Selector Sensor
U0073 84 B A Control Module Communication Bus Off
U0101 85 C A Lost Communication with TCM
U0110 87 A A Lost Communication with VNT System
U0167 177 C A Lost Communication With Vehicle Immobilizer Control Module
Overview Wirings
Overview Wirings
1/2
Cruise control switch

(Combination switch)
Cruise resume/accel. switch 65
Cruise set/coast switch
Cruise cancel switch
42
PTO throttle sensor 70 A
41
24 Ignition switch (on)
Idle up sensor 66 Ignition switch (start)
46
21 Key position
Main relay
40
Accelerator pedal position sensor 1 63 2
5 Dropping C
61 resistor
EURO 4 35
Accelerator pedal position sensor 2 64 Battery 24V
60 B
39 Case ground
81
BARO sensor 71 43 Signal ground
62 Signal ground
1 Power ground
23 EURO 4 3 Power ground
Mass air flow sensor 69 4 Power ground
22
Intake air temperature sensor 72 MIL A
6
7 Exhaust brake lamp
EURO 2 17 SVS lamp EURO 4
Intake air temperature sensor EURO 3
11 Glow plug lamp
80 EURO 4
ECM 9 DPD lamp
EURO 4
Exhaust differential pressure sensor
67 Oil pressure lamp
79 16 EURO 3
Exhaust temperature sensor 1 Oil pressure switch EURO 4
73
Exhaust temperature sensor 2 74 Glow relay
10
Vehicle speed sensor 19 C
Speed sensor C/U
Cruise control main switch Glow plug
25
DPD regeneration switch EURO 4
47
Clutch pedal switch Starter cut relay

26 14 B
Starter relay
Exhaust brake switch
A 45 15
Exhaust brake solenoid valve
Heater & A/C Refrigerant
relay pressure switch
34
8 Tachometer
C
A/C unit
Condenser A/C switch 38 EURO 2
fan relay EURO 3
1 2 3 4 5 6 7 8
Neutral switch 9 10 11 12 13 14 15 16
52
50
48 18
Parking brake switch
37
PTO switch 44
A EHCU TCM IP cluster BCM REA Air sus C/U
Oil level switch EURO 3
53 EURO 4
55
Brake switch 2
Stop light relay
A 54
Brake switch 1
MFWB1AXF001201

2/2
1 2 3 4 5 6 7 8 EURO 4
9 10 11 12 13 14 15 16
95
Crank shaft position sensor
107 58
109 Immobilizer
control unit
108 (ICU)
78
Boost pressure sensor 91

CAN resistor
ECM
EURO 3
Intake throttle position sensor EURO 4
85
EURO 3
112 M+ EURO 4
Engine coolant temperature sensor 84 M Intake throttle motor
M-
104
Fuel temperature sensor 83

121
Fuel injector 1 Cylinder #1
119
117
114
EURO 3
EURO 4 116
U 111 120
M V Fuel injector 4 Cylinder #6
EGR motor 103
W 118
110 Fuel injector 6 Cylinder #4
115
U 105
94 Fuel rail pressure regulator
V 113
EGR position sensor 93
W 89
99
97
Exhaust throttle solenoid valve
102 B EURO 4
87
Camshaft position sensor
98
101
100
Ground
68
82
Fuel rail pressure sensor
90
MFWB1AXF001301
Routing Diagrams
Fuel System Routing Diagram
2 5
3
1
12
10 7
11 9 6
8
MFWB1AMF000801
Legend
1. Fuel rail 7. Pre fuel filter
2. Fuel rail pressure (FRP) sensor 8. Fuel filter (with water separator)
3. Leak off pipe 9. Recirculation valve (with a built in fuel filter)
4. Engine control module (ECM) 10. Fuel supply pump
5. Fuel injector 11. Fuel temperature (FT) sensor
6. Fuel tank 12. Fuel rail pressure (FRP) regulator
Component Locator
Engine Controls Component Views
MFW81ASF000701
Legend
1. Speed sensor control unit 3. Barometric pressure (BARO) sensor
2. Accelerator pedal position (APP) sensor
3 2
MFW76EMF000701
Legend
1. Boost pressure sensor 3. Fuel rail pressure (FRP) sensor
2. Pressure limiter valve
3 MFW81ASF000601
Legend
1. Camshaft position (CMP) sensor 3. Rotary electric actuator (REA)
2. Turbocharger
3 2
MFWB1AMF000701
Legend
1. Intake throttle valve 3. Engine coolant temperature (ECT) sensor
2. Exhaust gas recirculation (EGR) valve
3
MFW76EMF000601
Legend
1. Fuel temperature (FT) sensor 3. Crankshaft position (CKP) sensor
2. Fuel rail pressure (FRP) regulator
1 2 3 4 5 6
MFW76ESF000301
Legend
1. Fuel injector No.1 cylinder 4. Fuel injector No.4 cylinder
4
1
2
3
MFW76ESF000201
Legend
1. Exhaust brake valve 4. Exhaust differential pressure sensor
2. Exhaust temperature sensor 2 (in front of oxidation 5. Exhaust throttle valve
catalyst) 6. DPD assembly
3. Exhaust temperature sensor 1 (in front of filter)
1 2
MFW81ASF001301
Legend
1. Mass air flow (MAF) sensor/ intake air temperature 2. Intake air temperature (IAT) sensor (except Euro 4
(IAT) sensor (Euro 4 specification) specification)
MFW76ESF000701
Legend
1. Sensor cover 2. Vehicle speed sensor (VSS)
1 2
MFW81ASF000501
Legend
1. CAN resistor (LHD) (with immobilizer model) 2. CAN resistor (RHD) (with immobilizer model)
MFW71AMF000301
Legend
1. Engine control module (ECM) 2. Dropping resistor

Engine Control Module (ECM) Connector Connector No. FB24
End Views Connector color Black
Engine Control Module (ECM)
Test adapter No. J-35616-64A
Pin No. Wire color Pin function
VSS signal (with digital
tachograph) or vehicle speed
19 YEL/ GRN
signal from speed sensor control
unit (without digital tachograph)
20 – Not used
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 5 4 21 BLU/ WHT ECM main relay control

25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
3 MAF sensor low reference (Euro 4
44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 22 BLK
63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 2 1
specification)
MAF sensor 12 volts reference
23 RED
(Euro 4 specification)
24 BLK/ BLU Ignition voltage
25 RED/ WHT Cruise control main switch signal
Clutch pedal switch signal
26 WHT/ BLU
LNW76ESH001501 (manual transmission)
27 – Not used
Connector No. FB24 28 – Not used
Connector color Black 29 – Not used
Test adapter No. J-35616-64A 30 – Not used
Pin No. Wire color Pin function 31 – Not used
1 BLK/ YEL ECM power ground 32 – Not used
2 WHT/ RED Battery voltage 33 – Not used
3 BLK/ YEL ECM power ground 34 BRN/ YEL A/C signal
4 BLK/ YEL ECM power ground Dropping resistor (Euro 4

35 GRN
specification)
5 WHT/ RED Battery voltage
36 – Not used
6 YEL/ BLK MIL control
37 BLU CAN low signal
7 BRN/ GRN Exhaust brake lamp control
Keyword 2000 serial data (except
8 LT GRN Engine speed signal output 38 LT BLU
Euro 4 specification)
LT GRN/ DPD amber lamp control (Euro 4 PTO throttle sensor, idle up
9
BLK specification) 39 GRY sensor and BARO sensor shield
10 WHT/ GRN Glow relay control ground
11 ORN/ BLU Glow plug lamp control 40 BLU/ WHT ECM main relay control
12 – Not used APP sensor 1, idle up sensor,

41 BLK cruise control switch and PTO
13 – Not used throttle sensor low reference
14 BLK/ RED Starter cut relay control APP sensor 1, idle up sensor and
Exhaust brake solenoid valve 42 WHT PTO throttle sensor 5 volts
15 GRN/ RED reference
control
16 BLU/ YEL Engine oil level lamp control 43 BLK/ YEL ECM signal ground
SVS lamp control (Euro 4 44 VIO/ WHT PTO switch signal

17 BLU/ BLK
specification) LT GRN/
45 Exhaust brake switch signal
18 BLU/ WHT CAN high signal RED
46 BLK/ WHT Ignition switch signal
Connector No. FB24 Connector No. FB24

Connector color Black Connector color Black
Test adapter No. J-35616-64A Test adapter No. J-35616-64A
Pin No. Wire color Pin function Pin No. Wire color Pin function
DPD regeneration switch signal Exhaust differential pressure
47 RED/ GRN
(Euro 4 specification) sensor, exhaust temperature
79 BLK sensor 1 and exhaust temperature
48 YEL Parking brake switch signal
sensor 2 low reference (Euro 4
49 – Not used specification)
50 BLK/ GRN Neutral switch signal Exhaust differential pressure
80 WHT/ ORN sensor 5 volts reference (Euro 4
51 – Not used specification)
52 GRY/ WHT Diagnostic request switch 81 BLK/ YEL ECM case ground
Engine oil level switch signal
53 VIO/ YEL
(except Euro 2 specification)
54 GRN/ BLK Brake switch 1 signal
55 GRN/ ORN Brake switch 2 signal
56 – Not used
57 – Not used
58 GRN/ WHT CAN high signal
121 120 119 113 112 111 110 109 108 107 106
59 – Not used 105 104 103 102 101 100 99 98
118 117
APP sensor 2, BARO sensor and 97 96 95 94 93 92 91 90
60 BLU 116 115 114 89 88 87 86 85 84 83 82
IAT sensor low reference
APP sensor 2 and BARO sensor 5
61 GRN
volts reference
62 BLK/ YEL ECM signal ground
63 RED APP sensor 1 signal
64 YEL APP sensor 2 signal LNW76ESH001601
65 BRN/ BLU Cruise control switch signal

66 YEL/ BRN Idle up sensor signal Connector No. E26
Exhaust differential pressure Connector color Black
67 GRN/ YEL sensor signal (Euro 4
specification) Test adapter No. J-35616-64A
68 BLK/ YEL Ground Pin No. Wire color Pin function
MAF sensor signal (Euro 4 82 BLK FRP sensor signal

69 WHT/ BLK
specification) LT GRN/
83 FT sensor signal
70 RED PTO throttle sensor signal WHT
71 WHT/ RED BARO sensor signal 84 GRN/ YEL ECT sensor signal
72 GRN/ WHT IAT sensor signal Intake throttle position sensor

85 VIO/ WHT signal (except Euro 2
Exhaust temperature sensor 1 specification)
73 YEL/ RED
signal (Euro 4 specification)
86 – Not used
Exhaust temperature sensor 2
74 RED/ YEL CMP sensor, FRP sensor and
signal (Euro 4 specification)
87 LT GRN EGR position sensor 5 volts
75 – Not used reference
76 – Not used 88 – Not used
77 – Not used 89 GRN/ BLK FRP regulator low side
78 GRN CAN low signal 90 BLK FRP sensor signal
Connector No. E26 Connector No. E26

Connector color Black Connector color Black
Test adapter No. J-35616-64A Test adapter No. J-35616-64A
Pin No. Wire color Pin function Pin No. Wire color Pin function
91 WHT Boost pressure sensor signal Common 2 (cylinder #4, #5 and
116 RED
#6) fuel injector charge voltage
92 – Not used
117 WHT/ BLU Cylinder #3 fuel injector control
EGR position sensor signal 2
93 BRN
(except Euro 2 specification) 118 BLK/ WHT Cylinder #6 fuel injector control
EGR position sensor signal 1 119 YEL Cylinder #1 fuel injector control
94 BLU
120 BLK/ BLU Cylinder #5 fuel injector control
CKP sensor, intake throttle
Common 1 (cylinder #1, #2 and
95 YEL position sensor and boost 121 WHT
#3) fuel injector charge voltage
pressure sensor 5 volts reference
96 – Not used
97 GRN/ BLK FRP regulator low side Engine Control Connector End Views
98 WHT CMP sensor signal Accelerator Pedal Position (APP) Sensor
EGR position sensor signal 3
99 GRY
CMP sensor and FRP sensor
100 BLK
shield ground
CMP sensor, FRP sensor and
101 YEL/ BLK EGR position sensor low
reference
Exhaust throttle solenoid valve 1 2 3
102 GRN/ ORN
control (Euro 4 specification)
EGR motor control 2 (PWM) 4 5 6
103 ORN
Intake throttle motor low side
104 GRN (PWM) (except Euro 2
specification)
FRP regulator control high side
105 WHT/ RED
(PWM)
RTW76ESH001201
106 – Not used
107 LT BLU CKP sensor signal
Connector No. FL1
CKP sensor and boost pressure
108 BLK Connector color Gray
sensor shield ground
CKP sensor, intake throttle Test adapter No. J-35616-33
position sensor, FT sensor, ECT Pin No. Wire color Pin function
109 BLK
sensor and boost pressure sensor
low reference APP sensor 2
1 GRN
5 volts reference
EGR motor control 3 (PWM)
110 BLK/ RED
(except Euro 2 specification) 2 YEL APP sensor 2 signal
LT GRN/ EGR motor control 1 (PWM) 3 BLU APP sensor 2 low reference
111
RED (except Euro 2 specification)
APP sensor 1
4 WHT
Intake throttle motor drive voltage 5 volts reference
112 BLK/ BLU
5 RED APP sensor 1 signal
FRP regulator control high side
113 WHT/ RED 6 BLK APP sensor 1 low reference
(PWM)
114 BLK/ RED Cylinder #2 fuel injector control
115 BLK/ RED Cylinder #4 fuel injector control

Barometric Pressure (BARO) Sensor
Connector No. E54
Connector color Black
Test adapter No. J-35616-33
1 WHT Sensor signal
2 BLK Sensor low reference
3 YEL Sensor 5 volts reference
1 2 3 Brake Switch 1
RTW76ESH000901
Connector No. FL52

Connector color Black 1 2
1 BLU Sensor low reference
2 WHT/ RED Sensor signal
3 GRN Sensor 5 volts reference
MFW81ASH001001
Boost Pressure Sensor

Connector No. FU159
1 GRN/ BLK Switch signal
2 BLK Switch ground
123
LNW46ESH001501

Brake Switch 2 Connector No. FU179
Connector color White
2 WHT/ BLU Switch signal
Camshaft Position (CMP) Sensor
1 2
MFW81ASH001001 1 2 3
Connector No. FB5 or FB144

RTW76ESH000701
1 GRN/ ORN Switch signal
2 BLK/ YEL Switch ground
Connector No. E48
Clutch Pedal Switch Connector color Black
1 WHT Sensor signal
2 YEL/ BLK Sensor low reference
3 LT GRN Sensor 5 volts reference
Crankshaft Position (CKP) Sensor

1
2
LNW46ESH000801
1 2 3
Connector No. FU179
1 BLK/ ORN Ignition voltage feed
RTW76ESH000701

Data Link Connector (DLC)
Connector No. E50
1 LT BLU Sensor signal
1 2 3 4 5 6 7 8
3 YEL Sensor 5 volts reference
9 10 11 12 13 14 15 16
Cruise Control Main Switch
LNW81ASH001401
Connector No. FU23

1 2 3 4
Connector color Light blue
5 6 7 8 9 10
1 – Not used
LT GRN/ Class 2 serial data (EHCU [ABS
2
RED module])
LNW76ESH004201 3 – Not used
4 BLK Ground
Connector No. FU208 5 BLK Ground
Connector color Brown 6 GRN/ WHT CAN high (Euro 4 specification)
Test adapter No. J-35616-33 Keyword serial data (ECM
[except Euro 4 specification], air
7 LT BLU suspension control unit, TCM,
1 – Not used SRS control unit, ICU, BCM and
IP cluster)
2 – Not used
Class 2 serial data (ABS control
Cruise control main switch 8 PNK
3 BLK/ ORN unit)
ignition voltage feed
Keyword serial data (HSA control
4 RED/ WHT Cruise control main switch signal 9 RED/ WHT
unit)
7 BLK Illumination lamp ground Diagnostic request switch (ECM
LT GRN/ [except Euro 4 specification], air
8 Illumination lamp voltage feed 12 GRY/ WHT
RED suspension control unit, IP
cluster and SRS control unit)
9 – Not used
LT GRN/ Diagnostic request switch (EHCU
10 – Not used BLU [ABS module])
13
Diagnostic request switch (ABS
WHT/ VIO
control unit)
14 GRN CAN low (Euro 4 specification)
Connector No. FU23 EGR Valve
Connector color Light blue

15 – Not used
16 RED Battery voltage
DPD Regeneration Switch

1 2 3 4
5 6 7 8
RTW76ESH002801
1 2 3 4
5 6 7 8 9 10
Connector No. E45
1 LT GRN Position sensor 5 volts reference
LNW76ESH004201
2 GRY Position sensor signal 3
3 BRN Position sensor signal 2
Connector No. FU142
4 BLU Position sensor signal 1
Connector color Blue
5 YEL/ BLK Position sensor low reference
6 BLK/ RED Motor control 3
7 ORN Motor control 2
1 BLK/ ORN Switch voltage feed
LT GRN/
8 Motor control 1
2 RED/ GRN Switch signal RED
3 – Not used
Engine Coolant Temperature (ECT) Sensor
4 – Not used
5 – Not used
6 – Not used
7 BLK Illumination lamp ground
LT GRN/
8 Illumination lamp voltage feed
RED
9 – Not used
10 – Not used
1 2
LNW46ESH001201

Exhaust Differential Pressure Sensor
Connector No. E55
Connector color Gray
1 GRN/ YEL Sensor signal
Exhaust Brake Solenoid Valve 1 2 3
RTW76ESH001301
1 2 Connector No. FB66

2 GRN/ YEL Sensor signal
LNW66ESH001101
3 WHT/ ORN Sensor 5 volts reference
Connector No. FB41 or J8 Exhaust Temperature Sensor 1

1 GRN/ BLK Ignition voltage feed
2 GRN/ RED Solenoid valve control
2 1
RTW76ESH001601

Exhaust Throttle Solenoid Valve
Connector No. FB67
Connector color Light gray
2 YEL/ RED Sensor signal
Exhaust Temperature Sensor 2 1 2
LNW66ESH001101
2 1 Connector No. FB112

1 GRN/ BLK Battery voltage feed
2 GRN/ ORN Solenoid valve ground
RTW76ESH000301
Fuel Injector #1 to #6 Cylinder

Connector No. FB68
Connector color Dark gray
Pin No. Wire color Pin function 3 2 1
2 RED/ YEL Sensor signal
LNW46ESH001001
E71, E72, E73

Connector No.
E74, E75 and E76
1 #1, #3 and #5:
WHT
Charge voltage
2 #2, #4 and #6:
RED
E71, E72, E73 Fuel Rail Pressure (FRP) Sensor

Connector No.
E74, E75 and E76
#1: GRN
#2: BRN
#3: YEL
3 Fuel injector control
#4: VIO
#5: BLU
#6: BLK
Fuel Rail Pressure (FRP) Regulator

123
LNW46ESH001501
1 2 Connector No.
Connector color
E49
Black
1 YEL/ BLK Sensor low reference
2 BLK Sensor signal
LNW46ESH001101
3 LT GRN Sensor 5 volts reference
Connector No. E47 Fuel Temperature (FT) Sensor

Regulator control high side
1 WHT/ RED
(PWM)
2 GRN/ BLK Regulator low side
1 2
LNW46ESH001201

Mass Air Flow (MAF)/ Intake Air Temperature (IAT)
Sensor (Euro 4 Specification)
Connector No. E30
LT GRN/
2 Sensor signal
WHT
Glow Plug 1 2 3 4 5
LNW46ESH001801
Connector No. J14 or FB128

1 RED MAF sensor 12 volts reference
2 BLK MAF sensor low reference
LNW46ESH000701
3 WHT/ BLK MAF sensor signal
4 GRN/ WHT IAT sensor signal
Connector No. E31
5 BLU IAT sensor low reference
Connector color –
Pin No. Wire color Pin function Intake Air Temperature (IAT) Sensor (Except Euro 4
1 BLK/ RED Power Supply Specification)
1 2
LNW81ASH001701

Idle Up Sensor
Connector No. J194 or FB196
1 GRN/ WHT Sensor signal
2 BLU Sensor low reference
Intake Throttle Valve 1 2 3
LNW46ESH002601
1 2 3 4 5 6 Connector No. FL33

BLU/ RED
1 Sensor low reference
BLK
RTW76ESH000401
YEL/ GRN
2 Sensor signal
YEL/ BRN
Connector No. E46
BLU
Connector color Black 3 Sensor 5 volts reference
WHT
Pin No. Wire color Pin function PTO Throttle Sensor
1 GRN Motor control low side (PWM)
2 BLK/ BLU Motor drive voltage
3 – Not used
4 BLK Position sensor low reference
5 YEL Position sensor 5 volts reference
6 VIO/ WHT Position sensor signal
1 2 3
LNW81ASH001601

Vehicle Speed Sensor (VSS)
Connector No. FB129
2 RED Sensor signal
3 WHT Sensor 5 volts reference
1 2 3
Rotary Electric Actuator (REA)
RTW76ESH000701
Connector No. FB156, FB157 or J117

1 2 3
4 5 6
1 GRN Ignition voltage feed
3 GRY Sensor signal
MFW76ESH001601
Connector No. E10

1 RED CAN high
2 – Not used
3 GRN/ BLK Voltage feed
4 GRN CAN low
5 – Not used
6 BLK ground
Diagnostic Information and Procedures

Engine Control System Check Sheet
ENGINE CONTROL SYSTEM CHECK SHEET Inspectors Name

Customers Name Model & Model Year
Drivers Name Chassis No.
Date Vehicle Brought In Engine No.
License No. Odometer Reading km/miles
Engine Does Engine does not crank No initial combustion No complete combustion
Not Run
Hard Start Engine cranks slowly Other ( )
Abnormal idling speed High idling speed ( RPM) Low idling speed ( RPM)
Problem Symptoms
Incorrect Idle Rough idling

Other ( )
Hesitation, sag, stumble Surge Cut out
Poor Lack of power, sluggishness, sponginess
Driveability
Other ( )
Soon after starting After accelerator pedal depressed
Engine Stall During A/C operation After accelerator pedal released Shifting from N to D
Other ( )
Black smoke White smoke Poor fuel economy
Others Abnormal combustion noise DPD manual regeneration frequently
DPD regeneration long time
Other ( )
Dates problem occurred
Problem frequency Constant Intermittently ( times per day/month) Once only
Other ( )
Weather Fine Cloudy Rainy Snow
Various/Other ( )
Outside Hot (approx. ) Warm Cool Cold (approx. )
Condition When Problem Occurs
Temperature Any temperature

Highway Suburbs City area Uphill
Place
Downhill Rough road Other ( )
Load Condition Over (approx. tons) No load
Other (approx. tons)
Engine Cold Warming up After warming up Any temperature
Temperature Other ( )
Starting Just after starting ( Min.) Idling
Engine Operation Racing Driving Constant speed Acceleration
Deceleration A/C switch On/Off
Other ( )
Fuel Amount Full Above 1/2 Below 1/2 Near empty
Fuel Bland
Condition of MIL or SVS lamp Remains On Intermittently turns On Does not turn On
Present Code Nothing P or U Code

No. ( )
Diagnostic Trouble
Code (DTC) or Flash
Code P or U Code
History Code Nothing No. ( )
DPD lamp or MID indicator Blinked Did not blink

DPD switch Pushed Did not push
DPD accumulation status 1 2 3 4 5
DPD System
DPD distance status 1 2 3 4
DPD incomplete regeneration status 0 1 2
DPD insufficient regeneration status 0 1 2
Exhaust differential pressure at instructed conditions kPa
Averaged MAF when exhaust differential pressure is measured g/s
LNW81AXF000101

Diagnostic Starting Point - Engine Controls Reading Flash Diagnostic Trouble Codes (DTC)
Begin the system diagnosis with Diagnostic System The provision for communicating with the ECM is the
Check - Engine Controls. The Diagnostic System Data Link Connector (DLC). The DTC(s) stored in the
Check - Engine Controls will provide the following ECM memory can be read either through a hand-held
information: diagnostic scanner such as Tech 2 plugged into the
• The identification of the control modules which DLC or by counting the number of flashes of the
command the system. malfunction indicator lamp (MIL) or the service vehicle
soon (SVS) lamp when the diagnostic test terminal of
• The ability of the control modules to communicate the DLC is grounded. The DLC terminal "12"
through the serial data circuit. (diagnostic request) is pulled "Low" (grounded) by
• The identification of any stored diagnostic trouble jumped to DLC terminal "4", which is a ground wire.
codes (DTCs) and the their statuses. Once terminals "12" and "4" have been connected, turn
The use of the Diagnostic System Check - Engine the ignition switch ON, with the engine OFF. The MIL
Controls will identify the correct procedure for (except Euro 4 specification) or the SVS lamp (Euro 4
diagnosing the system and where the procedure is specification) will indicate a DTC three times is a DTC
located. is present and history. If more than one DTC has been
stored in the ECM's memory, the DTCs will be output
Important: Engine Control System Check Sheet must numerical order with each DTC being displayed three
be used to verify the customer complaint, you need to times. The flash DTC display will continue as long as
know the correct (normal) operating behavior of the the DLC is shorted.
system and verify that the customer complaint is a valid
failure of the system.
Example:DTC 23 stored 2 3 Unit: Second
1.2 1.2 0.3 0.3 0.3
ON
OFF
2.4 0.6 0.6 0.6 0.6 2.4
2nd digit number 1st digit number
Example:DTC 225 stored 2 2 5
0.3 0.3 1.2 1.2 0.3 0.3 0.3 0.3 0.3
ON
OFF
2.4 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 2.4
3rd digit 2nd digit number 1st digit number

number
LNW76ESF000101
Diagnostic Trouble Codes (DTC) Clear Method by

Accelerator Pedal Operation (Except Euro 4 Notice: DO NOT touch the accelerator pedal when it is
Specification) released. Clearing DTCs may fail.
If there is no scan tool, history DTCs can be cleared
using accelerator pedal operation.
1. Turn ON the ignition, with the engine OFF.
2. Use a jumper wire and the DLC terminal "12"
(diagnostic request) is pulled "Low" (grounded) by
jumped to DLC terminal "4".
3. Depress accelerator pedal within 1 to 3 seconds.
4. Release accelerator pedal within 1 to 3 seconds.

Diagnostic System Check - Engine Diagnostic System Check Engine Controls
Controls Important:
Description • DO NOT perform this diagnostic if there is not a
driveability concern, unless another procedure
The Diagnostic System Check - Engine Controls is an
directs you to this diagnostic.
organized approach to identifying a condition that is
created by a malfunction in the electronic engine • Before you proceed with diagnosis, search for
control system. The Diagnostic System Check must be applicable service bulletins.
the starting point for any driveability concern. The • Unless a diagnostic procedure instructs you, DO
Diagnostic System Check directs the service technician NOT clear the DTCs.
to the next logical step in order to diagnose the • If there is a condition with the starting system, refer
concern. Understanding and correctly using the to Starting System in Section 1E Engine Electrical.
diagnostic table reduces diagnostic time, and prevents
• Ensure the battery has a full charge.
the replacement of good parts.
• Ensure the battery cables (+) (-) are clean and
Test Description tight.
The numbers below refer to the step numbers on the • Ensure the ECM grounds are clean, tight, and in
diagnostic table. the correct location.
2. Lack of communication may be because of a partial • Ensure the ECM harness connectors are clean
or a total malfunction of the serial data circuit. and correctly connected. DO NOT attempt to crank
7. The presence of DTCs which begin with U, indicate the engine with ECM harness connectors
that some other module is not communicating. disconnect.
10. If there are other modules with DTCs set, refer to • Ensure the ECM terminals are clean and correctly
the DTC list. The DTC list directs you to the appropriate mating.
diagnostic procedure. If the control module stores • Ensure the fuel injector ID code data is correctly
multiple DTCs, diagnose the DTCs in the following programmed in to the ECM.
order:
• Ensure the immobilizer security information is
• Component level DTCs, such as sensor DTCs, correctly programmed into the ECM and
solenoid DTCs, actuator DTCs, and relay DTCs. immobilizer control unit (ICU).
Diagnose the multiple DTCs within this category in
numerical order. Begin with the lowest numbered • If there are fuel system DTC’s (P0087, P0088,
DTC, unless the diagnostic table directs you P0089, P0093 or P1093), diagnose sensor DTCs,
otherwise. solenoid DTCs, actuator DTCs and relay DTCs
first.
• If there are DPD system DTC's (P1455, P1471,
P242F, P2452, P2453 or P2458), diagnose sensor
DTCs, solenoid DTCs, actuator DTCs and relay
DTCs first.
Diagnostic System Check - Engine Controls (Euro 4 Specification)
Step Action Value(s) Yes No

Install a scan tool.
1 — Go to Scan Tool
Does the scan tool turn ON? Go to Step 2 Does Not Power Up
2. Attempt to establish communication with the Go to Scan Tool
2 ECM. — Does Not
Communicate with
Does the scan tool communicate with the ECM? Go to Step 3 CAN Device
Notice: If an immobilizer system is active the ECM
will disable the fuel injection causing the engine to
stall immediately after starting and energize the
3 starter cut relay to disable cranking. Attempt to —
crank the engine.
Does the engine crank? Go to Step 4 Go to Step 5

Attempt to start the engine. Go to Engine
4 — Cranks but Does
Does the engine start and idle? Go to Step 6 Not Run

Does the scan tool display ECM DTCs P0633, Problem is relating
P161B or U0167? to starting system.
5 — Refer to Starting
Go to Applicable System in Section
DTC 1E Engine Electrical
Select the DTC display function for the following
control modules:
• ECM
• Transmission control module (TCM) (Smoother
6 only) —
• Electronic hydraulic control unit (EHCU) [ABS
module] or ABS control unit (If so equipped)
• Immobilizer control unit (ICU) (If so equipped)
Does the scan tool display any DTCs? Go to Step 7 Go to Step 11

Does the scan tool display DTCs which begin with
7 U or other control module communication fault — Go to Applicable
DTCs? DTC Go to Step 8
Does the scan tool display ECM DTCs P0601, Go to Applicable
8 —
P0602, P0604, P0606, P060B or P1621? DTC Go to Step 9
Does the scan tool display ECM DTC P0563? Go to Applicable
9 —
DTC Go to Step 10
Is there any other code in any controller that has Go to Applicable
10 —
not been diagnosed? DTC Go to Step 11
Is the customer's concern with the transmission? Go to Diagnostic
System Check-
Transmission
11 —
Controls in Section
5A Transmission
Control System Go to Step 12
Is the customer's concern with the anti-lock brake Go to Diagnostic
system? System Check -
12 — ABS Controls in
Section 4C1 ABS/
ASR or 4C ABS Go to Step 13
Is the customer’s concern with the immobilizer Go to Diagnostic
13 — Immobilizer
Controls in Section
9I Security and Lock Go to Step 14

1. Review the following symptoms.
2. Refer to the applicable symptom diagnostic
table:
• Hard Start
• Rough, Unstable, or Incorrect Idle and
Stalling
• High Idle Speed
• Cuts Out
• Surges
• Lack of Power, Sluggishness or
14 Sponginess —
• Hesitation, Sag or Stumble
• Abnormal Combustion Noise
• Poor Fuel Economy
• Excessive Smoke (Black Smoke)
• Excessive Smoke (White Smoke)
• DPD System Manual Regeneration
Frequently
• DPD System Regeneration Long Time
Go to Intermittent
Did you find and correct the condition? System OK Conditions
Diagnostic System Check - Engine Controls (Except Euro 4 Specification)

Install a scan tool.
1 — Go to Scan Tool
Does the scan tool turn ON? Go to Step 2 Does Not Power Up
2. Attempt to establish communication with the
listed control modules.
• ECM
• Hill start aid (HSA) control unit (If so
equipped)
2 —
• Supplemental restraint system (SRS)
control unit (If so equipped)
• Immobilizer control unit (ICU) (If so
equipped) Go to Scan Tool
Does Not
Does the scan tool communicate with all the listed Communicate with
control modules? Go to Step 3 Keyword Device
Notice: If an immobilizer system is active the ECM
will disable the fuel injection causing the engine to
stall immediately after starting and energize the
3 starter cut relay to disable cranking. Attempt to —
crank the engine.
Does the engine crank? Go to Step 4 Go to Step 5

Attempt to start the engine. Go to Engine
4 — Cranks but Does
Does the engine start and idle? Go to Step 6 Not Run
Does the scan tool display ECM DTCs P0633, Problem is relating
P161B or U0167? to starting system.
5 — Refer to Starting
Go to Applicable System in Section
DTC 1E Engine Electrical

Select the DTC display function for the following
control modules:
• ECM
• EHCU or ABS control unit (If so equipped)
6 • HSA control unit (If so equipped) —
• SRS control unit (If so equipped)
• ICU (If so equipped)
Does the scan tool display any DTCs? Go to Step 7 Go to Step 11

Does the scan tool display DTCs which begin with
7 U or other control module communication fault — Go to Applicable
DTCs? DTC Go to Step 8
Does the scan tool display ECM DTCs P0601, Go to Applicable
8 —
P0602, P0604, P0606, P060B or P1621? DTC Go to Step 9
Does the scan tool display ECM DTC P0563? Go to Applicable
9 —
DTC Go to Step 10
Is there any other code in any controller that has Go to Applicable
10 —
not been diagnosed? DTC Go to Step 11
Is the customer's concern with the anti-lock brake Go to Diagnostic
11 — ABS Controls in
Section 4C1 ABS/
ASR or 4C ABS Go to Step 12
Is the customer's concern with the HSA system? Go to Diagnostic
System Check -
12 —
HSA Controls in
Section 4E HSA Go to Step 13
Is the customer's concern with the SRS airbag Go to Diagnostic
13 — SRS Controls in
Section 8C SRS
Control System Go to Step 14
Is the customer’s concern with the immobilizer Go to Diagnostic
14 — Immobilizer
Controls in Section
9I Security and Lock Go to Step 15
1. Review the following symptoms.
2. Refer to the applicable symptom diagnostic
table:
• Hard Start
• Rough, Unstable, or Incorrect Idle and
Stalling
• High Idle Speed
• Cuts Out
15 • Surges —
• Lack of Power, Sluggishness or
Sponginess
Go to Intermittent
Did you find and correct the condition? System OK Conditions

Scan Tool Data List • The Engine Controls - Diagnostic System Check is
completed.
The Engine Scan Tool Data List contains all engine
related parameters that are available on the scan tool. • On-board diagnostics are functioning properly.
A given parameter may appear in any one of the data Scan tool values from a properly running engine may
lists, and in some cases may appear more than once, be used for comparison with the engine you are
or in more than one data list in order to group certain diagnosing. The Engine Scan Tool Data List represents
related parameters together. Use the Engine Scan Tool values that would be seen on a normal running engine.
Data List only after the following is determined: Only the parameters listed below are referenced in this
service manual for use in diagnosis.
Scan Tool Parameter Units Displayed Typical Data Value at Engine Idle Typical Data Value at 1400 RPM
Operating Conditions: Engine idling or 1400 RPM/ Engine coolant temperature is between 75 to 85°C (167 to 185°F)/
Accelerator pedal is constant/ Neutral or Park/ Accessories OFF/ Vehicle located at sea level/ DPD is not under regeneration
Engine Speed RPM Nearly 525 RPM Nearly 1400 RPM
Desired Idle Speed RPM 525 RPM 525 RPM
Calculated Engine Load % Less than 25% Less than 20%
Coolant Temperature °C/ °F 75 to 85°C/ 167 to 185°F 75 to 85°C/ 167 to 185°F
Engine Coolant Temperature Volts 0.4 to 0.6 volts 0.4 to 0.6 volts
Sensor
Intake Air Temperature °C/ °F 20 to 40°C/ 68 to 104°F 20 to 40°C/ 68 to 104°F
Intake Air Temperature Sensor Volts 1.4 to 2.3 volts 1.4 to 2.3 volts
Fuel Temperature °C/ °F 20 to 60°C/ 50 to 140°F 20 to 60°C / 50 to 140°F
Fuel Temperature Sensor Volts 0.8 to 2.3 volts 0.8 to 2.3 volts
Averaged MAF (Mass Air Flow) g/ s More than 20 g/ s at sea level More than 50 g/ s at sea level
MAF (Mass Air Flow) g /cyl More than 0.8 g/cyl at sea level More than 0.7 g/cyl at sea level
MAF Sensor (Mass Air Flow) Volts More than 1.5 volts at sea level More than 2.3 volts at sea level
Barometric Pressure kPa/ psi Nearly 100 kPa/ 14.5 psi at sea Nearly 100 kPa/ 14.5 psi at sea
level level
Barometric Pressure Sensor Volts Nearly 2.3 volts at sea level Nearly 2.3 volts at sea level
Desired Turbocharger Position % 10 to 20% 25 to 35%
Desired Boost Pressure kPa/ psi Nearly 100 kPa/ 14.5 psi at sea Less than 115 kPa/ 16.7 psi at
level sea level
Boost Pressure kPa/ psi Nearly 100 kPa/ 14.5 psi at sea Less than 115 kPa/ 16.7 psi at
level sea level
Boost Pressure Sensor Volts Nearly 1.0 volt at sea level Less than 1.3 volts at sea level
Desired Fuel Rail Pressure MPa/ psi Nearly 32 MPa/ 4,600 psi More than 70 MPa/ 10,000 psi
Fuel Rail Pressure MPa/ psi 28 to 35 MPa/ 4,000 to 5,000 psi More than 70 MPa/ 10,000 psi
Fuel Rail Pressure Sensor Volts 1.4 to 1.6 volts More than 2.0 volts
FRP Regulator Command (Fuel % 30 to 45% 25 to 35%
Rail Pressure)
FRP Regulator Commanded Fuel mm3/sec 900 to 1100 mm3/sec More than 3500 mm3/sec
Flow
FRP Regulator Feedback Current mA 900 to 1100 mA 800 to 900 mA
(Fuel Rail Pressure)
Accelerator Pedal Position % 0% 23 to 30%
APP Sensor 1 (Accelerator Pedal Volts 0.3 to 0.7 volts 1.2 to 1.6 volts
Position)
APP Sensor 2 (Accelerator Pedal Volts 4.1 to 4.5 volts 3.4 to 3.8 volts
Position)
Desired EGR Position % 0% Less than 35%
EGR Position 1 % 0% Less than 35%
EGR Position 1 Low/ High Low or High Low or High
Intake Throttle Solenoid % 0% 0%
Command
Desired Intake Throttle Position % More than 90% More than 90%
Intake Throttle Position % More than 100% More than 100%
Intake Throttle Position Sensor Volts More than 3.9 volts More than 3.9 volts
Idle-Up Sensor Volts 0.3 to 0.6 volts 0.3 to 0.6 volts
Fuel Compensation Cyl. 1 mm3 -5.0 to 5.0 mm3 (varies) 0.0 mm3
Fuel Supply Pump Status Not Learned/ Learned Learned
Learned
Rail Pressure Feedback Mode Wait Mode/ Feedback Mode Feedback Mode
Feedback Mode/
Shutoff Mode/ Wait
to Restart
Engine Running Status Off/ Ignition On/ Running Running
Cranking/ Running
Engine Runtime Time (hour: Varies Varies
minute: second)
Vehicle Speed km/h/ MPH 0 km/h/ 0 MPH 0 km/h/ 0 MPH
Starter Switch On/ Off Off Off
Ignition Switch On/ Off On On
Ignition Voltage Volts 22.0 to 30.0 volts 22.0 to 30.0 volts
Battery Voltage Volts 22.0 to 30.0 volts 22.0 to 30.0 volts
Brake Switch 1 Applied/ Released Released Released
Brake Switch 2 Applied/ Released Released Released
Clutch Pedal Switch Applied/ Released Applied or Released Applied or Released
Neutral Switch Neutral/ In Gear Neutral Neutral
Park Brake Switch Applied/Released Applied or Released Applied or Released
Exhaust Brake Switch On/ Off Off Off
Exhaust Brake Valve Command On/ Off Off Off
Exhaust Brake Cut Request from Inactive/ Active Inactive Inactive
ABS Module
Exhaust Brake Cut Request from Inactive/ Active Inactive Inactive
TCM
ASR Commanded APP % 100% 100%
(Accelerator Pedal Position)
PTO Switch On/ Off Off Off
PTO Remote Throttle % 0% 0%
PTO Remote Throttle Sensor Volts Less than 0.4 volts Less than 0.4 volts
Engine Warm Up Switch On/ Off Off Off
A/C Signal On/ Off Off Off
Refrigerator Switch On/ Off Off Off
Oil Level Normal/ Low Normal Normal
Glow Plug Relay Command On/ Off Off Off
Malfunction Indicator Lamp (MIL) On/ Off Off Off
Distance While MIL is Activated km/ Miles 0 km/ 0 Miles 0 km/ 0 Miles
Engine Runtime With MIL Active minutes 0 0
Total Engine Overspeed Events Counter Varies Varies
Total Engine Coolant Counter Varies Varies
Overtemperature Event
Total Fuel Temperature Counter Varies Varies
Total Intake Air Temperature Counter Varies Varies
DPD Regeneration Switch On/ Off Off Off
DPD Mode Varies 30 30
DPD Accumulation Status 0/ 1/ 2/ 3/ 4/ 5 0, 1, 2, 3 or 4 0, 1, 2, 3 or 4
DPD Distance Status 0/ 1/ 2/ 3/ 4 0, 1, 2 or 3 0, 1, 2 or 3
DPD Incomplete Regeneration 0/ 1/ 2 0 or 1 0 or 1
Status
DPD Insufficient Regeneration 0/ 1/ 2 0 or 1 0 or 1
Status
Exhaust Differential Pressure kPa/ psi Varies Varies
Exhaust Differential Pressure Volts Varies Varies
Sensor
Exhaust Temperature 1 °C/ °F Varies Varies
Exhaust Temperature Sensor 1 Volts Varies Varies
Exhaust Temperature 2 °C/ °F Varies Varies
Exhaust Temperature Sensor 2 Volts Varies Varies
Exhaust Throttle Status On/ Off Off Off
Vane Control Solenoid Error No/ Stuck/ Short No No
Circuit
Vane Position Sensor Error No/ All Low/ All No No
High
Turbocharger Control Module No/ High Voltage No No
Error
Cruise Main Switch On/ Off Off Off
Cruise Cancel Switch On/ Off Off Off
Cruise Resume/ Acceleration On/ Off Off Off
Switch
Cruise Set/ Coast Switch On/ Off Off Off
Immobilizer Signal Yes/ No Yes Yes
Wrong Immobilizer Signal Yes/ No No No
Immobilizer Function Yes/ No Yes Yes
Programmed
Security Wait Time Inactive/ Time Inactive Inactive
(hour: minute:
second)

Scan Tool Data Definitions Fuel Temperature Sensor
This parameter displays the voltage signal sent to the
This information will assist in emission or driveability
ECM from the fuel temperature (FT) sensor. FT sensor
problems. The displays can be viewed while the vehicle
is a range of value indicating a low voltage when the
is being driven. Always perform the Diagnostic System
temperature is high, and a high voltage when the
Check - Engine Controls first. The Diagnostic System
temperature is low.
Check will confirm proper system operation.
Averaged MAF (Mass Air Flow)
Engine Speed
This parameter displays the air flow averaged a second
This parameter displays the speed of the crankshaft as
as calculated by the ECM based on the mass air flow
calculated by the ECM based on inputs from the
(MAF) sensor input. The scan tool will display a high
crankshaft position (CKP) sensor or camshaft position
value at higher engine speeds, and a low value at lower
(CMP) sensor.
engine speed.
Desired Idle Speed
MAF (Mass Air Flow)
This parameter displays the idle speed requested by
This parameter displays the air flow into the engine as
the ECM. The ECM will change desired idle speed
calculated by the ECM based on the mass air flow
based on engine coolant temperature and other inputs.
(MAF) sensor input. The scan tool will display a high
Calculated Engine Load value at higher engine speeds, and a low value at lower
This parameter displays the engine load in percent engine speed.
based on inputs to the ECM from various engine
MAF Sensor (Mass Air Flow)
sensors. The scan tool will display a lower percentage
when the engine is at idle with little or no load. The
ECM from the mass air flow (MAF) sensor. MAF sensor
scan tool will display a higher percentage when the
is a range of value indicating a low voltage at lower
engine is running at high engine speed under a heavy
engine speed, and a high voltage at a higher engine
load.
speeds.
Coolant Temperature
Barometric Pressure
This parameter displays the temperature of the engine
This parameter displays the barometric pressure
coolant as calculated by the ECM using the signal from
(BARO) as calculated by the ECM using the signal from
the engine coolant temperature (ECT) sensor. The
the BARO sensor. The scan tool will display a low
scan tool will display a low temperature when the ECT
barometric pressure in high altitude area.
sensor signal voltage is high, and a high temperature
when the ECT sensor signal voltage is low. Barometric Pressure Sensor
Engine Coolant Temperature Sensor
ECM from the barometric pressure (BARO) sensor.
BARO sensor is a range of value indicating a low
ECM from the engine coolant temperature (ECT)
voltage in high altitude area, and a middle voltage in
sensor. ECT sensor is a range of value indicating a low
sea level.
voltage when the temperature is high, and a high
voltage when the temperature is low. Desired Turbocharger Position
This parameter displays turbocharger nozzle position
Intake Air Temperature
desired by the ECM based on current boost pressure.
This parameter displays the temperature of the intake
air as calculated by the ECM using the signal from the Desired Boost Pressure
intake air temperature (IAT) sensor. The scan tool will This parameter displays boost pressure desired by the
display a low temperature when the IAT sensor signal ECM based on current driving conditions. This can be
voltage is high, and a high temperature when the IAT compared to the actual boost pressure to determine
sensor signal voltage is low. sensor accuracy or turbocharger control problems.
Intake Air Temperature Sensor Boost Pressure
This parameter displays the voltage signal sent to the This parameter displays the boost pressure in the
ECM from the intake air temperature (IAT) sensor. IAT intake duct as calculated by the ECM using the signal
sensor is a range of value indicating a low voltage from the boost pressure sensor. The scan tool will
when the temperature is high, and a high voltage when display a low boost pressure when the low engine load,
the temperature is low. and a high boost pressure when the high engine load.
Note that the true boost pressure is determined by
Fuel Temperature
subtracting barometric pressure from the actual
This parameter displays the temperature of the fuel as
reading.
calculated by the ECM using the signal from the fuel
temperature (FT) sensor. The scan tool will display a
low temperature when the FT sensor signal voltage is
high, and a high temperature when the FT sensor
signal voltage is low.

Boost Pressure Sensor APP Sensor 1 (Accelerator Pedal Position)
This parameter displays the voltage signal sent to the This parameter displays the voltage signal sent to the
ECM from the boost pressure sensor. Boost pressure ECM from the accelerator pedal position (APP) sensor
sensor is a range of value indicating a low voltage 1 of the APP sensor assembly. APP sensor 1 is a range
when the boost pressure is low (idle or lower engine of value indicating a low voltage when the accelerator
load) and a high voltage when the boost pressure is pedal is not depressed, and a high voltage when the
high (higher engine load). accelerator pedal is fully depressed.
Desired Fuel Rail Pressure APP Sensor 2 (Accelerator Pedal Position)
This parameter displays fuel rail pressure desired by This parameter displays the voltage signal sent to the
the ECM based on current driving conditions. This can ECM from the accelerator pedal position (APP) sensor
be compared to the actual fuel rail pressure to 2 of the APP sensor assembly. APP sensor 2 is a range
determine sensor accuracy or fuel pressure control of value indicating a high voltage when the accelerator
problems. pedal is not depressed, and a low voltage when the
accelerator pedal is fully depressed.
Fuel Rail Pressure
This parameter displays the fuel rail pressure as Desired EGR Position
calculated by the ECM using the signal from the fuel This parameter displays EGR position desired by the
rail pressure (FRP) sensor. The scan tool will display a ECM based on current driving conditions. This can be
low pressure when the low engine load, and a high compared to the actual EGR position to determine
pressure when the high engine load. sensor accuracy or motor control problems.
Fuel Rail Pressure Sensor EGR Position 1
This parameter displays the voltage signal sent to the This parameter displays the EGR valve position
ECM from the fuel rail pressure (FRP) sensor. FRP calculated by the ECM using the signal from the
sensor is a range of value indicating a low voltage individual three EGR position sensors. The scan tool
when the fuel rail pressure is low, and a high voltage will display a low percentage when the EGR valve is
when the fuel rail pressure is high. closed, and a high percentage when the EGR valve is
opened.
FRP Regulator Command (Fuel Rail Pressure)
This parameter displays the fuel rail pressure (FRP) EGR Position 1
regulator control duty ratio based on inputs to the ECM This parameter displays the input state of the EGR
from various engine sensors. The scan tool will display position sensor 1 to the ECM. When the position
a lower percentage when the FRP regulator is sensor is opened, the scan tool displays Low. When the
controlled to open (fuel supply quantity to the fuel rail is position sensor is closed, the scan tool displays High.
increased). The scan tool will display higher
EGR Position 2
percentage when the FRP regulator is controlled to
This parameter displays the input state of the EGR
close (fuel supply quantity to the fuel rail is reduced).
position sensor 2 to the ECM. When the position
FRP Regulator Commanded Fuel Flow sensor is opened, the scan tool displays Low. When the
This parameter displays the commanded fuel flow position sensor is closed, the scan tool displays High.
quantity of the fuel rail pressure (FRP) regulator to the
EGR Position 3
fuel rail.
This parameter displays the input state of the EGR
FRP Regulator Feedback Current (Fuel Rail position sensor 3 to the ECM. When the position
Pressure) sensor is opened, the scan tool displays Low. When the
This parameter displays the fuel rail pressure (FRP) position sensor is closed, the scan tool displays High.
regulator control feedback current as measured by the
Intake Throttle Solenoid Command
ECM. The scan tool will display a low current when the
This parameter displays the intake throttle motor
FRP regulator is controlled to open (fuel supply
control duty ratio based on inputs to the ECM from
quantity to the fuel rail is increased). The scan tool will
various engine sensors. The scan tool will display a
display a high current when the FRP regulator is
lower percentage when the intake throttle motor is
controlled to close (fuel supply quantity to the fuel rail is
controlled to open. The scan tool will display a higher
reduced).
percentage when the intake throttle motor is controlled
Accelerator Pedal Position to close.
This parameter displays the angle of the accelerator
Desired Intake Throttle Position
pedal as calculated by the ECM using the signals from
This parameter displays intake throttle position desired
the accelerator pedal position (APP) sensors. The scan
by the ECM based on current driving conditions. This
tool will display linearly from 0 to 100% according to the
can be compared to the actual intake throttle position to
pedal operation.
determine sensor accuracy or motor control problems.

Intake Throttle Position Vehicle Speed
This parameter displays the intake throttle valve This parameter indicates the vehicle speed calculated
position calculated by the ECM using the signal from by the ECM using the signal from the vehicle speed
intake throttle position sensor. The scan tool will display sensor (VSS). The scan tool will display a low value at
a low percentage when the intake throttle valve is lower vehicle speeds, and a high value at higher
closed, and a high percentage when the intake throttle vehicle speeds.
valve is opened. Note that the intake throttle position
Starter Switch
indicates over 100% if the motor is commanded OFF.
This parameter displays the input status of the starter
Intake Throttle Position Sensor switch to the ECM. When the ignition switch is turned at
This parameter displays the voltage signal sent to the START position, the scan tool displays On.
ECM from the intake throttle position sensor. Intake
Ignition Switch
throttle position sensor is a range of value indicating a
This parameter displays the input status of the ignition
low voltage when the intake throttle valve is closed to a
switch to the ECM. When the ignition switch is turned
high voltage when the intake throttle valve is opened.
ON position, the scan tool displays On.
Idle-Up Sensor
Ignition Voltage
This parameter displays the ignition voltage measured
ECM from the idle up sensor. Idle up sensor is a range
at the ignition feed circuit of the ECM. Voltage is
of value indicating a low voltage when the idle up
applied to the ECM when the ignition switch is ON
sensor rotates in a counterclockwise direction to a high
position.
voltage when the idle up sensor rotates in a clockwise
direction. Battery Voltage
This parameter displays the battery voltage measured
Fuel Compensation Cyl. 1 to 6
at the ECM main relay switched voltage feed circuit of
This parameter displays the adjustment of fuel volume
the ECM. Voltage is applied to the ECM when the ECM
for each cylinder at low engine speed area as
main relay is energized.
calculated by the ECM. The scan tool will display a
negative value if the fuel volume is lowered. The scan Brake Switch 1
tool will display a positive value if the fuel volume is This parameter displays the input state of the brake
increased. If there is a cylinder that is excessively high switch 1 to the ECM. When the brake pedal is
or low value, it may indicate faulty fuel injector, weak or depressed, scan tool displays Applied.
slightly seized cylinder or an incorrectly programmed
Brake Switch 2
fuel injector ID code.
This parameter displays the input state of the brake
Fuel Supply Pump Status switch 2 to the ECM. When the brake pedal is
This parameter displays the learning state of the fuel depressed, scan tool displays Applied.
supply pump. Not Learned indicates initialized state
Clutch Pedal Switch
that is replaced to a new ECM or adjustment value is
This parameter displays the input state of the clutch
reset. After engine is warm upped, leaning will start at
pedal switch to the ECM. When the clutch pedal is
idle speed. Learned indicates learning process is
depressed, scan tool displays Applied. If the Smoother
completed state.
is installed, gearshift clutch input state from the TCM is
Rail Pressure Feedback Mode displayed.
This parameter displays the state of the fuel rail
Neutral Switch
pressure feedback to the ECM. Wait Mode indicates
This parameter displays the input state of the neutral
the ignition switch is turned ON position. Feedback
switch to the ECM. When the transmission gear is Park
Mode indicates the engine is during crank or run.
or Neutral, the scan tool displays Neutral.
Shutoff Mode indicates the ignition switch is turned
OFF position. Park Brake Switch
This parameter displays the input state of the park
Engine Running Status brake switch to the ECM. When the park brake lever is
This parameter displays the state of engine. Ignition On pulled, scan tool displays Applied.
indicates the ignition switch is turned ON position.
Cranking indicates the engine is during crank. Running Exhaust Brake Switch
indicates the engine is run. Off indicates the ignition This parameter displays the input state of the exhaust
switch is tuned OFF position. brake switch to the ECM. On indicates the exhaust
brake switch is closed and allows energizing the
Engine Runtime
exhaust brake solenoid valve and intake throttle
This parameter displays the time elapsed since the
depending upon driving condition. Off indicates the
engine start. The scan tool will display the time in
exhaust brake switch is open and exhaust brake will
hours, minutes and seconds.
not engage.

Exhaust Brake Valve Command Refrigerator Switch
This parameter displays the commanded state of the This parameter displays the state of the refrigerator
exhaust brake solenoid valve control circuit. On compressor engagement. On indicates the ECM
indicates the exhaust brake solenoid valve is being receiving a refrigerator compressor On signal. Off
grounded by the ECM, allowing vacuum pressure to indicates the ECM is not receiving a refrigerator
the exhaust brake valve. compressor On signal.
Exhaust Brake Cut Request from ABS Module Oil Level
This parameter displays the state of the exhaust brake This parameter displays the state of the engine oil level
cut request to the ECM from the EHCU [ABS module] switch to the ECM. Normal indicators the engine oil
or ABS control unit. Active indicates the EHCU [ABS level is not too low for safe operation of the engine. Low
module] or ABS control unit is commanding to release indicators the engine oil level is abnormally low and has
the exhaust brake. opened the engine oil level switch.
Exhaust Brake Cut Request from TCM Glow Plug Relay Command
This parameter displays the state of the exhaust brake This parameter displays the commanded state of the
cut request to the ECM from the transmission control glow relay control circuit. On indicates the glow relay
module (TCM). Active indicates the TCM is control circuit is being grounded by the ECM, allowing
commanding to release the exhaust brake. voltage to the glow plugs.
ASR Commanded APP (Accelerator Pedal Position) Malfunction Indicator Lamp (MIL)
This parameter displays the controlled angle of the This parameter displays the commanded state of the
accelerator pedal calculated by the EHCU [ABS malfunction indicator lamp (MIL) control circuit. The
module] or ABS control unit when anti slip regulator MIL should be On when the scan tool indicates
(ASR) system operated. The scan tool will display command On. The MIL should be Off when the scan
100% when the ECM is not controlled to reduce fuel tool indicates command Off.
injection quantity. The scan tool will display a lower
Distance While MIL is Activated
percentage when the ECM is controlled to reduce fuel
This parameter displays the mileage since the
injection quantity to reduce drive wheels spinning.
malfunction indicator lamp (MIL) is turned ON.
PTO Switch
Engine Runtime With MIL Active
This parameter displays the state of the PTO switch to
This parameter displays the accumulated ignition
the ECM. When the PTO switch is operated by control
switch ON time elapsed since the malfunction indicator
lever or button, scan tool displays On.
lamp (MIL) is turned ON. The scan tool will display the
PTO Remote Throttle time in minutes.
This parameter displays the angle of the PTO remote
Total Engine Overspeed Events
throttle sensor as calculated by the ECM using the
This parameter indicates counter of engine overspeed
signal from the PTO remote throttle sensor. The PTO
event. Counter will be zero if any DTC is cleared.
remote throttle angle is a range of values indicating a
low percentage when the throttle sensor is not operated Total Engine Coolant Overtemperature Event
to a high percentage when the throttle sensor is This parameter indicates counter of engine overheat
operated. event. The counter is active if engine coolant is over
110°C (230°F). Counter will be zero if any DTC is
PTO Remote Throttle Sensor
cleared.
ECM from the PTO remote throttle sensor. PTO remote Total Fuel Temperature Overtemperature Event
throttle sensor is a range of values indicating a low This parameter indicates counter of fuel temperature
voltage when the throttle sensor is not operated to a excessively high condition. The counter is active if fuel
high voltage when the throttle sensor is operated. temperature is over 90°C (194°F). Counter will be zero
if any DTC is cleared.
Engine Warm Up Switch
This parameter displays the input state of the engine Total Intake Air Temperature Overtemperature
warm up switch to the ECM. On indicates the engine Event
warm up switch is closed and allows energizing the This parameter indicates counter of intake air
exhaust brake solenoid valve and intake throttle valve temperature excessively high condition. The counter is
depending upon engine condition. active if intake air temperature is over 60°C (140°F).
Counter will be zero if any DTC is cleared.
A/C Signal
This parameter displays the state of the air conditioning
(A/C) compressor engagement. On indicates the ECM
receiving an A/C compressor On signal. Off indicates
the ECM is not receiving an A/C compressor On signal.

DPD Regeneration Switch Exhaust Temperature 1
This parameter displays the input state of the DPD This parameter displays the temperature of the exhaust
regeneration switch to the ECM. On indicates the DPD gas in front of filter as calculated by the ECM using the
regeneration switch is closed and allows entering the signal from the exhaust gas temperature sensor 1. The
regeneration process depending upon PM scan tool will display a low temperature when the
accumulation condition. exhaust gas temperature sensor 1 signal voltage is
high, and a high temperature when the exhaust gas
DPD Mode
temperature sensor 1 signal voltage is low.
This parameter displays the state of the DPD. It mainly
indicates an action request or status to the user during Exhaust Temperature Sensor 1
regeneration event. 1 or 50 indicates DTC is set, which This parameter displays the voltage signal sent to the
is not allowing the DPD regeneration. 30 indicates ECM from the exhaust gas temperature sensor 1.
under normal engine operation. Exhaust gas temperature sensor 1 is a range of value
indicating a low voltage when the temperature is high,
DPD Accumulation Status
and a high voltage when the temperature is low.
This parameter displays the state of the PM
accumulations. It indicates that the PM accumulative Exhaust Temperature 2
amount to the filter increases while parameter is This parameter displays the temperature of the exhaust
increasing from 0 to 5. This parameter uses together gas in front of oxidation catalyst as calculated by the
with DPD Distance Status parameter to determine ECM using the signal from the exhaust gas
regeneration type manually. temperature sensor 2. The scan tool will display a low
temperature when the exhaust gas temperature sensor
DPD Distance Status
2 signal voltage is high, and a high temperature when
This parameter displays the state of the distance since
the exhaust gas temperature sensor 2 signal voltage is
last regeneration. It indicates that the accumulative
low.
distance without regeneration event increases while
parameter is increasing from 0 to 4. This parameter Exhaust Temperature Sensor 2
uses together with DPD Accumulation Status This parameter displays the voltage signal sent to the
parameter to determine regeneration type manually. ECM from the exhaust gas temperature sensor 2.
Exhaust gas temperature sensor 2 is a range of value
DPD Incomplete Regeneration Status
indicating a low voltage when the temperature is high,
This parameter indicates an error status of the DPD
and a high voltage when the temperature is low.
regeneration. 1 or 2 indicates the frequency of the
regeneration event that did not finish within a Exhaust Throttle Status
predetermined time. This parameter displays the commanded state of the
exhaust throttle solenoid valve control circuit. On
DPD Insufficient Regeneration Status
indicates the exhaust throttle solenoid valve is being
This parameter indicates an error status of the DPD
grounded by the ECM, allowing air pressure to the
regeneration. 1 or 2 indicates the frequency of
exhaust throttle valve.
incomplete filter purification after the regeneration
event. Vane Control Solenoid Error
This parameter displays an error state of the
Exhaust Differential Pressure
turbocharger nozzle control actuator from the rotary
This parameter displays the exhaust differential
electric actuator (REA) control module. Stuck indicates
pressure as calculated by the ECM using the signal
the REA control module detects an open circuit on the
from the exhaust differential pressure sensor. The scan
solenoid circuit or a sticking the nozzle control actuator.
tool will display a low exhaust differential pressure at
Short Circuit indicates the REA control module detects
small PM accumulation, and a high exhaust differential
a short circuit on the solenoid circuit.
pressure at large PM accumulation.
Vane Position Sensor Error
Exhaust Differential Pressure Sensor
This parameter displays an error status of the
This parameter displays the voltage signal set to the
turbocharger nozzle position sensor from the rotary
ECM from the exhaust differential pressure sensor.
electric actuator (REA) control module. All High or All
Exhaust differential pressure sensor is a range of value
Low indicates the REA control module detects all
indicating a low voltage at a low differential pressure,
nozzle position sensor signal are stuck low or high.
such as small PM accumulation, and a high voltage at a
high differential pressure, such as large PM Turbocharger Control Module Error
accumulation. This parameter displays an error status of the rotary
electric actuator (REA) control module system voltage.
High voltage indicates the REA control module detects
system voltage is too high.

Cruise Main Switch
This parameter displays the input state of the cruise
control main switch to the ECM. When the cruise
control main switch is pushed, the scan tool displays
On.
Cruise Cancel Switch
cancel switch to the ECM. When the cruise cancel
switch is pushed, the scan tool displays On.
Cruise Resume/ Acceleration Switch
resume/ accel. switch to the ECM. When the cruise
resume/ accel. switch is applied, the scan tool displays
On.
Cruise Set/ Coast Switch
set/ coast switch to the ECM. When the cruise set/
coast switch is applied, the scan tool displays On.
Immobilizer Signal
This parameter displays the input state of the response
signal to the ECM. When the ECM received any
response signal from the immobilizer control unit (ICU),
the scan tool displays Yes.
Wrong Immobilizer Signal
This parameter displays the input state of the received
response signal to the ECM. When the ECM received
wrong response signal from the immobilizer control unit
(ICU), the scan tool displays Yes.
Immobilizer Function Programmed
This parameter displays the state of the immobilizer
function programming in the ECM. The scan tool will
display Yes or No. Yes indicates the immobilizer
security information is correctly programmed in the
ECM. No indicates the ECM is not programmed or
ECM is reset.
Security Wait Time
This parameter displays the security wait time length in
the ECM. Inactive indicates not in security wait time.
Time indicates under security wait time. This wait time
stage will prevent any further attempts to enter the
security code until the wait time has elapsed. Note that
this parameter is not count downed. It keeps displaying
the same time until that wait time has elapsed. The
ignition switch must be kept at ON position during the
wait time period.

Scan Tool Output Controls
Scan Tool Output Control Descriptions

Fuel Pressure Control The purpose of this test is for checking whether the fuel rail pressure is changing when
commanded. Faulty fuel supply pump, fuel rail pressure (FRP) regulator, pressure limiter
valve or other fuel lines could be considered if the differential fuel rail pressure is large.
Pre Injection Control The purpose of this test is for checking whether the pre fuel injection is operating when
commanded ON/ OFF. Faulty injector(s) could be considered if engine noise does not
change when commanded OFF.
Injection Timing Control The purpose of this test is for checking whether the main injection timing is changing when
commanded Retard/ Advance.
Injector Forced Drive The purpose of this test is for checking whether the fuel injector is correctly operating when
commanded ON. Faulty injector(s) could be considered if it does not create a clicking noise
(solenoid operating noise), contains an interrupted noise or has abnormal noise when
commanded ON.
Cylinder Balance Test Notice: If this test does not run, slightly increase the engine speed by pressing the
accelerator pedal.
The purpose of this test is for checking whether the fuel injector is operating when
commanded ON/ OFF. Faulty injector(s) could be considered if engine does not change
speed when commanded OFF.
Intake Throttle Solenoid Control The purpose of this test is for checking whether the intake throttle valve is correctly moved
with command. Restricted valve movement by foreign materials, excessive deposits or a
faulty valve could be considered if the position difference is large.
EGR Solenoid Control The purpose of this test is for checking whether the EGR valve is correctly moved with
command. Restricted valve movement by foreign materials, excessive deposits or a faulty
valve could be considered if the position difference is large.
Turbocharger Solenoid Control The purpose of this test is for checking whether the turbocharger nozzle control solenoid is
correctly moved with command. Restricted actuator movement by foreign materials,
excessive deposits, damaged linkage, a faulty solenoid or a faulty position sensor could be
considered if the solenoid is not moved correctly.
Glow Relay Control The purpose of this test is for checking whether the glow relay is operating when
commanded ON. Faulty circuit(s) or a faulty glow relay could be considered if not
energizing when commanded ON.
Exhaust Brake Control The purpose of this test is for checking whether the exhaust brake control solenoid is
operating when commanded ON. Faulty circuit(s) or a faulty solenoid could be considered if
not energizing when commanded ON.
Exhaust Throttle Control The purpose of this test is for checking whether the exhaust throttle solenoid valve is
operating when commanded ON. Faulty circuit(s) or a faulty exhaust throttle solenoid valve
could be considered if not energizing when commanded ON.
Fuel Supply Pump Learn Important: The fuel supply pump relearn procedure must be done when the fuel supply
Resetting pump or engine is replaced, or an ECM from another vehicle is installed. Refer to Repair
Instructions in this section.
The purpose of this test to reset the fuel supply pump adjustment value.
DPD Status Resetting Important: DPD status must be reset before regeneration with a scan tool.
The purpose of this function to reset the DPD status parameters.
DPD Normal Regeneration Important: Do Not perform this test if the exhaust differential pressure is more than a
Control threshold.
The purpose of this test is for DPD filter force regeneration.
DPD Slow Regeneration Control Important: Do Not perform this test if the exhaust differential pressure is more than a
threshold. And, engine oil must be replaced after DPD slow regeneration is completed.
The purpose of this test is for DPD filter force regeneration in case of excessively
accumulated PM. This very slow regeneration compared with another one.

Scan Tool Does Not Power Up • Scan tool power ground at terminal 4.
Circuit Description • Common signal ground at terminal 5.
The scan tool will power up with the ignition OFF. Some
The data link connector (DLC) is a standardized 16- modules however, will not communicate unless the
cavity connector. Connector design and location is ignition is ON.
dictated by an industry wide standard, and is required
to provide the following: Connector End View Reference: Engine Controls
• Scan tool power battery positive voltage at Connector End Views or ECM Connector End Views
terminal 16.
Circuit/ System Testing Scan Tool Does Not Power Up

Important: Make sure the scan tool and 24 volts
adapter works properly on another vehicle before
using this chart.
1 1. Turn OFF the ignition. —

2. Inspect the Dome Light (15A) fuse in the cabin
fuse block.
Is the Dome Light (15A) fuse open? Go to Step 2 Go to Step 3

Replace the Dome Light (15A) fuse. If the fuse
continues to open, repair the short to ground on
one of the circuits that is fed by the Dome Light
2 (15A) fuse or replace the shorted attached —
component.
Did you complete the repair? Go to Step 7 —

1. Check each circuit at the data link connector
(DLC) (FU23) for a backed out, spread or
missing terminal.
3 —
2. Repair the terminal as necessary.
Did you find and complete the repair? Go to Step 7 Go to Step 4

Connect a test lamp between the +B circuit (pin 16
4 of FU23) at the DLC and a known good ground. —
Does the test lamp illuminate? Go to Step 6 Go to Step 5
Repair the open in the battery voltage circuit to the
5 DLC. —
1. Test each ground circuit at the DLC (pins 4
and 5 of FU23) for an open circuit or high
resistance.
6 2. Repair the circuit(s), clean or tighten ground —
as necessary.
Go to Intermittent
Did you find and correct the condition? Go to Step 7 Conditions
1. Connect the scan tool to the DLC.
7 2. Attempt to turn ON the scan tool. —
Does the scan tool ON? System OK Go to Step 1

Scan Tool Does Not Communicate with Diagnostic Aids
CAN Device (Euro 4 Specification) The following conditions will cause a loss of CAN serial
Circuit Description data communication between the scan tool and the
ECM.
The ECM communicates with the scan tool over the
• A CAN serial data circuit open
controller area network (CAN) link. The ECM and the
immobilizer control unit (ICU) communicate with each • A CAN serial data circuit shorted to ground
other over the same CAN link. The ECM, the rotary • A CAN serial data circuit shorted to voltage
electric actuator (REA) control module, the electric • An internal condition within a module or connector
hydraulic control unit (EHCU) or ABS control unit, the on the CAN serial data circuit, that causes a short
transmission control module (TCM), the body control to voltage or ground to the CAN serial data circuit
module (BCM) or the data recording module (DRM)
and the instrument panel (IP) cluster communicate with Connector End View Reference: Engine Controls
each other over the separated CAN link that does not Connector End Views or ECM Connector End Views
affect to the scan tool communication.
Circuit/ System Testing Scan Tool Does Not Communicate with CAN Device (Euro 4 Specification)

Did you perform the Diagnostic System Check - Go to Diagnostic
1 Engine Controls? — System Check -
Go to Step 2 Engine Controls
Important: Make sure the CAN-di module is not
malfunctioning. When functioning properly, the
CAN-di module LED will be flashing. In the event of
a problem, the LED will be continually illuminated
or not illuminated.
2 1. Install a scan tool. —
ECM.
Go to Intermittent
Does the scan tool communicate with the ECM? Conditions Go to Step 3
1. Inspect for an intermittent, for poor
connections and for corrosion at the data link
connector (DLC) (pins 6 and 14 of FU23).
3 —
2. Repair the connection(s) as necessary.
Did you find and correct the condition? Go to Step 18 Go to Step 4

connections and for corrosion at the ECM E26
and FB24 connectors.
4 —

1. Check the ECM (40A) slow blow fuse and
ECM Main (15A) fuse in the chassis fuse
block, Engine Controller (10A) fuse in the
cabin fuse block. Replace and retest if open. If
any fuse continues to open, repair the short to
ground on each circuit fed by that fuse.
2. Turn OFF the ignition.
5 —
3. Disconnect the ECM FB24 harness connector.
5. Connect a test lamp to ground and check for
voltage at ignition voltage supply circuit at the
ECM (pin 24 of FB24).


Repair the open in the ignition voltage circuit to the
6 ECM. —
Notice: An open in a ground circuit at the ECM will
not cause a loss of communication.
1. Check ECM ground for corrosion and
7 tightness. —
2. Clean or tighten grounds as necessary.

2. Reconnect the ECM harness connector if
disconnected.
3. Replace the ECM main relay with the glow
8 relay or replace with a known good relay. —
ECM.
Does the scan tool communicate with the ECM? Go to Step 13 Go to Step 9
2. Remove the ECM main relay.
4. Using a test lamp, check for both voltage
9 —
supply circuit to the ECM main relay (pins 1
and 3 of X18).
5. Repair the open circuit(s) as necessary.

1. Reinstall the ECM main relay.
2. Turn the ignition ON and OFF while listening
of feeling for the ECM main relay click. Wait 7
10 seconds between transitions. —
Does the ECM main relay click when the ignition

switch is turned ON or OFF? Go to Step 12 Go to Step 11
Repair the ECM main relay ground circuit between
the ECM main relay (pin 5 of X18) and chassis
ground terminal (FB20) for the following conditions:
11 • An open circuit —
• High resistance or a poor connection at the ECM
main relay or ground terminal

1. Test the battery voltage circuit between the
ECM (pins 2 and 5 of FB24) and the ECM
main relay for the following conditions:
• An open circuit
12 • High resistance or a poor connection at —
the ECM or ECM main relay
2. Repair the circuit(s) as necessary.

Replace the ECM main relay.
13 —
Did you complete the replacement? Go to Step 18 —

2. Reconnect the ECM FB24 harness connector.
3. Disconnect the scan tool from the DLC if
connected.
4. Measure the resistance across the CAN Low
14 50 to 70 Ω
and High circuits by probing the DLC (pins 6
and 14 of FU23).
Is the resistance within the specified value (parallel

resistance of the 120 Ω resistor in the ECM and the
120 Ω CAN resistor should be 60 Ω)? Go to Step 16 Go to Step 15
2. Disconnect the ECM harness connector.
connections and corrosion at the harness
connector of the ECM (pins 58 and 78 of
FB24).
4. Test the CAN Low and High serial data circuits
between the DLC (pins 6 and 14 of FU23) and
the ECM (pins 58 and 78 of FB24), the
15 immobilizer control unit (ICU) (pins 5 and 6 of —
FL34) or the CAN resistor (pins 1 and 2 of
FU200) for the following conditions:
• An open circuit
• A short circuit each other
• High resistance
5. Repair the connection(s) or circuit(s) as
necessary.

1. Test the CAN Low and High serial data circuits
between the DLC (pins 6 and 14 of FU23) and
the ECM (pins 58 and 78 of FB24), the ICU
(pins 5 and 6 of FL34) or the CAN resistor
(pins 1 and 2 of FU200) for the following
16 conditions: —
• A short to ground
• A short to voltage

Important: Replacement ECM must be
programmed and learned.
17 Replace the ECM. Refer to ECM Replacement. —

2. Reconnect all previously disconnected fuse,
relay or harness connector(s).
18 3. Turn ON the ignition, with the engine OFF. —
ECM.
Does the scan tool communicate with the ECM? System OK Go to Step 3

Scan Tool Does Not Communicate with Diagnostic Aids
Keyword Device (Except Euro 4 The following conditions will cause a loss of Keyword
Specification) serial data communication between the SRS control
unit and HSA control unit or between the scan tool any
Circuit Description
control module:
The ECM, the hill start aid (HSA) control unit, the • A Keyword serial data circuit open
supplemental restraint system (SRS) control unit and
the immobilizer control unit (ICU) communicates with • A Keyword serial data circuit shorted to ground
the scan tool over the Keyword serial data link. • A Keyword serial data circuit shorted to voltage
However, the ECM, the electric hydraulic control unit • An internal condition within a module or connector
(EHCU) or ABS control unit, the data recording module on the Keyword serial data circuit, that causes a
(DRM) and the instrument panel (IP) cluster short to voltage or ground to the Keyword serial
communicate with each other over the controller area data circuit.
network (CAN) link. The CAN link is not used for
communication with the scan tool and is shared only Connector End View Reference: Engine Controls
among each module. Connector End Views or ECM Connector End Views
Circuit/ System Testing Scan Tool Does Not Communicate with Keyword Device (Except Euro 4
Specification)

1. Install a scan tool.
3. Attempt to communicate with the listed control
modules.
• ECM
• Hill start aid (HSA) control unit
2 (If so equipped) —
• Supplemental restraint system (SRS)
control unit (If so equipped)
• Immobilizer control unit (ICU)
(If so equipped)
Does the scan tool communicate with any of the

listed control modules? Go to Step 3 Go to Step 8
Does the scan tool communicate with the ECM? Go to Lost
Communication with
3 —
The Engine Control
Go to Step 4 Module (ECM)
Notice: If no HSA system is installed, skip to Step
5. Go to Diagnostic
4 — System Check -
Does the scan tool communicate with the HSA HSA Controls in
control unit? Go to Step 5 Section 4E HSA
Notice: If no airbag system is installed, skip to Step Go to Diagnostic
6. System Check -
5 — SRS Controls in
Does the scan tool communicate with the SRS Section 8C SRS
control unit? Go to Step 6 Control System
Notice: If no immobilizer system is installed, skip to Go to Diagnostic
Step 7. System Check -
6 — Immobilizer
Does the scan tool communicate with the ICU? Controls in Section
Go to Step 7 9I Security and Lock

Test the Keyword serial data circuit for an
intermittently short to ground or intermittently short
to voltage. Then, test the Keyword serial data
7 circuit for an intermittently open (based on which —
control module did not communicate) at the
connection in the circuit.
Did you find and correct the condition? Go to Step 18 System OK

1. Inspect for an intermittent, for a poor
connection and for corrosion at the data link
connector (DLC) (pins 7 and 9 of FU23).
8 —

2. Disconnect the ECM E26 and FB24 harness
connectors.
9 —
4. Attempt to communicate with the HSA control
unit, SRS control unit and ICU.
Does the scan tool communicate with the HSA

control unit, SRS control unit and ICU? Go to Step 14 Go to Step 10
Notice: If no HSA system is installed, skip to Step
11.
2. Reconnect the ECM E26 and FB24 harness
connectors if disconnected.
3. Disconnect the HSA control unit FU9 harness
10 connector. —
5. Attempt to communicate with the ECM, SRS
control unit and ICU.
Does the scan tool communicate with the ECM,

SRS control unit and ICU? Go to Step 16 Go to Step 11
Notice: If no airbag system is installed, skip to Step
12.
3. Reconnect the HSA control unit FU9 harness
connector if disconnected.
11 —
4. Disconnect the SRS control unit FL60 harness
connector.
6. Attempt to communicate with the ECM, HSA
control unit and ICU.

HSA control unit and ICU? Go to Step 16 Go to Step 12

Notice: If no immobilizer system is installed, skip to
Step 13.
3. Reconnect the HSA control unit FU9 harness
12 4. Reconnect the SRS control unit FL60 harness —
5. Disconnect the ICU FL34 harness connector .
7. Attempt to communicate with the ECM, HSA
control unit and SRS control unit.

HSA control unit and SRS control unit? Go to Step 17 Go to Step 13
Repair the open circuit, short to ground or short to
voltage on the Keyword serial data circuit between
13 the DLC and ECM, HSA control unit, SRS control —
unit or ICU.


Important: Replacement HSA control unit must be
learned.
15 Replace the HSA control unit. Refer to HSA Control —
Unit in Section 4E Hill Start Aid (HSA).

Replace the SRS control unit. Refer to SRS Control
Unit in Section 8B Supplemental Restraint System
16 (SRS). —

Important: Replacement ICU must be
programmed.
17 Replace the ICU. Refer to Immobilizer Control Unit —
& Programming in Section 9I Security and Lock.

Attempt to establish communication with the ECM,
HSA control unit, SRS control unit and ICU.
18 —
HSA control unit, SRS control unit and ICU? System OK Go to Step 2

Lost Communication with The Engine Connector End View Reference: Engine Controls
Control Module (ECM) (Except Euro 4 Connector End Views or ECM Connector End Views
Specification)
Circuit Description
The ECM, the hill start aid (HSA) control unit, the
supplemental restraint system (SRS) control unit and
the immobilizer control unit (ICU) communicates with
the scan tool over the Keyword serial data link.
However, the ECM, the electric hydraulic control unit
(EHCU) or ABS control unit, the data recording module
(DRM) and the instrument panel (IP) cluster
communicate with each other over the controller area
network (CAN) link. The CAN link is not used for
communication with the scan tool and is shared only
among each module.
Circuit/ System Testing Lost Communication with The Engine Control Module (ECM) (Except Euro 4
Specification)

Attempt to establish communication with the ECM.
2 — Go to Intermittent
Does the scan tool communicate with the ECM? Conditions Go to Step 3
connections and for corrosion at the ECM E26
and FB24 connectors.
3 —

1. Check the ECM (40A) slow blow fuse and
ECM Main (15A) fuse in the chassis fuse
block, Engine Controller (10A) fuse in the
cabin fuse block. Replace and retest if open. If
any fuse continues to open, repair the short to
ground on each circuit fed by that fuse.
4 —
5. Connect a test lamp to ground and check for
voltage at ignition voltage supply circuit at the

Repair the open in the ignition voltage circuit to the
5 ECM. —

connection and corrosion at the harness
connector of the ECM (pin 38 of FB24).
6 4. Test the Keyword serial data circuits between —
the ECM (pin 38 of FB24) and the DLC (pin 7
of FU23) for an open circuit or high resistance.
necessary.

Notice: An open in a ground circuit at the ECM will
not cause a loss of communication.
1. Check ECM ground for corrosion and
7 tightness. —
2. Clean or tighten grounds as necessary.

2. Reconnect the ECM harness connector if
disconnected.
ECM.
Does the scan tool communicate with the ECM? Go to Step 13 Go to Step 9
4. Using a test lamp, check for both voltage
9 —
supply circuit to the ECM main relay (pins 1
and 3 of X18).
5. Repair the open circuit(s) as necessary.

1. Reinstall the ECM main relay.
2. Turn the ignition ON and OFF while listening
of feeling for the ECM main relay click. Wait 7
10 seconds between transitions. —
Does the ECM main relay click when the ignition

switch is turned ON or OFF? Go to Step 12 Go to Step 11
Repair the ECM main relay ground circuit between
the ECM main relay (pin 5 of X18) and chassis
ground terminal (FB20) for the following conditions:
11 • An open circuit —
• High resistance or a poor connection at the ECM
main relay or ground terminal


1. Test the battery voltage circuit between the
ECM (pins 2 and 5 of FB24) and the ECM
main relay for the following conditions:
• An open circuit
12 • High resistance or a poor connection at —
the ECM or ECM main relay

13 —

ECM.
Does the scan tool communicate with the ECM? System OK Go to Step 3

Engine Cranks but Does Not Run • Fuse and slow blow fuse are normal.
Description
Diagnostic Aids
The Engine Cranks but Does Not Run diagnostic table
• If an intermittent condition is suspected, refer to
is an organized approach to identifying a condition that
Intermittent Conditions in this section.
causes an engine to not start. The diagnostic table
directs the service technician to the appropriate system
Test Description
diagnosis. The diagnostic table assumes the following
conditions are met: The number below refers to the step number on the
• The battery is completely charged and terminals Circuit/ System Testing.
are cleaned and tight. 5. If the fuel rail pressure (FRP) regulator low side
circuits between the ECM and the FRP regulator are
• The engine cranking speed is normal. shorted to ground, FRP Regulator Feedback Current
• There is adequate fuel in the fuel tank. will be approximately 300 mA or more low as compared
• There is no fuel leak in the fuel line. with normal.
• There is no air in the fuel line.
Connector End View Reference: Engine Controls
• Filters (air, fuel) are clean.
Connector End Views or ECM Connector End Views
Circuit/ System Testing Engine Cranks but Does Not Run

2. Turn OFF the ignition for 30 seconds.
3. Crank the engine for the specified amount of
2 time. 15 seconds
4. Monitor the DTC Information with a scan tool.
Does the scan tool display any DTCs that failed this Go to Applicable
ignition? DTC Go to Step 3
2. Wait 2 minutes for the fuel pressure to bleed
down from the fuel rail.
3 3. Turn ON the ignition, with the engine OFF. 0 MPa (0 psi)
4. Observe the Fuel Rail Pressure parameter
with a scan tool.
Does the scan tool indicate the specified value? Go to Step 4 Go to Step 6
Notice: If the vehicle has run out of fuel, air may be
trapped in the fuel system.
1. Make sure the fuel tank have adequate fuel
and the fuel quality is good (take a sample).
2. Observe the Fuel Rail Pressure parameter on 25 MPa (3,600
4
psi)
the scan tool while cranking over the engine
for 5 seconds.
Does the scan tool indicate more than the specified

value during crank? Go to Step 9 Go to Step 5
Observe the FRP Regulator Feedback Current
parameter on the scan tool while cranking over the
engine for 5 seconds. Go to Fuel System
5 800 mA Check Chart in
Does the scan tool indicate more than the specified Section 1D Engine
value during crank? Fuel Go to Step 8

2. Disconnect the FRP sensor harness
connector.
connector of the FRP sensor (pins 1, 2 and 3
of E49).
6 5. Inspect for an intermittent, for poor —
connector of the ECM (pins 82, 87, 90 and
101 of E26).
6. Test for high resistance on each circuit.
necessary.

Replace the FRP sensor. Refer to Fuel Pressure
7 Sensor in Section 1D Engine Fuel. —
Repair the short to ground between the ECM (pins
89 and 97 of E26) and the FRP regulator (pin 2 of
8 E47). —

1. Check for normal readings at key up for the
following sensor inputs: Use the Scan Tool
Data List or a known good vehicle to
determine nominal values.
• Engine Coolant Temperature Sensor
• Barometric Pressure (BARO) Sensor
9 —
• Boost Pressure Sensor
• Intake Throttle Position Sensor
2. Repair the circuit(s) or replace the sensor as
necessary.

1. Other possible causes for the no-start
condition:
• Engine mechanical timing
• Flywheel installed incorrectly causing the
crankshaft position (CKP) sensor to be
incorrectly timed to the engine.
Disconnect sensor and attempt to start
10 engine to verify. —
• Heavily restricted intake or exhaust
plugged solid.
• Poor engine compression.
• Water or gasoline contamination in fuel.
2. Repair as necessary.
Did you find and correct the condition? Go to Step 11 —

1. Reconnect all previously disconnected
harness connector(s).
11 2. Turn OFF the ignition for 30 seconds. —

3. Attempt to start the engine.
Does the engine start and continue to run? Go to Step 12 Go to Step 2


Observe the DTC Information with a scan tool.
12 —
Are there any DTCs that you have not diagnosed? Go to DTC List System OK

DTC P0016 (Flash Code 16)
Circuit Description • The CKP sensor signal pulse is detected.
The crankshaft position (CKP) sensor is located under • The CMP sensor signal pulse is detected.
the fuel supply pump. There are 56 notches spaced 6°
apart and a 30° section that is open span. This open Condition for Setting the DTC
span portion allows for the detection of top dead center • The ECM detects that the CKP sensor signal
(TDC). pulses and CMP sensor signal pulses are out of
The camshaft position (CMP) sensor is installed on the synchronization during engine rotations.
cylinder head at the rear of the camshaft gear. The
CMP sensor detects total of seven projections per one Action Taken When the DTC Sets
engine cycle (six projections arranged equally every
• The ECM illuminates the MIL when the diagnostic
60° and one reference projection on the camshaft gear
runs and fails. Refer to DTC Type Definitions for
surface).
Action Taken When the DTC Sets - Type A.
Detecting the open span portion from the CKP sensor
and one reference projection from the CMP sensor, the
Condition for Clearing the DTC
ECM determines cylinder #1 compression TDC to
ensure they correlate with each other. If the ECM • Refer to DTC Type Definitions for Condition for
detects both signals are out of synchronization, this Clearing the MIL/ DTC - Type A.
DTC will set.
Diagnostic Aids
Condition for Running the DTC • This DTC is cause by an incorrect mechanical
• DTCs P0335, P0336, P0340 and P0341 are not timing condition, which is most likely caused by
set. wrong installation of timing gear, flywheel or
• The ignition switch is ON. camshaft.
Circuit/ System Testing DTC P0016

3. Start the engine. If the engine does not start,
2 crank over the engine for 10 seconds. —
Go to Applicable
Is DTC P0335, P0336, P0340 or P0341 also set? DTC Go to Step 3

1. Inspect the crankshaft position (CKP) sensor
and the camshaft position (CMP) sensor for
the following conditions:
• Physical damage of sensor
• Loose or improper installation of sensor
• Excessive air gap
• Foreign material passing between sensor
and sensor rotor or camshaft gear
• Physical damage of sensor rotor or
camshaft gear
3 —
rotor or camshaft gear
2. Inspect the engine mechanical timing for an
incorrectly installed timing gear or camshaft.
Notice: If the flywheel dowel pin is missing or

pushed in and the flywheel is incorrectly
installed, this DTC may set.
3. Repair or replace as necessary.

harness connector(s) if disconnected.
2. Clear the DTCs with a scan tool.
crank over the engine for 10 seconds.
4 —
5. Operate the vehicle within the Conditions for
Running the DTC. You may also operate the
vehicle within the conditions that you
observed from the Freeze Frame/ Failure
Records.
Did the DTC fail this ignition? Go to Step 2 Go to Step 5

5 —

Circuit Description • The REA detects all of position sensor signals are
The position of the turbocharger nozzle is controlled by High or Low.
rotary electric actuator (REA) based on the command • The REA detects abnormal condition.
of the ECM. REA is installed on turbocharger. When
the engine is not under load, the turbocharger nozzles Action Taken When the DTC Sets
are in an open position. When the engine is under load, • The ECM illuminates the MIL when the diagnostic
the REA to close the turbocharger nozzles, thus runs and fails. Refer to DTC Type Definitions for
increasing the boost pressure. The ECM will vary the Action Taken When the DTC Sets - Type A.
target nozzle position dependent upon the boost
• The ECM limits fuel injection quantity.
requirements of the engine. If the REA senses an error
in the nozzle position signals, or abnormal condition, • The ECM inhibits EGR control.
the REA will send a message to the ECM via the • The ECM inhibits cruise control.
controller area network (CAN) communication bus and
the ECM will set this DTC. Condition for Clearing the DTC
• Refer to DTC Type Definitions for Condition for
Condition for Running the DTC Clearing the MIL/ DTC - Type A.
• The battery voltage is between 20 to 32 volts.
• The ignition switch is ON. Diagnostic Aids
Condition for Setting the DTC Intermittent Conditions in this section.
Either of following condition is met: • A sticking or intermittently sticking the REA may
• The REA detects the temperature around the DC set this DTC.
motor transistor is high.
• The REA detects the nozzle position is not at
predetermined value.

2 3. Start the engine. —
Is DTC U0073 set? Go to DTC U0073 Go to Step 3

1. Inspect the turbocharger assembly for the
following conditions:
• Physical damage of turbocharger
• Turbocharger nozzle control linkage
3 damaged —
• Physical damage of REA
2. Replace as necessary.

2. Disconnect the REA harness connector.
3. Connect a test lamp between the voltage feed
4 circuit (pin 3 of E10) and a known good —
ground.


Connect a test lamp between the voltage feed
5 circuit and the ground circuit (pins 3 and 6 of E10). —
1. Test the voltage and ground between ECM
Main (15A) fuse and REA (pin 3 of E10), or
between REA (pin 6 of E10) and ground for an
6 open circuit or high resistance. —

Repair the open circuit or high resistance between
the ECM Main (15A) fuse and the REA (pin 3 of
7 E10). Check the ECM Main (15A) fuse first. —

8 connections and corrosion at the harness —
connector of the REA (pins 3 and 6 of E10).

Replace the turbocharger. (REA is internal to
turbocharger). Refer to Turbocharger in Section 1J
9 Induction. —

4. Start the engine.
10 5. Operate the vehicle within the Conditions for —
Records.

Observe the DTC information with a scan tool.
11 —

DTC P0079 or P0080 (Flash Code 38)
Circuit Description Action Taken When the DTC Sets
The ECM controls the exhaust throttle solenoid valve • The ECM illuminates the MIL when the diagnostic
based on the diesel particulate defuser (DPD) system runs and fails. Refer to DTC Type Definitions for
regeneration status. The exhaust throttle solenoid valve Action Taken When the DTC Sets - Type A.
energizes to apply air pressure to the diaphragm
chamber of the exhaust throttle valve that is installed Condition for Clearing the DTC
rear of the DPD housing. If the ECM detects an • Refer to DTC Type Definitions for Condition for
improper voltage level on the exhaust throttle valve Clearing the MIL/ DTC - Type A.
control circuit, DTC P0079 or P0080 will set.
Diagnostic Aids
Condition for Running the DTC
• The battery voltage is between 18 to 32 volts. Intermittent Conditions in this section.
• The ignition switch is ON.
Test Description
Condition for Setting the DTC
The number below refers to the step number on the
• The ECM detects a low voltage condition on the Circuit/ System Testing.
exhaust throttle solenoid valve control circuit for DTC P0080
longer than 3 seconds when the solenoid valve is 3. If the exhaust throttle solenoid valve control circuit
commanded OFF. (DTC P0079) between the ECM and the solenoid valve is normal,
• The ECM detects a high voltage condition on the voltage level low DTC P0079 will set.
exhaust throttle solenoid valve control circuit for
longer than 3 seconds when the solenoid valve is Connector End View Reference: Engine Controls
commanded ON. (DTC P0080) Connector End Views or ECM Connector End Views

2. Perform the Exhaust Throttle Control with a
2 scan tool. —
3. Command the solenoid valve ON and OFF.
Go to Diagnostic
Does the solenoid valve click with each command? Aids Go to Step 3
2. Disconnect the exhaust throttle solenoid valve
harness connector.
3. Connect a test lamp between the ignition
3 voltage feed circuit (pin 1 of FB112) and a —
known good ground.

1. Connect a test lamp between the control
circuit (pin 2 of FB112) and battery voltage.
4 scan tool. —
Does the test lamp turn ON and OFF with each

command? Go to Step 9 Go to Step 5
Does the test lamp remain illuminated with each
5 —

the ECM Main (15A) fuse and the exhaust throttle
6 solenoid valve (pin 1 of FB112). Check the ECM —
Main (15A) fuse first.

1. Test the control circuit between the ECM (pin
102 of E26) and the solenoid valve (pin 2 of
FB112) for an open circuit or high resistance.
7 —

FB112) for a short to ground.
8 —

1. Inspect for an intermittent and for poor
connections at the harness connector of the
solenoid valve (pins 1 and 2 of FB112).
9 —

3. Inspect for an intermittent and for a poor
10 connection at the harness connector of the —
ECM (pin 102 of E26).

Replace the exhaust throttle solenoid valve.
11 —

13 3. Perform the Exhaust Throttle Control with a —
scan tool.
Does the solenoid valve click with each command? Go to Step 14 Go to Step 3
14 —


2 scan tool. —
Go to Diagnostic
Does the solenoid valve click with each command? Aids Go to Step 3
2. Disconnect the exhaust throttle solenoid valve
harness connector.
Is DTC P0079 set, but not DTC P0080? Go to Step 5 Go to Step 4

FB112) for a short to battery or ignition
4 voltage. —

Replace the exhaust throttle solenoid valve.
5 —

1. Reconnect all previously disconnected relay
or harness connector(s).
7 3. Perform the Exhaust Throttle Control with a —
scan tool.
Does the solenoid valve click with each command? Go to Step 8 Go to Step 3
8 —

Description Action Taken When the DTC Sets
The common rail fuel system is comprised of two fuel • The ECM illuminates the MIL when the diagnostic
pressure sections: a suction side between the fuel tank runs and fails. Refer to DTC Type Definitions for
and the fuel supply pump and a high-pressure side Action Taken When the DTC Sets - Type A.
between the fuel supply pump and the fuel injectors. • The ECM limits fuel injection quantity.
Fuel is drawn from the fuel tank via a feed pump and
• The ECM inhibits EGR control.
then pumped into the fuel rail by three plungers, all of
which are internal to the fuel supply pump. This high • The ECM inhibits cruise control.
pressure is regulated by the ECM using the fuel rail
pressure (FRP) regulator dependant upon values from Condition for Clearing the DTC
the FRP sensor attached to the fuel rail. In case of fuel • Refer to DTC Type Definitions for Condition for
rail overpressure, a pressure limiter valve threaded into Clearing the MIL/ DTC - Type A.
the fuel rail will open to release overpressure and
return fuel back to the fuel tank. If the ECM detects that Diagnostic Aids
the fuel rail pressure went excessively high, then • An intermittently sticking FRP regulator may have
sharply decreased, this DTC will set indicating high fuel allowed the fuel pressure to become high enough
pressure, which activated the pressure limiter valve. to open the pressure limiter valve.
Condition for Running the DTC • A skewed FRP sensor value can set this DTC. The
FRP Sensor on the scan tool should read 0.9 to
• DTCs P0192, P0193, P060B and P0651 are not 1.0 volt with the ignition switch ON and engine
set. OFF after the engine has stopped running for a
• The ignition switch is ON. minimum of 2 minutes.
• The engine is running.
Notice: If the fuel tank is empty or near empty, air
Condition for Setting the DTC might be allowed to go into the fuel system. With air in
the fuel system, smooth flow of fuel into the supply
• The ECM detects that the pressure limiter valve is
pump is interrupted and this DTC may set. Perform
activated with overpressure (more than 170 MPa
bleeding of fuel system after refilling.
[24,600 psi]) in the fuel rail.
Routing Reference: Fuel System Routing Diagram

2 —
Is DTC P0088, P0089, P0091, P0092, P0192, Go to Applicable

P0193, P0201 - P0206, P2146 or P2149 set? DTC Go to Step 3
2. Place the transmission in Neutral and set the
parking brake.
3 4. Accelerate the engine between idle and — An intermittent
W.O.T. (accelerator pedal full travel) many problem by foreign
times while observing the DTC Information material in the fuel
with a scan tool. system is
suspected. Go to
Does the DTC fail this ignition? Go to Step 4 Step 13

4 0.9 to 1.0 volt
4. Observe the Fuel Rail Pressure Sensor
parameter with the scan tool.
Does the scan tool indicate within the specified

value? Go to Step 5 Go to Step 12
2. Perform the Cylinder Balance Test with a scan
tool.
5 3. Command each injector OFF and verify an —
engine speed change for each injector.
Is there an injector that does not change engine

speed when commanded OFF? Go to Step 15 Go to Step 6
1. Inspect the fuel system line connections
between the fuel tank and the fuel supply
pump for tightness and all fuel hoses for cuts,
cracks and for the use of proper clamps.
Notice: The fuel system from the fuel tank(s)

to the fuel supply pump is under a slight
vacuum with the engine running. As a result,
air can enter the fuel system if these
connections are not tight. Air in the fuel
system will cause fuel rail pressure
fluctuations especially at high engine speed
6 and load, which may set this DTC. —
2. Pump the priming pump until it becomes firm.
If there is a leak on the suction side of the fuel
system between the priming pump and the
fuel supply pump, the priming pump will not
build up sufficient firmness and fuel leakage
may occur.
3. Start the engine and check for high side fuel
system leaks at the fuel supply pump and fuel
rail.
4. Repair any fuel system leaks as necessary.

1. Inspect the engine oil level.
Notice: Fuel may leak under the cylinder head

cover from the inlet high pressure line. In such
7 case, the engine oil level will rise. Inspect for —
fuel leakage into the engine oil.

1. Inspect the inlet high pressure joint to the fuel
injectors for fuel leaking from the sleeve
nut(s).
8 —


1. Inspect the fuel lines between the fuel supply
pump and fuel tank for being crushed or
kinked.
2. Inspect for a plugged fuel tank vent hose.
3. Inspect inside the fuel tank (if possible) for any
9 foreign material that may be getting drawn into —
the fuel line pickup causing a blocked
condition.

10 cracks and for the use of proper clamps. —

2. Disconnect the FRP regulator harness
connector.
connector of the FRP regulator (pins 1 and 2
of E47).
11 —
113 of E26).
necessary.

connector.
of E49).
12 —
101 of E26).
necessary.

Replace the fuel filter element. Refer to Fuel Filter
Element Replacement Procedure in Section 1D
13 Engine Fuel. —


Important: Replacement fuel injector must be
programmed.
Replace the appropriate fuel injector that does not
15 change engine speed when commanded OFF. —
Refer to Injector in Section 1D Engine Fuel.

Important: The fuel supply pump must be timed to
the engine and adjustment value must be learned
to the ECM.
Notice: Always replace the fuel filter element when

a fuel supply pump is replaced.
16 —
Replace the fuel supply pump and fuel filter
element. Refer to Engine Exterior Parts in Section
1B Engine Mechanical and Fuel Filter Element
Replacement Procedure in Section 1D Engine
Fuel.

Records.

18 —

Description • The ECM illuminates the MIL when the diagnostic
The common rail fuel system is comprised of two fuel runs and fails. Refer to DTC Type Definitions for
pressure sections: a suction side between the fuel tank Action Taken When the DTC Sets - Type A.
and the fuel supply pump and a high-pressure side (Except Euro 4 specification)
between the fuel supply pump and the fuel injectors. • The ECM limits fuel injection quantity.
Fuel is drawn from the fuel tank via a feed pump and • The ECM inhibits pre injection.
then pumped into the fuel rail by three plungers, all of • The ECM inhibits cruise control.
which are internal to the fuel supply pump. This high Second Stage
pressure (FRP) regulator dependant upon values from • The ECM illuminates the MIL when the diagnostic
the FRP sensor attached to the fuel rail. runs and fails. Refer to DTC Type Definitions for
If the ECM detects that the fuel pressure went Action Taken When the DTC Sets - Type A.
excessively high for a certain length of time, this DTC • The ECM limits fuel injection quantity.
will set (First Stage). If the ECM detects that during the • The ECM inhibits pre injection.
same ignition cycle the fuel pressure rose even higher • The ECM inhibits EGR control.
than the amount to set DTC P0088 for a certain length
• The ECM inhibits cruise control.
of time, the MIL will be illuminated (Second Stage). If
the MIL is illuminated, the fuel pressure was too high
and the pressure limiter valve did not active or did not
active quick enough. First Stage
Condition for Running the DTC Clearing the DTC - Type D. (Euro 4 specification)
• DTCs P0192, P0193, P060B and P0651 are not • Refer to DTC Type Definitions for Condition for
set. Clearing the MIL/ DTC - Type A. (Except Euro 4
• The ignition switch is ON. specification)
Second Stage
Condition for Setting the DTC Clearing the MIL/ DTC - Type A.
First Stage
Diagnostic Aids
• The ECM detects that the fuel rail pressure is more
• An intermittently sticking FRP regulator may have
than 185 MPa (26,800 psi) for longer than 5
allowed the fuel pressure to become high enough
seconds.
to set this DTC.
Second Stage
• Actual Fuel Rail Pressure and Desired Fuel Rail
• The ECM detects that the fuel rail pressure is more
Pressure parameter between idle and W.O.T.
than 190 MPa (27,500 psi) for longer than 5
(accelerator pedal full travel) in Park or Neutral
seconds.
should follow within ± 5 MPa (± 725 psi) quick
enough.
Action Taken When the DTC Sets
• A skewed FRP sensor value can set this DTC. The
First Stage
• The ECM will not illuminate the MIL or SVS lamp. 1.0 volt with the ignition switch ON and engine
Refer to DTC Type Definitions for Action Taken OFF after the engine has stopped running for a
When the DTC Sets - Type D. (Euro 4 minimum of 2 minutes.
specification)
Routing Reference: Fuel System Routing Diagram


2 —

P0201 - P0206, P2146 or P2149 set? DTC Go to Step 3
parking brake.
4. Accelerate the engine between idle and 180 MPa
3 An intermittent
W.O.T. (accelerator pedal full travel) many (26,000 psi)
times while observing the Fuel Rail Pressure problem by foreign
parameter with a scan tool. material in the fuel
system is
Does the Fuel Rail Pressure parameter ever suspected. Go to
exceed the specified value? Go to Step 4 Step 13
4 0.9 to 1.0 volt

tool.
5 3. Command each injector OFF and verify an —


may occur.
rail.




nut(s).
8 —

kinked.
condition.


connector.
of E47).
11 —
113 of E26).
necessary.


connector.
of E49).
101 of E26).
necessary.

13 Engine Fuel. —

programmed.

to the ECM.

16 —
Fuel.

Records.


18 —

Description • The ECM limits fuel injection quantity.
The common rail fuel system is comprised of two fuel • The ECM inhibits pre injection.
pressure sections: a suction side between the fuel tank • The ECM inhibits EGR control.
and the fuel supply pump and a high-pressure side • The ECM inhibits cruise control.
between the fuel supply pump and the fuel injectors.
Fuel is drawn from the fuel tank via a feed pump and Condition for Clearing the DTC
which are internal to the fuel supply pump. This high • Refer to DTC Type Definitions for Condition for
pressure is regulated by the ECM using the fuel rail Clearing the MIL/ DTC - Type A.
pressure (FRP) regulator dependant upon values from
the FRP sensor attached to the fuel rail. If the ECM Diagnostic Aids
detects that fuel pressure is a certain pressure higher • An intermittently sticking FRP regulator may have
than the desired pressure, this DTC will set. allowed the fuel pressure to become high enough
to set this DTC.
Condition for Running the DTC • Actual Fuel Rail Pressure and Desired Fuel Rail
• DTCs P0091, P0092, P0192, P0193, P0201 - Pressure parameter between idle and W.O.T.
P0206, P060B, P0651, P1261, P1262, P2146 and (accelerator pedal full travel) in Park or Neutral
P2149 are not set. should follow within ± 5 MPa (± 725 psi) quick
• The battery voltage is between 18 to 32 volts. enough.
• The ignition switch is ON. • A skewed FRP sensor value can set this DTC. The
1.0 volt with the ignition switch ON and engine
OFF after the engine has stopped running for a
minimum of 2 minutes.
• The ECM detects that the actual fuel rail pressure
is more than 40 MPa (5,800 psi) over the desired Routing Reference: Fuel System Routing Diagram
pressure for longer than 5 seconds.

2 —
Is DTC P0091, P0092, P0192, P0193, P0201 - Go to Applicable

P0206, P2146 or P2149 set? DTC Go to Step 3
3 0.9 to 1.0 volt


connector.
of E47).
113 of E26).
necessary.

connector.
of E49).
5 —
101 of E26).
necessary.

parking brake.
4. Accelerate the engine between idle and
W.O.T. (accelerator pedal full travel) many ± 5 MPa (± 725
6
times while observing the Fuel Rail Pressure psi)
and Desired Fuel Rail Pressure parameter
with a scan tool.
Does the Fuel Rail Pressure parameter follow

within the specified value quick enough (compare
with a similar unit if available)? Go to Step 7 Go to Step 9
Notice: An intermittent problem by foreign material
in the fuel is suspected.
7 Element Replacement Procedure in Section 1D —
Engine Fuel.


to the ECM.

9 —
Fuel.

Records.

11 —

The fuel rail pressure (FRP) regulator is installed to the • The ECM illuminates the MIL when the diagnostic
fuel supply pump and controls the suction fuel quantity runs and fails. Refer to DTC Type Definitions for
into the fuel rail. The FRP regulator is fully opened in Action Taken When the DTC Sets - Type A.
the normal state and larger drive current results in • The ECM limits fuel injection quantity.
smaller opening. The ECM calculates desired fuel rail
• The ECM inhibits pre injection.
pressure and fuel flow rate and it compares the
calculated desired fuel rail pressure to the actual value • The ECM inhibits EGR control.
to determine the FRP regulator position. When the • The ECM inhibits cruise control.
actual fuel rail pressure is higher than the desired
value, the FRP regulator is closed to decease the flow Condition for Clearing the DTC
rate. If the ECM detects an excessively low or high FRP • Refer to DTC Type Definitions for Condition for
regulator solenoid feedback current, DTC P0091 or Clearing the MIL/ DTC - Type A.
P0092 will set.
Diagnostic Aids
• DTC P060B is not set. Intermittent Conditions in this section.
• The ignition switch is ON. Test Description
The number below refers to the step number on the
Condition for Setting the DTC Circuit/ System Testing.
• The ECM detects that the FRP regulator feedback 7. If the FRP regulator high side circuit is shorted to
current is less than 50 mA, or more than 1000 mA voltage, engine stalls and will not start.
below the desired current. (DTC P0091) 8. If the FRP regulator low side circuit is shorted to
ground, this DTC may not set. This will cause engine
• The ECM detects that the FRP regulator feedback
stall or no engine start.
current is more than 2400 mA, or more than 1000
mA over the desired current. (DTC P0092)
Circuit/ System Testing DTC P0091 or P0092

Go to Diagnostic
Does the DTC fail this ignition? Go to Step 3 Aids
Observe the FRP Regulator Feedback Current
parameter with a scan tool.
3 300 mA
4 900 mA
value at Step 3? Go to Step 7 Go to Step 8

connector.
3. Connect a test lamp between the high side
5 circuit (pin 1 of E47) and a known good —
ground.

2. Connect a test lamp between the low side
6 circuit (pin 2 of E47) and battery voltage. —

1. Test the high side circuits between the ECM
(pins 105 and 113 of E26) and the FRP
regulator (pin 1 of E47) for a short to battery or
7 ignition voltage. —

1. Test the low side circuits between the ECM
(pins 89 and 97 of E26) and the FRP regulator
(pin 2 of E47) for a short to ground.
8 —

1. Test the high side circuits between the ECM
(pins 105 and 113 of E26) and the FRP
regulator (pin 1 of E47) for the following
conditions:
• An open circuit
9 • A short to ground —
• A short to the low side circuit
• High resistance

Important: The ECM may be damaged if the FRP
regulator low side circuit is shorted to a voltage
source.
1. Test the low side circuits between the ECM
(pins 89 and 97 of E26) and the FRP regulator
(pin 2 of E47) for the following conditions:
10 —
• An open circuit
• A short to battery or ignition voltage
• High resistance

FRP regulator (pins 1 and 2 of E47).
11 —


12 connections at the harness connector of the —
ECM (pins 89, 97, 105 and 113 of E26).

Replace the FRP regulator. Refer to Fuel Rail
Pressure (FRP) Regulator in Section 1D Engine
13 Fuel. —


Records.

16 —

Description • The ECM inhibits cruise control.
The common rail fuel system is comprised of two fuel
pressure sections: a suction side between the fuel tank Condition for Clearing the DTC
and the fuel supply pump and a high-pressure side • Refer to DTC Type Definitions for Condition for
between the fuel supply pump and the fuel injectors. Clearing the MIL/ DTC - Type A.
Fuel is drawn from the fuel tank via a feed pump and
then pumped into the fuel rail by three plungers, all of Diagnostic Aids
which are internal to the fuel supply pump. This high • An intermittently sticking FRP regulator may have
pressure is regulated by the ECM using the fuel rail allowed the fuel pressure to become low enough to
pressure (FRP) regulator dependant upon values from set this DTC.
the FRP sensor attached to the fuel rail. If the ECM
• Actual Fuel Rail Pressure and Desired Fuel Rail
detects that the fuel rail pressure is certain pressure
low as compared with the engine speed, this DTC will
(accelerator pedal full travel) in Park or Neutral
set.
enough.
• A skewed FRP sensor value can set this DTC. The
• DTCs P0087, P0091, P0092, P0192, P0193,
P0201 - P0206, P060B, P0651, P1261, P1262,
P2146 and P2149 are not set.
OFF after the engine has stopped running for a
• The battery voltage is between 18 to 32 volts. minimum of 2 minutes.
• The engine is running. Notice: This DTC most likely indicates a loss of fuel
pressure by a fuel leak from the high pressure side.
Condition for Setting the DTC Inspect the high pressure side fuel leakage between
the fuel supply pump and fuel injector first.
is lower than 15 MPa (2,180 psi) for longer than 3
seconds.
might be allowed to go into the fuel system. With air in
• The ECM illuminates the MIL when the diagnostic bleeding of fuel system after refilling.
Action Taken When the DTC Sets - Type A. Routing Reference: Fuel System Routing Diagram
• The ECM limits fuel injection quantity. Connector End View Reference: Engine Controls
• The ECM inhibits pre injection. Connector End Views or ECM Connector End Views


1. Inspect the high pressure side between the
fuel supply pump and the fuel injectors for fuel
leakage. The following components may
contain an external leak.
• Fuel supply pump
• Fuel rail
• Pressure limiter valve
• Fuel rail pressure (FRP) sensor
• Fuel pipe between the fuel supply pump
and fuel rail
• Fuel pipe between the fuel rail and fuel
injectors
2 • Each fuel pipe sleeve nuts —

case, the engine oil level will rise. Inspect for
Notice: Remove and inspect the inlet high

pressure joint to the fuel injectors for fuel
leaking from the sleeve nut(s). Replace the
fuel injector and injection pipe when foreign
material was in contact.

1. Remove each glow plug from the cylinder
head.
2. Inspect for fuel leakage into the combustion
3 chamber. —
Is there a cylinder that fuel leakage into the

combustion chamber? Go to Step 16 Go to Step 4
4 —

5 0.9 to 1.0 volt


parking brake.
6 tool. —
4. Command each injector OFF and verify an


may occur.
rail.



nut(s).
9 —

kinked.
condition.



connector.
of E47).
113 of E26).
necessary.

connector.
of E49).
13 —
101 of E26).
necessary.

14 Engine Fuel. —

programmed.
Replace the appropriate fuel injector that was
16 leaking fuel found at Step 3 and inspect the engine —
mechanical for any damage or poor engine
compression.


programmed.

to the ECM.

18 —
Fuel.

Records.

20 —

Circuit Description • The engine run time is longer than 5 seconds.
The mass air flow (MAF) sensor is an air flow meter
that measures the amount of air that enters the engine. Condition for Setting the DTC
It is fitted between the air cleaner and turbocharger. A • The ECM detects that the MAF sensor signal
small quantity of air that enters the engine indicates voltage is not within a predetermined range of the
deceleration or idle speed. A large quantity of air that calculated MAF value for longer than 10 seconds.
enters the engine indicates acceleration or a high load
condition. The ECM will calculate a predicted MAF Action Taken When the DTC Sets
value and compares the actual MAF sensor voltage • The ECM illuminates the MIL on the second
signal to the predicted MAF value. This comparison will consecutive driving cycle when the diagnostic runs
determine if the signal is stuck, or is too low or too high and fails. Refer to DTC Type Definitions for Action
for a given operating condition. If the ECM detects that Taken When the DTC Sets - Type B.
the actual MAF sensor signal voltage is not within a
predetermined range of the calculated MAF value, this
DTC will set.
Condition for Running the DTC • Refer to DTC Type Definitions for Condition for
Clearing the MIL/ DTC - Type B.
• DTCs P0045, P0079, P0080, P0102, P0103,
P0107, P0108, P0112, P0113, P0116, P0117,
Diagnostic Aids
P0118, P0122, P0123, P0234, P0404, P0409,
P0560, P060B, P0638, P0651, P0697, P1404, • Any unmetered air that enters the engine
P2227, P2228, P2229, U0073 and U0110 are not downstream of the MAF sensor will cause this
set. DTC to set.
• The battery voltage is between 18 to 32 volts. • High resistance in the MAF sensor circuit may set
• The ignition switch is ON. this DTC.
AND following conditions are met longer than 3 • A short between the signal circuit of the MAF
seconds sensor and the signal circuit of the intake air
• The engine speed is less than 1500 RPM. temperature (IAT) sensor will skew the MAF
sensor lower than normal at higher air flows.
• The EGR control is commanded OFF.
• The intake throttle control is commanded OFF. Connector End View Reference: Engine Controls
• The DPD filter regeneration is inactive. Connector End Views or ECM Connector End Views


1. Inspect the following conditions:
• Restricted air cleaner element, restricted
or collapsed air tubing between the air
cleaner and the intake manifold
• Any air induction leak
• Any contamination or objects that block
the MAF sensor inlet
• Skewed or slow MAF sensor
• Any water intrusion in the induction
system
• Any type of restriction in the exhaust
2 system —
• A sticking intake throttle valve
• A sticking EGR valve
• A sticking turbocharger nozzle control
actuator
• Exhaust throttle valve or exhaust brake
valve for stuck condition. Refer to
Exhaust System in Section 1G Engine
Exhaust.

2. Disconnect the MAF sensor harness
connector.
connector of the MAF sensor (pins 1, 2 and 3
of J14 or FB128).
3 4. Disconnect the ECM harness connector. —
connector of the ECM (pins 22, 23 and 69 of
FB24).

1. Test each sensor circuit between the ECM
(pins 22, 23 and 69 of FB24) and the MAF
sensor (pins 1, 2 and 3 of J14 or FB128) for
4 high resistance. —

Replace the MAF sensor. Refer to MAF/ IAT
5 Sensor in Section 1J Induction. —

Records.

7 —

Circuit Description • The ECM detects that the MAF sensor signal
The mass air flow (MAF) sensor is an air flow meter voltage is more than 4.9 volts for 3 seconds. (DTC
that measures the amount of air that enters the engine. P0103)
It is fitted between the air cleaner and turbocharger. A
small quantity of air that enters the engine indicates Action Taken When the DTC Sets
deceleration or idle speed. A large quantity of air that • The ECM illuminates the MIL when the diagnostic
enters the engine indicates acceleration or a high load runs and fails. Refer to DTC Type Definitions for
condition. The sensor has the following circuits. Action Taken When the DTC Sets - Type A.
• 12 volts reference circuit • The ECM uses a MAF substitution of default value.
• Low reference circuit • The ECM limits fuel injection quantity.
• MAF sensor signal circuit • The ECM inhibits EGR control.
The ECM monitors the MAF sensor signal voltage. This • The ECM inhibits cruise control.
output voltage will display on the scan tool as a voltage
parameter and as a grams per cylinder (g/cyl) Condition for Clearing the DTC
parameter. If the ECM detects an excessively low or
high signal voltage, DTC P0102 or P0103 will set.
Clearing the MIL/ DTC - Type A.
Diagnostic Aids
• DTCs P0560 and P060B are not set.
• The engine is running. Connector End View Reference: Engine Controls
• The ECM detects that the MAF sensor signal
voltage is less than 0.1 volts for 3 seconds. (DTC
P0102)

Is DTC P0560 also set? Go to DTC P0560 Go to Step 3

Observe the MAF (Mass Air Flow) Sensor
3 0.1 volts
Is the MAF Sensor parameter less than the Go to Diagnostic
specified value? Go to Step 4 Aids
connector.
3. Connect a test lamp between the 12 volts
4 reference circuit (pin 1 of J14 or FB128) and a —
known good ground.


Connect a 3-amp fused jumper wire between the
12 volts reference circuit and the signal circuit (pins
5 1 and 3 of J14 or FB128). 4.9 volts
Is the MAF Sensor parameter more than the
specified value? Go to Step 8 Go to Step 7
1. Test the 12 volts reference circuit between the
ECM (pin 23 of FB24) and the MAF sensor
(pin 1 of J14 or FB128) for an open circuit or

1. Test the signal circuit between the ECM (pin
69 of FB24) and the MAF sensor (pin 3 of J14
or FB128) for the following conditions:
• An open circuit
7 —
• A short to the low reference circuit
• High resistance

MAF sensor (pins 1 and 3 of J14 or FB128).
8 —

ECM (pins 23 and 69 of FB24).


Records.


13 —

2 4. Observe the MAF (Mass Air Flow) Sensor 4.9 volts
Is the MAF Sensor parameter more than the Go to Diagnostic

specified value? Go to Step 3 Aids
Monitor the DTC Information with a scan tool.
3 —
Is DTC P0560 also set? Go to Step 4 Go to Step 5
connector.
4 3. Turn ON the ignition, with the engine OFF. 0.1 volts
Is the MAF Sensor parameter less than the

specified value? Go to DTC P0560 Go to Step 7
connector.
Is the MAF Sensor parameter less than the

Connect a test lamp between the low reference
6 circuit (pin 2 of J14 or FB128) and battery voltage. —
Important: The MAF sensor may be damaged if
the sensor signal circuit is shorted to a voltage
source.
69 of FB24) and the MAF sensor (pin 3 of J14
or FB128) for the following conditions:
7 —
• A short to the 12 volts reference
• A short to any 5 volts reference


1. Test the low reference circuit between the
(pin 2 of J14 or FB128) for an open circuit or

connection at the harness connector of the
MAF sensor (pin 2 of J14 or FB128).
9 —



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14 —

Circuit Description Condition for Setting the DTC
The boost pressure sensor is located in the air • The ECM detects that the boost pressure sensor
induction tubing. The boost pressure sensor is a signal voltage is less than 0.1 volts for 3 seconds.
transducer that varies voltage according to changes in (DTC P0107)
the air pressure inside the air tubing. The sensor has • The ECM detects that the boost pressure sensor
the following circuits. signal voltage is more than 4.9 volts for 3 seconds.
• 5 volts reference circuit (DTC P0108)
• Low reference circuit
• Boost pressure sensor signal circuit
The boost pressure sensor provides a signal to the • The ECM illuminates the MIL when the diagnostic
ECM on the signal circuit, which is relative to the runs and fails. Refer to DTC Type Definitions for
pressure changes in the air tubing. The ECM should Action Taken When the DTC Sets - Type A.
detect a low signal voltage at a low boost pressure, • The ECM uses a boost pressure substitution of
such as low engine load. The ECM should detect high default value.
signal voltage at a high boost pressure, such as high • The ECM inhibits EGR control.
engine load. If the ECM detects an excessively low or
high signal voltage, DTC P0107 or P0108 will set. Condition for Clearing the DTC
• DTCs P060B and P0697 are not set.
• The battery voltage is between 18 to 32 volts. Diagnostic Aids
• The ignition switch is ON. • If an intermittent condition is suspected, refer to



Observe the Boost Pressure Sensor parameter
with a scan tool.
3 0.1 volts
Is the Boost Pressure Sensor parameter less than Go to Diagnostic
the specified value? Go to Step 4 Aids
2. Disconnect the boost pressure sensor
harness connector.
3. Connect a DMM between the 5 volts reference
4 circuit (pin 3 of E54) and a known good 4.5 volts
ground.
Is the DMM voltage more than the specified value? Go to Step 5 Go to Step 6

Connect a 3-amp fused jumper wire between the 5
volts reference circuit and the signal circuit (pins 1
5 and 3 of E54). 4.5 volts
Is the Boost Pressure Sensor parameter more than
the specified value? Go to Step 8 Go to Step 7
Notice: The boost pressure sensor shares the 5
volts reference circuit with other sensors. A fault
condition in the 5 volts reference circuit may set
DTCs on sensors that share this circuit.
6 ECM (pin 95 of E26) and the boost pressure —
sensor (pin 3 of E54) for an open circuit or
high resistance.

91 of E26) and the boost pressure sensor (pin
1 of E54) for the following conditions:
• An open circuit
7 —
• High resistance

boost pressure sensor (pins 1 and 3 of E54).
8 —

ECM (pins 91 and 95 of E26).

Replace the boost pressure sensor. Refer to Boost
10 Pressure Sensor in Section 1J Induction. —


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13 —

2 4. Observe the Boost Pressure Sensor 4.9 volts
Is the Boost Pressure Sensor parameter more than Go to Diagnostic

the specified value? Go to Step 3 Aids
3 —
harness connector.
4 0.1 volts
Is the Boost Pressure Sensor parameter less than

the specified value? Go to DTC P0697 Go to Step 7
harness connector.
5 0.1 volts
Is the Boost Pressure Sensor parameter less than

the specified value? Go to Step 6 Go to Step 7

Important: The boost pressure sensor may be
damaged if the sensor signal circuit is shorted to a
voltage source.
91 of E26) and the boost pressure sensor (pin
7 1 of E54) for the following conditions: —

Notice: The boost pressure sensor shares the low
reference circuit with other sensors. A fault
condition in the low reference circuit may set DTCs
on sensors that share this circuit.
8 ECM (pin 109 of E26) and the boost pressure —
sensor (pin 2 of E54) for an open circuit or
high resistance.

boost pressure sensor (pin 2 of E54).
9 —



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14 —

Circuit Description • The ECM detects that the IAT sensor signal
The intake air temperature (IAT) sensor is fitted voltage is more than 4.85 volts for 3 seconds.
between the air cleaner and turbocharger. It is internal (DTC P0113)
to the mass air flow (MAF) sensor (Euro 4
specification). The IAT sensor is a variable resistor and Action Taken When the DTC Sets
it measures the temperature of the air entering the • The ECM illuminates the MIL when the diagnostic
engine. The sensor has a signal circuit and a low runs and fails. Refer to DTC Type Definitions for
reference circuit. The ECM supplies 5 volts to the Action Taken When the DTC Sets - Type A.
signal circuit and a ground for the low reference circuit. • The ECM uses an IAT substitution of default value.
When the IAT sensor is cold, the sensor resistance is
high. When the air temperature increases, the sensor
resistance decreases. With high sensor resistance, the
ECM detects a high voltage on the signal circuit. With
lower sensor resistance, the ECM detects a lower • Refer to DTC Type Definitions for Condition for
voltage on the signal circuit. If the ECM detects an Clearing the MIL/ DTC - Type A.
excessively low or high signal voltage, DTC P0112 or
P0113 will set. Diagnostic Aids
Condition for Running the DTC Intermittent Conditions in this section.
• DTCs P060B and P0651 are not set. • Use the Temperature vs. Resistance table to test
• The battery voltage is between 18 to 32 volts. the IAT sensor at various temperature levels to
evaluate the possibility of a skewed sensor. A
skewed sensor could result in poor driveability
• The engine run time is longer than 3 minutes. concerns.
(DTC P0113)
Condition for Setting the DTC Connector End Views or ECM Connector End Views
• The ECM detects that the IAT sensor signal
voltage is less than 0.1 volts for 3 seconds. (DTC
P0112)


Observe the Intake Air Temperature Sensor
3 0.1 volts
Is the Intake Air Temperature Sensor parameter Go to Diagnostic
less than the specified value? Go to Step 4 Aids
2. Disconnect the mass air flow/ intake air
temperature (MAF/ IAT) sensor harness
connector (Euro 4 specification) or the IAT
4 sensor harness connector (except Euro 4 4.5 volts
specification).
Is the Intake Air Temperature Sensor parameter

more than the specified value? Go to Step 6 Go to Step 5

72 of FB24) and the IAT sensor (pin 4 of J14
or FB128 [Euro 4 specification] or pin 1 of
J194 or FB196 [except Euro 4 specification])
for the following conditions:
5 —

Replace the MAF sensor or the IAT sensor. Refer
6 to MAF/ IAT Sensor in Section 1J Induction. —
3. Inspect connections at the harness connector
of the ECM (pins 60 and 72 of FB24) for
7 corrosion. —
4. Repair or clean the connection(s) as
necessary.


Records.

10 —



Observe the Intake Air Temperature Sensor
3 4.8 volts
Is the Intake Air Temperature Sensor parameter Go to Diagnostic
more than the specified value? Go to Step 4 Aids
2. Disconnect the mass air flow/ intake air
temperature (MAF/ IAT) sensor harness
connector (Euro 4 specification) or the IAT
sensor harness connector (except Euro 4
specification).
4 3. Connect a DMM between the signal circuit 5.5 volts
(pin 4 of J14 or FB128 [Euro 4 specification] or
pin 1 of J194 or FB196 [except Euro 4
specification]) and a known good ground.
Important: The IAT sensor may be damaged if the
sensor signal circuit is shorted to a voltage source.
5 for the following conditions: —

• A short to the 12 volts reference

signal circuit and the low reference circuit (pins 4
and 5 of J14 or FB128 [Euro 4 specification] or pins
6 1 and 2 of J194 or FB196 [except Euro 4 0.1 volts
specification]).

less than the specified value? Go to Step 10 Go to Step 7
signal circuit (pin 4 of J14 or FB128 [Euro 4
specification] or pin 1 of J194 or FB196 [except
7 Euro 4 specification]) and a known good ground. 0.1 volts

8 —
for an open circuit or high resistance.


Notice: The IAT sensor shares the low reference
circuit with other sensors. A fault condition in the
low reference circuit may set DTCs on sensors that
share this circuit.
ECM (pin 60 of FB24) and the IAT sensor (pin
9 5 of J14 or FB128 [Euro 4 specification] or pin —
2 of J194 or FB196 [except Euro 4
specification]) for an open circuit or high
resistance.

10 —
for a short to any 5 volts reference circuit.

IAT sensor (pins 4 and 5 of J14 or FB128
[Euro 4 specification] or pins 1 and 2 of J194
11 —
or FB196 [except Euro 4 specification]).


Replace the MAF sensor or the IAT sensor. Refer
13 to MAF/ IAT Sensor in Section 1J Induction. —

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16 —

The engine coolant temperature (ECT) sensor is • The ECM detects that the difference of maximum
installed to the thermostat housing. The ECT sensor is and minimum engine coolant temperature is less
a variable resistor and it measures the temperature of than 1 to 12°C (1.8 to 22°F).
the engine coolant. If the ECM detects that the
difference of engine coolant temperature is smaller Action Taken When the DTC Sets
than the calculated range during the predetermined • The ECM illuminates the MIL on the second
conditions, this DTC will set. This DTC will only run consecutive driving cycle when the diagnostic runs
once per ignition cycle within the enabling condition. and fails. Refer to DTC Type Definitions for Action
Taken When the DTC Sets - Type B.
• DTCs P0117, P0118, P0201 - P0206, P0500, Condition for Clearing the DTC
P0502, P0503, P060B, P0697, P1261, P1262, • Refer to DTC Type Definitions for Condition for
P2146 and P2149 are not set. Clearing the MIL/ DTC - Type B.
• The vehicle runtime is longer than 5 minutes with • After starting the engine, the ECT should rise
the vehicle speed is more than 4 km/h (3 MPH). steadily to about 80 to 85°C (176 to 185°F) then
• The engine runtime is longer than 5 minutes with stabilize when the thermostat opens.
the engine speed is more than 1300 RPM. • Use the Temperature vs. Resistance table to test
• The accumulation fuel injection quantity since the ECT sensor at various temperature levels to
engine start is more than a threshold. evaluate the possibility of a skewed sensor. A
concerns.


1. Test the engine cooling system for the
following conditions. Refer to Cooling System
in Section 1C Engine Cooling for testing.
• Engine coolant level
2 —
• Engine coolant leakage

2. Disconnect the engine coolant temperature
(ECT) sensor harness connector.
connector of the ECT sensor (pins 1 and 2 of
E55).
E26).


(pins 84 and 109 of E26) and the ECT sensor
(pins 1 and 2 of E55) for high resistance.
4 —

Replace the ECT sensor. Refer to Engine Coolant
5 Temperature Sensor in Section 1C Engine Cooling. —
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7 —

Circuit Description • The ECM detects that the ECT sensor signal
The engine coolant temperature (ECT) sensor is voltage is more than 4.85 volts for 3 seconds.
installed to the thermostat housing. The ECT sensor is (DTC P0118)
a variable resistor and it measures the temperature of
the engine coolant. The sensor has a signal circuit and Action Taken When the DTC Sets
a low reference circuit. The ECM supplies 5 volts to the • The ECM illuminates the MIL when the diagnostic
signal circuit and a ground for the low reference circuit. runs and fails. Refer to DTC Type Definitions for
When the ECT sensor is cold, the sensor resistance is Action Taken When the DTC Sets - Type A.
high. When the engine coolant temperature increases, • The ECM uses an ECT substitution of default
the sensor resistance decreases. With high sensor value.
resistance, the ECM detects a high voltage on the
signal circuit. With lower sensor resistance, the ECM
detects a lower voltage on the signal circuit. If the ECM
detects an excessively low or high signal voltage, DTC
P0117 or P0118 will set. • Refer to DTC Type Definitions for Condition for
Diagnostic Aids
• Use the Temperature vs. Resistance table to test
• The engine run time is longer than 5 seconds. the ECT sensor at various temperature levels to
(DTC P0118) evaluate the possibility of a skewed sensor. A
Condition for Setting the DTC concerns.
• The ECM detects that the ECT sensor signal
voltage is less than 0.1 volts for 3 seconds. (DTC Connector End View Reference: Engine Controls
P0117) Connector End Views or ECM Connector End Views


Observe the Engine Coolant Temperature Sensor
3 0.1 volts
Is the Engine Coolant Temperature Sensor Go to Diagnostic
parameter less than the specified value? Go to Step 4 Aids
2. Disconnect the ECT sensor harness
connector.
Is the Engine Coolant Temperature Sensor

parameter more than the specified value? Go to Step 6 Go to Step 5

84 of E26) and the ECT sensor (pin 1 of E55)
5 —

of the ECM (pins 84 and 109 of E26) for
7 corrosion. —
necessary.


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10 —



Observe the Engine Coolant Temperature Sensor
3 4.8 volts
Is the Engine Coolant Temperature Sensor Go to Diagnostic
parameter more than the specified value? Go to Step 4 Aids
2. Disconnect the ECT sensor harness
connector.
(pin 1 of E55) and a known good ground.
Important: The ECT sensor may be damaged if
source.
5 84 of E26) and the ECT sensor (pin 1 of E55) —
for a short to battery or ignition voltage.

parameter less than the specified value? Go to Step 10 Go to Step 7
signal circuit (pin 1 of E55) and a known good
7 ground. 0.1 volts
8 —

Notice: The ECT sensor shares the low reference
share this circuit.
9 ECM (pin 109 of E26) and the ECT sensor —
(pin 2 of E55) for an open circuit or high
resistance.

for a short to any 5 volts reference circuit.
10 —


ECT sensor (pins 1 and 2 of E55).
11 —



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16 —

The intake throttle position sensor is installed on the • The ECM detects that the intake throttle position
intake throttle valve body together with the control sensor signal voltage is less than 0.1 volts for 3
motor. The intake throttle position sensor changes seconds. (DTC P0122)
output voltage according to intake throttle valve • The ECM detects that the intake throttle position
position. The sensor has the following circuits. sensor signal voltage is more than 4.9 volts for 3
• 5 volts reference circuit seconds. (DTC P0123)
• Intake throttle position sensor signal circuit
The intake throttle position sensor provides a signal to • The ECM illuminates the MIL when the diagnostic
the ECM on the signal circuit, which is relative to the runs and fails. Refer to DTC Type Definitions for
position changes of the intake throttle valve. If the ECM Action Taken When the DTC Sets - Type A.
detects an excessively low or high signal voltage, DTC • The ECM inhibits EGR control.
P0122 or P0123 will set.
• DTCs P060B and P0697 are not set. Clearing the MIL/ DTC - Type A.



Observe the Intake Throttle Position Sensor
3 0.1 volts
Is the Intake Throttle Position Sensor parameter Go to Diagnostic
2. Disconnect the intake throttle valve harness
connector.
ground.
Is the Intake Throttle Position Sensor parameter

Notice: The intake throttle position sensor shares
the 5 volts reference circuit with other sensors. A
fault condition in the 5 volts reference circuit may
set DTCs on sensors that share this circuit.
6 ECM (pin 95 of E26) and the intake throttle —
valve (pin 5 of E46) for an open circuit or high
resistance.

85 of E26) and intake throttle valve (pin 6 of
E46) for the following conditions:
• An open circuit
7 —
• High resistance

intake throttle valve (pins 5 and 6 of E46).
8 —


Replace the intake throttle valve. Refer to Intake
10 Throttle Valve in Section 1B Engine Mechanical. —

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13 —

2 4. Observe the Intake Throttle Position Sensor 4.9 volts
Is the Intake Throttle Position Sensor parameter Go to Diagnostic

3 —
connector.
4 0.1 volts

less than the specified value? Go to DTC P0697 Go to Step 7
connector.
5 0.1 volts

Important: The intake throttle position sensor may
be damaged if the sensor signal circuit is shorted to
a voltage source.
85 of E26) and the intake throttle valve (pin 6
7 of E46) for the following conditions: —

Notice: The intake throttle position sensor shares
the low reference circuit with other sensors. A fault
8 ECM (pin 109 of E26) and the intake throttle —
valve (pin 4 of E46) for an open circuit or high
resistance.


intake throttle valve (pin 4 of E46).
9 —



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14 —

Circuit Description • The ECM detects that the FT sensor signal voltage
The fuel temperature (FT) sensor is installed to the fuel is more than 4.85 volts for 3 seconds. (DTC
supply pump. The FT sensor is a variable resistor and it P0183)
measures the temperature of the fuel entering the fuel
supply pump. The sensor has a signal circuit and a low Action Taken When the DTC Sets
reference circuit. The ECM supplies 5 volts to the • The ECM illuminates the MIL when the diagnostic
signal circuit and a ground for the low reference circuit. runs and fails. Refer to DTC Type Definitions for
When the FT sensor is cold, the sensor resistance is Action Taken When the DTC Sets - Type A.
high. When the fuel temperature increases, the sensor • The ECM uses a FT substitution of default value.
ECM detects a high voltage on the signal circuit. With Condition for Clearing the DTC
lower sensor resistance, the ECM detects a lower
voltage on the signal circuit. If the ECM detects an
excessively low or high signal voltage, DTC P0182 or
P0183 will set.
Diagnostic Aids
Condition for Running the DTC • Before starting a cold engine, FT sensor and
engine coolant temperature (ECT) sensor
temperature should be relatively close to each
• The battery voltage is between 18 to 32 volts. other.
• The engine run time is longer than 3 minutes. Intermittent Conditions in this section.
(DTC P0183) • Use the Temperature vs. Resistance table to test
the FT sensor at various temperature levels to
Condition for Setting the DTC evaluate the possibility of a skewed sensor. A
• The ECM detects that the FT sensor signal voltage skewed sensor could result in poor driveability
is less than 0.1 volts for 3 seconds. (DTC P0182) concerns.



Observe the Fuel Temperature Sensor parameter
with a scan tool.
3 0.1 volts
Is the Fuel Temperature Sensor parameter less Go to Diagnostic
than the specified value? Go to Step 4 Aids
2. Disconnect the FT sensor harness connector.
Is the Fuel Temperature Sensor parameter more

than the specified value? Go to Step 6 Go to Step 5

83 of E26) and the FT sensor (pin 2 of E30) for
5 —

Replace the FT sensor. Refer to Fuel Temperature
of the ECM (pins 83 and 109 of E26) for
7 corrosion. —
necessary.


Records.

10 —



Observe the Fuel Temperature Sensor parameter
with a scan tool.
3 4.8 volts
Is the Fuel Temperature Sensor parameter more Go to Diagnostic
2. Disconnect the FT sensor harness connector.
3. Connect a DMM between the signal circuit
4 (pin 2 of E30) and a known good ground. 5.5 volts
Important: The FT sensor may be damaged if the
sensor signal circuit is shorted to a voltage source.
5 83 of E26) and the FT sensor (pin 2 of E30) for —
a short to battery or ignition voltage.

Is the Fuel Temperature Sensor parameter less
signal circuit of the sensor harness (pin 2 of E30)
7 and a known good ground. 0.1 volts
Is the Fuel Temperature Sensor parameter less
an open circuit or high resistance.
8 —

Notice: The FT sensor shares the low reference
share this circuit.
9 ECM (pin 109 of E26) and the FT sensor (pin —
1 of E30) for an open circuit or high
resistance.

a short to any 5 volts reference circuit.
10 —

FT sensor (pins 1 and 2 of E30).
11 —



Replace the FT sensor. Refer to Fuel Temperature

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16 —

Circuit Description • The ECM detects that the FRP sensor signal
The fuel rail pressure (FRP) sensor is installed to the voltage is more than 4.5 volts. (DTC P0193)
fuel rail and it detects the fuel pressure in the fuel rail,
converts the pressure into a voltage signal, and sends Action Taken When the DTC Sets
the signal to the ECM. The sensor has the following • The ECM illuminates MIL when the diagnostic runs
circuits. and fails. Refer to DTC Type Definitions for Action
• 5 volts reference circuit Taken When the DTC Sets - Type A.
• Low reference circuit • The ECM uses a FRP substitution of default value.
• FRP sensor signal circuit • The ECM limits fuel injection quantity.
The ECM monitors the FRP sensor signal voltage. • The ECM inhibits pre injection.
Higher fuel rail pressure provides higher signal voltage • The ECM inhibits EGR control.
while lower pressure provides lower signal voltage. The
ECM calculates actual fuel rail pressure (fuel pressure)
from the voltage signal and uses the result in fuel
injection control and other control tasks. If the ECM
detects an excessively low or high signal voltage, DTC • Refer to DTC Type Definitions for Condition for
P0192 or P0193 will set. Clearing the MIL/ DTC - Type A.
Condition for Running the DTC Diagnostic Aids

• DTCs P060B and P0651 are not set. • If an intermittent condition is suspected, refer to
• Electromagnetic interference may affect
intermittent condition.
• The ECM detects that the FRP sensor signal Connector End Views or ECM Connector End Views
voltage is less than 0.7 volts. (DTC P0192)


Observe the Fuel Rail Pressure Sensor parameter
with a scan tool.
3 0.7 volts
Is the Fuel Rail Pressure Sensor parameter less Go to Diagnostic
connector.
4 4.5 volts
Is the Fuel Rail Pressure Sensor parameter more

Connect a DMM between the 5 volts reference
5 circuit (pin 3 of E49) and a known good ground. 4.5 volts

1. Test the signal circuits between the ECM (pins
82 and 90 of E26) and the FRP sensor (pin 2
of E49) for the following conditions:
6 —

Notice: The FRP sensor shares the 5 volts
7 ECM (pin 87 of E26) and the FRP sensor (pin —
resistance.

FRP sensor (pin 3 of E49).
8 —



Records.

13 —


Did you perform the Diagnostic System Check- Go to Diagnostic
1 Engine Controls? — System Check

Observe the Fuel Rail Pressure Sensor parameter
with a scan tool.
3 4.5 volts
Is the Fuel Rail Pressure Sensor parameter more Go to Diagnostic
connector.
1. Connect a test lamp between the signal circuit
5 2. Connect a DMM between the probe of the test 4.5 volts
lamp and a known good ground.
signal circuit and the low reference circuit of the
6 sensor harness (pins 1 and 2 of E49). 0.1 volts
Is the Fuel Rail Pressure Sensor parameter less
Notice: The FRP sensor shares the low reference
share this circuit.
7 ECM (pin 101 of E26) and the FRP sensor —
resistance.

1. Test the signal circuit between the ECM (pins
of E49) for an open circuit or high resistance.
8 —

of E49) for a short to any 5 volts reference
9 circuit. —


Important: The FRP sensor may be damaged if
source.
10 82 and 90 of E26) and the FRP sensor (pin 2 —
of E49) for a short to battery or ignition
voltage.

FRP sensor (pins 1 and 2 of E49).
11 —

ECM (pins 82, 90 and 101 of E26).


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16 —

DTC P0201, P0202, P0203, P0204, P0205 or P0206 (Flash Code 271, 272, 273, 274, 275 or
276)
Circuit Description • The ECM detects that the fuel injector solenoid
The ECM calculates the optimum fuel injection ON time control circuit is shorted to voltage circuit or charge
using data sent from various engine sensors. The voltage circuit.
common 1 and 2 fuel injector charge voltage circuits
are high-voltage supply, which drives fuel injectors for Action Taken When the DTC Sets
each cylinder in conjunction with the ECM grounding • The ECM illuminates the MIL when the diagnostic
the fuel injector solenoid control circuit. The common 1 runs and fails. Refer to DTC Type Definitions for
covers fuel injectors in cylinders #1, #2 and #3, and the Action Taken When the DTC Sets - Type A.
common 2 covers fuel injectors in cylinders #4, #5 and • The ECM limits fuel injection quantity.
#6. If the fuel injector charge voltage circuit or solenoid
control circuit is open circuit, DTC P0201 - P0206 will
set depending upon which cylinder injector circuit
failed. If the fuel injector solenoid control circuit is
shorted to voltage circuit or common charge voltage • Refer to DTC Type Definitions for Condition for
circuit, this DTC will also set. Clearing the MIL/ DTC - Type A.

• DTCs P1261 and P2146 are not set. (DTC P0201, • If an intermittent condition is suspected, refer to
P0202 and P0203) Intermittent Conditions in this section.
• DTCs P1262 and P2149 are not set. (DTC P0204,
Notice: Each DTC agrees with engine cylinder order.
P0205 and P0206)
• P0201: Cylinder #1
Condition for Setting the DTC • P0205: Cylinder #5
Either of following condition is met: • P0206: Cylinder #6
• The ECM detects an open circuit on the fuel
injector solenoid circuits. Connector End View Reference: Engine Controls

Go to Diagnostic
2. Disconnect the in-line harness connector
(H78) from the cylinder head cover case.
3 1.0 volt
4. Connect a DMM between the cylinder #1
charge voltage circuit (pin 3 of H78 female
side) and a known good ground.
Is the DMM voltage less then the specified value? Go to Step 4 Go to Step 8

Connect a DMM between the cylinder #1 solenoid
control circuit (pin 2 of H78 female side) and a
4 known good ground. 16.0 volts
Is the DMM voltage less than the specified value? Go to Step 5 Go to Step 9
Is the DMM voltage more than the specified value
5 12.0 volts
at Step 4? Go to Step 6 Go to Step 10
connections at the in-line harness connector
(pins 2 and 3 of H78).
6 —

1. Remove the cylinder head cover. Refer to
Cylinder Head Cover in Section 1B Engine
Mechanical.
2. Inspect the fuel injector harness for loose
injector terminal nuts, objects touching injector
terminals.
7 —

119 of E26) and the in-line harness connector
(pin 2 of H78 female side) for a short to the
8 common 1 charge voltage circuit. —

(pin 2 of H78 female side) for a short to battery
9 or ignition voltage. —

(pin 2 of H78 female side) for an open circuit
10 or high resistance. —

1. Test the cylinder #1 fuel injector circuit
between the fuel injector terminals (pins 1, 2
and 3 of E71) and the in-line harness
connector (pins 2 and 3 of H80) for the
• An open circuit
11 —
• High resistance
2. Repair the circuit(s) or replace the fuel injector
harness as necessary.



programmed.
13 Replace the cylinder #1 fuel injector. Refer to —
Injector in Section 1D Engine Fuel.


Records.

16 —

Go to Diagnostic
3 1.0 volt

5 12.0 volts
6 —

Mechanical.
terminals.
7 —




• An open circuit
11 —
• High resistance



programmed.


Records.

16 —

Go to Diagnostic
3 1.0 volt

5 12.0 volts
6 —

Mechanical.
terminals.
7 —




• An open circuit
11 —
• High resistance



programmed.


Records.

16 —

Go to Diagnostic
3 1.0 volt

5 12.0 volts
6 —

Mechanical.
terminals.
7 —




• An open circuit
11 —
• High resistance



programmed.


Records.

16 —

Go to Diagnostic
3 1.0 volt

5 12.0 volts
6 —

Mechanical.
terminals.
7 —




• An open circuit
11 —
• High resistance



programmed.


Records.

16 —

Go to Diagnostic
3 1.0 volt

5 12.0 volts
6 —

Mechanical.
terminals.
7 —




• An open circuit
11 —
• High resistance



programmed.


Records.

16 —

Circuit Description Condition for Clearing the DTC
The engine coolant temperature (ECT) sensor is • Refer to DTC Type Definitions for Condition for
installed to the thermostat housing. The ECT sensor is Clearing the DTC - Type D.
a variable resistor and it measures the temperature of
the engine coolant. If the ECM detects an excessive Diagnostic Aids
high coolant temperature, this DTC will set. • After starting the engine, the ECT should rise
steadily to about 80 to 84°C (176 to 183°F) then
Condition for Running the DTC stabilize when the thermostat opens.
• DTCs P0116, P0117, P0118, P060B and P0697 • Use the Temperature vs. Resistance table to test
are not set. the ECT sensor at various temperature levels to
• The battery voltage is between 18 to 32 volts. evaluate the possibility of a skewed sensor. A
• The ignition switch is ON. skewed sensor could result in poor driveability
concerns.
• The Total Engine Coolant Overtemperature Events
Condition for Setting the DTC parameter on the scan tool indicates number of
overheat events.
Either of following condition is met:
• The ECM detects that the engine coolant Notice: This DTC is caused by an engine overheat
temperature is more than 110°C (230°F) for 5 condition (e.g. low engine coolant level). Since this
seconds. DTC does not illuminate any lamps, clear the DTC and
• The ECM detects that the engine coolant ensure there are no signs of engine damage.
temperature is more than 120°C (248°F) for 5 Excessive engine overheat may damage internal
seconds during the DPD filter regeneration. engine components.

• The ECM will not illuminate the MIL or SVS lamp.
Refer to DTC Type Definitions for Action Taken
When the DTC Sets - Type D.


1. Test the engine cooling system for the
following condition. Refer to Cooling System
in Section 1C Engine Cooling for testing.
• Engine coolant level
• Engine coolant leakage
• Cooling fan belt slippage
3 • Cooling fan clutch working —
• Thermostat working
• Water pump working
• Radiator clogging


Start the engine and wait until engine is fully warm
upped while observing the Coolant Temperature
4 parameter with a scan tool. 110°C (230°F)
Ask the driver if overheat is caused by low engine
coolant level, etc.
5 If engine overheat has experienced, the engine —
must be inspected and repaired as necessary.
Did you complete the action? Go to Step 7 —

1. Test the engine coolant temperature (ECT)
sensor at various temperature levels to
evaluate the possibility of a skewed sensor.
6 —
2. Replace the ECT sensor as necessary.
Go to Diagnostic
Did you find and correct the condition? Go to Step 7 Aids
7 4. Start the engine and wait until engine is fully 110°C (230°F)
warm upped while observing the Coolant
Temperature parameter with a scan tool.

8 —

The crankshaft position (CKP) sensor is located under • Refer to DTC Type Definitions for Condition for
the fuel supply pump. The ECM calculates the engine Clearing the DTC - Type D. (Euro 4 specification)
speed and exact position of the crankshaft based on • Refer to DTC Type Definitions for Condition for
the signal pulse from the CKP sensor. If the ECM Clearing the MIL/ DTC - Type A. (Except Euro 4
detects an engine overrun condition, this DTC will set. specification)
Condition for Setting the DTC Diagnostic Aids

• The ECM detects that the engine speed is more • Make sure the CKP sensor is tight and the sensor
than 3640 RPM. rotor teeth are not damaged.
• Electromagnetic interference in the CKP sensor
circuits may set this DTC.
• The ECM will not illuminate the MIL or SVS lamp. • The Total Engine Overspeed Events parameter on
Refer to DTC Type Definitions for Action Taken the scan tool indicates number of overrun events.
When the DTC Sets - Type D. (Euro 4
specification) Notice: This DTC is caused by an engine overspeed
• The ECM illuminates the MIL when the diagnostic condition, which was most likely caused by driver error
runs and fails. Refer to DTC Type Definitions for (i.e. downshifting a manual transmission on a steep
Action Taken When the DTC Sets - Type A. grade). Since the DTC does not illuminate any lamps,
(Except Euro 4 specification) clear the DTC and ensure there are no sign of engine
damage. Excessive engine overspeed may damage
internal engine components.

Important: If DTC P0335 or P0336 is set, diagnose
that DTC first.
2 3. Observe the Engine Speed parameter with a 3640 RPM
scan tool.
4. Accelerate the engine as necessary.
Does the Engine Speed parameter ever exceed the

Ask the driver if overrun is caused by gear slip-out,
shift error, down-slope driving, etc. If engine
3 overrun has experienced, the engine must be —
inspected and repaired as necessary.


1. Inspect the CKP sensor and sensor rotor for
4 and sensor rotor —
• Physical damage of sensor rotor
rotor

Replace the CKP sensor. Refer to Crankshaft
5 Position Sensor in Section 1B Engine Mechanical. —
6 5. Accelerate the engine between idle and 3640 RPM
W.O.T. (accelerator pedal full travel) many
times while observing the Engine Speed
Does the Engine Speed parameter ever exceed the

7 —

The boost pressure sensor is located in the air • Refer to DTC Type Definitions for Condition for
induction tubing. The sensor is a transducer that varies Clearing the MIL/ DTC - Type A.
voltage according to changes in the air pressure inside
the air tubing. The ECM monitors the boost pressure Diagnostic Aids
sensor signal for abnormal values. If the ECM detects • An open circuit or high resistance in the boost
that the sensor signal is excessively high, this DTC will pressure low reference circuit may set this DTC.
set. This indicates excessive high boost pressure.
• Check the turbocharger nozzle control solenoid for
a sticking.
• Use a scan tool to verify the integrity of the boost
• DTCs P0045, P0107, P0108, P060B, P0697,
pressure sensor signal. Compare the sensor
U0073 and U0110 are not set.
values under all load conditions for an excessively
• The ignition switch is ON. high value.
• The fuel with which gasoline was mixed may set
this DTC.
• The ECM detects that the boost pressure is higher
than 146 to 240 kPa (21 to 35 psi) for longer than 5 Test Description
seconds.
The numbers below refer to the step number on the
Circuit/ System Testing.
3. A skewed boost pressure sensor value (shifted to a
• The ECM illuminates the MIL when the diagnostic higher pressure) can set this DTC. The Boost Pressure
runs and fails. Refer to DTC Type Definitions for on the scan tool should read near Barometric Pressure
Action Taken When the DTC Sets - Type A. with the ignition switch ON and engine OFF.
• The ECM limits fuel injection quantity. 4. A skewed Barometric Pressure sensor value (shifted
• The ECM inhibits EGR control. to a lower pressure) may indicate a wrong boost
pressure. The Barometric Pressure on the scan tool
should read near surrounding barometric pressure.


2 —

P2228 or P2229 also set? DTC Go to Step 3
2. Observe the Boost Pressure and Barometric
Pressure with a scan tool. 10 kPa (1.5
3
psi)
Does the scan tool indicate that the difference
between the Boost Pressure and Barometric
Pressure is more than the specified value? Go to Step 4 Go to Step 5

Compare the Barometric Pressure value to the
range specified in the altitude vs. barometric
pressure table. Refer to Altitude vs. Barometric
4 Pressure. —
Is the Barometric Pressure parameter within the

range specified? Go to Step 6 Go to Step 7
1. Inspect the following for possible causes of
high boost pressure.
• Turbocharger nozzle control solenoid for
a stuck condition. Perform the
Turbocharger Solenoid Control with a
scan tool.
• Intake throttle valve sticking. Perform the
Intake Throttle Solenoid Control with a
5 scan tool. —
• Oil in the air induction tubing causing an
incorrect boost pressure sensor signal.
When there is adhesion of oil inside of
the tubing, intercooler or turbocharger it
needs to be wiped off.
Go to Diagnostic
Did you find and correction the condition? Go to Step 10 Aids
harness connector.
boost pressure sensor (pin 2 of E54).
6 5. Inspect for an intermittent, for a poor —
connector of the ECM (pin 109 of E26).
6. Test for high resistance of the low reference
circuit.
necessary.

2. Disconnect the BARO sensor harness
connector.
BARO sensor (pins 2 and 3 of FL52).
FB24).
necessary.


Replace the BARO sensor. Refer to BARO Sensor
9 Replacement. —
Records.

11 —

The boost pressure sensor is located in the air • Refer to DTC Type Definitions for Condition for
induction tubing. The sensor is a transducer that varies Clearing the MIL/ DTC - Type B. (Euro 4
voltage according to changes in the air pressure inside specification)
the air tubing. The ECM monitors the boost pressure • Refer to DTC Type Definitions for Condition for
sensor signal for abnormal values. If the ECM detects Clearing the MIL/ DTC - Type A. (Except Euro 4
that the sensor signal is excessively low, this DTC will specification)
set. This indicates excessive low boost pressure.
Diagnostic Aids
• Induction air leakage can cause a low boost
• DTCs P0045, P0079, P0080, P0087, P0088, pressure condition. A whistling noise may be heard
P0089, P0091, P0092, P0093, P0102, P0103, if a component is allowing air to enter the induction
P0107, P0108, P0116, P0117, P0118, P0122, system.
P0123, P0192, P0193, P0201 - P0206, P0401,
• Check for cracked air tubing that may only open
P0404, P0409, P0560, P060B, P0638, P0651,
during certain engine movement conditions.
P0697, P1093, P1261, P1262, P1404, P2146,
P2149, P2227, P2228, P2229, P2453, U0073 and • Check the turbocharger nozzle control solenoid for
U0110 are not set. a sticking.
• The ignition switch is ON. • Use a scan tool to verify the integrity of the boost
pressure sensor signal. Compare the sensor
• The engine speed is between 1200 to 2480 RPM.
values under all load conditions for an excessively
• The fuel injection quantity is higher than a low value.
predetermined range.
• Fuel system problem (low fuel pressure condition)
may set this DTC.
• The ECM detects that the boost pressure is lower Test Description
than 33 to 40 kPa (5 to 6 psi) for longer than 5
The numbers below refer to the step number on the
seconds.
4. A skewed boost pressure sensor value (shifted to a
lower pressure) can set this DTC. The Boost Pressure
• The ECM illuminates the MIL on the second on the scan tool should read near Barometric Pressure
consecutive driving cycle when the diagnostic runs with the ignition switch ON and engine OFF.
and fails. Refer to DTC Type Definitions for Action 5. A skewed Barometric Pressure sensor value (shifted
Taken When the DTC Sets - Type B. (Euro 4 to a higher pressure) may indicate a wrong boost
specification) pressure. The Barometric Pressure on the scan tool
• The ECM illuminates MIL when the diagnostic runs should read near surrounding barometric pressure.
and fails. Refer to DTC Type Definitions for Action
Taken When the DTC Sets - Type A. (Except Euro Connector End View Reference: Engine Controls
4 specification) Connector End Views or ECM Connector End Views

2 —
Is DTC P0045, P0107, P0108, P2227, P2228 or Go to Applicable

P2229 also set? DTC Go to Step 3

low boost pressure.
• Air leakage around the boost pressure
sensor or objects that block the sensor
hole.
• Air leaking around any of the air induction
tubing between the turbocharger and
intake manifold. Check for damaged
components and for loose clamps.
• Turbine shaft binding causing lower
turbocharger shaft spinning speeds.
Refer to Turbocharger Assembly in
Section 1J Induction.
• Turbocharger nozzle control solenoid for
a stuck condition. Perform the
3 Turbocharger Solenoid Control with a —
scan tool.
• Intake throttle valve sticking. Perform the
Intake Throttle Solenoid Control with a
scan tool.
cleaner and the boost pressure sensor.
• Oil in the air induction tubing causing an
incorrect boost pressure sensor signal.
When there is adhesion of oil inside of
the tubing, intercooler or turbocharger it
needs to be wiped off.

2. Observe the Boost Pressure and Barometric
Pressure with a scan tool. 10 kPa (1.5
4
psi)
Does the scan tool indicate that the difference
between the Boost Pressure and Barometric Go to Diagnostic
Pressure is more than the specified value? Go to Step 5 Aids
Compare the Barometric Pressure value to the
range specified in the altitude vs. barometric
5 Pressure. —
Is the Barometric Pressure parameter within the

range specified? Go to Step 6 Go to Step 7
harness connector.
boost pressure sensor (pins 1 and 3 of E54).
6 —
connector of the ECM (pins 91 and 95 of E26).
necessary.


connector.
BARO sensor (pin 1 of FL52).
7 5. Inspect for an intermittent, for a poor —
6. Test for high resistance of the low reference
circuit.
necessary.

9 Replacement. —
Records.

11 —

The crankshaft position (CKP) sensor is located under • The ECM illuminates the MIL when the diagnostic
the fuel supply pump. There are 56 notches spaced 6° runs and fails. Refer to DTC Type Definitions for
apart and a 30° section that is open span. This open Action Taken When the DTC Sets - Type A.
span portion allows for the detection of top dead center
(TDC). The CKP sensor is a magnetic resistance Condition for Clearing the DTC
element (MRE) type sensor, which generates a square • Refer to DTC Type Definitions for Condition for
wave signal pulse. The sensor has the following Clearing the MIL/ DTC - Type A.
circuits.
• 5 volts reference circuit Diagnostic Aids
• Low reference circuit • If an intermittent condition is suspected, refer to
• CKP sensor signal circuit Intermittent Conditions in this section.
The ECM monitors both CKP sensor and camshaft • Electromagnetic interference in the CKP sensor
position (CMP) sensor signal pulses to ensure they circuits may set this DTC.
correlate with each other. If the ECM receives a certain
• An intermittent CKP sensor signal pulse may set
amount of CMP sensor signal pulses without a CKP
this DTC.
sensor signal pulse, this DTC will set.
• Ensure the sensor is tight and the sensor rotor
Condition for Running the DTC teeth are not damaged.
• DTCs P0016, P0336, P0340 and P0341 are not Notice: If the CKP sensor signal pulse is lost while
set. running, the engine will stop.
• The CMP sensor signal pulse is detected. Connector End View Reference: Engine Controls
• The ECM detects that the CKP sensor signal
pulses are not generated during engine rotations.

3. Start the engine (Note a slight start delay may
2 be noticed). —
Go to Diagnostic
Is DTC P0340, P0341 or P0697 also set? Go to Applicable
3 —
DTC Go to Step 4
2. Disconnect the crankshaft position (CKP)
sensor harness connector.
ground.
Is the DMM voltage more than specified value? Go to Step 5 Go to Step 9

Connect a DMM between the signal circuit (pin 1 of
5 E50) and a known good ground. 5.5 volts

6 4.5 volts
8 circuit and low reference (pins 2 and 3 of E50). 4.5 volts
Notice: The CKP sensor shares the 5 volts
9 ECM (pin 95 of E26) and the CKP sensor (pin —
resistance.

Notice: The CKP sensor shares the low reference
share this circuit.
10 ECM (pin 109 of E26) and the CKP sensor —
resistance.

107 of E26) and the CKP sensor (pin 1 of E50)
• An open circuit
11 —
• High resistance

Important: The CKP sensor may be damaged if
source.
12 107 of E26) and the CKP sensor (pin 1 of E50) —

for a short to any 5 volts reference.
13 —


CKP sensor (pins 1, 2 and 3 of E50).
14 —

ECM (pins 95, 107, 108 and 109 of E26).

rotor


Records.

20 —

The crankshaft position (CKP) sensor is located under • The ECM illuminates the MIL when the diagnostic
the fuel supply pump. There are 56 notches spaced 6° runs and fails. Refer to DTC Type Definitions for
apart and a 30° section that is open span. This open Action Taken When the DTC Sets - Type A.
span portion allows for the detection of top dead center
(TDC). The ECM monitors both CKP sensor and Condition for Clearing the DTC
camshaft position (CMP) sensor signal pulses to • Refer to DTC Type Definitions for Condition for
ensure they correlate with each other. If the ECM Clearing the MIL/ DTC - Type A.
receives extra or missing CKP sensor signal pulse, this
DTC will set. Diagnostic Aids
Condition for Running the DTC • If an intermittent condition is suspected, refer to

• DTCs P0016, P0335, P0340 and P0341 are not
• Electromagnetic interference in the CKP sensor
set.
• An intermittent CKP sensor signal pulse may set
• The CKP sensor signal pulse is detected. this DTC.
• Ensure the sensor is tight and the sensor rotor
teeth are not damaged.
• The ECM detects extra or missing CKP sensor
signal pulses during engine rotations. Connector End View Reference: Engine Controls

3. Start the engine (Note a slight start delay may
2 be noticed). —
Go to Applicable
1. Inspect all of the circuits going to the
crankshaft position (CKP) sensor for the
following:
• Routed too closely to fuel injection wiring
or components
• Routed too closely to after-market add-
3 on electrical equipment —
• Routed too closely to solenoids and
relays
2. If you find incorrect routing, correct the
harness routing.


109 of E26).
4. Disconnect the CKP sensor harness
4 connector. —
connector of the CKP sensor (pins 1, 2 and 3
of E50).

rotor

Records.

8 —

The camshaft position (CMP) sensor is installed on the • The ECM illuminates the MIL when the diagnostic
cylinder head at the rear of the camshaft gear. The runs and fails. Refer to DTC Type Definitions for
CMP sensor detects total of seven projections per one Action Taken When the DTC Sets - Type A.
60° and one reference projection on the camshaft gear Condition for Clearing the DTC
surface). The CMP sensor is a magnetic resistance • Refer to DTC Type Definitions for Condition for
element (MRE) type sensor, which generates a square Clearing the MIL/ DTC - Type A.
wave signal pulse. The sensor has the following
circuits. Diagnostic Aids
• 5 volts reference circuit
• Low reference circuit Intermittent Conditions in this section.
• CMP sensor signal circuit • Electromagnetic interference in the CMP sensor
The ECM monitors both crankshaft position (CKP) circuits may set this DTC.
sensor and CMP sensor signal pulses to ensure they
• An intermittent CMP sensor signal pulse may set
correlate with each other. If the ECM receives a certain
this DTC.
amount of CKP sensor signal pulses without a CMP
sensor signal pulse, this DTC will set. • Ensure the sensor is tight and the camshaft gear is
not damaged.
Notice: If the CMP sensor signal pulse is lost while
• DTCs P0016, P0335, P0336 and P0341 are not running, the engine will operate normally. If the CMP
set. sensor signal pulse is not present on start-up, the
• The CKP sensor signal pulse is detected. engine will not start.
• The engine speed is more than 500 RPM.
Condition for Setting the DTC Connector End Views or ECM Connector End Views
• The ECM detects that the CMP sensor signal
pulses are not generated during engine rotations.

Go to Applicable
Is DTC P0601, P1261 or P1262 also set? DTC Go to Step 3
3 Is DTC P0651 also set? — Go to DTC P0651 Go to Step 4
2. Disconnect the camshaft position (CMP)
ground.

Connect a DMM between the signal circuit (pin 1 of
5 E48) and a known good ground. 5.5 volts

6 4.5 volts
circuit and low reference circuit (pins 2 and 3 of
8 E48). 4.5 volts
Notice: The CMP sensor shares the 5 volts
9 ECM (pin 87 of E26) and the CMP sensor (pin —
resistance.

Notice: The CMP sensor shares the low reference
share this circuit.
10 ECM (pin 101 of E26) and the CMP sensor —
resistance.

• An open circuit
11 —
• High resistance

Important: The CMP sensor may be damaged if
source.
12 98 of E26) and the CMP sensor (pin 1 of E48) —

98 of E26) and the CMP sensor (pin 1 of E48)
for a short to any 5 volts reference.
13 —


CMP sensor (pins 1, 2 and 3 of E48).
14 —

ECM (pins 87, 98, 100 and 101 of E26).

1. Inspect the CMP sensor and camshaft gear
16 and camshaft gear —
• Physical damage of camshaft gear
• Loose or improper installation of
camshaft gear

Replace the CMP sensor. Refer to Camshaft

Records.

20 —

The camshaft position (CMP) sensor is installed on the • The ECM illuminates the MIL when the diagnostic
cylinder head at the rear of the camshaft gear. The runs and fails. Refer to DTC Type Definitions for
CMP sensor detects total of seven projections per one Action Taken When the DTC Sets - Type A.
60° and one reference projection on the camshaft gear Condition for Clearing the DTC
surface). The ECM monitors both crankshaft position • Refer to DTC Type Definitions for Condition for
(CKP) sensor and CMP sensor signal pulses to ensure Clearing the MIL/ DTC - Type A.
they correlate with each other. If the ECM receives
extra or missing CMP sensor signal pulse, this DTC will Diagnostic Aids
set.
Condition for Running the DTC Intermittent Conditions in this section.
• Electromagnetic interference in the CMP sensor
• DTCs P0016, P0335, P0336 and P0340 are not
set.
• An intermittent CMP sensor signal pulse may set
• The CMP sensor signal pulse is detected.
this DTC.
• Ensure the sensor is tight and the camshaft gear is
not damaged.
• The ECM detects extra or missing CMP sensor Connector End View Reference: Engine Controls
signal pulses during engine rotations. Connector End Views or ECM Connector End Views

Go to Applicable
Is DTC P0340 or P0651 also set? DTC Go to Step 3
1. Inspect all of the circuits going to the camshaft
position (CMP) sensor for the following:
• Routed too closely to fuel injection wiring
or components
• Routed too closely to after-market add-
3 on electrical equipment —
• Routed too closely to solenoids and
relays
2. If you find incorrect routing, correct the
harness routing.


2. Disconnect the CMP sensor harness
connector.
connector of the CMP sensor (pins 1, 2 and 3
of E48).
101 of E26).

1. Inspect the CMP sensor and camshaft gear
5 and camshaft gear —
• Physical damage of camshaft gear
• Loose or improper installation of
camshaft gear

Records.

8 —

Circuit Description • The ECM illuminates the MIL when the diagnostic
The ECM controls the glow relay which supplies power runs and fails. Refer to DTC Type Definitions for
to the glow plugs based on engine coolant Action Taken When the DTC Sets - Type A.
temperature. In the after glow phase, the glow plug (Except Euro 4 specification)
lamp is not illuminated but glow plugs remain active for
a certain period. If the ECM detects an open circuit or Condition for Clearing the DTC
short circuit on the relay control circuit, this DTC will • Refer to DTC Type Definitions for Condition for
set. Clearing the SVS Lamp/ DTC - Type C. (Euro 4
specification)
• The battery voltage is between 18 to 32 volts. Clearing the MIL/ DTC - Type A. (Except Euro 4
Either of following condition is met: • If an intermittent condition is suspected, refer to

• The ECM detects a low voltage condition on the
glow relay control circuit for longer than 3 seconds
Test Description
when the relay is commanded OFF.
The numbers below refers to the step number on the
• The ECM detects a high voltage condition on the
glow relay control circuit for longer than 3 seconds
2. Listen for an audible click when the glow relay
when the relay is commanded ON.
operates. Command both the ON and OFF states.
• The ECM illuminates the SVS lamp when the Connector End Views or ECM Connector End Views
diagnostic runs and fails. Refer to DTC Type
Definitions for Action Taken When the DTC Sets -
Type C. (Euro 4 specification)

2. Perform the Glow Relay Control with a scan
2 tool. —
3. Command the relay ON and OFF.
Go to Diagnostic
Does the glow relay click with each command? Aids Go to Step 3
2. Replace the glow relay with the starter relay or
3 replace with a known good relay. —
Does the glow relay click with each command? Go to Step 7 Go to Step 4
2. Remove the glow relay.
4 4. Connect a test lamp between the ignition —
voltage feed circuit of the relay coil side (pin 3
of X19) and a known good ground.


10 of FB24) and the relay (pin 5 of X19) for the
• An open circuit
5 —
• High resistance

the Engine Controller (10A) fuse and the glow relay
6 coil side (pin 3 of X19). Check the Engine —
Controller (10A) fuse first.

7 connection on each relay terminal. —


Replace the glow relay.
9 —

11 3. Perform the Glow Relay Control with a scan —
tool.
Does the glow relay click with each command? Go to Step 12 Go to Step 3
12 —

Circuit Description • The ECM detects a high voltage condition on the
The glow plug lamp is located on the instrument panel glow plug lamp control circuit for longer than 3
(IP) cluster. The glow control system is operated when seconds when the lamp is commanded ON.
the engine coolant temperature is low, which allows
easier engine starting. If the ignition switch is turned Action Taken When the DTC Sets
ON when the engine coolant temperature is low, the • The ECM illuminates the SVS lamp when the
ECM illuminates the glow plug lamp and turns ON the diagnostic runs and fails. Refer to DTC Type
glow plugs. After a fixed time passes, the ECM turns Definitions for Action Taken When the DTC Sets -
OFF the glow plug lamp and the glow plugs. The ECM Type C. (Euro 4 specification)
monitors the glow plug lamp control circuit for • The ECM illuminates the MIL when the diagnostic
conditions that are incorrect for the commanded state runs and fails. Refer to DTC Type Definitions for
of the glow plug lamp. For example, a failure condition Action Taken When the DTC Sets - Type A.
exists if the ECM detects low voltage when the glow (Except Euro 4 specification)
plug lamp is commanded OFF, or high voltage when
the glow plug lamp is commanded ON. If the ECM Condition for Clearing the DTC
detects an improper voltage level on the control circuit,
this DTC will set.
Clearing the SVS Lamp/ DTC - Type C. (Euro 4
specification)
Clearing the MIL/ DTC - Type A. (Except Euro 4

Either of following condition is met: • If an intermittent condition is suspected, refer to
• The ECM detects a low voltage condition on the Intermittent Conditions in this section.
glow plug lamp control circuit for longer than 3
seconds when the lamp is commanded OFF. Connector End View Reference: Engine Controls

1. Verify whether the instrument panel (IP)
cluster is operational.
2 4. Turn ON the ignition for 10 seconds. —
Go to Diagnostic
2. Inspect the Meter (10A) fuse in the cabin fuse
3 block. —
Is the Meter (10A) fuse open? Go to Step 4 Go to Step 5

Replace the Meter (10A) fuse. If the fuse continues
to open, repair the short to ground on one of the
4 circuits that is fed by the Meter (10A) fuse or —
replace the shorted attached component.


Is the glow plug lamp OFF? Go to Step 6 Go to Step 12

1. Remove the Meter (10A) fuse that supplies
voltage to the glow plug lamp.
6 3. Measure the voltage from the glow plug lamp 1 volt
control circuit in the ECM harness connector
(pin 11 of FB24) to a known good ground.
Is the voltage less than the specified value? Go to Step 7 Go to Step 13

2. Reinstall the Meter (10A) fuse.
7 4. Connect a 3-amp fused jumper wire between —
the ECM harness connector (pin 11 of FB24)
and a known good ground.
Is the glow plug lamp illuminate? Go to Step 11 Go to Step 8

2. Remove the IP cluster.
voltage feed circuit of the IP cluster harness
8 connector (pin 40 of FU98) and a known good —
ground.

11 of FB24) and the IP cluster (pin 5 of FU98)
9 —

IP cluster (pins 5 and 40 of FU98).
10 —

11 —

Repair the short to ground between the ECM (pin
12 11 of FB24) and the IP cluster (pin 5 of FU98). —
Repair the short to battery or ignition voltage
between the ECM (pin 11 of FB24) and the IP
13 cluster (pin 5 of FU98). —


Repair the open circuit or high resistance on
ignition the voltage feed circuit between the Meter
14 (10A) fuse and the IP cluster (pin 40 of FU98). —

Repair or replace the IP cluster. Refer to Instrument
Panel (IP) Cluster in Section 9E Instrumentation/
15 Driver Info. —
Did you complete the repair or replacement? Go to Step 17 —


1. Reconnect all previously disconnected fuse or

18 —

The ECM controls the EGR valve opening based on the • The ECM detects that the MAF amount is not
engine running condition and by controlling the EGR within the calculated range during the EGR flow
motor. The EGR valve position is detected by the test. This indicates insufficient amount of EGR
position sensor, and relayed to the ECM. When the flow.
proper enabling conditions are met, the ECM will open
the EGR valve while monitoring the mass air flow Action Taken When the DTC Sets
(MAF) signal. An expected MAF difference should be • The ECM illuminates the MIL when the diagnostic
detected between the closed and open positions. If the runs and fails. Refer to DTC Type Definitions for
ECM detects the MAF difference less than expected, Action Taken When the DTC Sets - Type A.
this DTC will set. This DTC will only run once per
ignition cycle within the enabling conditions.
• DTCs P0079, P0080, P0102, P0103, P0112,
P0113, P0116, P0117, P0118, P0122, P0123, • Refer to DTC Type Definitions for Condition for
P0404, P0409, P0500, P0502, P0503, P0560, Clearing the MIL/ DTC - Type A.
P060B, P0638, P0651, P0697, P1404, P2227,
P2228 and P2229 are not set. Notice: A history DTC remains 9,600 hours
(accumulated engine runtime) and will not clear with a
scan tool.
• The engine is running. Diagnostic Aids
• A sticking or intermittently sticking the EGR valve
may set this DTC.

Go to Applicable
Warm up the engine (allow engine coolant
temperature to reach at least 75°C [167°F]) and let
3 idle for at least 3 minutes while observing the DTC —
Information with a scan tool.
Go to Diagnostic

• An EGR valve gasket that is missing or
damaged
• EGR gas leakage from any of the EGR
passages between the exhaust manifold
and intake manifold
• Restricted or collapsed EGR passage
between the exhaust manifold and the
EGR valve
system
4 • Any air induction leak —
system
• Skew or slow MAF sensor
Exhaust.
• A ventilation duct that is connected to the
exhaust tail pipe. Retest without the duct
if connected.

1. Perform the EGR Solenoid Control with a scan
tool several times.
2. Command the Desired EGR Position Increase
and Decrease while observing the EGR
5 Position 1. ± 5%
Does the EGR Position 1 parameter follow within

the specified value quick enough (compare with a Go to Diagnostic
similar unit if available)? Aids Go to Step 6
Replace the EGR valve.
6 —
Notice: A history DTC will not clear.

7 4. Start the engine and warm up (allow engine —
coolant temperature to reach at least 75°C
[167°F])
5. Let idle for at least 3 minutes while observing
the DTC Information with a scan tool.

8 —

The ECM controls the EGR valve opening based on the • The ECM illuminates the MIL when the diagnostic
engine running condition and by controlling the EGR runs and fails. Refer to DTC Type Definitions for
motor. The EGR valve position is detected by the Action Taken When the DTC Sets - Type A.
position sensor, and relayed to the ECM. If the ECM • The ECM limits fuel injection quantity.
detects a variance between the actual EGR valve
position and desired EGR valve position for a
calibrated amount of time while the EGR valve is • The ECM inhibits cruise control.
commanded ON, this DTC will set.
• DTCs P0112, P0113, P0116, P0117, P0118, Clearing the MIL/ DTC - Type A.
P0409, P060B, P0651, P0697, P2227, P2228 and
P2229 are not set. Notice: A history DTC remains 9,600 hours
(accumulated engine runtime) and will not clear with a
scan tool. (Euro 4 specification)
• The EGR control is commanded ON. Diagnostic Aids
• The ECM detects that the actual EGR valve • A sticking or intermittently sticking the EGR valve
position is more than 10% below the desired valve may set this DTC.
position for longer than 5 seconds.


tool several times.
2. Command the Desired EGR Position Increase
and Decrease while observing the EGR
3 Position 1. ± 5%
Does the EGR Position 1 parameter follow within

the specified value quick enough (compare with a Go to Diagnostic
similar unit if available)? Aids Go to Step 4

1. Remove the EGR valve assembly from the
engine.
2. Inspect the EGR valve for the following
conditions:
• Restricted EGR valve by foreign
4 materials —
• Excessive deposits at valve
• Bent valve shaft or valve

2. Disconnect the EGR valve harness connector.
connector of the EGR valve (pins 1, 2, 3, 4, 5,
6, 7 and 8 of E45).
5 —
connector of the ECM (pins 87, 93, 94, 99,
101, 103, 110 and 111 of E26).
6. Test for an open circuit or high resistance on
each circuit.
necessary.

1. Test the motor circuits between the ECM (pins
103, 110 and 111 of E26) and the EGR valve
(pins 6, 7 and 8 of E45) for the following
conditions:
6 —
• A short to the EGR position sensor
circuit(s)

7 —
Notice: A history DTC will not clear. (Euro 4

specification)
8 —
Records.




specification)

Records.

11 —

The exhaust gas recirculation (EGR) position sensor is • The ECM illuminates the MIL when the diagnostic
installed on the EGR valve body together with the runs and fails. Refer to DTC Type Definitions for
control motor. The sensor is made up three individual Action Taken When the DTC Sets - Type A.
sensors within one housing. The EGR position sensor • The ECM limits fuel injection quantity.
1, EGR position sensor 2 and EGR position sensor 3
are hall element type sensors, each with the following
circuits. • The ECM inhibits cruise control.
• 5 volts reference circuit
• Signal circuit Clearing the MIL/ DTC - Type A.
The EGR position sensor provides a low or high signal
state to the ECM on the signal circuits, which is relative Notice: A history DTC remains 9,600 hours
to the position changes of the EGR valve. If the ECM (accumulated engine runtime) and will not clear with a
detects that each EGR position sensor signal state is scan tool. (Euro 4 specification)
out of correlation such as all low signal state or high
signal state, this DTC will set. Diagnostic Aids
Condition for Running the DTC • If an intermittent condition is suspected, refer to

• The battery voltage is between 18 to 32 volts. Connector End View Reference: Engine Controls
• The ignition switch is ON. Connector End Views or ECM Connector End Views

• The ECM detects that all EGR valve position
sensor signals are stuck low or high for longer than
3 seconds.


3 —
4. Observe the EGR Position 1, 2 and 3
parameters with a scan tool.
Is there parameter which indicate High? Go to Step 7 Go to Step 4

4 circuit (pin 1 of E45) and a known good ground. 4.5 volts
circuit and low reference circuit (pin 1 and 5 of
5 E45). 4.5 volts

Observe the EGR Position 1, 2 and 3 parameter
with a scan tool while momentarily jumping a 3-
amp fused jumper wire across the EGR valve
harness connector between each signal circuit and
the 5 volts reference circuit.
6 • EGR position 1: pins 1 and 4 of E45 —
• EGR position 2: pins 1 and 3 of E45
• EGR position 3: pins 1 and 2 of E45
Is there parameter which did not indicate High

when the circuit is jumpered? Go to Step 10 Go to Step 11
Important: The EGR position sensor may be
voltage source.
1. Test the signal circuits (which ever parameter
indicates High at Step 3) between the ECM
(pins 93, 94 and 99 of E26) and the EGR
7 valve (pins 2, 3 and 4 of E45) for the following —
conditions:

Notice: The EGR position sensor shares the 5
volts reference circuit with other sensors. A fault
8 1. Test the 5 volts reference circuit between the —

ECM (pin 87 of E26) and the EGR valve (pin 1
of E45) for an open circuit or high resistance.

Notice: The EGR position sensor shares the low
9 ECM (pin 101 of E26) and the EGR valve (pin —
resistance.

1. Test the position sensor circuits (which ever
parameter did not indicate High at Step 6)
between the ECM (pins 93, 94 and 99 of E26)
and the EGR valve (pins 2, 3 and 4 of E45) for
• An open circuit
10 —
• High resistance


EGR valve (pins 1, 2, 3, 4 and 5 of E45).
11 —

(pins 6, 7 and 8 of E45) for a short to the EGR
12 position sensor circuit(s). —

ECM (pins 87, 93, 94, 99 and 101 of E45).

14 —


specification)
16 —
Records.

17 —

Circuit Description • The ECM limits fuel injection quantity
The exhaust temperature sensor 1 is installed to the • The ECM inhibits cruise control.
diesel particulate defuser (DPD) housing. The exhaust
temperature sensor 1 is a variable resistor and it Condition for Clearing the DTC
measures the temperature of the exhaust gas in front of • Refer to DTC Type Definitions for Condition for
DPD filter. If the ECM detects an excessively high Clearing the SVS Lamp/ DTC - Type C.
exhaust temperature, this DTC will set.
Diagnostic Aids
• Use the Temperature vs Resistance table to test
• DTCs P0427, P0428, P060B and P0697 are not the exhaust temperature sensor at various
set. temperature levels to evaluate the possibility of a
• The ignition switch is ON. skewed sensor.
• Fuel system problem (e.g. fuel injector damage)
Condition for Setting the DTC may set this DTC.
• The ECM detects that exhaust temperature 1 (in
front of filter) is higher than 880°C (1616°F) for 5 Notice: This DTC is caused by an excessively high
seconds. exhaust temperature condition, which was most likely
caused by uncontrolled burning while regeneration
Action Taken When the DTC Sets event of DPD filter. Excessive high exhaust gas
temperature may damage DPD filter or oxidation
• The ECM illuminates the SVS lamp when the
catalyst.
Type C.

Go to Applicable
Is DTC P0093, P0427 or P1093 also set? DTC Go to Step 3
1. Test the exhaust temperature sensor 1 at
various temperature levels to evaluate the
possibility of a skewed sensor.
3 2. Replace the exhaust temperature sensor as —
necessary. Refer to Exhaust Temperature
Sensor in Section 1G Engine Exhaust.

1. Remove the diesel particulate defuser (DPD)
assembly. Refer to Exhaust Pipe in Section
1G Engine Exhaust.
2. Inspect the DPD filter and the oxidation
catalyst for damage, cracks or melt.
4 Important: DPD status in the ECM must be —

reset when the DPD filter is replaced.
3. Replace the DPD filter or the oxidation
catalyst as necessary. Refer to Exhaust Pipe
in Section 1G Engine Exhaust.
Go to Diagnostic

5 —
observed from the Failure Records.

6 —

Circuit Description • The engine run time is longer than 3 to 10 minutes.
The exhaust temperature sensor 1 is installed to the (DTC P0428)
temperature sensor 1 is a variable resistor and it Condition for Setting the DTC
measures the temperature of the exhaust gas in front of • The ECM detects that the exhaust temperature
DPD filter. The sensor has a signal circuit and a low sensor 1 signal voltage is less than 0.2 volts for 3
reference circuit. The ECM supplies 5 volts to the seconds. (DTC P0427)
signal circuit and a ground for the low reference circuit. • The ECM detects that the exhaust temperature
When the exhaust temperature sensor 1 is cold, the sensor 1 signal voltage is more than 4.85 volts for
sensor resistance is high. When the exhaust 5 seconds. (DTC P0428)
temperature increases, the sensor resistance
decreases. With high sensor resistance, the ECM Action Taken When the DTC Sets
detects a high voltage on the signal circuit. With lower
• The ECM illuminates MIL when the diagnostic runs
sensor resistance, the ECM detects a lower voltage on
the signal circuit. If the ECM detects an excessively low
Taken When the DTC Sets - Type A.
or high signal voltage, DTC P0427 or P0428 will set.
Condition for Running the DTC • The ECM inhibits cruise control.
• DTCs P060B and P0697 are not set. (DTC P0427)
• DTCs P0112, P0113, P0116, P0117, P0118,
P060B, P0651, P0697, P2227, P2228 and P2229 • Refer to DTC Type Definitions for Condition for
are not set. (DTC P0428) Clearing the MIL/ DTC - Type A.
Diagnostic Aids
• The engine coolant temperature is more than 80°C
(176°F). (DTC P0428)
• The engine speed is more than 1300 RPM. (DTC
the exhaust temperature sensor 1 at various
P0428)
temperature levels to evaluate the possibility of a
• The desired fuel injection quantity is more than a skewed sensor.
predetermined value. (DTC P0428)
• The vehicle is running or the PTO control is Connector End View Reference: Engine Controls
inactive. Connector End Views or ECM Connector End Views


Observe the Exhaust Temperature Sensor 1
3 0.2 volts
Is the Exhaust Temperature Sensor 1 parameter Go to Diagnostic

2. Disconnect the exhaust temperature sensor 1
harness connector.
4 4.5 volts
Is the Exhaust Temperature Sensor 1 parameter

73 of FB24) and the exhaust temperature
sensor 1 (pin 2 of FB67) for the following
conditions:

Replace the exhaust temperature sensor 1. Refer
to Exhaust Temperature Sensor in Section 1G
6 Engine Exhaust. —

7 corrosion. —
necessary.


Records.

10 —



1. Start the engine and fully warm up (allow
engine coolant temperature to reach at least
80°C [176°F]).
3 times while observing the Exhaust 4.8 volts
Temperature Sensor 1 parameter with a scan
tool.

harness connector.
(pin 2 of FB67) and a known good ground.
Important: The exhaust temperature sensor 1 may
a voltage source.
5 73 of FB24) and the exhaust temperature —
sensor 2 (pin 2 of FB67) for a short to battery
or ignition voltage.

6 and 2 of FB67). 0.1 volts
signal circuit (pin 2 of FB67) and a known good
7 ground. 0.1 volts
sensor 1 (pin 2 of FB67) for an open circuit or


Notice: The exhaust temperature sensor 1 shares
9 ECM (pin 79 of FB24) and the exhaust —
temperature sensor 1 (pin 1 of FB67) for an
open circuit or high resistance.

sensor 1 (pin 2 of FB67) for a short to any 5
10 volts reference circuit. —

exhaust temperature sensor 1 (pins 1 and 2 of
11 FB67). —




80°C [176°F]).
15 4.8 volts
times while observing the Exhaust
tool.


16 —

DTC P042B (Flash Code 145)
Circuit Description • The ECM limits fuel injection quantity
The exhaust temperature sensor 2 is installed to the • The ECM inhibits cruise control.
temperature sensor 2 is a variable resistor and it Condition for Clearing the DTC
measures the temperature of the exhaust gas in front of • Refer to DTC Type Definitions for Condition for
oxidation catalyst. If the ECM detects an excessively Clearing the SVS Lamp/ DTC - Type C.
high exhaust temperature, this DTC will set.
Diagnostic Aids
• DTCs P042C, P042D, P060B and P0697 are not the exhaust temperature sensor at various
set. temperature levels to evaluate the possibility of a
• The ignition switch is ON. skewed sensor.
• Fuel system problem (e.g. fuel injector damage)
Condition for Setting the DTC may set this DTC.
• The ECM detects that exhaust temperature 2 (in
front of oxidation catalyst) is higher than 870°C Notice: This DTC is caused by an excessively high
(1600°F) for 5 seconds. exhaust temperature condition, which was most likely
caused by uncontrolled burning while regeneration
Action Taken When the DTC Sets event of DPD filter. Excessive high exhaust gas
temperature may damage DPD filter.
Type C.
Circuit/ System Testing DTC P042B

Go to Applicable
Is DTC P0093, P042C or P1093 also set? DTC Go to Step 3
1. Test the exhaust temperature sensor 2 at
various temperature levels to evaluate the
possibility of a skewed sensor.
3 2. Replace the exhaust temperature sensor as —
necessary. Refer to Exhaust Temperature
Sensor in Section 1G Engine Exhaust.

1. Remove the diesel particulate defuser (DPD)
1G Engine Exhaust.
2. Inspect the DPD filter and the oxidation
catalyst for damage, cracks or melt.
4 Important: DPD status in the ECM must be —

Go to Diagnostic

5 —

6 —

DTC P042C or P042D (Flash Code 49)
Circuit Description • The engine run time is longer than 5 to 10 minutes.
The exhaust temperature sensor 2 is installed to the (DTC P042D)
temperature sensor 2 is a variable resistor and it Condition for Setting the DTC
measures the temperature of the exhaust gas in front of • The ECM detects that the exhaust temperature
oxidation catalyst. The sensor has a signal circuit and a sensor 2 signal voltage is less than 0.2 volts for 3
low reference circuit. The ECM supplies 5 volts to the seconds. (DTC P042C)
signal circuit and a ground for the low reference circuit. • The ECM detects that the exhaust temperature
When the exhaust temperature sensor 2 is cold, the sensor 2 signal voltage is more than 4.85 volts for
sensor resistance is high. When the exhaust 5 seconds. (DTC P042D)
temperature increases, the sensor resistance
decreases. With high sensor resistance, the ECM Action Taken When the DTC Sets
detects a high voltage on the signal circuit. With lower
sensor resistance, the ECM detects a lower voltage on
the signal circuit. If the ECM detects an excessively low
or high signal voltage, DTC P042C or P042D will set.
Type C.
• DTCs P060B and P0697 are not set. (DTC P042C)
• DTCs P0112, P0113, P0116, P0117, P0118, Clearing the SVS Lamp/ DTC - Type C.
P060B, P0651, P0697, P2227, P2228 and P2229
are not set. (DTC P042D) Diagnostic Aids
• The ignition switch is ON. Intermittent Conditions in this section.
• The engine speed is more than 1300 RPM. (DTC • Use the Temperature vs. Resistance table to test
P042D) the exhaust temperature sensor 2 at various
• The engine coolant temperature is more than 80°C temperature levels to evaluate the possibility of a
(176°F). (DTC P042D) skewed sensor.
• The desired fuel injection quantity is more than a
predetermined value. (DTC P042D) Connector End View Reference: Engine Controls
• The vehicle is running or the PTO control is
inactive.
Circuit/ System Testing DTC P042C


Observe the Exhaust Temperature Sensor 2
3 0.2 volts

harness connector.
4 4.5 volts

sensor 2 (pin 2 of FB68) for the following
conditions:


7 corrosion. —
necessary.


9 —

10 —
Circuit/ System Testing DTC P042D



80°C [176°F]).
3 times while observing the Exhaust 4.8 volts
tool.

harness connector.
(pin 2 of FB68) and a known good ground.
Important: The exhaust temperature sensor 2 may
a voltage source.
5 74 of FB24) and the exhaust temperature —
sensor 2 (pin 2 of FB68) for a short to battery
or ignition voltage.

signal circuit (pin 2 of FB68) and a known good
7 ground. 0.1 volts
sensor 2 (pin 2 of FB68) for an open circuit or


Notice: The exhaust temperature sensor 2 shares
temperature sensor 2 (pin 1 of FB68) for an
open circuit or high resistance.

sensor 2 (pin 2 of FB68) for a short to any 5
10 volts reference circuit. —

exhaust temperature sensor 2 (pins 1 and 2 of
11 FB68). —




80°C [176°F]).
15 4.8 volts
times while observing the Exhaust
tool.


16 —

The vehicle speed sensor (VSS) is used by the ECM runs and fails. Refer to DTC Type Definitions for
and other modules, which generates a speed signal Action Taken When the DTC Sets - Type A.
from the transmission output shaft rotational speed. (Except Euro 4 specification)
The sensor has the following circuits. • The ECM limits fuel injection quantity.
• Ignition voltage feed circuit • The ECM inhibits pre injection.
• Low reference circuit • The ECM inhibits cruise control.
• VSS signal circuit
The VSS uses a hall effect element or magnetic Condition for Clearing the DTC
resistance element (MRE). It interacts with the • Refer to DTC Type Definitions for Condition for
magnetic field created by the rotating magnet and Clearing the DTC - Type B. (Euro 4 specification)
outputs square wave pulse signal. The ECM calculates • Refer to DTC Type Definitions for Condition for
the vehicle speed by the VSS. If the ECM detects VSS Clearing the MIL/ DTC - Type A. (Except Euro 4
signals are not generated, this DTC will set. specification)

• The battery voltage is between 18 to 32 volts. • If an intermittent condition is suspected, refer to
• The commanded fuel injection quantity is OFF • Electromagnetic interference in the vehicle speed
(accelerator pedal is not depressed). signal circuit may set this DTC.
• The engine speed is more than 2000 RPM. • An aftermarket signal pulse pickup device may
affect intermittent condition.
• The ECM detects that the vehicle speed signal Notice: If this DTC set, the Vehicle Speed parameter
pulses are not generated for longer than 7 on the scan tool will display 10 km/h (6 MPH).
seconds.
Action Taken When the DTC Sets Connector End Views or ECM Connector End Views

consecutive driving cycle when the diagnostic runs
Taken When the DTC Sets - Type B. (Euro 4
specification)

Go to Applicable
Drive the vehicle while observing the Vehicle
3 Speed parameter with a scan tool. — Go to Diagnostic
Does the scan tool indicate correct vehicle speed? Aids Go to Step 4

1. Inspect the VSS, drive gear, driven gear or
output shaft for the following conditions:
• Physical damage of sensor, drive gear or
driven gear
• Loose or improper installation of sensor,
drive gear or driven gear
4 • Transmission output shaft teeth damage —
• Excessive transmission output shaft play
2. Disconnect the aftermarket signal pulse
pickup device and retest if installed.

Notice: If no ZF transmission is installed, skip to
Step 6.
1. Inspect the impulse sensor and speed signal
5 distributor. —
Refer to Manual Transmission (ZF) section.

1. Remove the VSS.
2. Connect a 3-amp jumper wire between the
vehicle speed sensor and the battery voltage.
Refer to IP Cluster and Warning in Section 9D
Wiring System.
3. Connect a 3-amp jumper wire between the
vehicle speed sensor and a known good 0.5 to 1.5 volts
6 ground. Refer to IP Cluster and Warning in or 12 to 15
Section 9D Wiring System. volts
4. Connect a DMM between the vehicle speed
sensor and a known good ground. Refer to IP
Cluster and Warning in Section 9D Wiring
System.
5. Rotate the shaft of the VSS slowly.
Is the DMM voltage within the specified value? Go to Step 9 Go to Step 7

vehicle speed sensor. Refer to IP Cluster and
7 Warning in Section 9D Wiring System. —

Replace the VSS. Refer to Vehicle Speed Sensor in
8 Section 9E Instrumentation/ Driver Info. —
Replace the speed sensor control unit. Refer to
Speed Sensor Control Unit in Section 9E
9 Instrumentation/ Driver Info. —


4. Drive the vehicle while observing the Vehicle
Speed parameter with a scan tool.
Does the scan tool indicate correct vehicle speed? Go to Step 11 Go to Step 2
11 —

Circuit Description • The ECM detects that the vehicle speed signal
The vehicle speed sensor (VSS) is used by the ECM voltage is more than 20 volts. (DTC P0503)
and other module, which generates a speed signal
from the transmission output shaft rotational speed. Action Taken When the DTC Sets
The sensor has the following circuits. • The ECM illuminates the MIL when the diagnostic
• Ignition voltage circuit runs and fails. Refer to DTC Type Definitions for
The VSS uses a hall effect element or magnetic • The ECM inhibits pre injection.
resistance element (MRE). It interacts with the • The ECM inhibits cruise control.
magnetic field created by the rotating magnet and
outputs square wave pulse signal. The ECM calculates Condition for Clearing the DTC
the vehicle speed by the VSS. If the ECM detects an • Refer to DTC Type Definitions for Condition for
excessively low or high signal voltage, DTC P0502 or Clearing the MIL/ DTC - Type A.
P0503 will set.
Diagnostic Aids
• The battery voltage is between 21 to 32 volts. • An aftermarket signal pulse pickup device may
• The ignition switch is ON. affect intermittent condition.
Condition for Setting the DTC Notice: If this DTC set, the Vehicle Speed parameter
• The ECM detects that the vehicle speed signal on the scan tool will display 10 km/h (6 MPH).
voltage is less than 0.5 volts. (DTC P0502)
Circuit/ System Testing DTC P0502 or P0503 (With digital tachograph)

Go to Diagnostic
Step 4.
1. Inspect the impulse sensor and circuit.
3 Refer to Manual Transmission (ZF) section. —

1. Drive the vehicle.
2. Observe the Vehicle Speed parameter with
4 the scan tool. —
Does the Vehicle Speed parameter indicate correct Go to Diagnostic
vehicle speed? Aids Go to Step 5
Observe the speedometer in the instrument panel
(IP) cluster.
5 —
Does the speedometer indicate correct vehicle
speed? Go to Step 6 Go to Step 8

2. Disconnect the IP cluster harness connector
(FU97).
4. Intermittently jump the signal circuit of the IP
6 cluster (pin 16 of FU97) with a test lamp that is —
connected to 12 volts (apply form a battery)
while monitoring the Vehicle Speed parameter
with the scan tool.
Does the scan tool indicate any vehicle speed

when the circuit is intermittently pulled to 12 volts? Go to Step 17 Go to Step 7
1. Test the vehicle speed signal input circuit
between the engine control module (ECM)
(pin 19 of FB24) and the IP cluster (pin 16 of
FU97) for the following conditions:
• An open circuit
• High resistance

8 2. Inspect the Meter (10A) fuse. —
circuits that fed by the Meter (10A) fuse or replace
9 the shorted attached component fed by the Meter —
(10A) fuse.

1. Remove the vehicle speed sensor. Refer to
Vehicle Speed Sensor in Section 9E
Instrumentation/ Driver Info.
2. Visually inspect the vehicle speed sensor for
the following conditions.
• Physical damage
10 • Being loose —
• Loose or improper installation
• For speedometer driven gear teeth
damage

2. Disconnect the vehicle speed sensor harness
connector.
voltage feed circuit of the vehicle speed
11 sensor and a known good ground. Refer to IP —
System.


1. Keep the ignition switch ON.
2. Connect a test lamp between the low
reference circuit of the vehicle speed sensor
12 and battery voltage. Refer to IP Cluster and —
Warning in Section 9D Wiring System.

2. Intermittently jump the signal circuit of the
vehicle speed sensor with a test lamp that is
13 while monitoring the Vehicle Speed parameter —
with the scan tool. Refer to IP Cluster and

Repair any open circuits or high resistance in the
vehicle speed sensor power supply circuit between
the Meter (10A) fuse and the vehicle speed sensor.
14 Refer to IP Cluster and Warning in Section 9D —
Wiring System.

vehicle speed sensor ground circuit between the
vehicle speed sensor and the chassis ground
15 (FU51). Refer to IP Cluster and Warning in Section —
9D Wiring System.

1. Test the vehicle speed sensor signal circuit
between the IP cluster and the vehicle speed
sensor for the following conditions:
• An open circuit
16 • A short to battery or ignition voltage —
• High resistance
Wiring System.

17 —

connector.
output shaft speed sensor. Refer to IP Cluster
and Warning in Section 9D Wiring System.


connection on the vehicle speed sensor signal
19 circuit at the harness connector of the ECM —
(pin 19 of FB24).

Replace the IP cluster. Refer to Instrument Panel
(IP) Cluster in Section 9E Instrumentation/ Driver
20 Info. —

Replace the vehicle speed sensor. Refer to Vehicle
Speed Sensor in Section 9E Instrumentation/
21 Driver Info. —


23 —
5. Select the data display function of ECM.
the scan tool.
Does the Vehicle Speed parameter indicate correct

vehicle speed? Go to Step 24 Go to Step 3
24 —
Circuit/ System Testing DTC P0502 or P0503 (Without digital tachograph)

Go to Diagnostic
Step 4.
1. Inspect the impulse sensor and circuit.
3 Refer to Manual Transmission (ZF) section. —


2. Observer the Vehicle Speed parameter with
4 the scan tool. —
Does the Vehicle Speed parameter indicate correct Go to Diagnostic
vehicle speed? Aids Go to Step 5
Observer the speedometer in the instrument panel
(IP) cluster.
5 —
Does the speedometer indicate correct vehicle
between the engine control module (ECM)
(pin 19 of FB24) and the speed sensor control
unit (pin 3 of FU173) for the following
conditions:
• An open circuit
6 —
• High resistance

7 2. Inspect the Meter (10A) fuse. —
circuits that fed by the Meter (10A) fuse or replace
8 the shorted attached component fed by the Meter —
(10A) fuse.

• Physical damage
damage

connector.
voltage feed circuit of the vehicle speed
10 sensor and a known good ground. Refer to IP —
System.


1. Test the vehicle speed sensor power supply
circuit between the speed sensor control unit
and the vehicle speed sensor for open circuits
or high resistance. Refer to IP Cluster and
11 —

reference circuit of the vehicle speed sensor
12 and battery voltage. Refer to IP Cluster and —

vehicle speed sensor with a test lamp that is
13 while monitoring the Vehicle Speed parameter —
with the scan tool. Refer to IP Cluster and

2. Disconnect the speed sensor control unit
harness connector.
14 voltage feed circuit of the speed sensor —
control unit harness (pin 1 of FU173) and a
known good ground.

reference circuit of the speed sensor control
15 unit harness (pin 5 of FU173) and battery —
voltage.

speed sensor control unit (pin 3 of FU173)
with a test lamp that is connected to 12 volts
16 (apply form a battery) while monitoring the —
Vehicle Speed parameter with the scan tool.

vehicle speed sensor ground circuit between the
vehicle speed sensor and the chassis ground
17 (FU51). Refer to IP Cluster and Warning in Section —
9D Wiring System.


speed sensor control unit power supply circuit
18 between the Meter (10A) fuse and the speed —
sensor control unit (pin 1 of FU173).

speed sensor control unit ground circuit between
19 the speed sensor control unit (pin 5 of FU173) and —
the chassis ground (FU51).

between the speed sensor control unit and the
vehicle speed sensor for the following
conditions:
• An open circuit
• High resistance
Wiring System.

between the ECM (pin 19 of FB24) and the
speed sensor control unit (pin 3 of FU173) for
• An open circuit
• High resistance

speed sensor control unit (pins 3 and 7 of
22 FU173) . —

connector.


connection on the vehicle speed sensor signal
24 circuit at the harness connector of the ECM —
(pin 19 of FB24).

Replace the speed sensor control unit. Refer to
Speed Sensor Control Unit in Section 9E
25 Instrumentation/ Driver Info. —

26 Driver Info. —


28 —
5. Select the data display function of ECM.
the scan tool.
Does the Vehicle Speed parameter indicate correct

vehicle speed? Go to Step 29 Go to Step 3
29 —

The ECM provides 12 volts reference voltage to the • The ECM illuminates the MIL when the diagnostic
mass air flow (MAF) sensor. Battery voltage is supplied runs and fails. Refer to DTC Type Definitions for
in ECM through the dropping resistor, and it is Action Taken When the DTC Sets - Type A.
converted into 12 volt. The ECM monitors the voltage • The ECM limits fuel injection quantity.
on the 12 volts reference circuit. If the ECM detects the
voltage is excessively low or high, this DTC will set.
• DTC P060B is not set.
• The ECM detects that the 12 volts reference circuit Connector End View Reference: Engine Controls
voltage is less than 7 volts. Connector End Views or ECM Connector End Views
• The ECM detects that the 12 volts reference circuit
voltage more than 19 volts.

Go to Diagnostic
3 connector. —
Does the DTC fail this ignition? Go to Step 4 Go to Step 13

2. Leave the MAF sensor harness connector
disconnected.
4 3. Disconnect the dropping resistor harness —
connector.

Measure the resistance across the dropping
5 resistor. 45 to 55 Ω
Is the resistance within the specified value? Go to Step 6 Go to Step 15
1. Connect a DMM between the ignition voltage
feed circuit (pin 1 of FB53) and a known good
ground.
6 18.0 volts

Connect a DMM between the voltage supply circuit
7 (pin 2 of FB53) and a known good ground. 13.0 volts
Repair the open circuit or high resistance on the
ignition voltage feed circuit between the ECM Main
8 (15A) fuse and the dropping resistor (pin 1 of —
FB53). Check the ECM Main (15A) fuse first.

1. Test the voltage supply circuit between the
ECM (pin 35 of FB24) and the dropping
resistor (pin 2 of FB53) for an open circuit or

1. Test the voltage supply circuit between the
ECM (pin 35 of FB24) and the dropping
resistor (pin 2 of FB53) for the following
conditions:

(pin 1 of J14 or FB128) for the following
conditions:
11 —
• A short to the low reference

dropping resistor (pins 1 and 2 of FB53).
12 —
Go to Diagnostic
1. Inspect for corrosion at the harness connector
of the MAF sensor (pin 1 of J14 or FB128).
13 2. Repair the connection(s) as necessary. —


Replace the dropping resistor.
15 —


Records.

19 —

The ECM monitors the ignition voltage on the ignition runs and fails. Refer to DTC Type Definitions for
feed terminal to make sure that the voltage stays within Action Taken When the DTC Sets - Type A.
the proper range. If the ECM detects an excessively (Except Euro 4 specification)
high ignition voltage, this DTC will set.
• DTC P060B is not set. Clearing the SVS Lamp/ DTC - Type C. (Euro 4
specification)
Condition for Setting the DTC Clearing the MIL/ DTC - Type A. (Except Euro 4
specification)
• The ECM detects that the ignition voltage feed
circuit is more than 32 volts for 30 minutes. Diagnostic Aids
Action Taken When the DTC Sets • A charging system problem may set this DTC.
• The ECM illuminates the SVS lamp when the Connector End View Reference: Engine Controls
diagnostic runs and fails. Refer to DTC Type Connector End Views or ECM Connector End Views

Was the vehicle recently a battery charger placed
2 —
on the battery? Go to Step 7 Go to Step 3
2. Start the engine and let idle.
3. Observe the Ignition Voltage parameter with
3 the scan tool. 32.0 volts
Does the scan tool indicate less than the specified Go to Diagnostic
value? Aids Go to Step 4
Test the charging system. Refer to Charging
4 System in Section 1E Engine Electrical. — Go to Diagnostic
Did you find a charging system problem? Go to Step 5 Aids
Repair the charging system. Refer to Charging
5 System in Section 1E Engine Electrical. —
2. Clear the DTCs with the scan tool.
6 4. Start the engine and let idle. 32.0 volts
5. Observe the ignition Voltage parameter with a
scan tool.
Does the scan tool parameter less than the

7 —

The brake switches are installed to the brake pedal runs and fails. Refer to DTC Type Definitions for
bracket. Two brake switches are installed and both are Action Taken When the DTC Sets - Type A.
turned to ON when the brake pedal is depressed. The (Except Euro 4 specification)
power supply voltage is supplied to the brake switches
via the stoplight relay, stoplight relay diode and brake Condition for Clearing the DTC
switch diode. When the brake switch turns to ON, each • Refer to DTC Type Definitions for Condition for
ground circuit is completed and the signal is input to the Clearing the SVS Lamp/ DTC - Type C. (Euro 4
engine control module (ECM). The ECM sets the DTC specification)
when the number of signal inputs of brake switches 1 • Refer to DTC Type Definitions for Condition for
and 2 do not match to each other. Clearing the MIL/ DTC - Type A. (Except Euro 4
specification)
• The battery voltage is more then 20 volts. Diagnostic Aids
The ECM detects the brake switch 1 signal and brake
switch 2 signal correlation error for 32 times. Connector End View Reference: Engine Controls

3. Observe the Brake Switch 1 parameter with a
scan tool while fully depressing and releasing
2 —
the brake pedal.
Does the scan tool indicate Applied when the brake

pedal is applied and Released when the brake
pedal is released? Go to Step 10 Go to Step 3
1. Check for play or looseness in the installation
condition of the brake switch 1 connector,
ECM and coupling connector.
3 —

2. Disconnect the brake switch 1 harness
connector.
3. Connect a 3-amp fused jumper wire across
the switch harness connector (pins 1 and 2 of
4 FU159). —
4. Turn ON the ignition.
scan tool.
Does the scan tool indicate Applied? Go to Step 5 Go to Step 7


2. Disconnect the 3-amp fused jumper wire from
the brake switch 1 harness connector.
5 3. Turn ON the ignition. —
scan tool.
Does the scan tool indicate Released? Go to Step 6 Go to Step 9

Replace the brake switch 1.
6 —
1. Test the signal circuit between the Junction
Block 2 (pin 13 of FU134) and the brake
switch 1 (pin 1 of FU159) for an open circuit or

1. Test the ground circuit between the brake
switch 1 (pins 2 of FU159) and the ground
terminal (FU54) for an open circuit or high
8 resistance. —

1. Test the signal circuit between the Junction
Block 2 (pin 4 of FL67) and the ECM (pin 54 of
FB24) for an open circuit or high resistance.
9 —

scan tool while fully depressing and releasing
10 —
the brake pedal.

1. Check for play or looseness in the installation
condition of the brake switch 2 connector,
ECM and coupling connector.
11 —

2. Disconnect the brake switch 2 harness
connector.
3. Connect a 3-amp fused jumper wire across
the switch harness connector (pins 1 and 2 of
12 FB5 or FB144). —
scan tool.
Does the scan tool indicate Applied? Go to Step 13 Go to Step 15


2. Disconnect the 3-amp fused jumper wire from
the brake switch 2 harness connector.
13 3. Turn ON the ignition. —
scan tool.
Does the scan tool indicate Released? Go to Step 14 Go to Step 17

Replace the brake switch 2.
14 —
1. Test the signal circuit between the J/C-30P2
(pin 5 of FB35) and the brake switch 2 (pin 1
of FB5 or FB144) for an open circuit or high
15 resistance. —

1. Test the ground circuit between the brake
switch 2 (pin 2 of FB5 or FB144) and the
ground terminal (FB21) for an open circuit or

1. Test the signal circuit between the J/C-30P2
(pin 6 of FB35) and the ECM (pin 55 of FB24)
17 —


19 5. Observe the Brake Switch 1 and Brake Switch —
2 parameter with a scan tool while fully
depressing and releasing the brake pedal.

pedal is released on each parameter? Go to Step 2 Go to Step 20
20 —

This diagnostic applies to internal microprocessor • The ECM illuminates the MIL when the diagnostic
integrity conditions within the ECM. runs and fails. Refer to DTC Type Definitions for
• The ECM detects that the calculated checksum Condition for Clearing the DTC
does not agree with the read only memory (ROM) • Refer to DTC Type Definitions for Condition for
internal registered checksum. Clearing the MIL/ DTC - Type A.



4 Running the DTC. You may also operate the —
Records.

5 —

The electrically erasable & programmable read only • The ECM illuminates SVS lamp when the
memory (EEPROM) memorizes fuel injector ID code diagnostic runs and fails. Refer to DTC Type
information. If the ECM detects fuel injector ID codes Definitions for Action Taken When the DTC Sets -
are not programmed into the ECM or an error in the Type C. (Euro 4 specification)
programmed fuel injector ID codes, this DTC will set. • The ECM illuminates the MIL when the diagnostic
Condition for Running the DTC Action Taken When the DTC Sets - Type A.
• The ignition switch is ON. (Except Euro 4 specification)
Condition for Setting the DTC Condition for Clearing the DTC
Either of following condition is met: • Refer to DTC Type Definitions for Condition for
• The ECM detects that the fuel injector ID code is Clearing the SVS Lamp/ DTC - Type C. (Euro 4
not programmed. specification)
• The ECM detects an error in the programmed fuel • Refer to DTC Type Definitions for Condition for
injector ID code. Clearing the MIL/ DTC - Type A. (Except Euro 4
specification)
Notice: Clear the DTC with a scan tool after

programming the fuel injector ID code.

1. Ensure that all tool connections are secure.
2. Ensure that programming equipment is
operating correctly.

1. Verify the correct fuel injector ID codes are
entered into the ECM with a scan tool. Refer
to ECM Replacement. If the fuel injector ID
codes are correctly entered, clear the DTC
3 with a scan tool. —



Records.

6 —

DTC P0604, P0606 or P060B (Flash Code 153, 51 or 36)
This diagnostic applies to internal microprocessor • The ECM illuminates the MIL when the diagnostic
integrity conditions within the ECM. runs and fails. Refer to DTC Type Definitions for
Condition for Running the DTC • The ECM limits fuel injection quantity.
• The battery voltage is more than 16 volts. (DTC • The ECM inhibits pre injection.
P0604 and P0606) • The ECM inhibits cruise control.
• The ignition switch is ON. (DTC P0604 and P0606) • The ECM stops engine running. The engine will
run after the key is cycled when the ignition has
Condition for Setting the DTC been turned OFF for longer than 10 seconds.
• The ECM detects a malfunction in its internal (DTC P0604)
random access memory (RAM). (DTC P0604)
• The ECM detects a malfunction in its internal main Condition for Clearing the DTC
central processing unit (CPU) or sub integrated • Refer to DTC Type Definitions for Condition for
circuit (IC). (DTC P0606) Clearing the MIL/ DTC - Type A.
• The ECM detects a malfunction in its internal A/D
converter. (DTC P060B)
Circuit/ System Testing DTC P0604, P0606 or P060B



Records.

5 —

The electronically erasable & programmable read only runs and fails. Refer to DTC Type Definitions for
memory (EEPROM) memorizes immobilizer security Action Taken When the DTC Sets - Type A.
information for communication with the immobilizer (Except Euro 4 specification)
control unit (ICU) and enabling the engine to start. If the
ECM detects immobilizer security information are not Condition for Clearing the DTC
programmed into the ECM, this DTC will set. • Refer to DTC Type Definitions for Condition for
Condition for Setting the DTC specification)
• The ECM detects that the immobilizer security • Refer to DTC Type Definitions for Condition for
information is not programmed. Clearing the MIL/ DTC - Type A. (Except Euro 4
specification)
Diagnostic Aids
diagnostic runs and fails. Refer to DTC Type • Non-programmed ECM sets this DTC.

Go to Diagnostic
Program immobilizer security information into the
ECM. Refer to Immobilizer Control Unit &
3 Programming in Section 9I Security and Lock. —
Did you complete the programming? Go to Step 4 —

Records.

5 —

The ECM controls the intake throttle valve opening runs and fails. Refer to DTC Type Definitions for
based on the engine running condition and by Action Taken When the DTC Sets - Type A.
controlling the intake throttle motor. The intake throttle (Except Euro 4 specification)
valve position is detected by the position sensor, and • The ECM inhibits EGR valve control.
relayed to the ECM. If the ECM detects a variance
between the actual intake throttle valve position and Condition for Clearing the DTC
desired intake throttle valve position while the intake • Refer to DTC Type Definitions for Condition for
throttle motor is commanded ON, this DTC will set. Clearing the MIL/ DTC - Type B. (Euro 4
specification)
• DTCs P0122, P0123, P060B and P0697 are not Clearing the MIL/ DTC - Type A. (Except Euro 4
set. specification)
• The desired intake throttle valve position is stable. • If an intermittent condition is suspected, refer to
• The intake throttle motor is commanded ON.
• A sticking or intermittently sticking intake throttle
Condition for Setting the DTC valve may set this DTC.
• The ECM detects that the difference between the • A sticking intake throttle valve at full closed
actual and the desired intake throttle position is position will cause engine starting problem.
more than 40% for longer than 5 seconds.
Action Taken When the DTC Sets Connector End Views or ECM Connector End Views

specification)

Go to Applicable
1. Perform the Intake Throttle Solenoid Control
with a scan tool several times.
2. Command the Desired Intake Throttle Position
Increase and Decrease while observing the
3 Intake Throttle Position. ± 5%
Does the Intake Throttle Position parameter follow

within the specified value quick enough (compare Go to Diagnostic
with a similar unit if available)? Aids Go to Step 4

1. Remove the intake duct that is connected to
the intake throttle valve.
2. Inspect the intake throttle valve for the
• Restricted intake throttle valve by foreign
materials
4 • Excessive deposits at throttle bore —
• Bent butterfly valve
Notice: Replace the intake throttle valve if

there is any sticking.

connector.
connector of the intake throttle valve (pins 1,
2, 4, 5 and 6 of E46).
5 connections and corrosion on each intake —
throttle valve circuit at the harness connector
of the ECM (pins 85, 95, 104, 109 and 112 of
E26).
each circuit.
necessary.

104 and 112 of E26) and the intake throttle
valve (pins 1 and 2 of E46) for the following
conditions:
6 —
• A short to the intake throttle position
sensor circuit(s)


Records.


Records.

11 —

Circuit Description • The ECM detects that the 5 volts reference circuit
The ECM provides 5 volts reference voltage through 1 voltage is less than 4.5 volts.
the reference circuit 1 to the following sensors: • The ECM detects that the 5 volts reference circuit
• Accelerator pedal position (APP) sensor 1 1 voltage is more than 5.5 volts.
• PTO throttle sensor
• Idle up sensor
The ECM also provides 5 volts reference voltage
through the reference circuit 1 to the cruise control
switch on the combination switch. The 5 volts reference
circuits are bussed together outside the ECM. • The ECM blinks the exhaust brake indicator lamp
Therefore, a short circuit condition on one sensor 5 when the diagnostic runs and fails.
volts reference circuit may affect the entire 5 volts • The ECM limits fuel injection quantity.
reference circuit 1. The ECM monitors the voltage on • The ECM inhibits exhaust brake control.
the 5 volts reference circuit 1. If the ECM detects the
voltage is excessively low or high, this DTC will set.

Go to Diagnostic
2. Disconnect the idle up sensor harness
connector.
3 circuit (pin 3 of FL33) and a known good 5.5 volts
ground.
4 4.5 volts

1. Leave the DMM connected to the idle up
3. Disconnect the accelerator pedal position
5 (APP) sensor harness connector. 4.5 volts
Does the DMM voltage change to more than the

Notice: If no PTO throttle sensor is installed, skip
to Step 7.
1. Leave the DMM connected to the idle up
6 3. Disconnect the PTO throttle sensor harness 4.5 volts
connector.

ECM (pin 42 of FB24) and the following
components for a short to ground or short to
the low reference circuit:
• APP sensor 1 (pin 4 of FL1)
7 —
• PTO throttle sensor (pin 3 of FB129)
• Idle up sensor (pin 3 of FL33)

components for a short to battery or ignition
voltage.
• PTO throttle sensor (pin 3 of FB129)
8 • Idle up sensor (pin 3 of FL33) —
ECM (pin 65 of FB24) and the combination
switch (pin 5 of FL19) for a short to battery or
ignition voltage.

Replace the idle up sensor. Refer to Idle Up Sensor
9 in Section 1I Engine Speed Control System. —
Replace the APP sensor. Refer to Accelerator
Control Assembly in Section 1I Engine Speed
10 Control System. —

Replace the PTO throttle sensor.
11 —


Records.

14 —

The malfunction indicator lamp (MIL) is located on the • The ECM illuminates the MIL when the diagnostic
instrument panel (IP) cluster. The MIL informs the runs and fails. Refer to DTC Type Definitions for
driver that an emission system fault has occurred and Action Taken When the DTC Sets - Type A. (Euro
that the engine control system requires service. 4 specification)
The ECM monitors the MIL control circuit for conditions • The ECM will not illuminate the MIL or SVS lamp.
that are incorrect for the commanded state of the MIL. Refer to DTC Type Definitions for Action Taken
For example, a failure condition exists if the ECM When the DTC Sets - Type D. (Except Euro 4
detects low voltage when the MIL is commanded OFF, specification)
or high voltage when the MIL is commanded ON. If the
ECM detects an improper voltage level on the control Condition for Clearing the DTC
circuit, this DTC will set.
Clearing the MIL/ DTC - Type A. (Euro 4
specification)
• The ignition switch is ON. Clearing the DTC - Type D. (Except Euro 4
specification)
Either of following condition is met: Diagnostic Aids
• The ECM detects a low voltage condition on the • If an intermittent condition is suspected, refer to
MIL control circuit when the lamp is commanded Intermittent Conditions in this section.
OFF.
• The ECM detects a high voltage condition on the Connector End View Reference: Engine Controls
MIL control circuit when the lamp is commanded Connector End Views or ECM Connector End Views
ON.

Go to Diagnostic
3 block. —


Is the MIL OFF? Go to Step 6 Go to Step 12


voltage to the MIL.
6 3. Measure the voltage from the MIL control 1 volt
circuit in the ECM harness connector (pin 6 of
FB24) to a known good ground.

Is the MIL illuminate? Go to Step 11 Go to Step 8

ground.

9 —

IP cluster (pin 40 of FU98 and pin 31 of
10 FU97). —

11 —

Repair the short to ground between the ECM (pin 6
12 of FB24) and the IP cluster (pin 31 of FU97). —
between the ECM (pin 6 of FB24) and the IP cluster
13 (pin 31 of FU97). —

Repair the open circuit or high resistance on
ignition the voltage feed circuit between the Meter


15 Driver Info. —



18 —

Circuit Description • The ECM detects that the 5 volts reference circuit
The ECM provides 5 volts reference voltage through 2 or 5 voltage is more than 5.5 volts.
the reference circuit 2 to the following sensors:
• Accelerator pedal position (APP) sensor 2
• The ECM illuminates MIL when the diagnostic runs
• Barometric pressure (BARO) sensor
• Intake air temperature (IAT) sensor Taken When the DTC Sets - Type A.
• The ECM blinks the exhaust brake indicator lamp
through the reference circuit 5 to the following sensors:
when the diagnostic runs and fails.
• Fuel rail pressure (FRP) sensor
• Camshaft position (CMP) sensor
• EGR position sensor
The 5 volts reference circuits 2 and 5 are independent
of each other outside of the ECM, but are bussed • The ECM inhibits exhaust brake control.
together inside the ECM. Therefore, a short circuit • The ECM inhibits cruise control.
condition on one sensor 5 volts reference circuit may
affect the entire 5 volts reference circuit 2 and 5. The Condition for Clearing the DTC
ECM monitors the voltage on the 5 volts reference • Refer to DTC Type Definitions for Condition for
circuit 2 and 5. If the ECM detects the voltage is Clearing the MIL/ DTC - Type A.
excessively low or high, this DTC will set.
Diagnostic Aids
• The ignition switch is ON. Notice: If this DTC is set, the engine cranks but does
not start.
• The ECM detects that the 5 volts reference circuit
2 or 5 voltage is less than 4.5 volts.

Go to Diagnostic
2. Disconnect the camshaft position (CMP)
3. Connect a DMM between the CMP sensor 5
3 volts reference circuit (pin 3 of E48) and a 5.5 volts
known good ground.
4 4.5 volts

1. Leave the DMM connected to the CMP sensor
harness connector.
3. Disconnect the fuel rail pressure (FRP) sensor
5 harness connector. 4.5 volts

Notice: If n o EGR valve is installed, skip to step 7.
harness connector.
6 4.5 volts

harness connector.
3. Disconnect the barometric pressure (BARO)
7 sensor harness connector. 4.5 volts

harness connector.
8 (APP) sensor harness connector. 4.5 volts

1. Test the 5 volts reference circuit 2 between the
• BARO sensor (pin 3 of FL52)
ECM (pin 87 of E26) and the following
9 —
• FRP sensor (pin 3 of E49)
• CMP sensor (pin 3 of E48)
• EGR valve position sensor (pin 1 of E45)


voltage.
• BARO sensor (pin 3 of FL52)
10 —
voltage.
• FRP sensor (pin 3 of E49)
• CMP sensor (pin 3 of E48)
• EGR valve position sensor (pin 1 of E45)

13 —
14 Replacement. —


Records.

18 —

The ECM main relay is energized to feed the battery • The ECM illuminates the SVS lamp when the
voltage to the ECM through the relay switch side when diagnostic runs and fails. Refer to DTC Type
the ECM receives an ignition voltage switch ON signal. Definitions for Action Taken When the DTC Sets -
When the ignition switch is OFF, the ECM main relay is Type C. (Euro 4 specification)
de-energized after a certain length of time passed. • The ECM illuminates the MIL when the diagnostic
If the ECM detects a low voltage condition on the ECM runs and fails. Refer to DTC Type Definitions for
main relay voltage feed circuit when the relay is Action Taken When the DTC Sets - Type A.
commanded ON, DTC P0685 will set. (Except Euro 4 specification)
If the ECM detects the ECM has been ON when the
relay is commanded OFF, DTC P0687 will set. Condition for Clearing the DTC
• DTC P060B is not set (DTC P0685) specification)
• DTC P0606 is not set (DTC P0687) • Refer to DTC Type Definitions for Condition for
• The battery voltage is between 18 to 32 volts. Clearing the MIL/ DTC - Type A. (Except Euro 4
(DTC P0685) specification)
• The ignition switch is ON. (DTC P0685)
Diagnostic Aids
• The ignition switch is OFF. (DTC P0687)
• The ECM detects a low voltage condition on the
ECM main relay voltage feed circuit for 3 seconds
when the relay is commanded ON. (DTC P0685)
• The ECM detects that the ECM has been ON
when the ECM main relay is commanded OFF.
(DTC P0687)

Go to Diagnostic


1. Inspect for an intermittent, for poor tightening
and corrosion at the chassis ground terminal
(FB20).
2. Repair the tightening or clean the corrosion as
necessary.
3. Inspect the ECM (40A) slow blow fuse for an
4 open. —
4. Replace the ECM (40A) slow blow fuse if
open. If it continues to open, repair the short to
ground on one of the circuits that is fed by the
ECM (40A) slow blow fuse.

connector of the ECM (pin 2, 5, 21 and 40 of
FB24).
each relay circuit.
• Between pins 2 and 5 of FB24 and pin 2
5 of X18 —
• Between pins 21 and 40 of FB24 and pin
3 of X18
• Between ECM (40A) slow blow fuse and
pin 1 of X18
• Between pin 5 of X18 and chassis
ground (FB20)
necessary.

6 —


9 —


4. Monitor DTC Information with a scan tool.
Go to Diagnostic
3 —


Repair the short to battery on the battery voltage
feed circuits between the ECM (pins 2 and 5 of
5 FB24) and the ECM main relay (pin 2 of X18). —

Repair the short to battery on the battery voltage
supply circuits between the ECM (pins 21 and 40 of
6 FB24) and the ECM main relay (pin 3 of X18). —

7 —

9 —

The ECM provides 5 volts reference voltage through Either of following condition is met:
the reference circuit 3 to the following sensors: • The ECM detects that the 5 volts reference circuit
• Exhaust differential pressure sensor 3 or 4 voltage is less than 4.5 volts.
• Exhaust temperature sensor 1 • The ECM detects that the 5 volts reference circuit
• Exhaust temperature sensor 2 3 or 4 voltage is more than 5.5 volts.
through the reference circuit 4 to the following sensors: Action Taken When the DTC Sets
• Crankshaft position (CKP) sensor • The ECM illuminates the MIL when the diagnostic
• Boost pressure sensor runs and fails. Refer to DTC Type Definitions for
• Intake throttle position sensor
• Engine coolant temperature (ECT) sensor
• Fuel temperature (FT) sensor
The 5 volts reference circuits 3 and 4 are independent • The ECM inhibits EGR control.
of each other outside of the ECM, but are bussed • The ECM inhibits cruise control.
together inside the ECM. Therefore, a short circuit
condition on one sensor 5 volts reference circuit may Condition for Clearing the DTC
affect the entire 5 volts reference circuit 3 and 4. The • Refer to DTC Type Definitions for Condition for
ECM monitors the voltage on the 5 volts reference Clearing the MIL/ DTC - Type A.
circuit 3 and 4. If the ECM detects the voltage is
excessively low or high, this DTC will set. Diagnostic Aids
• The battery voltage is between 16 to 32 volts. Connector End View Reference: Engine Controls
• The ignition switch is ON. Connector End Views or ECM Connector End Views

Go to Diagnostic
harness connector.
ground.
4 4.5 volts

Notice: If vacuum control intake throttle valve is
installed, skip to Step 6.
1. Leave the DMM connected to the boost
pressure sensor harness connector.
5 3. Disconnect the intake throttle valve harness 4.5 volts
connector.

3. Disconnect the crankshaft position (CKP)
6 sensor harness connector. 4.5 volts

Notice: If no exhaust differential pressure sensor is
7 3. Disconnect the exhaust differential pressure 4.5 volts

ECM (pin 80 of FB24) and the exhaust
differential pressure sensor (pin 3 of FB66) for
a short to ground or short to the low reference
circuit.
8 the low reference circuit: —
• CKP sensor (pin 3 of E50)
• Boost pressure sensor (pin 3 of E54)
• Intake throttle position sensor (pin 5 of
E46)


a short to battery or ignition voltage.
9 voltage. —
• CKP sensor (pin 3 of E50)
• Boost pressure sensor (pin 3 of E54)
• Intake throttle position sensor (pin 5 of
E46)

Important: Replacement exhaust differential
pressure sensor must be learned.
Replace the exhaust differential pressure sensor.
13 Refer to Exhaust Differential Pressure Sensor in —
Section 1G Engine Exhaust.


Records.

16 —

Description • The ECM inhibits EGR control.
The common rail fuel system is comprised of two fuel • The ECM inhibits cruise control.
pressure sections: a suction side between the fuel tank
and the fuel supply pump and a high-pressure side Condition for Clearing the DTC
between the fuel supply pump and the fuel injectors. • Refer to DTC Type Definitions for Condition for
Fuel is drawn from the fuel tank via a feed pump and Clearing the MIL/ DTC - Type A.
which are internal to the fuel supply pump. This high Diagnostic Aids
• An intermittently sticking FRP regulator may have
pressure (FRP) regulator dependant upon values from
allowed the fuel pressure to become low enough to
the FRP sensor attached to the fuel rail. If the ECM
set this DTC.
detects that the fuel rail pressure is certain pressure
lower than the desired pressure, this DTC will set. • Actual Fuel Rail Pressure and Desired Fuel Rail
Condition for Running the DTC (accelerator pedal full travel) in Park or Neutral
• DTCs P0087, P0091, P0092, P0192, P0193,
enough.
P0201 - P0206, P060B, P0651, P1261, P1262,
P2146 and P2149 are not set. • A skewed FRP sensor value can set this DTC. The
• The ignition switch is ON. OFF after the engine has stopped running for a
• The engine is running. minimum of 2 minutes.
• The FRP regulator commanded fuel flow is more
than a threshold. Notice: This DTC most likely indicates a loss of fuel
pressure by a fuel leak from the high pressure side.
Condition for Setting the DTC Inspect the high pressure side fuel leakage between
the fuel supply pump and fuel injector first.
is more than 50 MPa (7,200 psi) below the desired
pressure for longer than 5 seconds.
might be allowed to go into the fuel system. With air in
• The ECM illuminates the MIL when the diagnostic bleeding of fuel system after refilling.
Action Taken When the DTC Sets - Type A. Routing Reference: Fuel System Routing Diagram
• The ECM limits fuel injection quantity. Connector End View Reference: Engine Controls
• The ECM inhibits pre injection. Connector End Views or ECM Connector End Views

2 —


3 0.9 to 1.0 volt


may occur.
rail.



nut(s).
6 —

kinked.
condition.



2. Unclamp or unplug the fuel line from the
previous step and reconnect the fuel line (if
disconnected).
3. Start the engine and allow it to run for at least
1 minute.
9 —
tool.
5. Command each injector OFF and verify an

connector.
of E47).
113 of E26).
necessary.

connector.
of E49).
11 —
101 of E26).
necessary.

12 Engine Fuel. —


programmed.

to the ECM.

15 —
Fuel.

Notice: There is a possibility that the pressure
limiter valve stuck open or operating pressure has
fallen.
16 —
Replace the pressure limiter valve. Refer to
Pressure Limiter in Section 1D Engine Fuel.

Records.

18 —

The charge up circuit in the ECM steps up the voltage • The ECM illuminates the MIL when the diagnostic
for fuel injectors and is divided into two banks, common runs and fails. Refer to DTC Type Definitions for
1 and 2. The common 1 covers fuel injectors in Action Taken When the DTC Sets - Type A.
cylinders #1, #2 and #3, and the common 2 covers fuel • The ECM limits fuel injection quantity.
injectors in cylinders #4, #5 and #6. If the common 1 or
common 2 fuel injector charge up circuit in the ECM is
an open circuit, DTC P1261 or P1262 will set. • The ECM inhibits EGR control.
• The battery voltage is between 18 to 32 volts. Condition for Clearing the DTC
• The ignition switch is ON. • Refer to DTC Type Definitions for Condition for
Diagnostic Aids
• The ECM detects its internal common 1 fuel
injector charge up circuit is open circuit. (DTC • If an intermittent condition is suspected, refer to
P1261) Intermittent Conditions in this section.
• The ECM detects its internal common 2 fuel
injector charge up circuit is open circuit. (DTC
P1262)
Circuit/ System Testing DTC P1261 or P1262



Records.

5 —

Circuit Description • The ECM detects that the EGR learned minimum
The ECM controls the EGR valve opening based on the position is not within a predetermined range when
engine running condition and by controlling the EGR the ignition switch is OFF.
motor. The EGR valve position is detected by the
position sensor, and relayed to the ECM. Action Taken When the DTC Sets
If the ECM detects that the actual EGR position is • The ECM illuminates the MIL when the diagnostic
higher than certain amount, this DTC will set. (Closed runs and fails. Refer to DTC Type Definitions for
Position Error DTC) Action Taken When the DTC Sets - Type A.
If the ECM detects a variance between the learned • The ECM limits fuel injection quantity.
closed position and actual closed position, this DTC will
also set. (Learned Position Error DTC)
Condition for Clearing the MIL/DTC
Closed Position Error DTC
• DTCs P0112, P0113, P0116, P0117, P0118,
P0409, P060B, P0651, P0697, P2227, P2228 and
P2229 are not set.
Notice: A history DTC remains 9,600 hours
• The battery voltage is between 16 to 32 volts. (accumulated engine runtime) and will not clear with a
• The desired EGR valve position is stable. scan tool. (Euro 4 specification)
Learned Position Error DTC
• DTCs P0404, P0409, P0500, P0502, P0503, Diagnostic Aids
P060B and P0651 are not set. • If an intermittent condition is suspected, refer to
Condition for Setting the DTC • A sticking or intermittently sticking the EGR valve
Closed Position Error DTC may set this DTC.
• The ECM detects that the difference between the
actual and the desired EGR valve position is more Connector End View Reference: Engine Controls
than 40% for longer than 5 seconds. Connector End Views or ECM Connector End Views
Learned Position Error DTC

Go to Applicable
engine.
conditions:
3 materials —
• Bent valve shaft or valve


6, 7 and 8 of E45).
101, 103, 110 and 111 of E26).
each circuit.
necessary.

(pins 6, 7 and 8 of E45) for the following
conditions:
5 —
• A short to the EGR position sensor
circuit(s)

6 —
Notice: Ignition switch must be cycled before

clear the DTC.
4. Turn ON the ignition and clear the DTCs with
a scan tool.
7 Notice: A history DTC will not clear. (Euro 4 —

specification)
Records.

8 —

The ECM detects the condition of PM accumulations • The ECM illuminates the MIL when the diagnostic
from the exhaust differential pressure sensor attached runs and fails. Refer to DTC Type Definitions for
to the chassis frame near the diesel particulate defuser Action Taken When the DTC Sets - Type A.
(DPD) assembly. When it is reached to a certain • The ECM limits fuel injection quantity.
amount of PM accumulations or a certain length of
mileage, the automatic regeneration starts. If the
automatic regeneration cannot be completed by some
reason, the manual regeneration is requested to the
driver by blinking the DPD amber lamp or "PUSH DPD • Refer to DTC Type Definitions for Condition for
SWITCH" indicator on the instrument panel cluster. If Clearing the MIL/ DTC - Type A.
the DPD filter regeneration interval is more than a
predetermined mileage, this DTC will set. Diagnostic Aids
• If manual regeneration is frequently requested,
Condition for Running the DTC refer to DPD System Manual Regeneration
• DTCs P0500, P0502 and P0503 are not set. Frequently Chart in symptom diagnostic table.
Notice: This DTC is caused by incomplete automatic
regeneration has occurred and manual regeneration
urged by the DPD lamp on the IP cluster was
• The DPD filter regeneration interval is more than disregarded or forgot, which was most likely caused by
520 km (325 miles). driver error. Primarily ask the driver about DPD amber
lamp or "PUSH DPD SWITCH" indicator blinking in the
past.

Ask the driver about DPD amber lamp or "PUSH
DPD SWITCH" indicator blinking in the past.
Explain DPD filter regeneration and lamp action to
the driver as necessary.
2 Notice: If manual regeneration is frequently —
requested, refer to DPD System Manual
Regeneration Frequently Chart in symptom
diagnostic table.


1. Turn ON the ignition for 30 seconds. DO NOT
start the engine. Make sure the DPD lamps or
“AUTO REGEN.”, “MANUAL REGEN.”
indicators on the instrument panel cluster is
turned OFF. (This is to relearn exhaust
differential pressure sensor.)
2. Clear the DTC and reset the DPD Status with
a scan tool.
5. Observe the Exhaust Temperature 1
3 parameter with a scan tool. Make sure the 5.2 kPa
temperature is less than 130°C (266°F). If
more than 130°C (266°F), let increase 1000
RPM without load. (Turn the idle up control
knob clockwise.)
6. Accelerate the engine to W.O.T. (accelerator
pedal full travel) and read the Exhaust
Differential Pressure parameter when the
Exhaust Temperature 1 parameter is reached
to 140°C (284°F).
Is the Exhaust Differential Pressure parameter less

2. Clear the DTC with a scan tool if set.
4 Important: Engine oil must be replaced after —

DPD slow regeneration is completed.
4. Perform the DPD Slow Regeneration with a
scan tool.

2. Replace the DPD filter. Refer to Exhaust Pipe
5 in Section 1G Engine Exhaust. —

parameter with a scan tool. Make sure the
knob clockwise.)
6 2. Accelerate the engine to W.O.T. (accelerator 3.3 kPa
Differential Pressure parameter when the Ash cleaning must
Exhaust Temperature 1 parameter is reached be performed. Refer
to 150°C (302°F). to appropriate
procedure in
Is the Exhaust Differential Pressure parameter less Section 1G Engine
than the specified value? Go to Step 7 Exhaust
7 —

Description • The intake throttle position is more than 22%.
The ECM detects the condition of PM accumulations • The DPD filter regeneration is finished.
from the exhaust differential pressure sensor attached
to the chassis frame near the diesel particulate defuser Condition for Setting the DTC
(DPD) assembly. When it is reached to a certain • The DPD filter regeneration has been incomplete
amount of PM accumulations or a certain length of purification status continuously.
automatic regeneration cannot be completed by some Action Taken When the DTC Sets
driver by blinking the DPD amber lamp or "PUSH DPD
SWITCH" indicator on the instrument panel cluster.
After the regeneration event is finished, an exhaust
differential pressure monitors a purification of the filter. • The ECM limits fuel injection quantity.
If the filter regeneration has been incomplete • The ECM inhibits cruise control.
purification status continuously, this DTC will set.
• DTCs P0079, P0080, P0116, P0117, P0118, Clearing the MIL/ DTC - Type A.
P0122, P0123, P0201 - P0206, P0335, P0336,
P0404, P0409, P0426, P042B, P042C, P042D, Diagnostic Aids
P0427, P0428, P0500, P0502, P0503, P060B, • If manual regeneration is frequently requested,
P0638, P0641, P0651, P1261, P1262, P1404, refer to DPD System Manual Regeneration
P2146, P2149, P2227, P2228, P2229, P2452 - Frequently Chart in symptom diagnostic table.
P2456 are not set.
• An excessive ash accumulation in the DPD filter
• The ignition switch is ON. will cause this DTC to set.
• The exhaust gas temperature 1 (in front of filter) is • The mass air flow (MAF) sensor problem will
more than 100°C (212°F). cause this DTC to set. Refer to DTC P0101 for
• The engine speed is more than 1000 RPM. MAF sensor diagnosis and Use the Scan Tool Data
• The EGR position is less than 95%. List or a known good vehicle to determine nominal
values.


• Misrouted or disconnected exhaust
differential pressure hoses or pipes
Important: There is installation

directionality in the exhaust differential
pressure hoses. Refer to Exhaust
Differential Pressure Sensor in Section
1G Engine Exhaust.
• Plugged, crushed or kinked exhaust
• Physical damage of the exhaust
differential pressure sensor
the exhaust differential pressure sensor
port
• Skewed or slow exhaust differential
pressure sensor
• An exhaust system gasket that is missing
or damaged
• Exhaust gas leakage from the exhaust
2 pipe, gasket, DPD assembly, exhaust —
temperature sensor(s) or exhaust
• Modified exhaust system
• Skewed or slow exhaust temperature
sensors
• Modified air induction system
the mass air flow (MAF) sensor inlet

harness connector(s) or components.

3 —
4. Observe the DPD Accumulation Status and
DPD Distance Status with a scan tool and plot
both readings on the DPD status table. Refer
to DPD Control System Check.
Is the intersected range located in C or D? Go to Step 4 Go to Step 5


2. Clear the DTC and the DPD status with a scan
tool.

scan tool.

tool.
4. Perform the DPD Normal Regeneration with a
scan tool.

knob clockwise.)
procedure in
7 —

DTC P161B (Flash Code 179)
The ECM communicates with the immobilizer control runs and fails. Refer to DTC Type Definitions for
unit (ICU) to execute immobilizer function. The ECM Action Taken When the DTC Sets - Type A.
transmits a specific request signal to the ICU and the (Except Euro 4 specification)
ICU sends back a response signal to the ECM. Both
communication signals are carried out via a controller Condition for Clearing the DTC
area network (CAN) communication bus. If the ECM • Refer to DTC Type Definitions for Condition for
receives a wrong response signal from the ICU, this Clearing the SVS Lamp/ DTC - Type C. (Euro 4
DTC will set. specification)
• The ECM receives a wrong immobilizer response specification)
signal from the ICU.
Diagnostic Aids
Action Taken When the DTC Sets • If an intermittent condition is suspected, refer to
• The ECM illuminates the SVS lamp when the Intermittent Conditions in this section.
diagnostic runs and fails. Refer to DTC Type • Electromagnetic interference may affect
Definitions for Action Taken When the DTC Sets - intermittent condition.
Circuit/ System Testing DTC P161B

Go to Applicable
Is DTC P0633 or U0167 also set? DTC Go to Step 3
Monitor the immobilizer DTC Information with a
scan tool. Go to Applicable
3 — DTC for Immobilizer
Does the immobilizer DTCs fail this ignition? Section Go to Step 4
Program immobilizer security information into the
ECM. Refer to Immobilizer Control Unit &
4 Programming in Section 9I Security and Lock. —


Records.


7 —

This diagnostic applies to internal microprocessor • The ECM illuminates MIL when the diagnostic runs
integrity conditions within the ECM. and fails. Refer to DTC Type Definitions for Action
Taken When the DTC Sets - Type A.
• The ignition switch is ON. Condition for Clearing the DTC
Condition for Setting the DTC Clearing the MIL/ DTC - Type A.
• The ECM detects that the calculated checksum
does not agree with the electrically erasable &
programmable read only memory (EEPROM)
internal registered checksum.

1. Ensure that all tool connections are secure.
2. Ensure that programming equipment is
operating correctly.



Records.

6 —

Circuit Description • The ECM detects a low voltage condition on the
The service vehicle soon (SVS) lamp is located on the SVS lamp control circuit when the lamp is
instrument panel (IP) cluster. The SVS lamp informs commanded OFF.
the driver that a non-emission related fault has • The ECM detects a high voltage condition on the
occurred and vehicle service required. SVS lamp control circuit when the lamp is
The ECM monitors the SVS lamp control circuit for commanded ON.
conditions that are incorrect for the commanded state
of the SVS lamp. For example, a failure condition exists Action Taken When the DTC Sets
if the ECM detects low voltage when the SVS lamp is • The ECM will illuminate the SVS lamp. Refer to
commanded OFF, or high voltage when the SVS lamp DTC Type Definitions for Action Taken when the
is commanded ON. If the ECM detects an improper DTC Sets - Type C.
voltage level on the control circuit, this DTC will set.
• The battery voltage is between 18 to 32 volts. Clearing the SVS Lamp/ DTC - Type C.
Diagnostic Aids
Condition for Setting the DTC • If an intermittent condition is suspected, refer to
Either of following condition is met: Intermittent Conditions in this section.


Go to Diagnostic
3 block. —


5 —
Is the SVS lamp OFF? Go to Step 6 Go to Step 12


voltage to the SVS lamp.
6 3. Measure the voltage from the SVS lamp 1 volt

Is the SVS lamp illuminate? Go to Step 11 Go to Step 8

ground.

9 —

10 —

11 —

Repair the short to ground between the ECM (pin
12 17 of FB24) and the IP cluster (pin 4 of FU98). —
between the ECM (pin 17 of FB24) and the IP
13 cluster (pin 4 of FU98). —

ignition voltage feed circuit between the Meter


15 Driver Info. —



18 —

The diesel particulate defuser (DPD) amber lamp is Either of following condition is met:
located on the instrument panel (IP) cluster. The DPD • The ECM detects a low voltage condition on the
amber lamp informs the driver that an incomplete DPD amber lamp control circuit when the lamp is
automatic regeneration has occurred and manual commanded OFF.
regeneration is required.
• The ECM detects a high voltage condition on the
The ECM monitors the DPD amber lamp control circuit
DPD amber lamp control circuit when the lamp is
for conditions that are incorrect for the commanded
commanded ON.
state of the DPD amber lamp. For example, a failure
condition exists if the ECM detects low voltage when
the DPD amber lamp is commanded OFF, or high
voltage when the DPD amber lamp is commanded ON. • The ECM will illuminate the SVS lamp. Refer to
If the ECM detects an improper voltage level on the DTC Type Definitions for Action Taken When the
control circuit, this DTC will set. DTC Sets - Type C.
If the IP cluster has a multi-information display (MID),
the DPD amber lamp is not installed. However, a wire Condition for Clearing the DTC
harness is remaining between the ECM and the IP • Refer to DTC Type Definitions for Condition for
cluster, and the ECM will set the DTC if an improper Clearing the SVS Lamp/ DTC - Type C.
voltage level on the circuit.
Diagnostic Aids
Circuit/ System Testing DTC P1669 (without Multi-information Display)

2 —
4. Turn ON the ignition for 40 seconds while
observing the DTC Information with a scan
tool.
Go to Diagnostic
3 block. —


5 —
Is the DPD lamp OFF? Go to Step 6 Go to Step 12


voltage to the DPD lamp.
6 3. Measure the voltage from the DPD lamp 1 volt

Is the DPD lamp illuminate? Go to Step 11 Go to Step 8

ground.

9 —

IP cluster (pin 40 of FU98 and pin 35 of
10 FU97). —

11 —

13 (pin 35 of FU97). —



15 Driver Info. —


17 —
tool.

18 —
Circuit/ System Testing DTC P1669 (with Multi-information Display)

2 —
tool.
Go to Diagnostic
3 block. —


5 4. Measure the voltage from the DPD lamp 20 volts
Is the voltage more than the specified value? Go to Step 6 Go to Step 7


1. Disconnect the DMM.
2. Connect a test lamp between the ECM
6 harness connector (pin 9 of FB24) to a known —
good ground.

ground.


for the following conditions:.
• An open circuit
• High resistance

10 —

11 —

12 —

13 Driver Info. —



15 —
tool.

16 —

The accelerator pedal position (APP) sensor is • The ECM illuminates the MIL on the second
mounted on the accelerator pedal bracket. The sensor consecutive driving cycle when the diagnostic runs
is made up of two individual sensors within one and fails. Refer to DTC Type Definitions for Action
housing. The ECM uses the APP sensors to determine Taken When the DTC Sets - Type B. (Euro 4
the amount of acceleration or deceleration that is specification)
desired. The APP sensor 1 has the following circuits. • The ECM illuminates the MIL when the diagnostic
• 5 volts reference circuit runs and fails. Refer to DTC Type Definitions for
• Low reference circuit Action Taken When the DTC Sets - Type A.
(Except Euro 4 specification)
• APP sensor 1 signal circuit
The APP sensor 1 provides a signal to the ECM on the • The ECM blinks the exhaust brake indicator lamp
signal circuit, which is relative to the position changes when the diagnostic runs and fails.
of the accelerator pedal angle. If the ECM detects an • The ECM limits fuel injection quantity.
excessively low or high signal voltage, DTC P2122 or • The ECM inhibits exhaust brake control.
P2123 will set.
• The battery voltage is between 18 to 32 volts. Clearing the DTC - Type B. (Euro 4 specification)
• The ECM detects that the APP sensor 1 signal
voltage is less than 0.2 volts. (DTC P2122) Diagnostic Aids
• The ECM detects that the APP sensor 1 signal • If an intermittent condition is suspected, refer to
voltage is more than 4.9 volts. (DTC P2123) Intermittent Conditions in this section.



Fully depress and release the accelerator pedal
while observing the APP Sensor 1 (Accelerator
3 Pedal Position) parameter with a scan tool. 0.2 volts
value during depressing or releasing the pedal? Go to Step 4 Aids

2. Disconnect the APP sensor harness
connector.
ground.
5 and 5 of FL1). 4.5 volts
Is the APP Sensor 1 parameter more than the
Notice: The APP sensor 1 shares the 5 volts
6 ECM (pin 42 of FB24) and the APP sensor —
(pin 4 of FL1) for an open circuit or high
resistance.

63 of FB24) and the APP sensor (pin 5 of FL1)
• An open circuit
7 —
• High resistance

APP sensor (pins 4 and 5 of FL1).
8 —





12 0.2 volts
5. Fully depress and release the accelerator
pedal while observing the APP Sensor 1
Does the scan tool indicate less than the specified

value during depressing or releasing the pedal? Go to Step 3 Go to Step 13
13 —

2 pedal while observing the APP Sensor 1 4.9 volts
(Accelerator Pedal Position) parameter with a
scan tool.
Does the scan tool indicate more than the specified Go to Diagnostic
3 —
connector.
Is the APP Sensor 1 parameter less than the

connector.

6 circuit (pin 6 of FL1) and battery voltage. —

Important: The APP sensor 1 may be damaged if
source.

Notice: The APP sensor 1 shares the low
resistance.

APP sensor (pin 6 of FL1).
9 —




13 4.9 volts

14 —

The accelerator pedal position (APP) sensor is • The ECM illuminates the MIL on the second
mounted on the accelerator pedal bracket. The sensor consecutive driving cycle when the diagnostic runs
is made up of two individual sensors within one and fails. Refer to DTC Type Definitions for Action
housing. The ECM uses the APP sensors to determine Taken When the DTC Sets - Type B. (Euro 4
the amount of acceleration or deceleration that is specification)
desired. The APP sensor 2 has the following circuits. • The ECM illuminates the MIL when the diagnostic
• 5 volts reference circuit runs and fails. Refer to DTC Type Definitions for
• Low reference circuit Action Taken When the DTC Sets - Type A.
(Except Euro 4 specification)
• APP sensor 2 signal circuit
The APP sensor 2 provides a signal to the ECM on the • The ECM blinks the exhaust brake indicator lamp
signal circuit, which is relative to the position changes when the diagnostic runs and fails.
of the accelerator pedal angle. If the ECM detects an • The ECM limits fuel injection quantity.
excessively low or high signal voltage, DTC P2127 or • The ECM inhibits exhaust brake control.
P2128 will set.
• The battery voltage is between 18 to 32 volts. Clearing the DTC - Type B. (Euro 4 specification)
• The ECM detects that the APP sensor 2 signal
voltage is less than 0.2 volts. (DTC P2127) Diagnostic Aids
• The ECM detects that the APP sensor 2 signal • If an intermittent condition is suspected, refer to
voltage is more than 4.9 volts. (DTC P2128) Intermittent Conditions in this section.



while observing the APP Sensor 2 (Accelerator
3 Pedal Position) parameter with a scan tool. 0.2 volts

connector.
ground.
Is the APP Sensor 2 parameter more than the
Notice: The APP sensor 2 shares the 5 volts
resistance.

• An open circuit
7 —
• High resistance

APP sensor (pins 1 and 2 of FL1).
8 —





12 0.2 volts
Does the scan tool indicate less than the specified

13 —

2 pedal while observing the APP Sensor 2 4.9 volts
(Accelerator Pedal Position) parameter with a
scan tool.
3 —
connector.

connector.


Important: The APP sensor 2 may be damaged if
source.

Notice: The APP sensor 2 shares the low
resistance.

APP sensor (pin 3 of FL1).
9 —




13 4.9 volts

14 —

The accelerator pedal position (APP) sensor is • The ECM detects that the APP sensor 1 and 2 are
mounted on the accelerator pedal bracket. The sensor more than 45% out of range of each other.
is made up of two individual sensors within one
housing. The APP sensor 1 and APP sensor 2 are hall Action Taken When the DTC Sets
element type sensors, each with the following circuits. • The ECM illuminates the MIL on the second
• 5 volts reference circuit consecutive driving cycle when the diagnostic runs
• Low reference circuit and fails. Refer to DTC Type Definitions for Action
• Signal circuit Taken When the DTC Sets - Type B. (Euro 4
The ECM supplies 5 volts to the APP sensor on the 5 specification)
volts reference circuit. The ECM also provides a ground • The ECM illuminates the MIL when the diagnostic
on the low reference circuit. The APP sensor provides runs and fails. Refer to DTC Type Definitions for
a signal to the ECM on the signal circuits, which is Action Taken When the DTC Sets - Type A.
relative to the position changes of the accelerator pedal (Except Euro 4 specification)
angle. The APP sensor 1 signal voltage is low at rest • The ECM blinks the exhaust brake indicator lamp
and increases as the pedal is depressed. The APP when the diagnostic runs and fails.
sensor 2 signal voltage is high at rest and decreases as • The ECM inhibits exhaust brake control.
the pedal is depressed. If the ECM detects that the
APP sensor 1 signal voltage and the APP sensor 2 Condition for Clearing the DTC
signal voltage are out of the correlation, this DTC will
set. • Refer to DTC Type Definitions for Condition for
Clearing the DTC - Type B. (Euro 4 specification)
• DTCs P060B, P0641 and P0651 are not set.
specification)
• The APP sensor 1 signal voltage is between 0.2 to • If an intermittent condition is suspected, refer to
4.9 volts. Intermittent Conditions in this section.
• The APP sensor 2 signal voltage is between 0.2 to
4.9 volts. Connector End View Reference: Engine Controls

2 —
Is DTC P0641, P0651, P2122, P2123, P2127 or Go to Applicable

P2128 also set? DTC Go to Step 3
while observing the DTC Information with a scan
3 tool. —
Go to Diagnostic

(APP) sensor harness connector.
connector of the APP sensor (pins 1, 2, 3, 4, 5
and 6 of FL1).
connector of the ECM (pins 41, 42, 60, 61, 63
and 64 of FB24).
6. Test for high resistance on each sensor circuit.
necessary.

63 and 64 of FB24) and the APP sensor (pins
2 and 5 of FL1) for a short circuit each other.
5 —


pedal while observing the DTC Information
with a scan tool.


pedal while observing the DTC Information
with a scan tool.

10 —

DTC P2146 or P2149 (Flash Code 158 or 159)
Circuit Description • The ECM detects that the common 2 fuel injector
The ECM calculates the optimum fuel injection ON time charge voltage circuit is open circuit, shorted to
using data sent from various engine sensors. The ground or shorted to voltage circuit, or cylinder #4,
common 1 and 2 fuel injector charge voltage circuits #5 or #6 fuel injector solenoid coil control circuit is
are high-voltage supply, which drives fuel injectors for shorted to ground. (DTC P2149)
each cylinder in conjunction with the ECM grounding
the fuel injector solenoid control circuit. The common 1 Action Taken When the DTC Sets
covers fuel injectors in cylinders #1, #2 and #3, and the • The ECM illuminates the MIL when the diagnostic
common 2 covers fuel injectors in cylinders #4, #5 and runs and fails. Refer to DTC Type Definitions for
#6. If the common 1 or 2 fuel injector charge voltage Action Taken When the DTC Sets - Type A.
circuit is open circuit, shorted to ground or shorted to • The ECM limits fuel injection quantity.
voltage circuit, DTC P2146 or P2149 will set depending
upon which bank injector common circuit failed. If the
fuel injector solenoid control circuit is shorted to • The ECM inhibits EGR control.
ground, this DTC will also set. • The ECM inhibits cruise control.
Condition for Running the DTC Condition for Clearing the DTC
• DTC P0201, P0202 and P0203 is not set. (DTC • Refer to DTC Type Definitions for Condition for
P2146) Clearing the MIL/ DTC - Type A.
• DTC P0204, P0205 and P0206 is not set. (DTC
P2149) Diagnostic Aids
• The battery voltage is between 18 to 32 volts. • If an intermittent condition is suspected, refer to
• The engine is running. Connector End View Reference: Engine Controls
• The ECM detects that the common 1 fuel injector
charge voltage circuit is open circuit, shorted to
ground or shorted to voltage circuit, or cylinder #1,
#2 or #3 fuel injector solenoid coil control circuit is
shorted to ground. (DTC P2146)

Go to Diagnostic
3 12.0 volts
4. Connect a DMM between the cylinder #1, #2
or #3 solenoid control circuit (pins 2, 6 or 7 of
H78 female side) and a known good ground.

Connect a test lamp between the charge voltage
circuit (pin 3 of H78 female side) and a known good
4 ground. —

circuit (pin 3 of H78 female side) and battery
5 voltage. —

1. Test the control circuits between the ECM and
the in-line harness connector for a short to
ground.
• Cylinder #1: Between pin 119 of E26 and
2 of H78
6 • Cylinder #2: Between pin 114 of E26 and —

7 of H78
6 of H78

1. Test the charge voltage circuits between the
ECM (pin 121 of E26) and the in-line harness
connector (pin 3 of H78) for a short to battery

connector (pin 3 of H78) for a short to ground.
8 —

connection at the in-line harness connector
(pin 3 of H78).
9 4. Inspect for an open circuit or high resistance —
on the charge voltage circuit between the
connector (pin 3 of H78).
necessary.


Mechanical.
terminals.
10 —
(pin 3 of H80).

Measure insulation resistance of the cylinder #1, #2
and #3 fuel injector between each fuel injector
11 terminal and a known good ground. 1 MΩ
Is the resistance more than the specified value? Go to Step 12 Go to Step 13

Repair or replace the fuel injector harness.
12 —
Did you complete the repair or replace? Go to Step 15 —
Important: Replacement injector must be
programmed.
Replace the appropriate fuel injector that was less
13 insulation resistance found at Step 11. Refer to —


Records.

16 —


Go to Diagnostic
3 12.0 volts
4. Connect a DMM between the cylinder #4, #5
or #6 solenoid control circuit (pins 2, 6 or 7 of
H79 female side) and a known good ground.
circuit (pin 3 of H79 female side) and a known good
4 ground. —

circuit (pin 3 of H79 female side) and battery
5 voltage. —

1. Test the control circuits between the ECM and
the in-line harness connector for a short to
ground.
2 of H79
6 • Cylinder #5: Between pin 120 of E26 and —
7 of H79
6 of H79

connector (pin 3 of H79) for a short to battery

connector (pin 3 of H79) for a short to ground.
8 —


(pin 3 of H79).
9 4. Inspect for an open circuit or high resistance —
on the charge voltage circuit between the
connector (pin 3 of H79).
necessary.

Mechanical.
terminals.
10 —
(pin 3 of H81).

Measure insulation resistance of the cylinder #4, #5
and #6 fuel injector between each fuel injector
11 terminal and a known good ground. 1 MΩ
Is the resistance more than the specified value? Go to Step 12 Go to Step 13

Repair or replace the fuel injector harness.
12 —
Did you complete the repair or replace? Go to Step 15 —
Important: Replacement injector must be
programmed.
Replace the appropriate fuel injector that was less
13 insulation resistance found at Step 11. Refer to —


Records.


16 —

DTC P215A (Flash Code 25)
The vehicle speed sensor (VSS) is used by the ECM • The ECM illuminates the MIL when the diagnostic
and other modules, which generates a speed signal runs and fails. Refer to DTC Type Definitions for
from the transmission output shaft rotational speed. Action Taken When the DTC Sets - Type A.
The sensor has the following circuits. • The ECM limits fuel injection quantity.
• Ignition voltage feed circuit • The ECM inhibits pre injection.
• Low reference circuit • The ECM inhibits cruise control.
The VSS uses a hall effect element or magnetic Condition for Clearing the DTC
resistance element (MRE). It interacts with the • Refer to DTC Type Definitions for Condition for
magnetic field created by the rotating magnet and Clearing the MIL/ DTC - Type A.
outputs square wave pulse signal. The ECM calculates
the vehicle speed by the VSS. Diagnostic Aids
The ECM receives the wheel speed information from
the electronic hydraulic control unit (EHCU) [ABS • If an intermittent condition is suspected, refer to
module] or the ABS control unit via a controller area Intermittent Conditions in this section.
network (CAN) communication bus. If the ECM detects • EHCU [ABS module] may output that wheel speed
that the wheel speed from the EHCU or the ABS signal is more than 20 km/h. Refer to Section 4C1
control unit is more than 20 km/h but the vehicle speed ABS/ ASR Air Over Hydraulic Type or Section 4C
signal pulses are not generated, this DTC will set. ABS Full Air Type.
Condition for Running the DTC Notice: If this DTC set, the Vehicle Speed
parameter on the scan tool will display 10 km/h (6
• DTCs P0502, P0503 and P060B are not set.
MPH).
• The ignition switch is ON. Connector End View Reference: Engine Controls
• The wheel speed is more than 20 km/h. Connector End Views or ECM Connector End Views

• The ECM detects that the vehicle speed signal
pulses are not generated for longer than 5
seconds.
Circuit/ System Testing DTC P215A

Go to Applicable
2. Observe the speed meter in the instrument
3 panel (IP) cluster. —
Does the speed meter indicate correct vehicle
1. Drive the vehicle. Go to Diagnostic
2. Monitor the DTC Information with a scan tool. System Check -
ABS Controls in
4 —
Does the DTC fail this ignition? Section 4C1 ABS/
ASR or Section 4C Go to Diagnostic
ABS Full Air Type Aids

Step 6.
1. Inspect the impulse sensor and speed signal
5 distributor. —
Refer to Manual Transmission (ZF) section.

1. Test the vehicle speed sensor signal circuit
between the speed sensor control unit and the
vehicle speed sensor for an open circuit. Refer
to IP Cluster and Warning in Section 9D
6 —
Wiring System.
Did you find and correct the condition ? Go to Step 10 Go to Step 7

• Physical damage
damage

connector.

9 Driver Info. —
Did you complete the replacement ? Go to Step 10 —

Records.

11 —

Circuit Description • The accelerator pedal is not depressed.
The barometric pressure (BARO) sensor is located • The vehicle is not running.
behind of the lower cover. The BARO sensor is a
transducer that varies voltage according to changes the Condition for Setting the DTC
barometric pressure. Within the ECM, the diagnostic • The ECM detects that the differential pressure
compares the BARO sensor input to the boost pressure between the BARO and the boost pressure is more
sensor input. If the ECM detects that the inputs are not than 10 kPa (1.5 psi) for longer than 7 seconds.
within a specified amount of each other, this DTC will
set. Action Taken When the DTC Sets
• DTCs P0102, P0103, P0107, P0108, P0116, Action Taken When the DTC Sets - Type B.
P0117, P0118, P0122, P0123, P0500, P0502,
P0503, P0560, P060B, P0638, P0651, P0697, Condition for Clearing the DTC
P2228 and P2229 are not set.
• The battery voltage is between 18 to 32 volts. Clearing the MIL/ DTC - Type B.
AND following conditions are met longer than 3 Diagnostic Aids
seconds
• The engine speed between 475 to 575 RPM. Intermittent Conditions in this section.
• The fuel injection quantity is less than a
predetermined value. Connector End View Reference: Engine Controls

Go to Applicable
2. Compare the Boost Pressure parameter to the
Barometric Pressure parameter with a scan 10 kPa (1.5
3 tool. psi)
Are both parameter within the range specified of Go to Diagnostic
each other? Aids Go to Step 4
Determine the outside barometric pressure from
your location specified in the altitude vs. barometric
4 Pressure. —
Is the Barometric Pressure parameter on the scan

tool close to the outside barometric pressure? Go to Step 5 Go to Step 7

harness connector.
connector of the boost pressure sensor (pins
1, 2 and 3 of E54).
E26).

(pins 91, 95 and 109 of E26) and the boost
pressure sensor (pins 1, 2 and 3 of E54) for

connector.
connector of the BARO sensor (pins 1, 2 and
3 of FL52).
FB24).

1. Test each sensor circuits between the ECM
(pins 60, 61 and 71 of FB24) and the BARO
sensor (pins 1, 2 and 3 of FL52) for high
8 resistance. —

10 Replacement. —

Records.

12 —

The barometric pressure (BARO) sensor is located • The ECM detects that the BARO sensor signal
behind of the lower cover. The BARO sensor is a voltage is less than 0.5 volts for 5 seconds. (DTC
transducer that varies voltage according to changes the P2228)
barometric pressure. The sensor has the following • The ECM detects that the BARO sensor signal
circuits: voltage is more than 4.0 volts for 5 seconds. (DTC
• 5 volts reference circuit P2229)
• BARO sensor signal circuit
The BARO sensor provides a signal to the ECM on the • The ECM illuminates the MIL when the diagnostic
signal circuit, which is relative to the pressure changes runs and fails. Refer to DTC Type Definitions for
of the barometric pressure. The ECM should detect a Action Taken When the DTC Sets - Type A.
low signal voltage at a low barometric pressure, such • The ECM uses a BARO substitution of default
as high altitude place. The ECM should detect high value.
signal voltage at a high barometric pressure. The ECM • The ECM inhibits EGR control.
uses this voltage signal to calibrate the fuel injection
quantity and injection timing for altitude compensation. Condition for Clearing the DTC
If the ECM detects an excessively low or high signal
voltage, DTC P2228 or P2229 will set. • Refer to DTC Type Definitions for Condition for
Diagnostic Aids


Observe the Barometric Pressure Sensor
3 0.5 volts
Is the Barometric Pressure Sensor parameter less Go to Diagnostic
connector.
ground.

Is the Barometric Pressure Sensor parameter more
Notice: The BARO sensor shares the 5 volts
6 ECM (pin 61 of FB24) and the BARO sensor —
resistance.

71 of FB24) and the BARO sensor (pin 2 of
FL52) for the following conditions:
• An open circuit
7 —
• High resistance

BARO sensor (pins 2 and 3 of FL52).
8 —


10 Replacement. —


Records.

13 —

2 4. Observe the Barometric Pressure Sensor 4.0 volts
Is the Barometric Pressure Sensor parameter more Go to Diagnostic

3 —
connector.
4 0.1 volts
Is the Barometric Pressure Sensor parameter less

than the specified value? Go to DTC P0651 Go to Step 7
connector.
5 0.1 volts
Is the Barometric Pressure Sensor parameter less


Important: The BARO sensor may be damaged if
source.
71 of FB24) and the BARO sensor (pin 2 of
7 FL52) for the following conditions: —

Notice: The BARO sensor shares the low
8 ECM (pin 60 of FB24) and the BARO sensor —
resistance.

BARO sensor (pin 1 of FL52).
9 —


11 Replacement. —

Records.

14 —

DTC P242F (Flash Code 131)
driver by blinking the DPD amber lamp or "PUSH DPD • Refer to DTC Type Definitions for Condition for
SWITCH" indicator on the instrument panel cluster. If Clearing the MIL/ DTC - Type A.
the ECM detects that the exhaust differential pressure
is more than a predetermined range of the calculated Diagnostic Aids
value, this DTC will set. • Misrouted, disconnected or plugged exhaust
differential pressure hoses or pipes may set this
Condition for Running the DTC DTC.
• DTCs P0500, P0502 and P0503 are not set. • If manual regeneration is frequently requested,
• The ignition switch is ON. refer to DPD System Manual Regeneration
Frequently Chart in symptom diagnostic table.
• The exhaust gas temperature 1 (in front of filter) is
more than 100°C (212°F).
Notice: This DTC is caused by incomplete automatic
• The engine speed is more than 1000 RPM. regeneration has occurred and manual regeneration
• The EGR position is less than 95%. urged by the DPD lamp on the IP cluster was
• The intake throttle position is more than 22%. disregarded or forgot, which was most likely caused by
• The DPD filter regeneration is inactive. driver error. Primarily ask the driver about DPD amber
lamp or "PUSH DPD SWITCH" indicator blinking in the
Condition for Setting the DTC past.
• The exhaust differential pressure is more than a

predetermined range of the calculated differential
pressure value for longer than 30 seconds.
Circuit/ System Testing DTC P242F

Ask the driver about DPD amber lamp or "PUSH
DPD SWITCH" indicator blinking in the past.
Explain DPD filter regeneration and lamp action to
the driver as necessary.
2 Notice: If manual regeneration is frequently —
requested, refer to DPD System Manual
Regeneration Frequently Chart in symptom
diagnostic table.


a scan tool.
3 parameter with a scan tool. Make sure the 5.2 kPa
knob clockwise.)
6. Accelerate the engine to W.O.T. (accelerator
to 140°C (284°F).
Is the Exhaust Differential Pressure parameter less


scan tool.

2. Replace the DPD filter. Refer to Exhaust Pipe
5 in Section 1G Engine Exhaust. —

knob clockwise.)
procedure in
7 —

The exhaust differential pressure sensor is attached to • The ECM illuminates the MIL when the diagnostic
the chassis frame near the diesel particulate defuser runs and fails. Refer to DTC Type Definitions for
(DPD) assembly. The exhaust differential pressure Action Taken When the DTC Sets - Type A.
sensor is a transducer that varies voltage according to • The ECM limits fuel injection quantity.
changes of the exhaust gas differential pressure
between in front and in rear of DPD filter. If the ECM
detects that the exhaust differential pressure is certain
pressure low under certain conditions, this DTC will set.
• DTCs P060B, P0697, P2454, P2455 and P2456
Diagnostic Aids
are not set.
• Misrouted, disconnected or plugged exhaust
• The engine coolant temperature is more than 80°C differential pressure hoses or pipes will set this
(176°F). DTC.
• The fuel injection quantity is more than a Connector End View Reference: Engine Controls
predetermined value. Connector End Views or ECM Connector End Views

• The ECM detects that the exhaust differential
pressure is less than 1.15 to 5.56 kPa for longer
than 30 seconds.

2 start the engine. —
Is DTC P2456 set? Go to DTC P2456 Go to Step 3


low exhaust differential pressure.

1G Engine Exhaust.
• Dislocated or inclined exhaust differential
pressure sensor. Refer to Exhaust Pipe
3 port —
pressure sensor
or damaged
pipe, gasket, DPD assembly, exhaust
Exhaust.


1. Remove the DPD filter from the DPD
1G Engine Exhaust.
2. Inspect the DPD filter for damage, cracks or
melt.
3. Inspect the oxidation catalyst for damage or
excessive deposits.
4 —
Important: DPD status in the ECM must be


2. Disconnect the exhaust differential pressure
connector of the exhaust differential pressure
sensor (pins 1, 2 and 3 of FB66).
5 —
FB24).
6. Test each sensor circuit between the ECM and
the exhaust differential pressure sensor for
high resistance.
necessary.


start the engine. (This is to relearn exhaust
7 a scan tool. —
scan tool. If the DPD filter was replaced at
Step 4, skip to Step 9.

knob clockwise.)
to 150°C (302°F).
Is the Exhaust Differential Pressure parameter

9 —

between in front and in rear of DPD filter. If the ECM
detects that the exhaust differential pressure went
excessively high, this DTC will set.
• DTCs P060B, P0697, P2454, P2455 and P2456
Diagnostic Aids
are not set.
• Misrouted, disconnected or plugged exhaust
differential pressure hoses or pipes will set this
DTC.
• The exhaust differential pressure is more than 60
kPa. Connector End View Reference: Engine Controls

2 start the engine. —
Is DTC P2456 set? Go to DTC P2456 Go to Step 3


high exhaust differential pressure.

1G Engine Exhaust.
3 • Any contamination or objects that block —
port
pressure sensor
• Restricted or collapsed exhaust system


4 —
FB24).
6. Test each sensor circuit between the ECM and
the exhaust differential pressure sensor for
high resistance.
necessary.

Important: Clear the DTC and the DPD Status in
the ECM must be reset when the DPD filter is
replaced.
5 Replace the DPD filter. Refer to Exhaust Pipe in —


start the engine. (This is to relearn exhaust
6 3. Clear the DTC and reset the DPD Status with —

a scan tool.
scan tool.

knob clockwise.)
procedure in
8 —

The exhaust differential pressure sensor is attached to • The ECM detects that the exhaust differential
the chassis frame near the diesel particulate defuser pressure sensor signal voltage is less than 0.2
(DPD) assembly. The exhaust differential pressure volts. (DTC P2454)
sensor is a transducer that varies voltage according to • The ECM detects that the exhaust differential
changes of the exhaust gas differential pressure pressure sensor signal voltage is more than 4.9
between in front and in rear of DPD filter. The sensor volts. (DTC P2455)
has the following circuits:
• 5 volts reference circuit Action Taken When the DTC Sets
• Low reference circuit • The ECM illuminates the MIL when the diagnostic
• Exhaust differential pressure sensor signal circuit runs and fails. Refer to DTC Type Definitions for
The exhaust differential pressure sensor provides a Action Taken When the DTC Sets - Type A.
signal to the ECM on the signal circuit, which is relative • The ECM limits fuel injection quantity.
to the differential pressure changes in front and in rear • The ECM inhibits pre injection.
of DPD filter. The ECM should detect a low signal
voltage at a low differential pressure, such as small PM
accumulation. The ECM should detect high signal
voltage at high differential pressure, such as large PM
accumulation. If the ECM detects an excessively low or • Refer to DTC Type Definitions for Condition for
high signal voltage, DTC P2454 or P2455 will set. Clearing the MIL/ DTC - Type A.

• DTCs P060B and P0697 are not set. • If an intermittent condition is suspected, refer to


Observe the Exhaust Differential Pressure Sensor
3 0.2 volts
Is the Exhaust Differential Pressure Sensor Go to Diagnostic
parameter less than the specified value? Go to Step 4 Aids
4 circuit (pin 3 of FB66) and a known good 4.5 volts
ground.

Is the Exhaust Differential Pressure Sensor
parameter more than the specified value? Go to Step 8 Go to Step 7
6 an open circuit or high resistance. —

67 of FB24) and the exhaust differential
pressure sensor (pin 2 of FB66) for the
• An open circuit
• High resistance

exhaust differential pressure sensor (pins 2
8 and 3 of FB66). —





Records.

13 —

2 4. Observe the Exhaust Differential Pressure 4.9 volts
Sensor parameter with a scan tool.
Is the Exhaust Differential Pressure Sensor Go to Diagnostic

parameter more than the specified value? Go to Step 3 Aids
3 —
4 0.1 volts

parameter less than the specified value? Go to DTC P0697 Go to Step 7
5 0.1 volts

6 circuit (pin 1 of FB66) and battery voltage. —

Important: The exhaust differential pressure
sensor may be damaged if the sensor signal circuit
is shorted to a voltage source.
67 of FB24) and the exhaust differential
pressure sensor (pin 2 of FB66) for the
7 following conditions: —


Notice: The exhaust differential pressure sensor
shares the low reference circuit with other sensors.
A fault condition in the low reference circuit may set
an open circuit or high resistance.

exhaust differential pressure sensor (pin 1 of
9 FB66). —





Records.

14 —

between in front and in rear of DPD filter.
The ECM learns a variance of the exhaust differential • The ECM inhibits cruise control.
pressure sensor signal at every ignition cycle after the
ignition switch has been ON with the engine OFF for 30 Condition for Clearing the DTC
seconds. (The DPD lamps or “AUTO REGEN.”, • Refer to DTC Type Definitions for Condition for
“MANUAL REGEN.” indicators on the instrument panel Clearing the MIL/ DTC - Type A.
cluster indicates this transition by commanded to OFF.)
If the ECM detects that learned exhaust differential Diagnostic Aids
pressure is not within a predetermined range, this DTC • If an intermittent condition is suspected, refer to
will set. Intermittent Conditions in this section.
Condition for Running the DTC • A skewed exhaust differential pressure sensor
value can set this DTC. The Exhaust Differential
• DTCs P060B, P0697, P2454 and P2455 are not Pressure Sensor on the scan tool should read 0.9
set. to 1.0 volts with the ignition switch ON and engine
• The battery voltage is between 18 to 32 volts. OFF.
• The engine is stopped.
• The ECM detects that the learned exhaust
differential pressure is not within -4.5 to 4.5 kPa.

Go to Applicable
Is DTC P2454 or P2455 set? DTC Go to Step 3
2. Disconnect a ventilation duct from the exhaust
tail pipe if connected.
3 3. Turn ON the ignition for 30 seconds while —
tool.
Go to Diagnostic

FB24).

(pins 67, 79 and 80 of FB24) and the exhaust
differential pressure sensor (pins 1, 2 and 3 of
5 FB66) for high resistance. —


7 —
tool.

8 —

driver by blinking the DPD amber lamp or “PUSH DPD • Refer to DTC Type Definitions for Condition for
SWITCH” indicator on the instrument panel cluster. Clearing the MIL/ DTC - Type A.
Once the regeneration starts, it must be finished within
a certain time. If the regeneration event is continuously Diagnostic Aids
over a predetermined time, this DTC will set. • Use the Temperature vs. Resistance table to test
the exhaust temperature sensor at various
Condition for Running the DTC temperature levels to evaluate the possibility or a
• DTCs P0079, P0080, P0116, P0117, P0118, skewed sensor.
P0122, P0123, P0201 - P0206, P0335, P0336, • Fuel system problem (e.g. fuel injector damage)
P0404, P0409, P0426, P0427, P0428, P042B, may set this DTC.
P042C, P042D, P0500, P0502, P0503, P060B, • Deteriorated or damaged oxidation catalyst will set
P0638, P0641, P0651, P1261, P1262, P1404, this DTC.
P2146, P2149, P2227, P2228, P2229, P2452 -
• If regeneration time is longer than normal, refer to
P2456 are not set.
DPD System Regeneration Long Time chart in
• The ignition switch is ON. symptom diagnostic table.
• The vehicle is running or the PTO control is
inactive. Notice: Under a driving condition that the exhaust
• The DPD filter regeneration is finished. temperature will not be stable during the DPD filter
regeneration event (e.g. frequent stop and start), this
Condition for Setting the DTC DTC will set.
• The DPD filter regeneration event continuously
exceeds a predetermined time.

2 —

P042B, P042C or P042D set? DTC Go to Step 3

Important: There is installation directionality

in the exhaust differential pressure hoses.
Refer to Exhaust Differential Pressure Sensor
port
pressure sensor
or damaged
3 temperature sensor(s) or exhaust —
Exhaust.
sensors
2. Test the engine cooling system for an
overheating condition. Refer to Cooling
System in Section 1C Engine Cooling for
testing.


4. Observe the DPD Accumulation Status and
DPD Distance Status with a scan tool and plot
both readings on the DPD status table. Refer
to DPD Status Table in DPD Control System
Check.
Is the intersected of a range located in C or D? Go to Step 5 Go to Step 6


2. Clear the DTC and the DPD Status with a
scan tool.

scan tool.

tool.
scan tool.

knob clockwise.)
procedure in
8 —

The power take off (PTO) throttle sensor (body builder • The ECM illuminates the SVS lamp when the
installed) detects the PTO control throttle angle. The diagnostic runs and fails. Refer to DTC Type
ECM receives the PTO control throttle angle from the Definitions for Action Taken When the DTC Sets -
throttle sensor and controls the fuel injection quantity Type C. (Euro 4 specification)
(engine speed) during PTO. The PTO throttle sensor • The ECM illuminates the MIL when the diagnostic
has the following circuits. runs and fails. Refer to DTC Type Definitions for
• 5 volts reference circuit Action Taken When the DTC Sets - Type A.
• Low reference circuit (Except Euro 4 specification)
• PTO throttle sensor signal circuit • The ECM disables PTO throttle sensor control.
The PTO throttle sensor provides a signal to the ECM
on the signal circuit, which is relative to the position Condition for Clearing the DTC
changes of the PTO throttle angle. If the ECM detects • Refer to DTC Type Definitions for Condition for
an excessively high signal voltage, this DTC will set. Clearing the SVS Lamp/ DTC - Type C. (Euro 4
specification)
• DTCs P060B and P0641 are not set. Clearing the MIL/ DTC - Type A. (Except Euro 4
• The battery voltage is between 18 to 32 volts. specification)
Diagnostic Aids
Condition for Setting the DTC • If an intermittent condition is suspected, refer to
• The ECM detects that the PTO throttle sensor
signal voltage is more than 4.8 volts. • PTO throttle sensor may have an intermittent open
somewhere in the operating range.


Notice: If no PTO throttle sensor is installed,

2 skip to Step 3. 4.8 volts
4. Observe the PTO Remote Throttle Sensor
parameter with a scan tool while operating the
PTO throttle sensor.
value during operating the throttle? Go to Step 3 Aids
3 —
Is the DTC P0641 also set? Go to Step 4 Go to Step 5
2. Disconnect the PTO throttle sensor harness
connector.
4 0.1 volts
Is the PTO Remote Throttle Sensor parameter less

than the specified value? Go to DTC P0641 Go to Step 7

2. Disconnect the PTO throttle sensor harness
connector.
5 0.1 volts
Is the PTO Remote Throttle Sensor parameter less

6 circuit (pin 1 of FB129) and battery voltage. —
Important: The PTO throttle sensor may be
voltage source.
70 of FB24) and the PTO throttle sensor (pin 2
7 of FB129) for the following conditions: —

Notice: The PTO throttle sensor shares the low
8 ECM (pin 41 of FB24) and the PTO throttle —
sensor (pin 1 of FB129) for an open circuit or
high resistance.

PTO throttle sensor (pin 1 of FB129).
9 —


Replace the PTO throttle sensor.
11 —


13 4.8 volts
5. Observe the PTO Remote Throttle Sensor
parameter with a scan tool while operating the
PTO throttle sensor.

value during operating the throttle? Go to Step 3 Go to Step 14
14 —

The idle up sensor controls the idle speed during warm • The ECM illuminates the SVS lamp when the
up and it is installed in the driver’s side instrument diagnostic runs and fails. Refer to DTC Type
panel. This sensor is active only when the gear position Definitions for Action Taken When the DTC Sets -
is in the neutral position. When the shift lever is moved Type C. (Euro 4 specification)
to another position, the signal is ignored. The ECM • The ECM illuminates the MIL when the diagnostic
receives the idle up signal from the idle up sensor and runs and fails. Refer to DTC Type Definitions for
controls the fuel injection quantity. The idle up sensor Action Taken When the DTC Sets - Type A.
has following circuits (Except Euro 4 specification)
• 5 volts reference circuit • The ECM disables idle up sensor control.
• Idle up sensor signal circuit Condition for Clearing the DTC
The idle up sensor provides a signal to the ECM on the • Refer to DTC Type Definitions for Condition for
signal circuit, which is relative to the position changes Clearing the SVS Lamp/ DTC - Type C. (Euro 4
of the idle up sensor angle. If the ECM detects an specification)
excessively low or high signal voltage, this DTC will set. • Refer to DTC Type Definitions for Condition for
Condition for Running the DTC specification)
• The battery voltage is between 18 to 32 volts. Diagnostic Aids
Condition for Setting the DTC • Idle up sensor may have an intermittent open
Either of following condition is met: somewhere in the operating range.
• The ECM detects that the idle up sensor signal
voltage is less than 0.1 volts for longer than 3
seconds.
• The ECM detects that the idle up sensor signal
voltage is more than 4.9 volts for longer than 3
seconds.

4. Fully turn the idle up sensor between lowest
position (full counterclockwise direction) and
2 0.2 to 4.8 volts
highest position (full clockwise direction) while
observing the Idle Up Sensor parameter with a
scan tool.
Does the scan tool indicate within the specified Go to Diagnostic

value during turning the sensor? Aids Go to Step 3
3 —
Is the Idle Up Sensor parameter less than the
4 0.1 volts
specified value at Step 2? Go to DTC P0641 Go to Step 8

Turn the idle up sensor to lowest position (full
counterclockwise direction).
5 0.1 volts
connector.
ground.
Is the Idle Up Sensor parameter more than the
connector.

connector.

Notice: The idle up sensor shares the 5 volts
11 ECM (pin 42 of FB24) and the idle up sensor —
resistance.

66 of FB24) and the idle up sensor (pin 2 of
FL33) for the following conditions:
• An open circuit
12 —
• High resistance


Important: The idle up sensor may be damaged if
source.
66 of FB24) and the idle up sensor (pin 2 of
13 FL33) for the following conditions: —

Notice: The idle up sensor shares the low
14 ECM (pin 41 of FB24) and the idle up sensor —
resistance.

Idle up sensor (pins 1, 2 and 3 of FL33).
15 —

ECM (pins 41, 42 and 66 of FB24).

Replace the idle up sensor. Refer to Idle Up Sensor
17 in Section 1I Engine Speed Control System. —

19 5. Fully turn the idle up sensor between lowest 0.2 to 4.8 volts
position (full counterclockwise direction) and
highest position (full clockwise direction) while
observing the Idle Up Sensor parameter with a
scan tool.

value during turning the sensor? Go to Step 20 Go to Step 3

20 —

DTC U0073 (Flash Code 84)
The ECM, the rotary electric actuator (REA), the runs and fails. Refer to DTC Type Definitions for
electric hydraulic control unit (EHCU) or ABS control Action Taken When the DTC Sets - Type A.
unit, the transmission control module (TCM), the body (Except Euro 4 specification)
control module (BCM) or the data recording module • The ECM blinks the exhaust brake indicator lamp
(DRM) and instrument panel (IP) cluster communicate when the diagnostic runs and fails.
control and diagnostic information via a controller area • The ECM limits fuel injection quantity.
network (CAN) communication bus. The ECM monitors • The ECM inhibits exhaust brake control.
CAN operational status by expecting a constant flow of
messages from each module. If the ECM sets CAN Bus • The ECM inhibits cruise control.
OFF status, this DTC will set.
• The battery voltage is more than 20 volts. Clearing the MIL/ DTC - Type B. (Euro 4
specification)
specification)
• The ECM sets the CAN Bus OFF status.
Diagnostic Aids
• The ECM illuminates the MIL on the second Intermittent Conditions in this section.
• Parallel resistance of the 120 Ω resistor in the
ECM and the IP cluster should be 60 Ω.
specification)
Circuit/ System Testing DTC U0073

Go to Diagnostic
Notice: If no rotary electric actuator (REA) is
2. Disconnect the rotary electric actuator E10
3 harness connector. —
Is DTC U0110 set, but not DTC U0073? Go to Step 11 Go to Step 4


Notice: If no ABS is installed, skip to Step 5.
2. Reconnect the rotary electric actuator E10
harness connector if disconnected.
3. Disconnect the electric hydraulic control unit
4 (EHCU) J7 or ABS control unit FU2 harness —
connector.
Is DTC U0073 set? Go to Step 5 Go to Step 12

Notice: If no Smoother transmission is installed,
skip to Step 6.
3. Reconnect the EHCU J7 or ABS control unit
5 FU2 harness connector if disconnected. —
4. Disconnect the TCM FU108 harness
connector.
Is DTC P0101 set, but not DTC U0073? Go to Step 15 Go to Step 6

Notice: If no multi-information display is installed,
skip to Step 7.
2. Reconnect the TCM FU108 harness
6 3. Disconnect the body control module (BCM) —
FL105 harness connector.

3. Reconnect the EHCU J7 or ABS control unit
FU2 harness connector if disconnected.
4. Reconnect the TCM FU108 harness
7 connector if disconnected. —
5. Disconnect the data recording module (DRM)
FL101 harness connector.


2. Reconnect the BCM FL105 or DRM FL101
3. Remove the bezel surrounding the instrument
panel (IP) cluster enough to remove the IP
cluster.
8 —
4. Disconnect the IP cluster FU97 harness
connector.

1. Test the CAN Low and High circuits among
each control module for the following
conditions:

10 Info. —

turbocharger.) Refer to Turbocharger in Section 1J
11 Induction. —

Important: Replacement EHCU must be
programmed.
Replace the EHCU or ABS control unit. Refer to
12 EHCU in Section 4C1 ABS/ ASR or ABS Control —
Unit in Section 4C ABS.

Important: Replacement BCM must be
programmed.
13 Replace the BCM. Refer to BCM in Section 10B —
Vehicle Control.

Replace the DRM.
14 —
Important: Replacement TCM must be
15 Replace the TCM. Refer to TCM Replacement in —
Section 5A Transmission Control System



components or harness connector(s).
Records.

18 —

The ECM and the transmission control module (TCM) runs and fails. Refer to DTC Type Definitions for
communicate control and diagnostic information via a Action Taken When the DTC Sets - Type A.
controller area network (CAN) communication bus. The (Except Euro 4 specification)
ECM monitors CAN operational status by expecting a • The ECM blinks the exhaust brake indicator lamp
constant flow of messages from each module. If the when the diagnostic runs and fails.
ECM fails to receive an expected message from the • The ECM inhibits exhaust brake control.
TCM, this DTC will set.
• DTC U0073 is not set. Clearing the SVS Lamp/ DTC - Type C. (Euro 4
• The battery voltage is more than 20 volts. specification)
• The ECM detects that the CAN Bus messages
Diagnostic Aids
from the TCM are not being received.
Action Taken When the DTC Sets Intermittent Conditions in this section.

Go to Applicable
Is DTC U0073 or U0110 also set? DTC Go to Step 3
Attempt to communicate with the transmission Go to Diagnostic
control module (TCM) via the transmission data System Check -
table. Transmission
3 —
Controls in Section
Does the scan tool communicate with the TCM? 5A Transmission
Go to Step 4 Control System
2. Disconnect the TCM FU108 harness
connector.
4. Connect a DMM between the CAN Low circuit
4 (pin 13 of FU108) and a known good ground. 1.5 to 3.5 volts
5. Connect a DMM between the CAN High circuit

(pin 12 of FU108) and a known good ground.
Are both voltage readings within the specified


CAN Low and High circuits (which ever voltage
reading did not read within the specified value at
5 Step 4) between the TCM (pins 12 and 13 of —
FU108) and the CAN joint connectors.

connector of the TCM (pins 12 and 13 of
6 FU108). —

Important: Replacement TCM must be
7 Replace the TCM. Refer to TCM in Section 5A —
Transmission Control System.

Records.

9 —

The ECM and the rotary electric actuator (REA) • The ECM illuminates the MIL when the diagnostic
communicate control and diagnostic information via a runs and fails. Refer to DTC Type Definitions for
controller area network (CAN) communication bus. Action Taken When the DTC Sets - Type A.
REA is internal to turbocharger. The ECM monitors • The ECM inhibits cruise control.
CAN operational status by expecting a constant flow of
messages from the REA. If the ECM receive an Condition for Clearing the DTC
expected message from the REA, this DTC will set.
• DTC U0073 is not set. Diagnostic Aids
• The battery voltage is more than 20 volts. • If an intermittent condition is suspected, refer to
Condition for Setting the DTC Connector End View Reference: Engine Controls
• The ECM detects that the CAN Bus messages Connector End Views or ECM Connector End Views
from the REA are not being received.

Go to Applicable
Is DTC U0073 or P0045 also set? DTC Go to Step 3
3. Measure the resistance across the CAN Low
3 and High circuits (pins 1 and 4 of E10). 50 to 70 Ω
Is the resistance within the specified value (parallel
resistance of the 120 Ω resistor in the ECM and the
IP cluster should be 60 Ω)? Go to Step 8 Go to Step 4
1. Leave the DMM connected to the REA
harness connector.
4 2. Disconnect the IP cluster harness connector. 110 to 130 Ω

Measure the resistance of the IP cluster (pins 13
5 and 14 of FU97). 110 to 130 Ω

2. Disconnect the electronic hydraulic control
unit (EHCU) or ABS control unit harness
connector if installed.
3. Disconnect the transmission control module
(TCM) harness connectors if installed.
4. Disconnect the data recording module (DRM)
or body control module (BCM) harness
connector.
6. Connect a DMM between the CAN Low circuit
6 (pin 4 of E10) and a known good ground. 1.5 to 3.5 volts
7. Connect a DMM between the CAN High circuit

8. Test the CAN Low and High circuits (which
ever voltage reading did not read within the
specified value) between the ECM (pins 18
and 37 of FB24) and the REA (pins 1 and 4 of
E10) for an open circuit or high resistance.
9. Repair the circuit(s) or connection(s) as
necessary.

1. Test the CAN Low and High circuits between
the IP cluster (pins 13 and 14 of FU97) and
the joint connection for an open circuit or high
resistance.
connector of the IP cluster (pins 13 and 14 of
FU97).
3. Repair the circuit(s) or connection(s) as
necessary.

1. Connect a DMM between the ignition voltage
feed circuit to the REA (pin 3 of E10) and a
known good ground.
8 20.0 volts
Connect a DMM across the ignition voltage feed
9 circuit and ground circuit (pins 3 and 6 of E10). 20.0 volts
the ECM MAIN (15A) fuse and the REA (pin 3 of
10 E10). Check the ECM MAIN (15A) fuse first. —

the REA (pin 6 of E10) and the ground terminal
11 (E20). Clean or tighten ground as necessary. —


12 connector of the REA (pins 1, 3, 4 and 6 of —
E10).

13 connector of the ECM (pins 18 and 37 of —
FB24).

14 Info. —


turbocharger). Refer to Turbocharger in Section 1J
16 Induction. —

Records.

18 —

The ECM communicates with the immobilizer control runs and fails. Refer to DTC Type Definitions for
unit (ICU) to execute immobilizer function. The ECM Action Taken When the DTC Sets - Type A.
sends a request signal to the ICU. The ECM receives a (Except Euro 4 specification)
response signal from the ICU. Both communication
signals are carried out via a controller area network Condition for Clearing the DTC
(CAN) communication bus. If the ECM does not detect • Refer to DTC Type Definitions for Condition for
a response signal from the ICU, this DTC will set. Clearing the SVS Lamp/ DTC - Type C. (Euro 4
specification)
Condition for Setting the DTC • Refer to DTC Type Definitions for Condition for
• The ECM does not receive a signal from the ICU. Clearing the MIL/ DTC - Type A. (Except Euro 4
specification)
Diagnostic Aids
diagnostic runs and fails. Refer to DTC Type • If an intermittent condition is suspected, refer to
Definitions for Action Taken When the DTC Sets - Intermittent Conditions in this section.
Type C. (Euro 4 specification) • Electromagnetic interference may affect
intermittent condition.
• Any communication fault with the ICU may set this
DTC.

Attempt to communicate with the immobilizer Go to Diagnostic
control unit (ICU) via the Immobilizer Data table. System Check -
2 — Immobilizer
Does the scan tool communicate with the ICU? Controls in Section
Go to Step 3 9I Security and Lock
Monitor the immobilizer DTC Information with a
scan tool. Go to Applicable
3 — DTC for Immobilizer
Does the immobilizer DTCs fail this ignition? Section Go to Step 4

5 —

6 —

EGR Control System Check
Description EGR Control Operation
The EGR system recirculates a part of exhaust gas • The engine coolant temperature (ECT) is between
back into the intake manifold, which results in reducing 70 to 100°C (158 to 212°F).
NOx emissions. The EGR control system uses an • The intake air temperature (IAT) is more than 0°C
electronic control system to ensure both driveability (32°F).
and low emission. A control current from the ECM
• The barometric pressure (BARO) is more than 90
operates a motor to control the lift amount of EGR
kPa (13 psi).
valve. Also, EGR position sensors are provided at the
rear of the motor to feed actual valve lift amount back to
the ECM for more precision control.
The EGR control starts when the conditions for engine
speed, engine coolant temperature, intake air
temperature and barometric pressure are satisfied.
Then, the valve opening is calculated according to the
engine speed, and target fuel injection quantity. Based
on this valve opening, the drive duty of the motor is
determined and the valve is driven accordingly.
Circuit/ System Testing EGR Control System Check

2 4. Monitor the DTC Information with a scan tool. —
Are any DTCs set in which the "Action Taken When

the DTC Sets" under that particular code states, Go to Applicable
"The ECM inhibits EGR control"? DTC Go to Step 3

• An EGR valve gasket that is missing or
damaged
• EGR gas leakage any of the EGR
passage between the exhaust manifold
and intake manifold
• Restricted or collapsed EGR passage
between the exhaust manifold and the
EGR valve
system
3 system —
• Skewed engine coolant temperature
(ECT) sensor. Refer to Temperature vs.
Resistance table to test the ECT sensor
at various temperature levels to evaluate
the possibility of a skewed sensor.
• Skewed barometric pressure (BARO)
sensor. Determine the outside barometric
pressure from you location specified in
the altitude vs. barometric pressure table.
Refer to Altitude vs. Barometric
Pressure.
• A sticking intake throttle valve
2. Repair the condition as necessary.

parking brake.
2. Start the engine and warm up (arrow engine
coolant temperature to reach at least 75°C
[167°F]).
4 W.O.T (accelerator pedal full travel) many ± 5%
times while observing the Desired EGR
Position and EGR Position parameter with a
scan tool.
Does the EGR Position parameter follow within the

tool several times.
2. Command the Desired EGR Position Increase If Euro 4
and Decrease while observing the EGR specification, go to
5 ± 5%
Position. Step 6
If except Euro 4
Does the EGR Position parameter follow within the specification,
specified value quick enough? system OK Go to Step 7

1. Perform the Intake Throttle Solenoid Control
with a scan tool several times.
2. Command the Desired Intake Throttle Position
6 Increase and Decrease while observing the ± 5%
Intake Throttle Position.
Does the Intake Throttle Position parameter follow

within the specified value quick enough? System OK Go to Step 9
engine.
conditions:
7 materials —
• Bent valve shaft

6, 7 and 8 of E45).
101 103, 110 and 111 of E26).
necessary.

1. Remove the intake duct that is connected to
the intake throttle valve.
2. Inspect the intake throttle valve for the
• Restricted intake throttle valve by foreign
materials
9 • Excessive deposits at throttle bore —
• Bent butterfly valve
Notice: Replace the intake throttle valve if

there is any sticking.


connector.
connector of the intake throttle valve (pins 1,
2, 4, 5 and 6 of E46).
connector of the ECM (pins 85, 95, 104, 109
and 112 of E26).
necessary.

11 —
Reconnect all previously disconnected components
13 or harness connector(s). —

Glow Control System Check
Description Glow Control Operation
The glow control system consists of the ECM, the glow • The glow plug lamp illuminates between 1.5
relay, the glow plug lamp and glow plugs. The glow seconds to approximately 10 seconds depending
control system is operated when the engine coolant upon the engine coolant temperature. It illuminates
temperature is low, which allows easier engine starting. 1.5 seconds at -5°C (23°F) or more.
The ECM commands the glow relay ON for a certain • In pre glow phase, the glow relay energizes
length of time at ignition switch is ON with engine OFF. between 3 seconds to approximately 15 seconds
In after glow phase, the glow plugs remain energized depending upon the engine coolant temperature.
for a certain period with engine run.
• In after glow phase, the glow relay energizes
between 3 seconds to approximately 30 seconds
depending upon the engine coolant temperature.

Circuit/ System Testing Glow Control System Check

Go to Applicable
Is DTC P0117, P0118, P0380 or P0381 set? DTC Go to Step 3
2. Make sure the metal bus bar that connects
switched battery voltage supply terminal (E31)
and all glow plugs is secured tightly.
4. Connect a test lamp between the metal bus
bar (glow plug power supply E31 terminal) and
3 a known good ground. —
tool.
6. Command the relay ON while observing the
test lamp.
Does the test lamp turn ON only when commanded

ON? Go to Step 4 Go to Step 5
2. Remove the metal bus bar from the glow
plugs.
3. Measure resistance of each glow plug
between the glow plug terminals and a known
4 good ground. Make sure to record all 1Ω
measurements and take them quickly as to
not allow engine temperature changes
between measurements.
Are the resistances within the specified value each

other? System OK Go to Step 15

2. Replace the glow relay with the starter relay or
replace with a known good relay.
bar (glow plug power supply E31 connector)
5 and a known good ground. —
tool.
test lamp.

Inspect the Glow (60A) slow blow fuse in the
6 chassis side fuse & relay box. —
Is the Glow (60A) slow blow fuse open? Go to Step 7 Go to Step 8
Replace the Glow (60A) slow blow fuse. If the slow
blow fuse continues to open, repair the short to
7 ground on a circuit fed by the slow blow fuse or —
check for a shorted attached component.

3. Connect a test lamp between the battery
8 —
voltage feed circuit of the relay (pin 1 of X19)

1. Connect a test lamp between the voltage
supply circuit of glow plugs (pin 2 of X19) and
a known good ground.
9 —

the Glow (60A) slow blow fuse and the glow relay
10 (pin 1 of X19). —

the glow relay (pin 2 of X19) and the glow plugs
11 (E31 terminal). —

Important: The glow plugs may be burnt out if the
battery voltage supply circuit is shorted to a voltage
source.
12 Repair the short to battery or ignition voltage —
between the glow relay (pin 2 of X19) and the glow
plugs (E31 terminal).

13 connection on each glow relay terminal. —


Replace the glow relay.
14 —
Replace the appropriate glow plug.
15 —
components, relay, fuse or harness
connector(s).
bar (glow plug power supply E31 connector)
16 and a known good ground. —
tool.
test lamp.


Exhaust Brake Control System Check
Description Test Description
The exhaust brake control system consists of the ECM, The number below refers to the step number on the
the intake throttle valve, the exhaust brake valve, the Circuit/ System Table.
exhaust brake solenoid valve and the exhaust brake 4. Use the scan tool to observe the Accelerator Pedal
switch. The ECM commands the intake throttle motor Position. The Accelerator Pedal Position parameter
and the exhaust brake solenoid valve to close each should change linearly from 0 to 100% according to the
valve based on vehicle running conditions and exhaust accelerator pedal operation.
brake switch input signal. 8. If the Exhaust Brake Solenoid Command parameter
indicates OFF, use the scan tool to observe the Vehicle
Exhaust Brake Control Operation Speed, Accelerator Pedal Position and Clutch Pedal
• The exhaust brake switch is ON. Switch parameters which allows the exhaust brake
control. Refer to engine control wirings and Scan Tool
Data List for diagnosis.
• The accelerator pedal is not depressed.
• The clutch pedal is not depressed (manual Connector End View Reference: Engine Controls
transmission). Connector End Views or ECM Connector End Views
• The vehicle speed is higher than predetermined
range.
Circuit/ System Testing Exhaust Brake Control System Check (1 of 2)

2 —
3. Apply the exhaust brake switch ON and OFF.
Does the exhaust brake indicator lamp turn ON and

OFF with each switch transition? Go to Step 3 Go to 2 of 2 Step 1
1. Drive the vehicle in order to gain exhaust
brake ON time long enough.
2. Apply the exhaust brake switch ON.
3. Release the accelerator pedal.
3 —
Does exhaust brake apply enough (if the vehicle
speed is reduced by applying the exhaust brake but
engine valve noise is heard, intake throttle valve
may not be closed enough)? Go to Step 4 Go to Step 7
1. Reenter the exhaust brake control. Observe the
2. Apply the accelerator pedal while in exhaust Accelerator Pedal
brake control. Position parameter
4 —
for accelerator pedal
Does the exhaust brake control cancel? position sensor
Go to Step 5 diagnosis
Notice: If no Smoother is installed, skip to Step 6. Go to Diagnostic
1. Reenter the exhaust brake control. System Check -
5 2. Operate the selector lever while in exhaust — Transmission
brake control. Controls in Section
5A Transmission
Does the exhaust brake control cancel? System OK Control System
1. Reenter the exhaust brake control.
2. Apply the clutch pedal while in exhaust brake
6 control. —
Does the exhaust brake control cancel? System OK Go to Step 9


1. Park the vehicle.
7 —
Are any DTCs set in which the “Action Taken When

the DTC Sets” under that particular code states, Go to Applicable
“The ECM inhibits exhaust brake control”? DTC Go to Step 8
1. Reenter the exhaust brake control.
2. Trigger the Snapshot function in order to
capture and store engine parameters while in
exhaust brake control.
8 3. Review the Exhaust Brake Valve Command —
parameter. The ECM is not
allowing exhaust
Does the Exhaust Brake Valve Command brake control. Refer
parameter indicate ON when the exhaust brake to Exhaust Brake
may operate enough? Go to Step 18 Control Operation
3. Observe the Clutch Pedal Switch parameter
with a scan tool while fully depressing and
9 —
releasing the clutch pedal.
Does the scan tool indicate Applied when the clutch

pedal is applied and Released when the clutch
1. Check to ensure the clutch pedal switch is
adjusted correctly. The plunger should be all
the way in when the pedal is released, yet
should not impede with the clutch pedal full
10 —
upward travel.
2. Adjust the clutch pedal switch as necessary.

2. Disconnect the clutch pedal switch harness
connector.
11 —
voltage feed circuit (pin 1 of FU179) and a
known good ground.

Observe the Clutch Pedal Switch parameter with a
scan tool while momentarily jumping 3-amp fused
jumper wire across the switch harness connector
12 between pins 1 and 2 of the FU179. —
Does the scan tool indicate Released when the
circuit is jumpered and Applied when the circuit is
not jumpered? Go to Step 15 Go to Step 14
the Engine Controller (10A) fuse and the switch
13 (pin 1 of FU179). —


26 of FB24) and the switch (pin 2 of FU179)
• An open circuit
• High resistance

switch (pins 1 and 2 of FU179).
15 —


Replace clutch pedal switch. Refer to Clutch
17 Control in Section 5E Clutch. —
1. Perform the Exhaust Brake Control with a Problem is relating
scan tool. to solenoid valve,
2. Command the solenoid ON and OFF. solenoid valve
wiring or exhaust
Does the solenoid valve click with each command? brake valve stuck.
Or faulty air
18 —
pressure lines.
Refer to applicable
diagnostic chart in
Section 1G Engine
Exhaust or engine
control wirings. Go to Step 19
2. Disconnect the exhaust brake solenoid valve
harness connector.
19 —
voltage feed circuit (pin 1 of J8, FB41) and a
known good ground.

1. Connect a test lamp across the exhaust brake
solenoid valve harness connector (pins 1 and
2 of J8, FB41).
2. Perform the Exhaust Brake Control with a
20 scan tool. —
3. Command the solenoid ON and OFF.
Does the test lamp turn ON and OFF with each

Does the test lamp remain illuminate with each
21 —

the ECM Main (15A) fuse and the solenoid valve
22 (pin 1 of J8, FB41). —

15 of FB24) and the solenoid valve (pin 2 of
J8, FB41) for the following conditions:
• An open circuit
• High resistance

15 of FB24) and the solenoid valve (pin 2 of
J8, FB41) for a short to ground.
24 —
Did you find and correct the condition? Go to Step 29 —

solenoid valve (pins 1 and 2 of J8, FB41).
25 —


Replace the exhaust brake solenoid valve.
27 —

Reconnect all previously disconnected
29 components, fuse or harness connector(s). —
Circuit/ System Testing Exhaust Brake Control System Check (2 of 2)

3. Apply the exhaust brake switch ON and OFF
1 while observing the Exhaust Brake Switch —
Does the scan tool indicate ON and OFF with each

switch transition? Go to Step 2 Go to Step 3

Does the exhaust brake indicator lamp always ON
2 —
with each switch transition? Go to Step 10 Go to Step 11
2. Disconnect the combination switch harness
connector (FL73).
3 circuit of combination switch harness (pin 13 —
of FL73) and a known good ground.

Observe the Exhaust Brake Switch parameter with
a scan tool while momentarily jumping 3-amp fused
jumper wire across the switch harness connector
4 between pins 13 and 15 of FL73. —
Does the scan tool indicate ON when the circuit is
jumpered and OFF when the circuit is not
jumpered? Go to Step 7 Go to Step 6
5 (pin 13 of FL73). Check the Engine Controller (10A) —
fuse first.

45 of FB24) and the switch (pin 15 of FL73) for
• An open circuit
• High resistance

switch (pins 13 and 15 of FL73).
7 —

8 —

Repair or replace the combination switch.
9 —
Is the exhaust brake indicator lamp OFF? Go to Step 19 Go to Step 16


voltage to the exhaust brake indicator lamp.
11 1 volt
5. Measure the voltage from the exhaust brake
indicator lamp control circuit in the ECM
harness connector (pin 7 of FB24) to a known
good ground.

Is the exhaust brake indicator lamp illuminate? Go to Step 15 Go to Step 13

13 —

connection at the harness connector of the IP
cluster (pin 13 of FU98).
14 —

15 —

17 (pin 13 of FU98). —

18 Driver Info. —


Did you complete the action? Go to 1 of 2 Step 2 —

Cruise Control System Check
Description 4. Function of "ACCEL"
The cruise control system consists of the ECM, the If the resume/ accel. switch is turned to RES (+) while
cruise control main switch, set/ coast switch, resume/ the cruise control system is operating, the vehicle
accel. switch and cancel switch. The cruise control speed is increased. Then, when the resume/ accel.
keeps the vehicle speed at a driver's set speed. When switch is released, the vehicle will maintain the vehicle
the cruise control main switch is pressed ON, signal is speed at that time.
provided to the ECM and the cruise control main 5. Function of "TAP UP"
indicator lamp on the instrument panel cluster will light If the resume/ accel. switch is tapped (momentarily
up. When the cruise set/ coast switch is turned to SET turned) while the cruise control system is operating, the
(-), the switch signal is provided to the ECM and the vehicle speed is increased 1 km/h (0.6 MPH) at a time.
vehicle speed is set. The vehicle speed is increased or 6. Function of "TAP DOWN"
decreased if the set/ coast switch or the resume/ accel. If the set/ coast switch is tapped (momentarily turned)
switch is turned to RES (+) or SET (-). When the cruise while the cruise control system is operating, the vehicle
cancel switch is applied, the switch signal is provided to speed is decreased 1 km/h (0.6 MPH).
the ECM and the cruise control system is inactive. 7. Function of Temporary Acceleration
If the accelerator pedal is depressed while the cruise
Condition for Running the Cruise Control control system is operating, the vehicle speed is
increased.
• The vehicle speed is between approximately 40 to 8. Function of Temporary Cancellation
60 km/h (25 to 37 MPH). (Speed limiter setting 60 The cruise control is canceled temporarily if any of the
km/h [37 MPH]) following condition is met:
• The vehicle speed is between approximately 40 to • The cruise cancel switch is applied.
70 km/h (25 to 43 MPH). (Speed limiter setting 70
• The brake pedal is depressed.
km/h [43 MPH])
• The selector lever is operated.
• The vehicle speed is between approximately 40 to
80 km/h (25 to 50 MPH). (Speed limiter setting 80 • The exhaust brake is applied.
km/h [50 MPH]) • The actual vehicle speed becomes less than
• The vehicle speed is between approximately 40 to approximately 40 km/h (25 MPH).
85 km/h (25 to 53 MPH). (Speed limiter setting 85 • The actual vehicle speed is more than 40 km/h (25
km/h [53 MPH]) MPH) below the set speed.
• The vehicle speed is between approximately 40 to By applying the resume/ accel. switch, the vehicle
90 km/h (25 to 56 MPH). (Speed limiter setting 90 speed is returned to the vehicle speed memorized by
km/h [56 MPH]) the ECM (resume function) if within the condition for
running the cruise control are satisfied.
• The vehicle speed is between approximately 40 to
9. Function of Complete Cancellation
100 km/h (25 to 62 MPH). (Speed limiter setting
The cruise control is canceled completely if any of the
100 km/h [62 MPH])
following condition is met:
• The cruise control main switch is ON.
• The cruise control main switch is OFF.
1. Function of "SET"
If the set/ coast switch is turned to SET (-) and released • The ignition switch is OFF.
while condition for running the cruise control are • The DTCs relating to the cruise control system
satisfied, the ECM memorize and maintain the vehicle inhibits are set.
speed at that time.
2. Function of "COAST" Connector End View Reference: Engine Controls
If the set/ coast switch is turned to SET (-) while the Connector End Views or ECM Connector End Views
cruise control system is operating, the vehicle speed is
decreased. Then, when the set/ coast switch is
released, the vehicle will maintain the vehicle speed at
that time.
3. Function of "RESUME"
If the resume/ accel. switch is turned to RES (+) while
the cruise control system is operating and the ECM
memorizes the vehicle speed, the vehicle speed is
returned to the vehicle speed memorized by the ECM.

Circuit/ System Testing Cruise Control System Check

1. Drive the vehicle at 50 km/h (30 MPH) on a
flat level road.
2. Press and release the cruise control main
switch.
3. Turn and release the cruise set/ coast switch.
4. Verify the 50 km/h (30 MPH) vehicle speed is
2 maintained. —
5. Tap (momentarily turn) the cruise set/ coast
switch 10 times.
Did the vehicle maintain the set speed of 50 km/h

(30 MPH), and then decreased by 1 km/h (0.6
MPH) each time the switch was tapped
(momentarily turned to SET [-])? Go to Step 3 Go to Step 7
Tap (momentarily turn) the cruise resume/ accel.
switch 10 times.
3 Does the vehicle speed increase 1 km/h (0.6 MPH) —
each time the switch was tapped (momentarily
turned to RES [+])? Go to Step 4 Go to Step 10
Are the cruise control main and set lamps in the IP Refer to Cab and
cluster illuminated while in cruise control? Chassis Electrical
4 — Section for IP
cluster circuits
Go to Step 5 diagnosis
Press and release the cruise cancel switch.
5 —
Does the cruise control cancel? Go to Step 6 Go to Step 11
1. Reenter the cruise control. ECM does not
2. Depress and release the brake pedal. support brake
switch parameters
Does the cruise control cancel? on the scan tool.
Use transmission
data display and
6 — refer to Cab and
Chassis Electrical
Section or
Transmission
Control Section for
brake switch circuits
System OK diagnosis
1. Park the vehicle.
7 —
Are any DTCs set in which the “Action Taken When
the DTC Sets” under that particular code states, Refer to Applicable
“The ECM inhibits cruise control”? DTC Go to Step 8
Observe the Cruise Main Switch parameter with a
scan tool.
8 —
Does the scan tool indicate ON then OFF each
time the switch is pressed? Go to Step 9 Go to Step 12

Observe the Cruise Set/ Coast Switch parameter
with a scan tool. Retest the cruise
control. Refer to
9 Does the scan tool indicate ON when the switch is — Condition for
turned to SET (-) and OFF when the switch is Running the Cruise
released? Control Go to Step 17
Observe the Cruise Resume/ Acceleration Switch
10 Does the scan tool indicate ON when the switch is —
turned to RES (+) and OFF when the switch is Go to Intermittent
released? Conditions Go to Step 17
Observe the Cruise Cancel Switch parameter with
a scan tool.
11 —
Does the scan tool indicate ON when the switch is Go to Intermittent
pressed and OFF when the switch is released? Conditions Go to Step 17
2. Disconnect the cruise control main switch
harness connector. (Remove the switch from
the IP bezel as necessary)
12 —
voltage feed circuit of the cruise control main
switch (pin 3 of FU208) and a known good
ground.

Observe the Cruise Main Switch parameter with a
scan tool while momentarily jumping 3-amp fused
jumper wire across the cruise control main switch
13 harness connector between pins 3 and 4 of FU208. —
Does the scan tool indicate ON then OFF each

time the circuit is jumpered? Go to Step 16 Go to Step 15
the Engine Controller (10A) fuse and the cruise
14 control main switch (pin 3 of FU208). —

25 of FB24) and the cruise control main switch
(pin 4 of FU208) for an open circuit or high
15 resistance. —

cruise control main switch (pins 3 and 4 of
16 FU208). —


2. Disconnect the combination switch harness
connector (FL19). (Remove the steering cowl
cover)
17 3. Connect a DMM between the cruise control 4.5 volts
switch signal circuit (pin 5 of FL19) and a
known good ground.
Observe the Cruise Cancel Switch parameter with
a scan tool while momentarily jumping 3-amp fused
jumper wire across the combination switch harness
connector between the cruise control switch signal
18 circuit and low reference circuit (pins 4 and 5 of —
FL19).

1. Test the cruise control switch signal circuit
between the ECM (pin65 of FB24) and the
combination switch (pin 5 of FL19) for the
• An open circuit
• High resistance

Notice: The cruise control switch shares the low
20 ECM (pin 41 of FB24) and the combination —
switch (pin 4 of FL19) for an open circuit or
high resistance.

combination switch (pins 4 and 5 of FL19).
21 —


Repair or replace the cruise control main switch.
23 —

Repair or replace the combination switch.
24 —


Diesel Particulate Defuser (DPD) Control System Check
Description Range A: Normal range
The ECM detects the condition of PM accumulations Range B: DPD amber lamp or “PUSH DPD SWITCH”
from the exhaust differential pressure sensor attached indicator blinks but manual regeneration is possible.
to the chassis frame near the diesel particulate defuser Range C: Exhaust differential pressure is excessive
(DPD) assembly or from mileage. The exhaust high range and manual regeneration is inhibited.
differential pressure sensor is a transducer that varies Range D: Distance status is abnormal range and
voltage according to changes of the exhaust gas manual regeneration is inhibited.
differential pressure between in front and in rear of
filter. When it is reached to a certain amount of PM Test Description
accumulations or a certain length of mileage, the The number below refers to the step number on the
automatic regeneration starts. If the automatic Circuit/ System Table.
regeneration cannot be completed by some reason, the 6. 8. 9. If the regeneration is not started, any DTCs may
manual regeneration is requested to the driver by be set which inhibits regeneration control. If no DTC is
blinking the DPD amber lamp or “PUSH DPD SWITCH” set, use the scan tool to observe the Vehicle Speed,
indicator on the instrument panel cluster. Once the Accelerator Pedal Position, Neutral Switch, Idle Up
regeneration starts, it must be finished within a certain Sensor and PTO Switch parameters which allows the
time. After regeneration is finished, a purification of the DPD regeneration control. Refer to engine control
filter is judged by monitoring an exhaust differential wirings and Scan Tool Data List for diagnosis.
pressure. If an excessive PM accumulation has been
detected, the regeneration will not start since Connector End View Reference: Engine Controls
uncontrolled burning might be happened during Connector End Views or ECM Connector End Views
regeneration event.
The DPD Status Table is used to determine type of the
DPD filter regeneration procedure by comparing the
DPD Accumulation Status parameter and the DPD
Distance Status parameter. To use this table, observe
both parameters with a scan tool, and plot both
readings on the DPD status table. The intersected
range indicates A, B, C or D. (e.g. DPD Accumulation
Status is 3 and DPD Distance Status is 1. The range is
located in B)
5 C
DPD Accumulation Status
4
B
3
D
2
1 A
0 1 2 3 4
DPD Distance Status
LNW76ESH003501
Circuit/ System Testing Diesel Particulate Defuser (DPD) Control System Check


cluster is operational. Go to P1669 for
2. Turn ON the ignition for 30 seconds, with the Turn OFF the DPD amber lamp
engine OFF. DO NOT start the engine. ignition for 30 circuit diagnosis or
2 —
seconds to relearn Go to IP cluster
Does the DPD amber lamp or “AUTO REGEN.”, exhaust differential diagnosis in Section
“MANUAL REGEN.” indicators turn ON, and then pressure sensor. 9E Instrumentation/
turn OFF? Go to Step 3 Driver Info.
1. Inspect engine oil level. Make sure the oil
amount is within a range.
3 —
4. Observe the DPD Regeneration Switch



1G Engine Exhaust.
• Dislocated or inclined exhaust differential
pressure sensor. Refer to Exhaust Pipe
port
pressure sensor
or damaged
4 —
Exhaust.
sensors
• Modified air induction
the mass air flow (MAF) sensor inlet


Start the engine and let idle for 30 seconds.
5 Does the DPD amber lamp or “PUSH DPD —
SWITCH” indicator blink? Go to Step 6 Go to Step 7
Perform the DPD manual regeneration by pressing ECM is not allowing
the DPD regeneration switch. the DPD
regeneration
6 Does the regeneration start? —
control. Refer to
Test Description and
Go to Step 10 DTC List

Observe the DPD Accumulation Status and DPD
Distance Status with a scan tool, and plot both
7 readings on the DPD status table. —
Is the intersected range located in A or B? Go to Step 8 Go to Step 9

Important: Reset the DPD Status before ECM is not allowing
regeneration with a scan tool. the DPD
Perform the DPD Normal Regeneration with a scan regeneration
8 —
tool. control. Refer to
Does the regeneration start? Go to Step 10 DTC List
Important: Reset the DPD Status before
regeneration with a scan tool.
Important: Engine Oil must be replaced after DPD ECM is not allowing
slow regeneration is completed. the DPD
9 — regeneration
Perform the DPD Slow Regeneration with a scan
tool. control. Refer to
Does the regeneration start? Go to Step 10 DTC List
10 Does the regeneration complete? — Go to Step 11 Go to Step 13
knob clockwise.)
procedure in
Is the Exhaust Differential Pressure parameter Refer to DTC P2452
more than the specified value? for excessive low
12 1.0 kPa
exhaust differential
System OK pressure diagnosis
Notice: If the scan tool displays a message
"Regeneration is impossible", go to applicable
DTC.
1. Remove the DPD filter from the DPD
1G Engine Exhaust. Inspect the following
conditions:
• DPD filter for damage, cranks or melt
• Oxidation catalyst for damage, cranks
melt or excessive deposits
13 • Deteriorated oxidation catalyst —
2. Test the engine cooling system for an
overheating condition. Refer to Cooling
System in Section 1C Engine Cooling for
testing.
3. Inspect the fuel system problem. Refer to Fuel
System Check chart and appropriate
procedure in Section 1D Engine Fuel.


Reconnect all previously disconnected components
14 or harness connector(s). —
2. Remove the bezel surrounding the IP cluster
enough to disconnect the DPD regeneration
switch.
3. Disconnect the DPD regeneration switch
15 harness connector. —
circuit of the DPD regeneration switch harness
(pin 1 of FU142) and a known good ground.

Observe the DPD Regeneration Switch parameter
with a scan tool while momentarily jumping 3-amp
fused jumper wire across the switch harness
16 connector between pins 1 and 2 of FU142. —
17 (pin 1 of FU142). Check the Engine Controller —
(10A) fuse first.

47 of FB24) and the switch (pin 2 of FU142)
• An open circuit
• High resistance

switch (pins 1 and 2 of FU142).
19 —

20 —

Repair or replace the DPD regeneration switch.
21 —


components, fuse or harness connector(s).
23 3. Observe the DPD Regeneration Switch —

Symptoms - Engine Controls

Symptoms - Engine Controls Reform or replace connector terminals in the problem
circuit in order to ensure proper contact tension.
Important Preliminary Inspections Before Starting
Remove the terminal from the connector body in order
Perform Diagnostic System Check - Engine Controls to inspect for poor terminal wire connection.
before using the symptom tables, and verify that all of Road test the vehicle with the DMM connected to the
the following are true: suspected circuit. An abnormal reading that occurs
• The ECM and malfunction indicator lamp (MIL)/ when the malfunction occurs is a good indication that
service vehicle soon (SVS) lamp are operating there is a malfunction in the circuit being monitored.
correctly. Use the scan tool in order to help detect intermittent
• The scan tool data is within the normal operating conditions. Useful features of the Tech 2 scan tool
range. Refer to Scan Tool Data List in this section. include the following:
• Verify the customer concern and locate the correct • Trigger the Snapshot feature in order to capture
symptom in the table of contents. Inspect the items and store engine parameters when the malfunction
indicated under that symptom. occurs. Review this stored information in order to
see the specific running conditions that caused the
Visual and Physical Inspection malfunction.
Several of the symptom procedures ask for careful • Freeze Frame/ Failure Record can also aid in
visual and physical inspection. This step is extremely locating an intermittent condition. Review and
important. The visual and physical inspection can lead capture the information in the Freeze Frame/
to correcting a problem without further inspections, and Failure Record associated with the intermittent
can save valuable time. Ensure that: DTC being diagnosed. Drive the vehicle within the
conditions that were present when the DTC
• The ECM grounds are clean, tight, and in their originally set.
proper location.
• Use the Plot Function on the scan tool in order to
• The air hoses are not split or kinked, and properly plot selected data parameters. Review this stored
connected. Inspect thoroughly for any type of leak information to aid in locating an intermittent
or restriction. problem. Refer to the scan tool Users Guide for
• The air intake ducts are not collapsed or damaged. more information.
• The exhaust pipes are not collapsed or damaged. Use the data recording module (DRM) or body control
• The engine harness wiring and terminals are module (BCM) data recording function in order to help
properly connected and are not pinched or cut. detect intermittent conditions. The DRM or the BCM
has ability to store engine log data when an event of
Intermittent DTC. Maximum three log data can be stored in the
DRM or the BCM memory. If more than maximum
Important: Inspect for improper installation of electrical number of storage is set, oldest log data is overwritten.
components if an intermittent condition exists. Inspect However, if same DTC is set within eight hours that
for aftermarket add-on electrical equipment devices, DTC is not stored in the DRM or the BCM memory.
lights, and cellular phones. Verify that no aftermarket The manual trigger function is to store the log data by
equipment is connected to the controller area network an arbitrary operation of the driver when an event of
(CAN) or other serial data circuit. wrong vehicle performance that is instead of an event
of DTC. If the driver presses and releases the manual
Important: The problem may or may not turn ON the trigger switch once, that time becomes a trigger and
MIL/ SVS lamp or store a DTC. Faulty electrical one log data before and behind the trigger is stored in
connections or wiring cause most intermittent the DRM or the BCM memory. When there is a space in
problems. Perform a careful visual and physical the DRM or the BCM memory, log data is stored in that
inspection of the suspect connectors for the following space. However, when more than maximum number of
conditions: storage is set, oldest log data is overwritten.
• Improperly mated connector halves
• Terminals that are not seated Important: If the intermittent condition exists as a start
• Terminals that are damaged or improperly formed and then stall, test for DTCs relating to the vehicle theft
deterrent system. Test for improper installation of
electrical options such as lights, cellular phones, etc.
Important: Any of the following may cause an

intermittent MIL/ SVS lamp with no stored DTC:
• The ECM grounds are loose or dirty. Refer to
engine control wirings.

• The MIL/ SVS lamp circuit intermittently shorted to
ground
• Electrical system interference caused by a
malfunctioning relay, ECM driven solenoid, or
switch. The electrical component can cause a
sharp electrical surge. Normally, the problem will
occur when the malfunctioning component is
operating.
• There are any open diodes.
Important: The following symptom tables contain

groups of possible causes for each symptom. The
order of these procedures is not important. If the scan
tool readings do not indicate the problems, then
proceed in a logical order, easiest to check or most
likely to cause first. In order to determine if a specific
vehicle is using a particular system or component, refer
to engine control wirings for an application.
Important: Use the following tables when diagnosing a

symptom complaint:
• Intermittent Conditions
• Hard Start
• Rough, Unstable, or Incorrect Idle and Stalling
• High Idle Speed
• Cuts Out
• Surges
• Lack of Power, Sluggishness or Sponginess
• DPD System Manual Regeneration Frequently
• DPD System Regeneration Long Time

Intermittent Conditions
Checks Action
Definition:
The problem is not currently present but is indicated in DTC History.
OR
There is a customer complaint, but the symptom cannot currently be duplicated, if the problem is not DTC related.
Preliminary Checks • Refer to Symptoms - Engine Controls before starting.
Harness/ Connector Many intermittent open or shorted circuits are affected by harness/ connector
movement that is caused by vibration, engine torque, bumps/ rough pavement, etc.
Test for this type of condition by performing the applicable procedure from the following
list:
• Move related connectors and wiring while monitoring the appropriate scan tool data.
• Move related connectors and wiring with the component commanded ON, and OFF,
with the scan tool. Observe the component operation.
• With the engine running, move related connectors and wiring while monitoring
engine operation.
If harness or connector movement affects the data displayed, component/ system
operation, or engine operation, inspect and repair the harness/ connections as
necessary.
Electrical Connections or Wiring Poor electrical connections, terminal tension or wiring problems cause most
intermittent. To perform the following inspections:
• Poor mating of the connector halves, or terminals improperly seated in the
connector body.
• Improperly formed or damaged terminals. Test for poor terminal tension.
• Poor terminal to wire connections including terminals crimped over insulation. This
requires removing the terminal from the connector body.
• Corrosion/ water intrusion. Pierced or damaged insulation can allow moisture to
enter the wiring. The conductor can corrode inside the insulation, with little visible
evidence. Look for swollen and stiff sections of wire in the suspect circuits.
• Wires that are broken inside the insulation.
• Harness for pinched, cut or rubbed through wiring.
• Ensure that the wiring does not come in contact with hot exhaust components.
Control Module Power and Grounds Poor power or ground connections can cause widely varying symptoms.
Component Power and Grounds • Test all control module power supply circuits. Many vehicles have multiple circuits
supplying power to the control module. Other components in the system may have
separate power supply circuits that may also need to be tested. Inspect connections
at the module/ component connectors, fuses, and any intermediate connections
between the power source and the module/ component. A test lamp or a DMM may
indicate that voltage is present, but neither tests the ability of the circuit to carry
sufficient current. Ensure that the circuit can carry the current necessary to operate
the component.
• Test all control module ground and system ground circuits. The control module may
have multiple ground circuits. Other components in the system may have separate
grounds that may also need to be tested. Inspect grounds for clean and tight
connections at the grounding point. Inspect the connections at the component and
in splice packs, where applicable. Ensure that the circuit can carry the current
necessary to operate the component.
Checks Action
Temperature Sensitivity • An intermittent condition may occur when a component/ connection reaches normal
operating temperature. The condition may occur only when the component/
connection is cold, or only when the component/ connection is hot.
• Freeze Frame, Failure Records or Snapshot Data may help with this type of
intermittent conditions, where applicable.
• If the intermittent is related to heat, review the data for a relationship with the
following:
- High ambient temperatures.
- Underhood/ engine generated heat.
- Circuit generated heat due to a poor connection, or high electrical load.
- Higher than normal load conditions, towing, etc.
• If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a
connection or component. Test for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
• Information from the customer may help to determine if the trouble follows a pattern
that is temperature related.
Electromagnetic Interference (EMI) Some electrical components/ circuits are sensitive to EMI or other types of electrical
and Electrical Noise noise. Inspect the following conditions:
• A misrouted harness that is too close to high voltage/ high current devices such as
injection components, motors, generator etc. These components may induce
electrical noise on a circuit that could interfere with normal circuit operation.
• Electrical system interference caused by a malfunctioning relay, or the ECM driven
solenoid or switch. These conditions can cause a sharp electrical surge. Normally,
the problem will occur when the malfunctioning component is operating.
• Improper installation of non-factory or aftermarket add on accessories such as
lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell
phones, etc. These accessories may lead to an emission related failure while in
use, but do not fail when the accessories are not in use.
• Test for any open diodes. Some relays may contain a clamping diode.
• Test the generator for a bad rectifier bridge that may be allowing AC noise into the
electrical system.
Incorrect ECM Programming • There are only a few situations where reprogramming a ECM is appropriate:
- An ECM from another vehicle is installed.
- Revised software/ calibration files have been released for this vehicle.
Important: DO NOT reprogram the ECM with the SAME software/ calibration files that
are already present in the ECM. This is not an effective repair for any type of driveability
problem.
• Verify that the ECM contains the correct software/ calibration. If incorrect
programming is found, reprogram the ECM with the most current software/
calibration.
Duplicating Failure Conditions • If none of the previous tests are successful, attempt to duplicate and/ or capture the
failure conditions.
• Freeze Frame/ Failure Records data, where applicable, contains the conditions that
were present when the DTC set.
- Review and record Freeze Frame/ Failure Records data.
- Operate the vehicle under the same conditions that were noted in Freeze
Frame/ Failure Records data, as closely as possible. The vehicle must also be
operating within the Conditions for Running the DTC. Refer to Conditions for
Running the DTC in the supporting text of the DTC being diagnosed.
• An alternate method is to drive the vehicle with the DMM connected to a suspected
circuit. An abnormal reading on the DMM when the problem occurs, may help you
locate the problem.
Checks Action
Scan Tool Snapshot The scan tool can be set up to take a Snapshot of the parameters available via serial
data. The Snapshot function records live data over a period of time. The recorded data
can be played back and analyzed. The scan tool can also graph parameters singly or in
combinations of parameters for comparison. The Snapshot can be triggered manually
at the time the symptom is noticed, or set up in advance to trigger when a DTC sets.
An abnormal value captured in the recorded data may point to a system or component
that needs to be investigated further.
Refer to the scan tool Users Guide for more information.
DRM or BCM Memory Use data stored in the DRM or the BCM memory or use manual trigger function. The
DRM or the BCM has ability to store engine log data when an event of DTC. The
manual trigger function is to store the log data by an arbitrary operation of the driver
when an event of wrong vehicle performance that is instead of an event of DTC. If the
driver presses and releases the manual trigger switch once, that time becomes a
trigger and one log data before and behind the trigger is stored in the DRM or the BCM
memory.

Hard Start
Checks Action
Definition:
The engine cranks OK, but does not start for a long time. The engine does eventually run, or may start but immediately dies.
Preliminary Checks • Diagnostic System Check - Engine Controls.
• Ensure the driver is using the correct starting procedure.
• Inspect the ECM grounds for being clean, tight, and in their proper locations.
• Inspect that the harness connectors are correctly connected.
• Inspect the fuel type and quality.
• Inspect the programmed fuel injector ID code for each cylinder.
• Inspect the Scan Tool Data List in this section.
• Inspect the Service Bulletin.
Sensor Checks Inspect the engine control sensors for the following conditions. Refer to Scan Tool Data
List in this section.
• Compare the Coolant Temperature with the Intake Air Temperature (IAT) and Fuel
Temperature (FT) parameters on a cold engine condition. If the difference among
temperature reading is more than 5°C (9°F) on a cold engine, check for high
resistance in each circuit or for a skewed sensor.
Notice: The mass air flow (MAF) sensor is heated and as a result the IAT may indicate
a higher than normal intake air temperature if the ignition switch is being ON.
• Observe the Fuel Rail Pressure Sensor parameter with the engine OFF. The FRP
Sensor should read 0.9 to 1.0 volt with the ignition switch ON and engine OFF after
the engine has stopped running for a minimum of 1 minute. If not, check for high
• Crankshaft position (CKP) sensor is tight and the sensor rotor is not damaged.
• Camshaft position (CMP) sensor is tight and the camshaft gear is not damaged.
Fuel System Checks Inspect the fuel system for the following conditions. Refer to Fuel System Check chart
and appropriate procedure in Section 1D Engine Fuel.
• Air in the fuel system.
• Water contamination in the fuel.
• Fuel waxing or icing.
• Fuel filter clogging.
• External fuel leaks or high engine oil level.
• Fuel leak off from the fuel pressure limiter valve and fuel injectors.
• Fuel lines between the fuel tank and fuel supply pump for being crushed, kinked,
tightness, cracks and plugged.
• A plugged fuel tank vent hose.
• Inside the fuel tank for any foreign material that may be getting drawn into the fuel
line pickup causing a blocked condition.
• Fuel supply pump operation.
Notice: The fuel supply pump must be timed to the engine and adjustment value must
be learned to the ECM.
• Perform the Cylinder Balance Test with a scan tool.

• Perform the Injector Forced Drive with a scan tool.
• Observe the FRP Regulator Feedback current on the scan tool.
Checks Action
Air Intake System Checks Inspect the air intake system for the following conditions.
• Air cleaner, air intake ducts and charge air cooler for a restriction, holes, or leaks.
• A restriction in the turbocharger inlet duct.
• Intake throttle valve for a stuck condition.
• A restriction or leak in the intake manifold.
Exhaust System Checks Inspect the exhaust system for a possible restriction. Refer to Exhaust System in
Engine Mechanical Checks Inspect the engine mechanical for the following conditions. Refer to Section 1B Engine
Mechanical.
• Poor cylinder compression.
• Improper mechanical timing (timing gear).
• Improper valve gap.
• Broken or weak valve springs.
• Worn camshaft lobes.
Electrical System Checks Inspect the engine electrical for the following conditions. Refer to Section 1E Engine
Electrical.
• Glow plug control system operation. Refer to Glow Control System Check in this
section.
• Slow cranking speed.
• Weakened batteries.

Rough, Unstable, or Incorrect Idle and Stalling
Checks Action
Definition:
Engine runs unevenly at idle. If severe, the engine or vehicle may shake. Engine idle speed may vary in RPM. Either condition
may be severe enough to stall the engine.
• Remove the air cleaner and check for dirt, or for air ducts being plugged or
restricted. Replace as necessary.
• Observe the Fuel Rail Pressure parameter at idle in Neutral. The Fuel Rail Pressure
should always be more than 25 MPa (3,600 psi) after warm up.
• Camshaft position (CMP) sensor is tight and the camshaft gear is not damaged.

• Observe the Fuel Compensation for each cylinder at idle on the scan tool.
• Observe the FRP Regulator Feedback current on the scan tool.
Checks Action
Mechanical.
• Incorrect basic engine parts such as camshaft, cylinder head, pistons, etc.
Additional Checks • Electromagnetic interference (EMI) on the reference circuit can cause an engine
miss condition. The scan tool can usually detect EMI by monitoring the engine
speed. A sudden increase in speed with little change in actual engine speed change
indicates that EMI is present. If a problem exists, check routing of high voltage
components, such as fuel injector solenoid valve wiring, near the sensor circuits.
• Faulty engine mounts.
• Faulty crank pulley.
• Faulty generator & A/C compressor.
• Generator output voltage.
• EGR system operating correctly. Refer to EGR Control System Check in this
section.
• A/C operation.

High Idle Speed
Checks Action
Definition:
Engine idle speed is higher than normal in regardless of engine coolant temperature or DPD system regeneration.
• Use the scan tool to compare the engine speed and tachometer on the instrument
panel (IP) cluster.
• Inspect the A/C operation.
• Inspect the engine oil level.
• Observe the Fuel Rail Pressure parameter at idle in Neutral. The Fuel Rail Pressure
should always be more than 25 MPa (3,600 psi) after warm up.
• Observe the Accelerator Pedal Position (APP). APP parameter should change
linearly from 0 to 100% according to the accelerator pedal operation.
• Observe the Idle Up Sensor. Idle Up Sensor parameter should read less than 0.6
volts at full counterclockwise. If not, check for high resistance in the low reference
circuit or skewed sensor.
• Observe the PTO Remote Throttle Sensor. PTO Remote Throttle Sensor parameter
should read less than 0.4 volts at lowest position. If not, check for high resistance in
the low reference circuit or skewed sensor.
Fuel System Checks Inspect the fuel system for the following conditions. Refer to Fuel System in Section 1D
Engine Fuel.
• Fuel injectors. Remove the injectors and visually inspect. (Injector tip(s) may be
damaged)

Cuts Out
Checks Action
Definition:
A constant jerking that follows the engine speed, usually more pronounced as the engine load increase. The exhaust has a
steady spitting sound at idle, low speed, or hard acceleration for the fuel starvation that can cause the engine to cut-out.
Preliminary Check • Diagnostic System Check - Engine Controls.
• Observe the Mass Air Flow (MAF) parameter for a skewed or slow MAF sensor.
• Observe the Fuel Rail Pressure and Desired Fuel Rail Pressure parameter between
idle and W.O.T. (accelerator pedal full travel) in Neutral. Fuel Rail Pressure
parameter should follow within ± 5 MPa (± 725 psi) quick enough.
Additional Checks • Electromagnetic interference (EMI) on the reference circuit can cause an engine
miss condition. The scan tool can usually detect EMI by monitoring the engine
speed. A sudden increase in speed with little change in actual engine speed change
indicates that EMI is present. If a problem exists, check routing of high voltage
components, such as fuel injector solenoid valve wiring, near the sensor circuits.

Surges
Checks Action
Definition:
The engine has a power variation under a steady throttle or cruise. The vehicle seems to speed up and slow down with no
change in the accelerator pedal.
• Ensure the driver understands the A/C compressor operation.
• Use the scan tool in order to make sure the Vehicle Speed parameter reading
matches the vehicle speedometer.
• Observe the Mass Air Flow (MAF) parameter for a skewed or slow MAF sensor.

• Turbocharger nozzle control solenoid for a stuck condition. Refer to Turbocharger
Assembly in Section 1J Induction. (Euro 4 specification)
Checks Action
Additional Checks • Inspect the EGR system operating correctly. Refer to EGR Control System Check in
this section.
• Inspect deformed tire(s) that may cause surges at fixed vehicle speed range.

Lack of Power, Sluggishness or Sponginess
Checks Action
Definition:
The engine delivers less than expected power. There is little or no increase in speed when partially applying the accelerator
pedal.
• Compare the vehicle with a similar unit. Ensure the vehicle has an actual problem.
• Have the tire sizes changed?
• Are excessively heavy loads being carried?
• Inspect for clutch slip.
• Inspect brake drag.
• Inspect for a proper transmission shift pattern and down shift operation.
• Inspect the fuel quality (cetane index).
• Inspect the engine oil level and quality.
• Use the scan tool in order to make sure the Vehicle Speed parameter reading
matches the vehicle speedometer.
• Observe the Boost Pressure and Barometric Pressure (BARO) with ignition ON and
engine OFF. Both parameters should be within the 7.0 kPa (1.0 psi) each other.
Checks Action

• A worn or damaged turbocharger turbine wheel, shaft or compressor wheel. Refer to
Turbocharger Assembly in Section 1J Induction.
Mechanical.
this section.
• Inspect for an engine overheat condition. Refer to Cooling System in Section 1C
Engine Cooling.

Hesitation, Sag or Stumble
Checks Action
Definition:
The vehicle has a momentary lack of response when pushing down on the accelerator. The condition can occur at any vehicle
speed. The condition is usually most severe when trying to make the vehicle move from a stop. If severe enough, the condition
may cause the engine to stall.
• Compare the vehicle with a similar unit. Ensure the vehicle has an actual problem.
• Inspect for a proper transmission shift pattern and down shift operation.
• Observe the MAF parameter for a skewed or slow MAF sensor.

Checks Action

• A worn or damaged turbocharger turbine wheel, shaft or compressor wheel. Refer
to Turbocharger Assembly in Section 1J Induction.
Mechanical.
this section.
• Inspect for an engine overheat condition. Refer to Cooling System in Section 1C
Engine Cooling.

Abnormal Combustion Noise
Checks Action
Definition:
A mild to severe ping, usually worse under acceleration. The engine makes sharp metallic knocks that change with the throttle
opening.
• Ensure the vehicle has an actual problem.
• Inspect for smoke associated with the combustion noise.
Fuel System Checks • If excessive smoke is present, check for a stuck open fuel injector. Inspect for fuel
leakage into the combustion chamber.
• Inspect the fuel injectors. Remove the injectors and visually inspect.
Mechanical.
• Incorrect basic engine parts such as camshaft, cylinder head, pistons, etc.
• Inspect for any excessive oil entering combustion chamber.
Additional Checks • Inspect other possible causes that can make similar noise such as loose component
parts, bracket, mount and weak clutch damper spring.

Poor Fuel Economy
Checks Action
Definition:
Fuel economy, as measured by actual road tests and several tanks of fuel, is noticeably lower than expected. Also, the
economy is noticeably lower than it was on this vehicle at one time, as previously shown by actual road tests.
Preliminary Checks • Remove the air cleaner and check for dirt, or for air ducts being plugged or
• Inspect the driving habits of the owner.
• Is the A/C ON full time, defroster mode ON?
• Are the tires at the correct pressure?
• Are the tire sizes changed?
• Are excessively heavy loads being carried?
• Is the acceleration too much, too often?
• Inspect for clutch slip.
• Inspect brake drag.
• Inspect dive belt tension.
• Inspect for a proper transmission shift pattern and down shift operation (Smoother
only).
• Suggest to the owner to fill the fuel tank and recheck the fuel economy.
• Inspect the odometer is correctly operated.
Engine Fuel.
• Fuel type and quality.
• Check fuel leak.
Cooling System Checks Inspect the cooling system for the following conditions. Refer to Cooling System in
Section 1C Engine Cooling.
• Engine coolant level.
• Engine thermostat for always being open or for the wrong heat range.
• Engine cooling fan for always being ON.
Checks Action
Mechanical.

Excessive Smoke (Black Smoke)
Checks Action
Definition:
Black smoke under load, idle or start up hot or cold.
Preliminary Check • Ensure the vehicle has an actual problem.

Engine Fuel.
• Fuel injectors. Remove the injectors and visually inspect.
• Perform the Pre Injection Control with a scan tool.
• A restriction or damaged at MAF sensor.
Checks Action
Mechanical.
• Inspect for poor cylinder compression.
• Any excessive oil entering combustion chamber.
Additional Checks • EGR system operating correctly. Refer to EGR Control System Check in this
section.
• Excessive blow-by gasses.

Excessive Smoke (White Smoke)
Checks Action
Definition:
White smoke under load, idle or start up hot or cold.
Preliminary Check • Ensure the vehicle has an actual problem.
Fuel System Checks • If excessive smoke is present, check for a stuck open fuel injector. Inspect for fuel
leakage into the combustion chamber.
• Fuel injectors. Remove the injectors and visually inspect.
• Perform the Pre Injection Control with a scan tool.
• A restriction or damaged at MAF sensor.
• A worn or damaged turbocharger turbine wheel, shaft or compressor wheel. Oil leak
from turbocharger. Refer to Turbocharger Assembly in Section 1J Induction.
Exhaust System Checks If an excessive white smoke is present while DPD filter regeneration event, a
deteriorated or damaged oxidation catalyst is suspected.
Checks Action
Mechanical.
• Thermostat working (open stuck).
• Any excessive oil entering combustion chamber.
Electrical System Checks • Glow plug control (preheating) system operation. Refer to Glow Control System
Check in this section.

DPD System Manual Regeneration Frequently
Checks Action
Definition:
The manual regeneration is frequently requested to the driver by blinking the DPD amber lamp. Or, it is frequently requested as
compared with before. (The automatic regeneration cannot be completed frequently.)
Preliminary Checks • Inspect the fuel quality.
• Inspect the odometer is correctly operated.
• If an excessive black smoke is present, refer to Excessive Smoke (Black Smoke)
chart in symptom diagnostic table.
• An excessive ash accumulation in the DPD filter.
Inspect the driving habits/conditions of the owner for the following conditions. Suggest
to the owner to use the selectable regeneration as necessary:
In normal operation;
• Is the idling time too long?
• Is the driving at slow vehicle speed too often?
• Is the driving at long downhill?
• Is a small cargo delivery truck or a garbage truck?
• Is the PTO operating time too long?
In regeneration;
• Is the PTO operating too often and/or for a long time?
• Is the engine runtime short?
• Is the vehicle runtime short?
• Is the accelerator pedal ON and OFF too often?
Sensor Checks Inspect the engine control sensors relating to the DPD system control for the following
conditions. Refer to Scan Tool Data List in this section.
• Misrouted or disconnected exhaust differential pressure hoses or pipes.
Notice: There is installation directionality in the exhaust differential pressure hoses.

Refer to Exhaust Differential Pressure Sensor in Section 1G Engine Exhaust.
• Plugged, crushed or kinked exhaust differential pressure hoses or pipes.

• Dislocated or inclined exhaust differential pressure sensor. Refer to Exhaust Pipe in
• Physical damage of the exhaust differential pressure sensor.
• Any contamination or objects that block the exhaust differential pressure sensor
port.
• Observe the Exhausts Differential Pressure parameter for a skewed or slow exhaust
differential pressure sensor.
• Skewed or slow exhaust temperature sensors. Use the Temperature vs. Resistance
table to test the exhaust temperature sensor at various temperature levels to
evaluate the possibility or a skewed sensor.
Fuel System Checks Inspect the fuel system problem. Refer to Fuel System Check chart and appropriate
Checks Action
• Modified air induction system.
• A restriction or damaged or any contamination or objects that block at MAF sensor.
Exhaust System Checks Inspect the exhaust system for the following conditions. Refer to Exhaust System in
• An exhaust system gasket that is missing or damaged.
• Exhaust gas leakage from the exhaust pipe, gasket, DPD assembly, exhaust
temperature sensor(s) or exhaust differential pressure hoses or pipes.
• Modified exhaust system.
• Exhaust throttle valve or exhaust brake valve for stuck condition. Refer to Exhaust
System in Section 1G Engine Exhaust.
• An excessive ash accumulation in the DPD filter.
• DPD filter for damage, cracks, melt or excessive deposits.
• Oxidation catalyst for damage, cracks, melt or excessive deposits.
• If an excessive white smoke is present while regeneration event, a deteriorated or
damaged oxidation catalyst is suspected.

DPD System Regeneration Long Time
Checks Action
Definition:
The regeneration time longer than an expected time. Or, it takes longer than before.
Preliminary Checks • Inspect the fuel quality.
• Is the engine warm up control misunderstood as the DPD regeneration?
Inspect the driving habits/conditions of the owner for the following conditions:
In regeneration;
• Has the manual regeneration started from cold engine?
• Is the PTO operating too often and/or for a long time?
• Is the engine runtime short?
• Is the vehicle runtime short?
• Is the accelerator pedal ON and OFF too often?
• Is the ambient temperature excessively high?
Sensor Checks Inspect the engine control sensors relating to the DPD system control for the following
conditions. Refer to Scan Tool Data List in this section.
• Misrouted or disconnected exhaust differential pressure hoses or pipes.
Notice: There is installation directionality in the exhaust differential pressure hoses.

Refer to Exhaust Differential Pressure Sensor in Section 1G Engine Exhaust.
• Plugged, crushed or kinked exhaust differential pressure hoses or pipes.

• Dislocated or inclined exhaust differential pressure sensor. Refer to Exhaust Pipe in
• Physical damage of the exhaust differential pressure sensor.
• Any contamination or objects that block the exhaust differential pressure sensor
port.
• Observe the Exhausts Differential Pressure parameter for a skewed or slow exhaust
differential pressure sensor.
• Skewed or slow exhaust temperature sensors. Use the Temperature vs. Resistance
table to test the exhaust temperature sensor at various temperature levels to
evaluate the possibility or a skewed sensor.
Fuel System Checks Inspect the fuel system problem. Refer to Fuel System Check chart and appropriate
Cooling System Checks Inspect the cooling system for an overheating conditions. Refer to Cooling System in
Section 1C Engine Cooling.
• Engine coolant level.
• Engine coolant leakage.
• Cooling fan belt slippage.
• Cooling fan clutch working.
• Thermostat working.
• Water pump working.
• Radiator clogging.
• Modified cooling system which is less cooling capacity.
Checks Action
• Modified air induction system.
• A restriction or damaged or any contamination or objects that block at MAF sensor.
Exhaust System Checks Inspect the exhaust system for the following conditions. Refer to Exhaust System in
• An exhaust system gasket that is missing or damaged.
• Exhaust gas leakage from the exhaust pipe, gasket, DPD assembly, exhaust
temperature sensor(s) or exhaust differential pressure hoses or pipes.
• Modified exhaust system.
• Exhaust throttle valve or exhaust brake valve for stuck condition. Refer to Exhaust
System in Section 1G Engine Exhaust.
• DPD filter for damage, cracks, melt or excessive deposits.
• Oxidation catalyst for damage, cracks, melt or excessive deposits.
• If an excessive white smoke is present while regeneration event, a deteriorated or
damaged oxidation catalyst is suspected.
Additional Checks • Inspect for an engine overheat condition. Refer to Cooling System in Section 1C
Engine Cooling.
Repair Instructions
Engine Control Module (ECM)
Replacement
Description
The following A to G steps provide an overview
procedure to replace and reprogram an ECM. Each A -
G steps is explained further in this section.
1
SAMPLE
A. Upload the fuel injector ID codes from the old ECM. 2 64 05 4F
6HK1
08 F5 F5 F5 DD 0A 00 00 14
B. Reset the immobilizer security information in the old 3
64 F0 00 12 0E 04 16 00 0A 0A 20 BA
64 00 31 06 0A 14 00 10 FA 00 25 82
ECM. (If so equipped) 64 E5 00 00 10 12 0F 16 0C 11 23 A4
4 64 05 3A 0C F6 D9 FB DA 00 EE EC 5B
C. Replace the old ECM with the new ECM. 64 32 61 1B 1C 0C 0D FA 1D 0F 0C D5
D. Program the immobilizer security information into the 5
new ECM. (If so equipped) 6
E. Program the latest software and calibrations into the 7
new ECM using the Service Programming System
(SPS).
F. Program the uploaded fuel injector ID codes and
MFW81ASH000601
program the vehicle identification number (VIN) into
the ECM using a scan tool programming function. Legend
G. Perform the fuel supply pump relearn procedure by 1. Cylinder #1 fuel injector ID code
allowing the engine to idle in Park or Neutral until 2. Cylinder #2 fuel injector ID code
normal operating temperature is achieved. 3. Cylinder #3 fuel injector ID code
4. Cylinder #4 fuel injector ID code
A. Uploading Fuel Injector ID Code 5. Cylinder #5 fuel injector ID code
6. Cylinder #6 fuel injector ID code
The current fuel injector ID code data can be uploaded 7. Injector ID code label
with a scan tool. If the old ECM cannot be
communicated with a scan tool, go to Retrieving the
Recording from each fuel injector
Fuel Injector ID Code Data with a Non-communicating
ECM. 1. Remove the cylinder head cover. Refer to Cylinder
Head in Section 1B Engine Mechanical.
2. Record 24 figures of each fuel injector ID plate.
The correct order for the fuel injector ID codes of
3. Select Diagnostics > appropriate vehicle the following illustration is as follows:
identification > appropriate engine model > 64 DA A5 05 2F 4C 0F 36 FA 17 25 8C
Programming > Store ECU setting (Euro 4
specification) or Injector ID Code (except Euro 4
specification) < Upload ID Code (except Euro 4 2 1
specification)
4. After complete the uploading, turn OFF the scan
tool. 64DA A505
5. Turn OFF the ignition. 2F4C 0F36
FA17 25 00
Retrieving the Fuel Injector ID Code Data with a 0000 8C
Non-communicating ECM
If a scan tool does not communicate, the fuel injector ID
codes must be recorded from the factory affixed label 3
on the cylinder head cover or each fuel injector ID
plate.
Recording from the label on cylinder head cover
LNW76ESH002601
Notice: Only perform this procedure if the fuel injectors
are not being replaced in the past. Legend
1. Record all numbers of each cylinder on the label. 1. Fuel injector ID plate
2. Fuel injector ID code
3. Fuel injector

B. Resetting Immobilizer Security Information (If so F. Programming Fuel Injector ID Codes and VIN
equipped) Euro 4 specification
Reset immobilizer security information in the old ECM. 1. Install a scan tool.
Refer to Resetting and Programming Guidelines in the
immobilizer section. If the old ECM cannot be
communicated with a scan tool, go to the next 3. Select Diagnostics > appropriate vehicle
procedure. identification > appropriate engine model >
Programming > Program ECU.
C. Removal and Installation 4. In order to get programming approval, the on-
Removal Procedure screen displays a message to user. Get
programming approval from the TIS 2000 using
1. Disconnect the negative battery cable. the following procedure:
2. Disconnect the ECM harness connectors. a. Connect a scan tool to the terminal that
3. Loosen the nuts (4) and remove the ECM with installed TIS 2000 with the latest software and
bracket. the hardware key is plugged into port.
4. Loosen the bolts (2) from the bracket (3) and b. Turn ON the scan tool and keep at title screen.
remove the ECM (1). c. Launch the TIS application.
1 d. Select the Security Access at the main screen.
2 e. Highlight the “Tech 2” on the Diagnostic Tool
3 Selection screen and click “Next”.
f. Click “Close” on the Security Access Enabled
screen.
g. Turn OFF the scan tool.
h. Disconnect the scan tool from the terminal.
5. Install a scan tool to the vehicle.
4
7. Select Diagnostics > appropriate vehicle
identification > appropriate engine model >
Programming > Program ECU.
8. Verify the VIN on the screen and follow the on
screen messages. If not programmed or incorrect
VIN, input correct VIN.
MFW71ASH002501 9. Verify the fuel injector ID code on the screen and
follow the on screen messages. If not programmed
Installation Procedure or incorrect ID cord, input ID code.
1. Install the ECM (1) to the bracket (3) and tighten 10. After complete the programming, turn OFF the
the ECM fixing bolts (2). ignition for 30 seconds.
2. Install the ECM with bracket (3) and tighten the 11. Start the engine and let idle.
nuts (4). 12. Inspect for a proper engine running condition and
3. Reconnect the ECM harness connectors. for no DTC's. Refer to Diagnostic System Check -
4. Reconnect the negative battery cable. Engine Controls if needed.
D. Programming Immobilizer Security Information Except Euro 4 specification

(If so equipped) 1. Install a scan tool.
Program immobilizer security information into the ECM. 2. Turn ON the ignition, with the engine OFF.
Refer to Resetting and Programming Guidelines in the 3. Select Diagnostics > appropriate vehicle
immobilizer section. identification > appropriate engine model >
Programming > Download ID code. If the old ECM
E. Programming Software and Calibrations cannot be communicated with a scan tool, select
Program latest software/ calibrations if released. Refer Diagnostics > appropriate vehicle identification >
to Service Programming System (SPS) Description and appropriate engine model > Programming >
SPS (Remote Procedure) or SPS (Pass-Thru Replace Injector and input 22 digits of each fuel
Procedure) in this section. injector ID code.

4. Select VIN Programming. Verify the VIN on the - The software/ calibrations identification
screen if programmed at previously described numbers
SPS. If not programmed or incorrect VIN, input - The control module security information
correct VIN. In order to get programming approval,
• Flash Read Only Memory-Flash Memory
the on-screen displays a message to user. Get
Flash memory has increased memory storage
programming approval from the TIS 2000 using
capacity. During programming, all information
the following procedure:
within this type of memory is erased, and then
a. Connect a scan tool to the terminal that replaced with entirely new information.
installed TIS 2000 with the latest software and
the hardware key is plugged into port. Service Programming Methods
b. Turn ON the scan tool and keep at title screen. The two methods of programming a ECM are listed
c. Launch the TIS application. below:
d. Select the Security Access at the main screen. • Remote Programming
e. Highlight the “Tech 2” on the Diagnostic Tool • Pass Thru Programming
Selection screen and click “Next”. For information on programming an ECM using one of
f. Click “Close” on the Security Access Enabled the methods listed above, refer to Service
screen. Programming System (SPS) (Remote Procedure) or
g. Turn OFF the scan tool. Service Programming System (SPS) (Pass-Thru
Procedure).
h. Disconnect the scan tool from the terminal.
5. After complete the programming, turn OFF the Before Programming a Control Module
ignition for 30 seconds.
Important: DO NOT program an existing ECM with the
6. Start the engine and let idle. identical software/ calibration file. This procedure is not
7. Inspect for a proper engine running condition and a short cut to correct the driveability concern. This is an
for no DTC's. Refer to Diagnostic System Check - ineffective repair. An ECM should only be programmed
Engine Controls if needed. when the following occurs:
• When a service procedure instructs you to replace
G. Supply Pump Relearn the ECM.
1. Install a scan tool. • An updated software/ calibrations is released.
2. Start the engine and let idle until engine coolant Ensure that the following conditions are met before
temperature reads 65°C (149°F) or higher while programming an ECM:
observing the Fuel Supply Pump Status parameter • The scan tool PCMCIA card is programmed with
with a scan tool. The scan tool parameter changes the latest software.
status Not Learned > Learned. • The TIS 2000 is installed with the latest software.
• The hardware key is plugged into the computer
Service Programming System (SPS) port.
Description • Vehicle system voltage:
The service programming system (SPS) allows a - There are no charging system concerns. All
technician to program a control module through the charging system concerns must be repaired
data link connector (DLC). The information transfer before programming the ECM.
circuit that is used at the DLC is the same serial data - The battery voltage is greater than 24 volts but
circuit used by the scan tool for retrieving DTCs, less than 30 volts. The battery must be fully
displaying data, clearing DTCs etc. This procedure charged before programming the ECM.
offers the ability to install software/ calibrations - A battery charger is NOT connected to the
matched to a particular vehicle. vehicles battery. Incorrect system voltage or
Most control modules have two types of memory. The voltage fluctuations from a battery charger may
software/ calibrations reside in the flash memory. The cause programming failure or ECM damage.
two types of memory are listed below:
- Turn OFF or disable any system that may put a
• Electrically Erasable Programmable Read Only load on the vehicles battery. Turn OFF or
Memory (EEPROM) disable systems such as:
This type of memory allows selected portions of
◊ Heating, ventilation, and air conditioning
memory to be programmed while other portions
(HVAC) systems
remain unchanged.
Certain learned values reside in the EEPROM, ◊ Headlights
such as: ◊ Room lights
- The vehicle identification number (VIN) ◊ Accessory equipment

• The ignition switch is in the proper position. The f. During obtaining information, the scan tool is
scan tool prompts you to turn ON the ignition, with receiving information from all modules at the
the engine OFF. DO NOT change the position of same time. But only ECM information is
the ignition switch during the programming displayed on the screen.
procedure unless instructed to do so. g. Turn OFF all accessories and press "Okay".
• All tool connections are secure: h. Verify that the correct VIN is displayed on the
- The RS-232 cable scan tool. If the VIN is incorrect or no VIN,
- The connection at the DLC record the correct VIN.
- The voltage supply circuits 2. Turn OFF the ignition.
• DO NOT disturb the tool harnesses while 3. Turn OFF the scan tool and disconnect from the
programming. If an interruption occurs during the vehicle.
programming procedure, programming failure or 4. Transfer the data from the terminal to the scan tool
ECM damage may occur. using the following procedure:
• If you are performing the Pass-Thru programming
procedure using a notebook computer without the Notice: The TIS supports service programming
power cord, ensure that the internal battery is fully with the Tech 2 scan tool only.
charged. a. Connect the scan tool to the terminal.
b. Launch the TIS application.
Service Programming System (SPS) c. Select the Service Programming System at the
main screen.
(Remote Procedure)
d. Highlight the following information on the Select
Notice: Some module will not accept SPS remote Diagnostic Tool and Programming Process
procedure using 10MB PCMCIA card. In such case, screen, then click "Next":
use 32MB PCMCIA card or SPS pass-thru procedure.
The Remote SPS method is a three-step process that • Select Diagnostic Tool - Tech 2
involves the following procedures: • Select Programming Process - Identify
1. Connecting the scan tool to the vehicle and whether an existing ECM is being
obtaining the information from the ECM. reprogrammed or an ECM is being replaced
with a new one
2. Connecting the scan tool to the terminal and
downloading a new calibration file from the • Select ECU Location - Vehicle
terminal into the scan tool memory. e. Verify the connections on the Preparing for
3. Reconnecting the scan tool to the vehicle and Communication screen, then click "Next".
uploading the new calibration file into the ECM. f. Verify the VIN on the Validate Vehicle
Identification Number (VIN) screen, then click
Performing the Remote Procedure "Next".
1. Connect a scan tool to the vehicle and obtain the
Notice: If the ECM is replaced to new one, VIN
ECM information using the following procedure:
does not displayed. Input correct VIN reading
from stamped VIN or affixed VIN plate on the
Notice: Ensure the ECM is installed in the vehicle
vehicle. If the ECM from another vehicle is
and the battery is fully charged before
installed, input correct VIN by same way.
programming.
g. Highlight Engine on the Select System Type
a. Install a scan tool.
screen, then click "Next", if on-screen
b. Turn ON the ignition, with the engine OFF. instruction displayed.
c. Select Service Programming System (SPS) > h. Complete the following information based on
Request Info. the service ID plate on the Validate Vehicle
d. If there is already stored in the scan tool, the Data screen until "Next" is highlighted, then
existing data is displayed on the screen. The click "Next".
scan tool asks user to keep existing data "Keep • Model
Data" or "Continue" to request new vehicle
• Model year
information from the ECM. If there is no data in
the scan tool, it will immediately start vehicle • Engine type
identification. • Model designator
e. Select the vehicle description by following the • Destination code
on-screen instructions based on stamped VIN • Transmission type
or affixed VIN plate on the vehicle.

i. Verify your selection on the Summary screen. • Select Programming Process - Identify whether
as existing ECM is being reprogrammed or an
Notice: Refer to Service Bulletin and ECM is being replaced with a new one.
Description column before service • Select ECU Location - Vehicle
programming is performed if the bulletins are
4. Complete all vehicle data on the Preparing for
listed along with the calibration files.
Communication/ Determine Vehicle screen until
Notice: Select Cancel if you receive a message
"Next" is highlighted, then click "Next".
stating that the calibration selected is already
the current calibration in the ECM and 5. Follow the instruction on the Preparing for
reprogramming with the same download is not Communication screen, then click "Next".
allowed.
Notice: In order to reduce the potential for signal
j. Click "Reprog".
loss, the RS-232 cable should not be more than 25
k. The Transfer Data screen will appear until the feet long.
progress bar reaches 100%.
6. Verify the VIN on the Validate Vehicle Identification
5. Close the application and return to the TIS Number (VIN) screen, then click "Next".
application selection screen after the download is
complete. Notice: If the ECM is replaced to new one, VIN
6. Turn OFF the scan tool and disconnect from the does not displayed. Input correct VIN reading from
terminal. stamped VIN or affixed VIN plate on the vehicle. If
7. Transfer the data from the scan tool to the ECM the ECM from another vehicle is installed, input
using the following procedure: correct VIN by same way.
a. Install a scan tool. 7. Highlight Engine on the Select System Type
screen, then click "Next", if on-screen instruction
b. Turn ON the ignition, with the engine OFF.
displayed.
c. Select Service Programming System (SPS) >
8. Complete the following information based on the
Program ECU.
service ID plate on the Validate Vehicle Data
d. Turn OFF all accessories and press "Continue". screen until "Next" is highlighted, then click "Next".
e. Programming in Process will appear until the • Model
progress bar reaches 100%.
• Model year
Notice: Some warning lamp may turn ON or • Engine type
blink while programming the ECM since • Model designator
communication between the ECM and other • Destination code
modules are interrupted. Clear DTC in any
• Transmission type
module after programming.
9. Verify your selection on the Summary screen.
f. Press "Continue" and exit the program after the
scan tool displays "Programming Was
Notice: Refer to Service Bulletin and Description
Successful".
column before service programming is performed if
8. Turn OFF the ignition. the bulletins are listed along with the calibration
9. Turn OFF the scan tool and disconnect from the files.
vehicle. Notice: Select Cancel if you receive a message
stating that the calibration selected is already the
current calibration in the ECM and reprogramming
Service Programming System (SPS) (Pass- with the same download is not allowed.
Thru Procedure) 10. Click "Reprog".
Pass-Thru programming allows the scan tool to remain 11. The Transfer Data screen will appear until the
connected to the terminal and to the vehicle throughout progress bar reaches 100%.
the programming process. The vehicle must be in close Some warning lamp may turn ON or blink while
proximity to the terminal while using Pass-Thru. programming the ECM since communication
1. Launch the TIS application. between the ECM and other modules are
2. Select the Service Programming System at the interrupted. Clear DTC in any module after
main screen. programming.
3. Highlight the following information on the Select 12. Close the application and return to the TIS
Diagnostic Tool and Programming Process screen, application selection screen after the download is
then click "Next": complete.
• Select Diagnostic Tool-Select Pass - Thru 13. Turn OFF the ignition.

14. Turn OFF the scan tool and disconnect from the
vehicle.
Description and Operation

Engine Control Module (ECM) Description • The exhaust gas recirculation (EGR) system
control
Engine Control Module (ECM) Service Precautions
• The turbocharger system control
• The diesel particulate defuser (DPD) system
control
• The preheating (glow) system control
• The exhaust brake system control
• The immobilizer system control
• On-board diagnostics for engine control
The ECM constantly observes the information from
various sensors. The ECM controls the systems that
affect vehicle performance. The ECM performs the
CAUTION diagnostic function of the system. The ECM can
recognize operational problems, alert the driver
To avoid electric shock; through the malfunction indicator lamp (MIL), and store
Set the key switch to the "OFF" or "LOCK" diagnostic trouble codes (DTCs). DTCs identify the
position before checking or repairing the system faults to aid the technician in making repairs.
computer, wiring or/and connectors.
LNW76ESH000301
Important: The symbol “!” warns you of an electric

shock hazard. To avoid shock and possible serious
injury, DO NOT touch the terminals. When
disconnecting the harness connectors, always turn
OFF the ignition switch or disconnect the battery cable.
-------------------------------------------------------
-----------------------
------------------------------------------------------- -----------------------------------
-----------------------------------
----------------------------
---------------------------
---------------------------
CAUTION
---------------------------------
--------------------------------------------------------
------------------------------ -------------------- ------------------------------------------------------
-------------------------------------------------
MFW84CSH002201
The engine control module (ECM) is designed to

withstand normal current draws associated with vehicle
operation. Avoid overloading any circuit. When testing
for opens and shorts, do not ground or apply voltage to
any of the ECM circuits unless instructed to do so. In
some cases, these circuits should only be tested using
a DMM. The ECM should remain connected to the
ECM harness. The ECM mainly controls the following
items:
• The fuel system control
Sensor inputs Fuel injection controls
Intake air temperature (IAT) sensor Fuel rail pressure (FRP) regulator
Mass air flow (MAF) sensor (Euro 4 specification) Fuel injector #1
ECM Input & Output
Engine coolant temperature (ECT) sensor Fuel injector #2

Fuel temperature (FT) sensor Fuel injector #3
Barometric pressure (BARO) sensor Fuel injector #4
Boost pressure sensor Fuel injector #5
Accelerator pedal position (APP) sensor Fuel injector #6
EGR position sensor (except Euro 2 specification)
Intake throttle position sensor (except Euro 2 specification) Actuator controls
Crankshaft position (CKP) sensor Intake throttle motor (except Euro 2 specification)
Camshaft position (CMP) sensor EGR motor (except Euro 2 specification)
Fuel rail pressure (FRP) sensor Exhaust brake solenoid (Euro 4 specification)
Vehicle speed sensor (VSS) Exhaust throttle solenoid (Euro 4 specification)
Exhaust differential pressure sensor (Euro 4 specification) Rotary electric actuator (REA)
Exhaust temperature sensor 1 (Euro 4 specification)
Exhaust temperature sensor 2 (Euro 4 specification)
Idle up sensor Relay controls

ECM Glow relay
PTO throttle sensor
Starter cut relay
ECM main relay
Switch inputs
Ignition switch (ON/ start position) Lamp controls
Clutch switch Malfunction indicator lamp (MIL)
Parking brake switch Service vehicle soon (SVS) lamp (Euro 4 specification)
Neutral switch Glow plug lamp
DPD regeneration switch (Euro 4 specification) Exhaust brake lamp
Exhaust brake switch DPD lamp (Euro 4 specification)
Oil level switch Oil pressure lamp
Cruise control main switch Cruise control main lamp
Cruise control set/ coast switch Cruise control set lamp
Cruise resume/ accel switch
Cruise cancel switch
Communications
A/C switch
Controller area network (CAN) (Euro 4 specification)
Diagnostic request switch
Engine Control System (6HK1)
Keyword serial data (except Euro 4 specification)
MFWB1AXF001401
1A-365

ECM Voltage Description • If the part has been handled while sliding across
The ECM supplies a buffered voltage to various the seat, while sitting down from a standing
switches and sensors. The ECM can do this because position, or while walking a distance, touch a
resistance in the ECM is so high in value that a test known good ground before installing the part.
lamp may not illuminate when connected to the circuit. • Charge by induction occurs when a person with
An ordinary shop voltmeter may not give an accurate well insulated shoes stands near a highly charged
reading because the voltmeter input impedance is too object and momentarily touches ground. Charges
low. Use a 10-megaohm input impedance DMM, to of the same polarity are drained off leaving the
ensure accurate voltage readings. The input and/ or person highly charged with opposite polarity.
output devices in the ECM include analog-to-digital
converters, signal buffers, counters, and special Malfunction Indicator Lamp (MIL) Operation
drivers. The ECM controls most components with The MIL is located in the instrument panel cluster. The
electronic switches which complete a ground circuit MIL will display the engine symbol when commanded
when turned ON. ON:
Aftermarket Electrical and Vacuum Equipment

Aftermarket or add-on electrical and vacuum
equipment is defined as any equipment which connects
to the vehicle's electrical or vacuum systems that is
installed on a vehicle after the vehicle leaves the
factory. No allowances have been made in the vehicle
design for this type of equipment. No add-on vacuum
equipment should be added to this vehicle. Add-on
electrical equipment must only be connected to the
vehicle's electrical system at the battery power and
ground. Add-on electrical equipment, even when
installed to these guidelines, may still cause the power
train system to malfunction. This may also include
equipment not connected to the vehicle electrical
system such as portable telephones and audios.
Therefore, the first step in diagnosing any power train
fault is to eliminate all aftermarket electrical equipment MFW81ASH000301
from the vehicle. After this is done, if the fault still
exists, the fault may be diagnosed in the normal The MIL indicates that an emission related fault (Type
manner. A or B) has occurred (Euro 4 specification) or engine
performance related fault has occurred (except Euro 4
Electrostatic Discharge Damage specification) and vehicle service is required. The
Electronic components used in the ECM are often following is a list of the modes of operation for the MIL:
designed to carry very low voltage. Electronic • The MIL illuminates when the ignition switch is
components are susceptible to damage caused by turned ON, with the engine OFF. This is a lamp test
electrostatic discharge. By comparison, as much as to ensure the MIL is able to illuminate. (Euro 4
4,000 volts may be needed for a person to feel even specification)
the zap of a static discharge. There are several ways
• The MIL illuminates for approximately 3 seconds
for a person to become statically charged. The most
when the ignition switch is turned ON, with the
common methods of charging are by friction and
engine OFF. This is a lamp test to the MIL is able
induction.
to illuminate. (except Euro 4 specification without
• An example of charging by friction is a person speed limiter device)
sliding across a vehicle seat.
• The MIL illuminates for approximately 15 seconds
Important: To prevent possible electrostatic discharge
and blinks 3 times when the ignition switch is
damage, follow these guidelines:
turned ON, with the engine OFF. This is a lamp test
• Do not touch the ECM connector pins or soldered to the MIL is able to illuminate and a speed limiter
components on the ECM circuit board. device installation check. (except Euro 4
• Do not open the replacement part package until specification with speed limiter device)
the part is ready to be installed. • The MIL turns OFF after the engine is started if a
• Before removing the part from the package, diagnostic fault is not present.
ground the package to a known good ground on
the vehicle.

• The MIL remains illuminated after the engine is • The SVS lamp illuminates for approximately 15
started if the ECM detects a fault. A DTC is stored seconds and blinks 3 times when the ignition
any time the ECM illuminates the MIL due to an switch is turned ON, with the engine OFF. This is a
emission related fault (Euro 4 specification), and lamp test to the SVS lamp is able to illuminate and
engine performance related fault has occurred a speed limiter device installation check. (with
(except Euro 4 specification). speed limiter device)
• The SVS lamp turns OFF after the engine is
started if a diagnostic fault is not present.
• The SVS lamp remains illuminated after the engine
Except Euro 4 specification with speed limiter device is started if the ECM detects a fault. A DTC is
stored any time the ECM illuminates the SVS lamp
due to a non-emission related fault.
Ignition switch ON 1 sec. 1 sec. 1 sec.
ON
Euro 4 specification with speed limiter device
OFF
15 sec.
1 sec. 1 sec. 1 sec.
Ignition switch ON 1 sec. 1 sec. 1 sec.
ON
LNW76ESH006201
OFF
Service Vehicle Soon (SVS) Lamp Operation 15 sec.

1 sec. 1 sec. 1 sec.
The service vehicle soon (SVS) lamp is located in the

instrument panel cluster. The SVS lamp will display the
vehicle with wrench symbol when commanded ON:
LNW76ESH006301
Engine Control Component Description

Accelerator Pedal Position (APP) Sensor
1 2
MFW81ASH000501
The SVS lamp indicates that an non-emission related

fault (Type C DTC) has occurred and vehicle service
required. The following is a list of the modes of
operation for the SVS lamp:
LNW81ASH000801
• The SVS lamp illuminates when the ignition switch
is turned ON, with the engine OFF. This is a lamp Legend
test to ensure the SVS lamp is able to illuminate. 1. Accelerator pedal bracket
2. Accelerator pedal position (APP) sensor
3. Accelerator pedal

The APP sensor is mounted on the accelerator pedal Boost Pressure Sensor
bracket. The sensor is made up of two individual
sensors within one housing. The ECM uses the APP
sensors to determine the amount of acceleration or
deceleration that is desired. The APP sensors are hall
element type sensors. Each APP sensor provides a
different signal to the ECM on the each signal circuit,
which relative to the position changes of the
accelerator pedal angle. The APP sensor 1 signal
voltage is low at rest and increases as the pedal is
depressed. The APP sensor 2 signal voltage is high at
rest and decreases as the pedal is depressed.
Barometric Pressure (BARO) Sensor
LNW76ESH002101
The boost pressure sensor is located in the air

induction tubing. The boost pressure sensor is a
transducer that varies voltage according to changes in
the air pressure inside the air tubing. The boost
pressure sensor provides a signal to the ECM on the
signal circuit, which is relative to the pressure changes
in the air tubing. The ECM should detect a low signal
voltage at a low boost pressure, such as low engine
load. The ECM should detect high signal voltage at a
high boost pressure, such as high engine load.
RTW76ESH002401 Camshaft Position (CMP) Sensor
The BARO sensor is located behind of the lower cover.

The BARO sensor is a transducer that varies voltage
according to changes the barometric pressure. The 1
BARO sensor provides a signal to the ECM on the
signal circuit, which is relative to the pressure changes
of the barometric pressure. The ECM should detect a 60
low signal voltage at a low barometric pressure, such
as high altitude place. The ECM should detect high 15
signal voltage at a high barometric pressure. The ECM
uses this voltage signal to calibrate the fuel injection
quantity and injection timing for altitude compensation. 2
LNW76ESH002001
Legend
1. Camshaft gear
2. Rotating direction
3. Camshaft position (CMP) sensor

The CMP sensor is installed on the cylinder head at the The CKP sensor is located under the fuel supply pump.
rear of the camshaft gear. The CMP sensor detects The sensor rotor is fixed on the flywheel. There are 56
total of seven projections per one engine cycle (six notches spaced 6° apart and a 30° section that is open
projections arranged equally every 60° and one span. This open span portion allows for the detection of
reference projection on the camshaft gear surface). top dead center (TDC). The CKP sensor is a magnetic
The CMP sensor is a magnetic resistance element resistance element (MRE) type sensor, which
(MRE) type sensor, which generates a square wave generates a square wave signal pulse. Detecting the
signal pulse. open span portion from the CKP sensor and one
reference projection from the camshaft position (CMP)
Crankshaft Position (CKP) Sensor sensor, the ECM determines cylinder #1 compression
TDC to ensure they correlate with each other.
Engine Coolant Temperature (ECT) Sensor
1
1
MFW76ESH000601
MFW76ESH000501
A Legend
2
1. Engine coolant temperature (ECT) sensor
The ECT sensor is installed to the thermostat housing.

The ECT sensor is a variable resistor and it measures
6
the temperature of the engine coolant. When the ECT

sensor is cold, the sensor resistance is high. When the
30
engine coolant temperature increases, the sensor

1
lower sensor resistance, the ECM detects a lower
A
voltage on the signal circuit.
Section A-A
MFW76ESH000801
Legend
1. Crankshaft position (CKP) sensor
2. Flywheel

Fuel Temperature (FT) Sensor Euro 2 Specification
2
1
LNW81ASH001301
BLWA1ASH000401
Legend The IAT sensor is fitted between the air cleaner and
1. Fuel rail pressure (FRP) regulator turbocharger. It is internal to the mass air flow (MAF)
2. Fuel temperature (FT) sensor sensor. The IAT sensor is a variable resistor and it
measures the temperature of the air entering the
The FT sensor is installed to the fuel supply pump. The engine. When the IAT sensor is cold, the sensor
FT sensor is a variable resistor and it measures the resistance is high. When the air temperature increases,
temperature of the fuel entering the fuel supply pump. the sensor resistance decreases. With high sensor
When the FT sensor is cold, the sensor resistance is resistance, the ECM detects a high voltage on the
high. When the fuel temperature increases, the sensor signal circuit. With lower sensor resistance, the ECM
resistance decreases. With high sensor resistance, the detects a lower voltage on the signal circuit.
lower sensor resistance, the ECM detects a lower Mass Air Flow (MAF) Sensor (Except Euro 2
voltage on the signal circuit. Specification)
Intake Air Temperature (IAT) Sensor

Except Euro 2 Specification
AAW46ESH001401
AAW46ESH001401

The MAF sensor is an air flow meter that measures the
amount of air that enters the engine. It is fitted between
the air cleaner and turbocharger. A small quantity of air
that enters the engine indicates deceleration or idle
speed. A large quantity of air that enters the engine
indicates acceleration or a high load condition. The
MAF sensor assembly consists of a MAF sensor
element and an intake air temperature (IAT) sensor that
are both exposed to the air flow to be measured. The
MAF sensor element measures the partial air mass
through a measurement duct on the sensor housing.
Fuel System Description
Pressure
Pressure sensor Fuel rail limiter valve
Fuel filter
Supply pump
Pre Fuel filter
Injectors
Fuel tank ECM
Various sensors
(accelerator position sensor, coolant temperature,
Camshaft Crankshaft mass air flow, etc.)
position position
sensor sensor
MFWB1AMF001001
The common rail system uses a type of accumulator 1. High Pressure Control
chamber called the common rail (fuel rail) to store • Enables high pressure injection from low engine
pressurized fuel, and injectors that contain speed range.
electronically controlled solenoid valves to spray the
• Optimizes control to minimize particulate matter
pressurized fuel in the combustion chambers. The
and NOx emissions.
injection system (injection pressure, injection rate, and
2. Injection Timing Control
injection timing) is controlled by the ECM, and therefore
the common rail system can be controlled • Enables finely tuned optimized control in
independently, free from the influence of engine speed accordance with running conditions.
and load. This ensures a stable injection pressure at all 3. Injection Rate Control
time, particularly in the low engine speed range, so that • Pre injection control that performs a small amount
black smoke specific to diesel engines generated of injection before main injection.
during vehicle starting or acceleration can be reduced The common rail system consists primarily of a fuel
dramatically. As a result, exhaust gas emissions are supply pump, fuel rail, injectors, and ECM.
clear and reduced, and higher output is achieved.

Fuel System Component Description
Injector
6
64
00 2
0000
3
5
LNW76EMH000101
Legend
1. Terminal stud
2. Fuel leak off port
3. O-ring
4. Fuel inlet port
5. Injector parts number marking
6. QR plate
Electronic control type injectors controlled by the ECM

are used. Compared with conventional injection
nozzles, a command piston, solenoid valve, etc. are
added.
ID codes displaying various injector characteristic are
laser marked in the plate, and ID codes showing these
in numeric form (30 alphanumeric figures are displayed
and only 24 are used). This system uses fuel injector
flow rate information (ID codes) to optimize injection
quantity control. When an injector is newly installed in a
vehicle, it is necessary to input the ID codes in the
ECM.
QR (Quick Response) codes or fuel injector flow rate
(ID codes) have been adopted to enhance the injection
quantity precision of the injectors. The adoption of
codes enables injection quantity dispersion control
throughout all pressure ranges, contributing to
improvement in combustion efficiency and reduction in
exhaust gas emissions.
Return port
Solenoid
Driving current Driving current Driving current
TWV
Outlet orifice From fuel rail

Control chamber
Inlet orifice
Pressure in Pressure in Pressure in

Command piston control chamber control chamber control chamber
Nozzle
Injection rate Injection rate
No injection Injection Injection end
RTW76EMF000601
1) Non-injection state
The two way valve (TWV) closes the outlet orifice by
means of a spring force, when no current is supplied
from the ECM to the solenoid. At this time, the fuel
pressure applied to the nozzle leading end is equal to
the fuel pressure applied to the control chamber
through the inlet orifice. As for the force competition in
this state, the pressure on the command piston upper
surface + nozzle spring force defeat the pressure on
the nozzle leading end, and consequently the nozzle is
pushed downward to close the injection holes.
2) Injection start
The TWV is pulled up to open the outlet orifice, and
thus the fuel leaks toward the return port, when the
current is supplied from the ECM to the solenoid. As a
result, the nozzle is pushed up together with the
command piston by the fuel pressure applied to the
nozzle leading end, and then the nozzle injection holes
open to inject the fuel.
3) Injection end
The TWV lowers to close the outlet orifice, when the
ECM shuts off a current supply to the solenoid. As a
result, the fuel cannot leak from the control chamber,
and thus the fuel pressure in the control chamber rises
abruptly and then the nozzle is pushed down by the
command piston to close the nozzle injection holes,
resulting in the end of fuel injection.

Fuel Supply Pump
Injector Fuel rail

Suction pressure
Delivery valve Suction valve Feed pressure
High pressure
Plunger
Return pressure
Return
FRP regulator
Fuel overflow
Regulation valve
Feed pump
Driveshaft Fuel inlet
Suction
Fuel filter
Fuel tank
Pre fuel filter MFWB1AMF000901
The fuel supply pump is the heart of the common rail Fuel Rail (Common Rail)
type electronic fuel injection system. The fuel supply
pump is installed at the same location as the
conventional injection type pump, which spins at a 1 to
1 ratio of fuel supply pump to crankshaft speed. A fuel
rail pressure (FRP) regulator and fuel temperature
sensor are part of the fuel supply pump assembly.
Fuel is drawn from the fuel tank via the fuel supply 1
pump by the use of an internal feed pump (trochoid
type). This feed pump pumps fuel into a 3-plunger
chamber also internal to the fuel supply pump. Fuel into
this chamber is regulated by the FRP regulator solely
controlled by current supplied from the ECM. No
current to the solenoid results in maximum fuel flow
whereas full current to the solenoid produces no fuel 2
flow. As the engine spins, these three plungers produce
high pressure in the fuel rail. Since the ECM controls
the flow of fuel into this 3-plunger chamber, it therefore
controls the quantity and pressure of the fuel supply to
the fuel rail. This optimizes performance, improves MFW76ESH000401
economy and reduces NOx emissions. Legend

1. Pressure limiter valve
2. Fuel rail pressure (FRP) sensor

Along with the employment of a common rail type Fuel Rail Pressure (FRP) Regulator
electronic control fuel injection system, the fuel rail is
provided to store high pressure fuel between supply 2
pump and injectors. A pressure sensor and a pressure 1
limiter are installed on the fuel rail. The pressure sensor
detects the fuel pressure inside the fuel rail and sends
its signal to the ECM. Based on this signal, the ECM
controls the fuel pressure inside the fuel rail via the fuel
rail pressure (FRP) regulator of the supply pump. The
pressure limiter opens the valve mechanically to relieve
the pressure when the fuel pressure inside the fuel rail
is excessive.
Fuel Rail Pressure (FRP) Sensor

The FRP sensor is installed to the fuel rail and it
detects the fuel pressure in the fuel rail, converts the
pressure into a voltage signal, and sends the signal to
the ECM. The ECM monitors the FRP sensor signal
voltage. Higher fuel rail pressure provides higher signal
BLWA1ASH000401
voltage while lower pressure provides lower signal
voltage. The ECM calculates actual fuel rail pressure Legend
(fuel pressure) from the voltage signal and uses the 1. Fuel rail pressure (FRP) regulator
result in fuel injection control and other control tasks. 2. Fuel temperature (FT) sensor
Pressure Limiter Valve The fuel rail pressure (FRP) regulator [also known as
suction control valve (SCV)] is attached to the fuel
supply pump.
The ECM controls the duty ratio of the linear type fuel
rail pressure (FRP) regulator (the length of time that the
current is applied to the FRP regulator), in order to
control the quantity of fuel that is supplied to the high-
1 2 3 4 5 pressure plungers. Since only the quantity of fuel that is
required for achieving the target rail pressure is drawn
in, the drive load of the supply pump is decreased.
When current flows to the FRP regulator, variable
6 7
electromotive force is created in accordance with the
duty ratio, moving the solenoid plunger and changing
the opening of the fuel passage and thus regulating the
fuel quantity. With the FRP regulator OFF, the return
spring stretches, completely opening the fuel passage
and supplying fuel to the plungers (Full quantity intake
and full quantity discharge). By turning the FRP
regulator ON/ OFF, fuel is supplied in an amount
LNW41ASH001301
corresponding to the actuation duty ratio, and fuel is
Legend discharged by the plungers.
1. Valve
2. Valve body
3. Valve guide
4. Spring
5. Housing
6. Fuel rail
7. Fuel return pipe
The pressure limiter relieves pressure by opening the

valve if abnormally high pressure is generated. The
valve opens when pressure in rail reaches
approximately 220 MPa (32,000 psi), and closes when
pressure falls to approximately 50 MPa (7,250 psi).
Fuel leakage through the pressure limiter re-turns to
the fuel tank.

Fuel Injection System Description
Fuel Injection Quantity Control
This control determines the fuel injection quantity by
adding coolant temperature, fuel temperature, intake
air temperature, barometric pressure, mass air flow and
some switch inputs information corrections to the basic
injection quantity is calculated by the ECM based on
the engine operating conditions (engine speed,
accelerator pedal pressing amount and boost pressure
sensor). More fuel rate indicates if the engine load is
increased as the accelerator pedal is stepped on at
constant engine speed.
Combined with high pressure injection of atomized fuel,
this control improves exhaust gas and ensures proper
fuel consumption. Compared with conventional
mechanical governors, an electronic control system
provides higher degree of freedom of fuel injection
quantity control, thereby presenting high accelerator
response (acceleration feeling and pressing feeling).
Starting Injection Quantity Control

At the engine starting (after the key switch is turned to
the START position to start the engine, up to return of
key switch to the ON position), optimum fuel injection
quantity is controlled based on the information on the
engine speed and coolant temperature. At low
temperature, the fuel injection quantity increases.
When the engine started completely, this boosted
quantity mode at the starting is cancelled and normal
running mode is restored.
Idle Speed Control

A control is made so as to achieve stable idling speed
at all time regardless of engine secular changes or
engine condition variations. The ECM sets target idling
speed and controls the fuel injection quantity according
to the engine conditions (actual engine speed, coolant
temperature and engine load) to follow actual engine
speed to the target idling speed so as to ensure stable
idling speed.
Idle Vibration Control

A control is made so as to reduce the engine vibration
caused by torque variations between cylinders due to
variations in fuel injection quantity of each cylinder or
injector performance. The ECM corrects the injection
quantity between cylinders based on the revolution
signals from the crankshaft position (CKP) sensor.
Normal range of correction quantity between cylinders
is within ± 5 mm3.

Exhaust Gas Recirculation (EGR) System Description
1
2
MFW76EMF000801
Legend
1. EGR cooler 4. ECM
2. Oil cooler & EGR cooler 5. MAF sensor
3. EGR valve 6. Intake throttle valve
The EGR system recirculates a part of exhaust gas

back into the intake manifold, which results in reducing
nitrogen oxide (NOx) emissions. The EGR control
system uses an electronic control system to ensure
both driveability and low emission. A control current
from the ECM operates a motor to control the lift
amount of EGR valve. Also, EGR position sensors are
provided at the rear of the motor to feed actual valve lift
amount back to the ECM for more precision control of
the EGR amount.
The EGR control starts when the conditions for engine
speed, engine coolant temperature, intake air
temperature and barometric pressure are satisfied.
Then, the valve opening is calculated according to the
engine speed, and target fuel injection quantity. Based
on this valve opening, the drive duty of the motor is
provided and the valve is driven accordingly.

EGR Valve Intake Throttle Valve (Except Euro 2 Specification)
RTW56ESH001101
The intake throttle valve is located on the intake

manifold inlet. The ECM controls the intake throttle
valve opening based on the engine running condition.
The ECM controls the intake throttle valve by
controlling the motor. The motor is controlled based on
pulse width modulation (PWM) signal sent from the
ECM. A duty ratio change 0% to appropriate
percentage controls intake throttle valve opening angle.
MFWB1AMH000101
To close the valve, duty ratio is increased. To open the
valve, duty ratio becomes small.
The EGR valve is mounted on the intake manifold. The The intake throttle valve position is detected by the
ECM controls the EGR valve opening based on the position sensor, and relayed to the ECM. The position
engine running condition. The ECM controls the EGR sensor provides a signal to the ECM on the signal
valve by controlling the motor. The motor is controlled circuit, which is relative to the position changes of the
based on pulse width modulation (PWM) signal sent intake throttle valve angle. The ECM should detect a
from the ECM. The EGR valve position is detected by low signal voltage at a small opening amount or closed
the position sensor, and relayed to the ECM. The position. The ECM should detect high signal voltage at
position sensor is made up three individual sensors a large opening amount or full opened position.
within one housing. The EGR position sensor 1, 2 and
3 are hall element type sensors. The position sensor
provides a low or high signal state to the ECM on the
signal circuits, which is relative to the position changes
of the EGR valve.

Turbocharger Description
Euro 4 Specification
3 4
2
1 3
6 1
4
5
MFW76ESH001501
Legend
1. Rotary electric actuator (REA)
MFW76ESH001201
2. Close direction of nozzles
Legend 3. Open direction of nozzles
1. Exhaust gas 4. Control rod
2. Turbine wheel 5. Nozzle
3. Nozzle
4. Compressor wheel
5. Air cleaner The position of the turbocharger nozzle is controlled by
6. Intercooler the rotary electric actuator (REA) control module based
on the command from the ECM. When the engine is
The turbocharger is used to increase the amount of air low load condition, the turbocharger nozzles are moved
that enters the engine cylinders. This allows a to the open direction and boost pressure becomes low.
proportional increase of fuel to be injected into the When the engine is high load condition, the REA
cylinders, resulting in higher power output, more control module commands the control solenoid to close
complete combustion, and decreasing temperature of the turbocharger nozzles, and boost pressure becomes
cylinder heads, pistons, valves, and exhaust gas. This high. The ECM will vary the target boost pressure
cooling effect helps engine life longer. dependent upon the requirements of the engine power
Heat energy and pressures in the exhaust gas are output.
utilized to drive the turbine. Exhaust gas is directed to The intercooler also helps the performance of the
the turbine housing, and rotate the turbine wheel. Since engine. Pressurized air from the turbocharger have
the compressor wheel is attached directly to the turbine higher temperature than intake air, and intercooler
shaft, the compressor wheel rotates same speed as the cools the pressurized air. Cooling the intake air
turbine wheel. Clean air from the air cleaner is drawn temperature make the engine efficiency higher and
into the compressor housing and wheel. The air is engine power higher.
compressed and flow through the intercooler, intake
manifold, and go into the cylinders.

Except Euro 4 Specification The turbocharger is used to increase the amount of air
that enters the engine cylinders. This allows a
proportional increase of fuel to be injected into the
cylinders, resulting in higher power output, more
complete combustion, and decreasing temperature of
cylinder heads, pistons, valves, and exhaust gas. This
cooling effect helps engine life longer.
3
Heat energy and pressures in the exhaust gas are
4
5 utilized to drive the turbine. Exhaust gas is directed to
the turbine housing. and rotate the turbine wheel. Since
the compressor wheel is attached directly to the turbine
1 shaft, the compressor wheel rotates same speed as the
turbine wheel. Clean air from the air cleaner is drawn
into the compressor housing and wheel. The air is
2 compressed and flow through the intercooler, intake
6
manifold, and go into the cylinders.
The amount of air pressure rise and air volume
delivered to the engine from the compressor outlet is
regulated by a waste gate valve in the turbine housing.
The position of the waste gate valve is controlled by the
amount of intake side pressure of the turbocharger. The
diaphragm inside of the waste gate actuator is pressure
sensitive, and controls the position of the valve inside
the turbocharger. The position of the valve will increase
or decrease the amount of boost pressure. The
intercooler also helps the performance of the engine.
Pressurized air from the turbocharger have higher
temperature than intake air, and intercooler cools the
pressurized air. Cooling the intake air temperature
RTW56EMH000201
make the engine efficiency higher and engine power
Legend higher.
1. Exhaust gas
2. Waste gate valve
3. Turbine wheel
4. Compressor wheel
5. Air cleaner
6. Charge air cooler (Intercooler)

Diesel Particulate Defuser (DPD) System Description
2 1
15
17
14
8 16
6 7 12
5
4
11 13
9 10
LNW81AMF000801
Legend
1. Air cleaner 10. DPD filter
2. Mass air flow (MAF) sensor 11. Exhaust throttle valve
3. Engine assembly 12. Exhaust throttle solenoid valve
4. Exhaust brake valve 13. Exhaust silencer
5. Exhaust brake solenoid valve 14. ECM
6. Exhaust temperature sensor 2 15. Other inputs
7. Exhaust temperature sensor 1 16. DPD regeneration switch
8. Exhaust differential pressure sensor 17. DPD lamps (green and amber)
9. Oxidation catalyst
4
1
2
3
MFW76ESF000201
Legend
1. Exhaust brake valve 4. Exhaust differential pressure sensor
2. Exhaust temperature sensor 2 (in front of oxidation 5. Exhaust throttle valve
catalyst) 6. DPD assembly
3. Exhaust temperature sensor 1 (in front of filter)
The DPD is a system that uses an oxidation catalyst to Exhaust Differential Pressure Sensor
clean the exhaust gas, and a filter to collect PM
discharged from the engine. When PM accumulated in
the filter, regeneration is performed. The ECM detects
the condition of PM accumulations from the exhaust
differential pressure sensor or from mileage. When it is
reached to a certain amount of PM accumulations or a
certain length of mileage, the automatic regeneration
starts. If the automatic regeneration cannot be
completed by some reason, the manual regeneration is
requested to the driver by blinking the DPD amber lamp
or “PUSH DPD SWITCH” indicator on the instrument
panel cluster. During regeneration, the temperature
inside the filter is raised, and the accumulated PM is
burned off. In order to adjust to optimized temperature,
the ECM detects exhaust temperature using the
exhaust temperature sensors, and then raises the
temperature by controlling fuel injections, the exhaust
throttle valve and exhaust throttle valve to burn off the
accumulated PM. Once the regeneration starts, it must MFW4ADSH002301
be finished within a certain time. After regeneration is

finished, a purification of the filter is judged by The exhaust differential pressure sensor is attached to
monitoring the exhaust differential pressure. the chassis frame near the DPD assembly. The
exhaust differential pressure sensor is a transducer
that varies voltage according to changes of the exhaust
gas differential pressure between in front and in rear of
DPD filter. The exhaust differential pressure sensor
provides a signal to the ECM on the signal circuit,
which is relative to the differential pressure changes in
front and in rear of DPD filter. The ECM should detect a
low signal voltage at a low differential pressure, such
as small PM accumulation. The ECM should detect
high signal voltage at high differential pressure, such as
large PM accumulation.

Exhaust Temperature Sensor
MFW4ADSH002401
The exhaust temperature sensor 1 and 2 are installed

to the DPD housing. Both exhaust temperature sensors
have thermistor (negative temperature coefficient
resistor type). The sensor 1 measures the temperature
of the exhaust gas in front of DPD filter and the sensor
2 measures the temperature of the exhaust gas in front
of oxidation catalyst. While the sensor detects that the
exhaust temperature is low, the sensor resistance is
high. When the exhaust temperature increases, the
sensor resistance decreases. With high sensor
resistance, the ECM detects a high voltage on the
signal circuit. With lower sensor resistance, the ECM
detects a lower voltage on the signal circuit.
Exhaust Throttle Valve & Exhaust Brake Valve

The exhaust throttle valve is installed in rear of the DPD
housing and it composes a part of the exhaust system.
The ECM controls the exhaust throttle solenoid valve,
which supplies power to the exhaust throttle solenoid
valve based on the DPD system regeneration status.
The exhaust throttle solenoid air energizes to apply
vacuum pressure to the diaphragm chamber to operate
exhaust throttle valve.
The exhaust brake valve is installed in front of the DPD
housing and it also composes a part of the exhaust
system. The ECM controls the exhaust brake solenoid
valve based on the DPD regeneration status or exhaust
brake command signal. The exhaust brake solenoid
valve energizes to apply air pressure to operate
exhaust brake valve.
Special Tools and Equipment

Special Tools and Equipment
Illustration Tool Number/ Description Illustration Tool Number/ Description
5-8840-2835-0 (J-35616-C)
Connector Test Adapter Kit
Adapter Harness
(With Test Lamp)
5884028350 ADAPTER-H
5-8840-2691-0
Digital Multimeter
5884026910
Tech2 Kit
AAW0Z0SH015701
THA-10
Tech2 DC24 Volt Adapter 2
ADAPTER2
CAN-di Module (Euro4

specification)
CANDI
C Breaker Box
BREAKER
69200_MG6HKED-WE-0871_奥付 2011.5.9 4:02 PM ページ 1
Published: May, 2011 All rights reserved.

Ninth Edition
WORKSHOP MANUAL
(6HK1 model)
Issued by ISUZU MOTORS LIMITED
E-Solutions & Service Marketing Dept.
Shinagawa-ku, Tokyo, 140-8722 Japan
0-XXXKI
69200_MG6HKED-WE-0871_奥付 2011.5.9 4:02 PM ページ 2
2008-2011MY
2008-2011MY
WORKSHOP MANUAL
WORKSHOP MANUAL ENGINE CONTROL SYSTEM (6HK1 model)

(6HK1 model)
No.MG6HKED-WE-0871

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2008-2011MY

WORKSHOP MANUAL ENGINE CONTROL SYSTEM (6HK1 model)

Engine Control System (6HK1) 1A-1

1A-2 Engine Control System (6HK1)

Engine Control System (6HK1) 1A-3

1A-4 Engine Control System (6HK1)

Altitude vs. Barometric Pressure

Engine Control System (6HK1) 1A-5

Non-Emissions Related DTCs

Conditions for Clearing the SVS Lamp/ DTC - Type

1A-6 Engine Control System (6HK1)

Engine Control System (6HK1) 1A-7

1A-8 Engine Control System (6HK1)

Engine Control System (6HK1) 1A-9

Cruise control switch

Clutch pedal switch Starter cut relay

1A-10 Engine Control System (6HK1)

Boost pressure sensor 91

Fuel temperature sensor 83

Engine Control System (6HK1) 1A-11

1A-12 Engine Control System (6HK1)

Engine Control System (6HK1) 1A-13

1A-14 Engine Control System (6HK1)

Engine Control System (6HK1) 1A-15

1A-16 Engine Control System (6HK1)

Engine Control System (6HK1) 1A-17

1A-18 Engine Control System (6HK1)

6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 5 4 21 BLU/ WHT ECM main relay control

Connector No. FB24 28 – Not used

Connector color Black 29 – Not used

Test adapter No. J-35616-64A 30 – Not used

Pin No. Wire color Pin function 31 – Not used

1 BLK/ YEL ECM power ground 32 – Not used

2 WHT/ RED Battery voltage 33 – Not used

3 BLK/ YEL ECM power ground 34 BRN/ YEL A/C signal

4 BLK/ YEL ECM power ground Dropping resistor (Euro 4

12 – Not used APP sensor 1, idle up sensor,

SVS lamp control (Euro 4 44 VIO/ WHT PTO switch signal

Engine Control System (6HK1) 1A-19

Connector No. FB24 Connector No. FB24

65 BRN/ BLU Cruise control switch signal

68 BLK/ YEL Ground Pin No. Wire color Pin function

MAF sensor signal (Euro 4 82 BLK FRP sensor signal

72 GRN/ WHT IAT sensor signal Intake throttle position sensor

1A-20 Engine Control System (6HK1)

Connector No. E26 Connector No. E26

Engine Control System (6HK1) 1A-21

Connector No. FL52

Boost Pressure Sensor

1A-22 Engine Control System (6HK1)

Camshaft Position (CMP) Sensor

Connector No. FB5 or FB144

Crankshaft Position (CKP) Sensor

Engine Control System (6HK1) 1A-23

Connector No. FU23

1A-24 Engine Control System (6HK1)

Connector No. FU23 EGR Valve

Connector color Light blue

DPD Regeneration Switch