For DENSO Authorized ECD Service Dealer OnlyDiesel Injection Pump SERVICE MANUAL Common Rail System for HINO J05D/J08E Type Engine OPERATION October, 2003 00400041E -1 TABLE OF CONTENTS 1. Product Application ------------------------------------------------------------------------------------1.1 Application ------------------------------------------------------------------------------------------------------------------1.2 System Components Parts Numbers --------------------------------------------------------------------------------2.1 Features of System ------------------------------------------------------------------------------------------------------[1] System Characteristics -----------------------------------------------------------------------------------------------[2] Comparison to the Conventional System ------------------------------------------------------------------------2.2 Outline of System ---------------------------------------------------------------------------------------------------------[1] Composition -------------------------------------------------------------------------------------------------------------[2] Operation ----------------------------------------------------------------------------------------------------------------2.3 Fuel System and Control System -------------------------------------------------------------------------------------[3] Fuel System -------------------------------------------------------------------------------------------------------------[4] Control System ---------------------------------------------------------------------------------------------------------3.1 Description of Main Components ------------------------------------------------------------------------------------[1] Supply Pump (HP3, HP4) --------------------------------------------------------------------------------------------- 1 1 1 2 2 3 4 4 4 5 5 5 6 6 2. Outline ------------------------------------------------------------------------------------------------------ 2 3. Construction and Operation--------------------------------------------------------------------------- 6 [2] Description of Supply Pump Components ------------------------------------------------------------------------ 13 [3] Rail -------------------------------------------------------------------------------------------------------------------------- 16 [4] Injector (G2 Type) ------------------------------------------------------------------------------------------------------- 17 [5] Engine ECU (Electronic Control Unit) ------------------------------------------------------------------------------ 22 3.2 Description of Control System Components ------------------------------------------------------------------------ 22 [1] Engine Control System Diagram ------------------------------------------------------------------------------------ 22 [2] Sensor and Relays ----------------------------------------------------------------------------------------------------- 23 3.3 Various Types of Controls ----------------------------------------------------------------------------------------------- 29 [1] Fuel Injection Rate Control ------------------------------------------------------------------------------------------- 30 [2] Fuel Injection Quantity Control --------------------------------------------------------------------------------------- 31 [3] Fuel Injection Timing Control ----------------------------------------------------------------------------------------- 35 3.4 Other Relevant Engine Control ----------------------------------------------------------------------------------------- 36 [1] EGR Control -------------------------------------------------------------------------------------------------------------- 36 3.5 Engine ECU ----------------------------------------------------------------------------------------------------------------- 37 [1] Diagnosis Codes -------------------------------------------------------------------------------------------------------- 37 [2] ECU External Wiring Diagram --------------------------------------------------------------------------------------- 44 [3] ECU Connector Diagram ---------------------------------------------------------------------------------------------- 45 0 1. Product Application 1.1 Application Vehicle Name Vehicle Model HINO145, HINO165, HINO185 HINO238, HINO268, HINO308, HINO338 Engine Model J05D J08E Exhaust Volume 4.73L 7.68L Reference Sales from Early ’04 Medium Truck 1.2 System Components Parts Number Part Name Supply Pump Injector Rail Engine ECU Medium Truck HINO238, Coolant Temp. Sensor HINO268, Crankshaft Position Sensor HINO308, HINO338 Cylinder Recognition Sensor Accelerator Position Sensor Intake Air Pressure Sensor EGR Valve Air Flow Meter Supply Pump Injector Rail Engine ECU Accelerator Position Sensor Coolant Temp. Sensor Crankshaft Position Sensor Cylinder Recognition Sensor Intake Air Pressure Sensor EGR Valve Air Flow Meter Medium Truck HINO145, HINO165, HINO185 Vehicle Name DENSO Part Number 294050-0011 095000-5281 095440-0480 102758-3010 198800-3160 071560-0110 029600-0570 949979-1360 079800-5890 135000-7091 197400-2000 294000-0251 095000-5391 095440-0530 102758-3010 198800-3160 071560-0110 029600-0570 949979-1360 079800-5890 135000-7071 197400-2000 Car Manufacturer Reference Part Number 22730-1311A 23910-1360A 22760-1180A 89560-6540A 78010-1200A 83420-1250A 89410-1280A 89410-1590A 89390-1080A 17350-1220A 22204-21010B 22730-1321A 23910-1310A 22760-1220A 89560-6540A 78010-1200A 83420-1250A 89410-1280A 89410-1590A 89390-1080A 17350-1210A 22204-21010B For EGR Control For EGR Control 1 2. Outline 2.1 Features of System The common rail system was developed primarily to cope with exhaust gas regulations for diesel engines, and aimed for 1. further improved fuel economy; 2. noise reduction; and 3. high power output. [1] System Characteristics The common rail system uses a type of accumulation chamber called a rail to store pressurized fuel, and injectors that contain electronically controlled solenoid valves to spray the pressurized fuel into the cylinders. Because the engine ECU controls the injection system (including the injection pressure, injection rate, and injection timing), the system is unaffected by the engine speed or load. This ensures a stable injection pressure at all times, particularly in the low engine speed range, and dramatically decreases the amount of black smoke ordinarily emitted by a diesel engine during start-up and acceleration. As a result, exhaust gas emissions are cleaner and reduced, and higher power output is achieved. (1) Injection Pressure Control a. Enables high-pressure injection, even in the low engine speed range. b. Optimizes control to minimize particulate matter and NOx emissions. (2) Injection Timing Control a. Optimally controls the timing to suit driving conditions. (3) Injection Rate Control a. Pilot injection control sprays a small amount of fuel before the main injection. Common Rail System Injection Pressure Control Optimization, High Pressurization Common Rail System Injection Pressure Injection Timing Injection Timing Control Optimization Common Rail System Injection Rate Control Injection Rate Speed Pilot Injection Main Injection Crankshaft Angle Particulate NOx Injection Quantity Control Conventional Pump Speed Cylinder Injection Volume Correction Conventional Pump Speed Injection Pressure QD0734E (4) EGR (Exhaust Gas Recirculation) Control a. By recirculating the exhaust gas into the intake side of the engine, the combustion temperature is reduced and NOx is decreased. 2 [2] Comparison to the Conventional System In-line, VE Pump High-pressure Pipe Momentary High Pressure Timer Governor System In-line Pump Feed Pump SCV (Suction Control Valve) Nozzle Supply Pump Usually High Pressure Delivery Valve Rail TWV Common Rail System Injector Fuel Tank VE Pump Injection Quantity Control Injection Timing Control Rising Pressure Distributor Injection Pressure Control Pump (Governor) Pump (Timer) Pump Pump Dependent upon Speed and Injection Quantity Engine ECU, Injector (TWV)*1 Engine ECU, Injector (TWV)*1 Engine ECU, Supply Pump Engine ECU, Rail QD2341E Engine ECU, Supply Pump (SCV)*2 *1 TWV: Two Way Valve *2 SCV: Suction Control Valve 3 rail. determines the quantity. The supply pump draws fuel from the fuel tank. and engine ECU. as well as the EGR (exhaust gas recirculation). The SCV (Suction Control Valve) in the supply pump effects this control in accordance with the command received from the ECU. (2) Rail a. Fuel Temperature Sensor Vehicle Speed Accelerator Opening Intake Air Pressure Intake Air Temperature Coolant Temperature Crankshaft Position Cylinder Recognition Sensor Intake Airflow Rate Engine ECU Rail Rail Pressure Sensor Pressure Limiter Injector Fuel Temperature Sensor Supply Pump SCV (Suction Control Valve) Fuel Tank Q000144E [2] Operation (1) Supply pump (HP3) a.2. Signals from the ECU determine the length of time and the timing in which current is applied to the injector. (4) Engine ECU a. The engine ECU calculates data received from the sensors to comprehensively control the injection quantity. This in turn. and pumps the high pressure fuel to the rail. timing and pressure. This injector replaces the conventional injection nozzle. rate and timing of the fuel that is injected from the injector. and achieves optimal injection by effecting control in accordance with signals from the ECU. (3) Injector (G2 type) a. The quantity of fuel discharged from the supply pump controls the pressure in the rail. The rail is mounted between the supply pump and the injector.2 Outline of System [1] Composition The common rail system consists primarily of a supply pump. and stores the highpressure fuel. injectors. 4 . (1) Sensors a. The injection quantity and timing are determined by controlling the length of time and the timing in which the current is applied to the TWV (Two-Way Valve) in the injector. (2) ECU. Sensor Engine Speed Crankshaft Position Sensor NE Injector Cylinder Recognition Cylider Recognition Sensor G Load Engine ECU Supply Pump (SCV) Rail Pressure Sensor •Injection Pressure Control EGR.2. Engine Warning Light Other Sensors and Switches Q000282E Actuator •Injection Quantity Control •Injection Timing Control Accelerator Position Sensor 5 . (3) Actuators a. The components of this system can be broadly divided into the following three types: (1) Sensors. Performs calculations based on the electrical signals received from the sensors. and is injected through the injector. the engine ECU controls the fuel injection system in accordance with the signals received from various sensors. (2) Engine ECU a. and (3) Actuators. via the rail. The injection pressure is determined by controlling the SCV (Suction Control Valve) in the supply pump. and sends them to the actuators in order to achieve optimal conditions. Detect the engine and driving conditions.3 Fuel System and Control System [1] Fuel System This system comprises the route through which diesel fuel flows from the fuel tank to the supply pump. as well as the route through which the fuel returns to the tank via the overflow pipe. and convert them into electrical signals. [2] Control System In this system. Operate in accordance with electrical signals received from the ECU. Injection system control is undertaken by electronically controlling the actuators. using signals from the engine ECU. The internal camshaft drives the two plungers. Construction and Operation 3. fuel temperature sensor. ring cam. b. and draws the fuel from the fuel tank. The supply pump has a built-in feed pump (trochoid type). The engine drives the supply pump at a ratio of 1:1. d. The two plungers for HP3 or the three plungers for HP4 are positioned vertically on the outer ring cam for compactness. The supply pump consists primarily of the pump body (cam shaft. and feed pump. and they pressurize the fuel sent to the plunger chamber and send it to the rail. The quantity of fuel supplied to the rail is controlled by the SCV.1 Description of Main Components [1] Supply Pump (HP3. The SCV is a normally opened type (the intake valve opens during de-energization). c. HP4) (1) Outline a. sending it to the plunger chamber. SCV (Suction Control Valve).3. and plungers). HP3 SCV Fuel Temperature Sensor Q000252E HP4 Fuel Temperature Sensor SCV Q000253E 6 . Injector Rail Discharge Valve Intake Valve Plunger Return Spring Intake Pressure Feed Pressure High Pressure Return Pressure Return Fuel Overflow SVC Regulating Valve Filter Camshaft Feed Pump Fuel Inlet Intake Fuel Tank Fuel Filter (with Priming Pump) QD0704E 7 . HP3 SCV Plunger Feed Pump Pump Body Ring Cam Fuel Temperature Sensor Regulating Valve Drive Shaft Filter Plunger Q000254E 8 . HP4 SCV Plunger Fuel Temperature Sensor Filter Feed Pump Ring Cam Regulating Valve Pump Body Drive Shaft Plunger Q000255E 9 . Supply Pump Interior Regulating Valve Feed Pump Overflow Fuel Tank Q000283E SCV (Suction Control Valve) Intake Valve Pumping Portion (Plunger) Rail (3) Construction of Supply Pump (in case of HP3 pump) a. As the cam shaft rotates. The eccentric cam is connected to the ring cam. The eccentric cam is attached to the cam shaft. and the ring cam moves up and down while rotating. Cam Shaft Eccentric Cam Ring Cam QD0706E b. the eccentric cam rotates eccentrically. The fuel that is drawn from the fuel tank passes through the route in the supply pump as illustrated. and is fed into the rail. Plunger Eccentric Cam Ring Cam Cam Shaft QD0727E 10 .(2) Supply Pump Internal Fuel Flow a. The plunger and the suction valve are attached to the ring cam. Plunger A Ring Cam Feed Pump Plunger B QD0728E 11 . The feed pump is connected to the rear of the cam shaft.c. 12 . in the case of the 6-cylinder engine used with the HP4 pump. 3 plungers pump fuel in a reciprocal movement for each one rotation of the cam. As a result.(4) Operation of the Supply Pump a. Conversely. Due to the spring force. Suction Valve Plunger A Eccentric Cam Delivery Valve Ring Cam SCV Plunger B Plunger A: Complete Compression Plunger B: Complete Intake Plunger A: Begin Intake Plunger B: Begin Compression Plunger A: Begin Compression Plunger B: Begin Intake Plunger A: Complete Intake Plunger B: Complete Compression QD0707E NOTE: There are 3 plungers for the HP4. Plunger B is pulled in the opposite direction to Plunger A. As shown in the illustration below (in case of HP3 pump). Plunger B draws in fuel. while Plunger A pumps it to the rail. the rotation of the eccentric cam causes the ring cam to push Plunger A upwards. each plunger pumps fuel in a reciprocal movement during the 360° cam rotation. In the case of the 4-cylinder engine used with the HP3 pump. and fuel is discharged by the plungers. the actuating load of the supply pump decreases. draws fuel from the fuel tank and feeds it to the two plungers via the fuel filter and the SCV (Suction Control Valve). which is integrated in the supply pump. Quantity Decrease Outer Rotor to Pump Chamber Quantity Decrease (Fuel Discharge) Inner Rotor Intake Port from Fuel Tank Discharge Port Quantity Increase Quantity Increase (Fuel Intake) QD0708E (2) SCV: Suction Control Valve (Normally open type) a. (Full quantity intake and full quantity discharge) e. the return spring contracts. in order to control the quantity of fuel that is supplied to the high-pressure plunger. When the SCV is ON. This is done in accordance with the space that increases and decreases with the movement of the outer and inner rotors. b. The feed pump is driven by the drive shaft. The trochoid type feed pump. A linear solenoid type valve has been adopted. When current flows to the SCV. With the rotation of the inner rotor. Exterior View of SCV Cross-section of SCV Return Spring SCV Pump Body Cylinder Q000270E 13 . changing the opening of the fuel passage and thus regulating the fuel quantity. the feed pump draws fuel from its suction port and pumps it out through the discharge port. c. The armature moves the cylinder to the left side. Because only the quantity of fuel that is required for achieving the target rail pressure is drawn in. moving the armature to the left side. The ECU controls the duty ratio (the duration in which current is applied to the SCV). With the SCV OFF. completely opening the fuel passage and supplying fuel to the plungers. f. the force of the return spring moves the cylinder to the right. By turning the SCV ON/OFF.[2] Description of Supply Pump Components (1) Feed Pump a. closing the fuel passage (normally opened). variable electromotive force is created in accordance with the duty ratio. d. fuel is supplied in an amount corresponding to the actuation duty ratio. [In case of short time ON duty] Short time ON duty → large valve opening → maximum intake quantity Feed Pump Plunger SCV Cylinder Large Opening Cylinder Q000051E 14 . [In case of long time ON duty] Long time ON duty → small valve opening → minimum intake quantity Feed Pump Plunger SCV Cylinder Small Opening Cylinder Q000052E 15 . 5 kg/cm2}) that has been delivered from the supply pump and distributes the fuel to each cylinder injector. Valve Open 200 MPa (2038 kg/cm2) Valve Close 50 MPa (509. A rail pressure sensor and a pressure limiter are adopted in the rail. When the rail pressure reaches approximately 200 MPa (2038 kg/cm2). When the pressure drops to approximately 50 MPa (509. The pressure limiter opens to release the pressure if an abnormally high pressure is generated. b. the pressure limiter returns to its normal state (the valve closes) in order to maintain the proper pressure. b. the pressure limiter prevents the rail pressure from being abnormally high.5 kg/cm2).[3] Rail (1) Outline a. This ensures optimum combustion and reduces combustion noise.5 kg/cm2) Q000257E Q000271E 16 . it trips the pressure limiter (the valve opens). Stores pressurized fuel (0 to 150 MPa {0 to 1528. Pressure Limiter Pressure Sensor Q000256E (2) Pressure Limiter a. The rail pressure sensor (Pc sensor) detects the fuel pressure in the rail and sends a signal to the engine ECU. 2 V 1.0 V VC VOUT GND 0 Q000258E 200 MPa (2038 kg/cm2) Q000272E REFERENCE: It is necessary to reset the ECU default value using the Hino diagnosis tool at the time of supply pump service replacement. b. 4. whereby the electrical resistance changes when pressure is applied to it. so ensure sufficient time (several minutes) is available. In addition.(3) Pressure Sensor a. the ECU has a function enabling it to learn the performance of the supply pump at the time of ECU service replacement. 17 . The rail pressure sensor (Pc sensor) is attached to the rail in order to detect the fuel pressure. It is a semiconductor type pressure sensor that utilizes the characteristics of silicon. QR codes displaying various injector characteristics and the ID codes showing these in numeric form (30 alphanumeric figures) are engraved on the injector head. rate. energy-saving solenoid-control type TWV (Two-Way Valve) injector has been adopted. When an injector is newly installed in a vehicle. A compact. The injectors inject the high-pressure fuel from the rail into the combustion chambers at the optimum injection timing. (3) Construction 30 Alphanumeric Figures A A BC A BC D ABBC D EEFG CDD E FG H EFFG H H QR Codes Solenoid Valve Control Chamber Pressurized Fuel (from Rail) Command Piston Nozzle Spring Pressure Pin Nozzle Needle Q000259E 18 . The J05/J08 engine common rail system optimizes injection volume control using this information. in accordance with commands received from the ECU. and spray condition. it is necessary to enter the ID codes in the engine ECU using the HINO Diagnostic tool. b.[4] Injector (G2 Type) (1) Outline a. (2) Characteristics a. Leak pipe Solenoid TWV Actuation current Valve spring Actuation current Actuation current Outlet orifice Inlet orifice Rail Command piston Nozzle needle Control chamber pressure Control chamber pressure Control chamber pressure Injection rate Injection rate Injection rate No injection Injection End of injection Q000149E 19 . which helps improve the nozzle's opening and closing response. effectively opening the outlet orifice and allowing fuel to flow out of the control chamber. This closes the nozzle needle.(4) Operation a. the spring force is stronger than the hydraulic pressure in the control chamber. effectively closing the outlet orifice. The fuel that flows below the piston lifts the piston needle upward. [No injection] • When no current is supplied to the solenoid. the solenoid valve is pushed downward. When current to the solenoid is turned OFF. the attraction force of the solenoid pulls the solenoid valve up. Thus. and the start and end of injection. pulling the command piston up. the hydraulic pressure that is applied to the command piston causes the nozzle spring to compress. causing the nozzle needle to close immediately and the injection to stop. where the injection rate is also at the maximum level. the pressure in the control chamber decreases. fuel is not injected. This causes the nozzle needle to rise and the injection to start. [Injection] • When current is initially applied to the solenoid. For this reason. the nozzle reaches its maximum lift. The TWV (Two-Way Valve) solenoid valve opens and closes the outlet orifice to control both the pressure in the control chamber. After the fuel flows out. • The fuel that flows past the outlet orifice flows to the leak pipe and below the command piston. • When current continues to be applied to the solenoid. the solenoid valve falls. and as a result. b. Q000261E 20 . [QR code correction points] QR code on the injector connector Injection quantity Q Pressure Parameter Actuating pulse width TQ Q000260E *1: Location of QR codes QR Codes ( 9. The characteristics of the engine cylinders have been further unified.(5) QR Codes a. In order to minimize performance tolerance of injectors at replacing them. contributing to improvements in combustion efficiency. Using QR codes has resulted in a substantial increase in the number of fuel injection quantity correction points. QR*1 (Quick Response) codes have been adopted to enhance correction precision. and thus the injection quantity control precision has improved.9mm) ID Codes (30 alphanumeric figures) 16 figure alphanumeric notations of fuel injection quantity correction information for market service use. reductions in exhaust gas emissions and so on. (6) Repair Procedure Changes a. so no electrical recognition capability" Spare Injector Engine ECU * Necessary to record the injector ID codes in Engine ECU QD1536E Replacing the Engine ECU "No correction resistance.) New (Injector with QR Codes) 30 alphanumeric figures-sixteen figure alphanumeric notations of fuel injection quantity correction information displaed for market service use ID Code Q000284E Replacing the Injector "No correction resistance. Differences in comparison with the conventional method of replacing injectors assembly are as shown below. it is necessary to record the ID codes (QR codes) in the ECU. or the engine ECU. so no electrical recognition capability" Vehicle-side Injector Spare Engine ECU * Necessary to record the injector ID codes in the engine ECU QD1537E 21 . NOTE: When replacing injectors with QR codes. (If the ID codes of the installed injector are not registered correctly. engine failure such as rough idling and noise will result. This is the command center that controls the fuel injection system and engine operation in general. Outline Diagram Sensor Detection Engine ECU Calculation Actuator Actuation QD2352E 3. J05D-single) Mass Airflow Meter Intake Air Pressure Sensor Inter-Cooler G2 Injector EGR Cooler VGT Controller VGT Actuator Coolant EGR Valve Lift Sensor Oxidation Catalyst Q000262E 22 .[5] Engine ECU (Electronic Control Unit) (1) Outline a.2 Description of Control System Components [1] Engine Control System Diagram Intake Air Temperature Sensor EGR Valve (J08E-double. e. generating alternating voltage. outputs 4 + 1 = 5 TDC signal pulses. This causes variations in the generated current. i. This signal is used to detect the engine speed and the crankshaft position in 7. The J05D and J08E use different types of gear. so the signal outputs differ as follows. Therefore every revolution of the gear. two revolutions of the engine. i. There are a total of 56 holes. As the pulsar near the sensor revolves.5-degree intervals. there is an extra signal hole on the gear. every two revolutions of the engine outputs 112 pulses. TDC (Cylinder Recognition) Sensor Q000264E 23 . Unlike the NE sensor. the magnetic line of force passing through the coil changes. the TDC sensor is an MRE (magnetic resistance element) sensor. The signal holes are located on the flywheel at 6. the magnetic field changes. Therefore every revolution of the gear. Therefore. there is an extra signal hole on the gear.e. which are amplified in the internal circuits of the sensor unit before a signal is output to the engine ECU. with holes missing in three places. The engine camshaft gear (one revolution for every two revolutions of the engine) is used as a pulsar.[2] Sensor and Relays (1) NE Sensor (Crankshaft Position Sensor) a. When the signal holes on the flywheel move past the sensor. For the J05D: In addition to four knock pins located at 90-degree intervals. two revolutions of the engine. For the J08E: In addition to six knock pins located at 60-degree intervals. b. outputs 6 + 1 = 7 TDC signal pulses. NE (Crankshaft Position) Sensor Q000263E (2) TDC Sensor (Cylinder Recognition Sensor) a. b. c.5-degree intervals. c. and the irregular pulse is used to determine the No. A combination of the NE pulse and the TDC pulses are used for the cylinder reference pulse. 1 cylinder. For J08E VCC TDC Input circuit GND NE GND Input circuit ECU VCC Q000273E For the J05D engine The cylinder at a rotation of 96° following the No. For the J08E engine The cylinder at a rotation of 78° following the No. For J05D VCC TDC Input circuit GND NE GND Input circuit ECU VCC Q000274E 24 . 1 TDC reference signal after the irregular pulse is the number one cylinder TDC (refer to the chart on the following page). 1 TDC reference signal after the irregular pulse is the number one cylinder TDC (refer to the chart on the following page). For J08E 0°CA 120°CA #5TDC 240°CA #3TDC 360°CA #6TDC 480°CA #2TDC 600°CA #4TDC 720°CA #1TDC 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 NE+ (NE.Standard) 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 4th Missing Tooth 96°CA 96°CA 3°CA 96°CA 3°CA Extra Tooth 96°CA Q000276E 25 .Standard) 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 4th Missing Tooth 3°CA 78°CA 78°CA Extra Tooth 30°CA 78°CA G (G-GND Standard) 78°CA 78°CA 78°CA 3°CA Q000275E For J05D 0°CA #1TDC 180°CA #3TDC 360°CA #4TDC 540°CA #2TDC 0°CA #1TDC 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 NE+ (NE.Standard) G (G. it uses a voltage resulting from the division of the computer internal resistance and the thermistor resistance to detect the temperature. which varies resistance according to temperature. As the ECU applies voltage to the thermistor. The fuel temperature sensor detects the fuel temperature and outputs it to the ECU. which varies resistance according to temperature. As the ECU applies voltage to the thermistor. it uses a voltage resulting from the division of the computer internal resistance and the thermistor resistance to detect the temperature. The coolant temperature sensor detects the temperature of the engine coolant and outputs it to the ECU. VTHL (V) ECU +5V VTHL Output Voltage 2 5 4 3 A-GND 1 0 THL -40 -20 -40 -4 0 32 20 40 60 80 100 120 (°C) 68 104 140 176 212 248 (°F) Q000106E Fuel Temperature 26 .(3) Coolant Temperature Sensor a. The sensor uses a thermistor. ECU +5V VTHW Output Voltage 2 1 0 VTHW 5 4 3 (V) A-GND THW -40 -20 -40 -4 0 32 20 40 60 80 100 120 (°C) 68 104 140 176 212 248 (°F) Q000105E Coolant Temperature (4) Fuel Temperature Sensor (THL) a. Q000277E b. The sensor uses a thermistor. 8 107 {1.0 V VPA2 VPA1 3. A magnet is mounted on the shaft that moves in unison with the accelerator pedal. VPATM Output Voltage (V) 3. VPA1 GND1 VC1 VPA2 GND2 VC2 Q000266E Hall elements (2 pieces) VPA1 GND1 VC1 VPA2 GND2 VC2 Magnets (1 pair) Output Voltage VPA1 GND1 VC1 VPA2 GND2 VC2 1.8 V 0 5 10 15 20 5 4 3 2 1 4.6 V 0.(5) Atmospheric Air Pressure Sensor (Built-in ECU) a.2 V Accelerator Opening Angle (°) Q000265E 27 . This sensor converts the angle of the pedal effort applied to the accelerator pedal into electrical signals and sends them to the ECU. The changes in the magnetic field orientation generate voltage.09} Atmospheric Air Pressure (kPa {kg/cm2}) Q000278E (6) Accelerator Position Sensor a. and the magnetic field orientation changes with the rotation of the shaft. This sensor converts the atmospheric air pressure into an electrical signal to correct fullload injection volume. The accelerator sensor uses hall elements. ECU A-VCC +5V VPIM 4. thermometer.019} 200 {2. The intake airflow is converted to a voltage value and this signal is transmitted to the ECU. Outline Diagram of Hot-Wire Type Airflow Meter Throttle Body Temperature Compensating Resistor (Hot-Wire) Heating Resistor (Hot-Wire) Intake Air from Air Cleaner Intake Air Temperature Sensor Bypass Flow Q000285E 28 . It diverts a portion of the intake air from the air cleaner and measures the intake airflow at the hot-wire measuring part. Detects the intake airflow (mass flow rate) in the hot-wire type airflow meter. The airflow sensor is installed to the rear of the air cleaner.5 0 100 {1. E2 THA VG E2G +B Airflow Sensor Intake Air Temperature Sensor Q000280E c.(7) Boost Pressure Sensor a. and consists of a heater.45 VPIM Output Valtage (V) 2.038} 300 {3. b. and control circuit (base). intake air temperature sensor. In order to correct the full-load injection volume.0 A-GND 0. this sensor converts the intake air pressure (absolute pressure) into an electrical signal. then amplifies it into a voltage signal to the computer.0 3.057} Q000279E Intake Air Pressure PIM (kPa {kg/cm2}) (8) Air Flow Sensor a. and controls the fuel injection to achieve an optimal injection timing according to the engine speed and the injection quantity. replaces the conventional timer function. replaces the conventional governor function. (2) Fuel Injection Quantity Control Function a. Fuel Injection Rate Control Control Output Fuel Injection Quantity Control Fuel Control Computer (ECU) Fuel Injection Timing Control Atmospheric Air Pressure Sensor Diagnosis Q000109E 29 . (1) Fuel Injection Rate Control Function a. b. Input Signal Accelerator sensor NE Sensor (Crankshaft Position Sensor) TDC Sensor (Cylinder Recognition Sensor) Rail Pressure Sensor Fuel Injection Pressure Control Various Sensors ·Water Temperature Sensor ·Fuel Temperature Sensor ·Atmospheric Air Temperature Sensor etc. and controls fuel injection to achieve an optimal injection quantity based on the engine speed and the accelerator opening. the ECU makes the necessary calculations based on signals received from sensors located in the engine and on the vehicle in order to control the timing and duration in which current is applied to the injectors.3. The fuel injection pressure control function (rail pressure control function) uses a rail pressure sensor to measure fuel pressure. For system control. (3) Fuel Injection Timing Control Function a. and feeds this data to the ECU to control the pump discharge quantity. Pressure feedback control is implemented to match the optimal quantity (command quantity) set according to the engine speed and the fuel injection quantity.3 Various Types of Control This system controls the fuel injection quantity and injection timing more optimally than the mechanical governor or timer used in conventional injection pumps. thus realizing optimal injection timing. (4) Fuel Injection Pressure Control Function (Rail Pressure Control Function) a. The fuel injection timing control function. The fuel injection quantity control function. The fuel injection rate control function controls the ratio of the quantity of fuel that is injected through the nozzle hole during a specified period. resulting in explosive combustion together with ignition. While the adoption of higher pressure fuel injection is associated with an increase in the injection rate. (2) Pilot Injection a. TDC Combustion Process Small Injection Amount Prior to Ignition High Injection Rate Injection Rate Improvement Pilot Injection Large Pre-mixture Combustion (NOx. Same as conventional fuel injection. the quantity of fuel injected before ignition increases. the initial injection rate is kept to the minimum required level dampening.[1] Fuel Injection Rate Control (1) Main Injection a. As a result. Main Injection Pilot Injection Q000110E b. the lag (injection lag) that occurs from the time fuel is injected until combustion starts cannot be reduced below a certain value. the explosive first-period combustion and reducing NOx emissions. by providing a pilot injection. Noise) Small Pre-mixture Combustion Heat Generation Rate Ignition Delay Q000111E 30 . Pilot injection is the injection of a small amount of fuel prior to the main injection. and an increase in the amount of NOx and noise. Therefore. Injection Quantity Change in Accelerator Opening Injection Quantity after Correction Delay Time Time Q000128E 31 . a small amount of fuel is injected several times prior to main injection. When the rotation is low at starting time. Starting Injection Quantity Water Temperature Engine Speed Q000127E (2) Transient Injection Quantity Correction a. the increase in fuel volume is delayed to inhibit the discharge of black smoke.(3) Split Injection a. Split Injection Q000112E [2] Fuel Injection Quantity Control (1) Starting Injection Quantity a. The injection quantity is determined based on the engine speed (NE) and water temperature while starting. When the changes in the accelerator opening are great during acceleration. Basic Injection Quantity Accelerator Opening Engine Speed Q000129E (4) Injection Quantity for Maximum Speed Setting a. Injection Quantity for Maximum Speed Setting Engine Speed Q000130E (5) Maximum Injection Quantity a.(3) Basic Injection Quantity a. Increasing the accelerator opening while the engine speed remains constant causes the injection quantity to increase. Is determined in accordance with the engine speed and corrected by the coolant temperature signal. Basic Maximum Injection Quantity Engine Speed Q000131E 32 . This quantity is determined in accordance with the engine speed (NE) and the accelerator opening. The injection quantity is regulated by a value that is determined in accordance with the engine speed. b. Amount of Atmospheric Air Pressure Correction Engine Speed Q000134E (8) Idle Speed Control System (ISC) a. which has been calculated by the computer. The functions of the ISC can be broadly divided into the following two items: • Auto ISC Controls the idle speed in accordance with the water temperature. Target Speed Water Temperature Q000135E • Manual ISC Controls the idle speed in accordance with the idle speed indicated on the manual idle setting 33 . Amount of Intake Air Pressure Correction Engine Speed Q000133E (7) Amount of Injection Quantity by Atmospheric Air Pressure Correction a. Controls the idle speed by regulating the injection quantity in order to match the target speed. in order to minimize the discharge of smoke when the intake air pressure is low. Limits the maximum injection quantity in accordance with the intake pressure. the maximum injection quantity curve is corrected as shown in the right figure. With using atmospheric air pressure sensor signal. with the actual speed.(6) Amount of Injection Quantity Intake Pressure Correction a. Target Speed ISC Knob Terminal Voltage Q000136E • Air Conditioner Idle-up Control When the conditions shown in the chart on the right are realized.knob provided at the driver's seat. Controls the actual vehicle speed by regulating the injection quantity in order to match the target speed that has been calculated by the computer with the actual speed. b. Conditions Air Conditioning SW = "ON" Clutch SW = "ON" (Clutch Connection) Neutral SW = "ON" (Neutral) Q000137E (9) Auto Cruise Control a. bring the idle-up speed to constant rpm. The CRS ECU controls the injection quantity in accordance with signals from the cruise control computer. 34 . Basic Injection Timing Final Injection Quantity Engine Speed Q000138E (2) Pilot Injection timing (Pilot Interval) a. While starting. Although either the NE sensor or the auxiliary NE sensor is the reference for controlling the injection timing. it is calculated in accordance with the water temperature and the engine speed. the engine speed. Pilot Interval Final Injection Quantity Engine Speed Q000139E (3) Fuel Injection Pressure a. and the water temperature (with map correction). While starting. the engine speed. b. Rail Pressure Final Injection Quantity Engine Speed Q000140E 35 . it is calculated in accordance with the water temperature and the engine speed. The pilot injection timing is controlled by adding the pilot interval to the main injection timing. and the water temperature (with map correction). b. b. the NE sensor is ordinarily used for this purpose. c. The pilot interval is calculated in accordance with the final injection quantity. it is calculated in accordance with the water temperature and the engine speed. (1) Main Injection Timing a. A value is calculated as determined in accordance with the final injection quantity and the engine speed.[3] Fuel Injection Timing Control The characteristics of the fuel injection timing vary depending on whether it is the main injection or the pilot injection. While starting. The basic injection timing is calculated in accordance with the final injection quantity. and a valve with an opening that alters in response to the nozzle position. The lower section is constructed of a nozzle that moves up and down in response to the electromagnetic force. The upper section receives output signals from the engine ECU.3. • Atmospheric pressure sensor: Detects the atmospheric pressure around the engine (built into the ECU). • Coolant temperature sensor: Detects the engine coolant temperature.4 Other Relevant Engine Control [1] EGR Control (1) Control System ECU EGR Target Opening Final EGR Target Opening Calculation EGR Deviation Compensation Control Processing/Duty Ratio Calculation Feed Back EGR Valve Lift Sensor (Detects Actual Opening) EGR Valve Actuation EGR Valve Assy Q000267E (2) Related Sensors The related sensors are as follows: • Air volume sensor: Detects the volume of air flowing into the engine. and contains a solenoid that generates electromagnetic force. An EGR valve is utilized as the system actuator for the electric exhaust gas recirculation (E-EGR) system. (3) EGR Valve a. For J05D For J08E Q000268E Q000281E 36 . It is constructed of an upper section and a lower section. There is a possibility of the fuel leakage." "The temperature cannot be detected properly." The mass air flow sensor has a malfunction. Sensor Malfunction (LO) air flow sensor." Engine Coolant Temperature Sensor Malfunction (LO) Engine Coolant Temperature Sensor Malfunction (HI) 37 The temperature cannot be detected properly. short circuit to ground in the harness. Description The VNT actuator has a malfunction. There are possibilities of the sensor malfunction and short circuit in the harness. open and short circuit to ground in the harness. (Fuel leak) Remarks For the VNT. "The mass air flow sensor has a malfunction. P0088 High fuel pressure has been detected. The turbine rotation sensor has been detected. "The temperature cannot be detected properly." P0113 P0117 P0118 . The boost pressure cannot be detected properly. open and short circuit to +B in the harness. P0093 P0102 P0103 P0108 P0112 "The temperature cannot be detected properly. other than start-up. open and short circuit to +B in the harness. Intake Air Temperature Integrated in the mass There are possibilities of the sensor malfunction. Q NE Q000269E 3.). Perform the fuel leakage check.(4) Control Operation Operation Start Conditions: During engine warm-up. There are possibilities of the sensor malfunction. There are possibilities of the sensor malfunction and short circuit to ground in the harness. EGR Operating Range: During medium engine load. There are possibilities of the sensor malfunction. Over speed of the turbo has been detected. Intake Air Temperature Integrated in the mass There are possibilities of the sensor malfunction. There are possibilities of the sensor malfunction and short circuit to +B in the harness.5 Engine ECU [1] Diagnosis Codes P-Code P0045 P0049 DST-1 Display VNT Malfunction Turbo Charger Turbine Over speed Common Rail Pressure -Too high Fuel System Leak Detected Mass Air Flow Sensor Malfunction (LO) Mass Air Flow Sensor Malfunction (HI) Boost Pressure Sensor Malfunction (HI) The pump does not work properly. Sensor Malfunction (HI) air flow sensor. when not overheating (etc. open and short circuit to +B in the harness. Fuel Temperature Integrated in the supply There are possibilities of the sensor malfunction." Rail Pressure Sensor Malfunction Rail Pressure Sensor Malfunction (LO) Rail Pressure Sensor Malfunction (HI) ECU Charge Circuit Malfunction (HI) Injector 1 Open Circuit Injector 2 Open Circuit Injector 3 Open Circuit Injector 4 Open Circuit Injector 5 Open Circuit Injector 6 Open Circuit Over Temperature Condition Engine Over speed Condition Turbo Charger Overboost Condition Boost Pressure Sensor Malfunction (LO) Characteristic malfunc. open and short circuit to +B in the harness." "The temperature cannot be detected properly. "The intake air pressure cannot be detected properly. There are possibilities of the sensor malfunction. There is a possibility of the Injector 4 malfunction or open circuit in the harness. There is a possibility of the Injector 2 malfunction or open circuit in the harness. The engine speed exceeded the rated value. There is a possibility of the Injector 6 malfunction or open circuit in the harness. tion There is a possibility of the sensor malfunction. There are possibilities of the sensor malfunction. Replace the ECU.P-Code P0182 DST-1 Display Remarks Description "The temperature cannot be detected properly. The rail pressure cannot be detected properly. Sensor Malfunction (LO) pump." The rotation fluctuation in the cylinder 1 became bigger than other cylinders. There is a possibility of the Injector 5 malfunction or open circuit in the harness. There is a possibility of the Injector 3 malfunction or open circuit in the harness. short circuit to ground in the harness. There is a possibility of the Injector 1 malfunction or open circuit in the harness. Check the cooling system. There is a possibility that the flow damper is operating. open and short circuit in the harness. Sensor Malfunction (HI) pump. Fuel Temperature Integrated in the supply There are possibilities of the sensor malfunction." The voltage for the injector activation is too high. "The rail pressure cannot be detected properly. There are possibilities of the sensor malfunction and short circuit to ground in the harness. The rotation fluctuation in the cylinder 2 became bigger than other cylinders. The over temperature condition has been detected. The boost pressure is too higher than the specified value. There is a possibility that the flow damper is operating.The rail pressure cannot be detected properly. 38 P0183 P0191 P0192 P0193 P0200 P0201 P0202 P0203 P0204 P0205 P0206 P0217 P0219 P0234 P0237 P0263 Correction Error Between Cylinders #1 P0266 Correction Error Between Cylinders #2 . 39 P0405 EGR Lift Sensor 1 Malfunction (LO) EGR Lift Sensor 1 Malfunction (HI) EGR Lift Sensor 2 Malfunction (LO) EGR Lift Sensor 2 Malfunction (HI) P0406 P0407 P0408 P0489 EGR Solenoid Valve 1 Malfunction P0490 EGR Solenoid Valve 1 Malfunction P0500 Vehicle Speed Sensor Malfunction (LO) Open circuit . There are possibilities of the sensor and harness malfunctions. There are possibilities of the sensor malfunction. There are possibilities of the sensor malfunction and short circuit to +B in the harness. The rotation fluctuation in the cylinder 4 became bigger than other cylinders. "The EGR lift sensor 1 has a malfunction." P0335 Crankshaft Position Sensor Malfunction The pulse from the crankshaft position sensor cannot be detected. There is a possibility that the flow damper is operating. There are possibilities of the solenoid valve malfunction. The pulse from the engine speed sensor cannot be detected. The pulse from the vehicle speed sensor cannot be detected . open and short circuit to ground in the harness. There is a possibility that the flow damper is operating. The rotation fluctuation in the cylinder 5 became bigger than other cylinders. "The EGR solenoid valve 1 has a malfunction. open and short circuit to ground in the harness. sor." The EGR lift sensor 1 has a malfunction. "The EGR lift sensor 2 has a malfunction. There are possibilities of the sensor and harness malfunctions. There is a possibility that the flow damper is operating. There are possibilities of the solenoid valve malfunction and short circuit to +B in the harness." The EGR solenoid valve 1 has a malfunction. There are possibilities of the sensor malfunction and short circuit to +B in the harness. There are possibilities of the sensor malfunction. There is a possibility that the flow damper is operating. open and short circuit to ground in the harness." The EGR lift sensor 2 has a malfunction. There are possibilities of the sensor and harness malfunctions.P-Code DST-1 Display Correction Error Between Cylinders #3 Remarks Description The rotation fluctuation in the cylinder 3 became bigger than other cylinders. P0269 P0272 Correction Error Between Cylinders #4 P0275 Correction Error Between Cylinders #5 P0278 Correction Error Between Cylinders #6 "In case that the NE and G sensor have malfunctions.The EGR valve 1 is clogged in the open state. P0340 Engine Speed Sensor Malfunction P0404 EGR Valve 1 Clogged Clogging has been detected by the lift sen. The rotation fluctuation in the cylinder 6 became bigger than other cylinders. this P code will be output. The intake heater relay has a malfunction. There is a short in the starter switch circuit. The clutch switch cannot be detected properly. open and short circuit to +B in the harness. P0501 Noise P0510 P0524 Idle Switch Malfunction Engine Oil Pressure Too Low EGR Valve Clogged Clogging has been detected by the lift sensor. The accelerator position sensor for operation cannot be detected properly. There are possibilities of the sensor malfunction. There is an internal malfunction in the ECU.P-Code DST-1 Display Vehicle Speed Sensor Malfunction (HI) Remarks Description The pulse from the vehicle speed sensor has an error. Check the relay. Replace the ECU. There are possibilities of open and short circuit to ground. "The temperature cannot be detected properly. Replace the ECU. P0540 Preheating System Malfunction Exhaust Gas Temperature Sensor 1 Malfunction (LO) Exhaust Gas Temperature Sensor 1 Malfunction (HI) Flash ROM Malfunction CPU Malfunction (Hardware Detected) CPU Monitoring ID Malfunction ECU Charge Circuit Malfunction Starter Switch Malfunction Main Relay Malfunction Clutch Switch Malfunction Neutral Switch Malfunction Accelerator Position Sensor for Operation (LO) P0545 P0546 P0605 P0606 P0607 P0611 P0617 P0686 P0704 P0850 P1132 P1133 Accelerator Position Sensor for Operation (HI) 40 . Monitor the state and check the ON/OFF judgment. Monitor the state and check the ON/OFF judgment. There is a possibility of short circuit to +B. There is an internal malfunction in the ECU. The idle switch does not function properly. The main relay cannot be turned OFF. There are possibilities of the relay and harness malfunctions. Monitor the state and check the ON/OFF judgment. Replace the ECU. The engine oil pressure became too low. The temperature cannot be detected properly." There is an internal malfunction in the ECU. There are possibilities of the sensor malfunction and short circuit to ground in the harness. The neutral switch cannot be detected properly. P1401 The EGR valve 2 system is clogged in the open state. Monitor the state and check the ON/OFF judgment. Check the sensor voltage. Replace the ECU. The accelerator position sensor for operation cannot be detected properly. Check the sensor voltage. The voltage for the injector activation is too low. There are possibilities of the sensor and harness malfunctions. There is a possibility of open or short circuit to +B. P1477 Transmission retarder relay linked with the Cruise Control Retarder cruise control system Relay Malfunction for the medium-size vehicle Transmission retarder relay linked with the Cruise Control Retarder cruise control system Relay Malfunction for the medium-size vehicle Engine Stop Switch Close Malfunction Cruise Control Switch Malfunction QR Code Error "The cruise control retarder relay has a malfunction. Check the injector and wiring. Check the sensor voltage. There are possibilities of the relay malfunction and short circuit to +B in the harness. open and short circuit to ground in the harness. Monitor the state and check the ON/OFF judgment. There is a possibility of short circuit to ground. Check the injector and wiring.and medium-size vehicles Transmission retarder relay linked with the cruise control system for the large. There are possibilities of the sensor malfunction and short circuit to +B in the harness. The engine stop switch has a malfunction or there is short circuit in the wiring. The idle volume cannot be detected properly. There are possibilities of the relay malfunction.P-Code DST-1 Display Remarks Description The idle volume cannot be detected properly.and medium-size vehicles P1211 P1212 P1214 P1215 P1427 P1428 P1472 Transmission Retarder Relay Malfunction "The transmission retarder relay has a malfunction. The cruise control switch has a malfunction and remains ON. Check the QR code. Check the injector and wiring." P1473 Transmission Retarder Relay Malfunction The transmission retarder relay has a malfunction. There are possibilities of the sensor malfunction. There are possibilities of the relay malfunction. There is a possibility of short circuit to ground. P1530 P1565 P1601 41 . The QR code has an error. There is a possibility of short circuit to +B. Check the injector and wiring. open and short circuit to ground in the harness." The exhaust pressure cannot be detected properly. Monitor the state and check the ON/OFF judgment. There are possibilities of open and short circuit to ground. "The exhaust pressure cannot be detected properly. Check the sensor voltage. P1142 Idle Volume (LO) P1143 Idle Volume (HI) Injector Common 1 Malfunction Injector Common 1 Malfunction Injector Common 2 Malfunction Injector Common 2 Malfunction Exhaust Pressure Sensor Malfunction (LO) Exhaust Pressure Sensor Malfunction (HI) Transmission retarder relay linked with the cruise control system for the large. There is a possibility of open or short circuit to +B." P1478 The cruise control retarder relay has a malfunction. There are possibilities of the relay malfunction and short circuit to +B in the harness. open and short circuit to ground in the harness. The accelerator position sensor 1 cannot be detected properly. There are possibilities of the solenoid valve malfunction. it is necessary to repair or replace the ECU. There are possibilities of the sensor malfunction. If the malfunction occurs frequently. The accelerator position sensor 1 cannot be detected properly. "The atmosphere pressure sensor (in ECU) has a malfunction. "The temperature cannot be detected properly. There are possibilities of the melt down and clogging. There is a possibility of short circuit to +B. open and short circuit to +B in the harness. Check the sensor voltage. Check the sensor voltage. Communication with the transmission ECU is lost. Check the sensor voltage. open and short circuit to ground in the harness. it is necessary to repair or replace the ECU." P1681 P1682 Exhaust Brake Solenoid Valve Malfunction DPR System Malfunction Exhaust Gas Temperature Sensor 2 Malfunction (LO) Exhaust Gas Temperature Sensor 2 Malfunction (HI) Accelerator Position Sensor 1&2 Malfunction Accelerator Position Sensor 1 Malfunction Accelerator Position Sensor 1 Malfunction (LO) Accelerator Position Sensor 1 Malfunction (HI) Accelerator Position Sensor 2 Malfunction Accelerator Position Sensor 2 Malfunction (LO) Accelerator Position Sensor 2 Malfunction (HI) Atmospheric Air Pressure Sensor Malfunction (LO) Atmospheric Air Pressure Sensor Malfunction (HI) CAN Communication Malfunction (Engine) Lost Communication (Transmission) Lost Communication (Cruise control) 42 For middle-sized VNT Communication error between pro-shift and AT-ECU P2002 P2032 P2033 P2120 P2121 P2122 P2123 P2126 P2127 P2128 P2228 P2229 U0073 There is a malfunction of communication with the VNT." The exhaust brake solenoid valve has a malfunction. Check the sensor voltage. .P-Code DST-1 Display Exhaust Brake Solenoid Valve Malfunction Remarks Description "The exhaust brake solenoid valve has a malfunction. The accelerator position sensor 2 cannot be detected properly. If the malfunction occurs frequently. The accelerator position sensor 1 cannot be detected properly. Check the sensor voltage. There are possibilities of the solenoid valve malfunction and short circuit to +B in the harness. There are possibilities of the sensor and harness malfunctions. The DPR system has a malfunction. There is possibility of short circuit to +B. U0101 U0104 Communication with the auto cruise ECU is lost. The accelerator position sensor 2 cannot be detected properly." "The atmosphere pressure sensor (in ECU) has a malfunction. There are possibilities of the sensor malfunction and short circuit to ground in the harness. The temperature cannot be detected properly. The accelerator position sensor 2 cannot be detected properly. Perform the DPR system check." Both the accelerator sensor 1 and 2 have malfunctions. There are possibilities of open and short circuit to ground. Check the sensor voltage. " The EGR solenoid 2 has a malfunction. "The EGR solenoid 2 has a malfunction. Communication with the meter ECU is lost. There are possibilities of solenoid valve malfunction. TBD TBD TBD TBD 43 . CAN communication bus OFF judgment When linear solenoid specific P code is obtained When linear solenoid specific P code is obtained When linear solenoid specific P code is obtained When linear solenoid specific P code is obtained There is a malfunction of communication with other computers equipped in vehicle. open and short circuit to ground in the harness. open and short circuit to ground in the harness.P-Code U0121 U0132 U0155 U1001 DST-1 Display Lost Communication (ABS) Lost Communication (Air suspension) Lost Communication (Meter) CAN Communication error (Vehicle) EGR Solenoid 1 Malfunction EGR Solenoid 1 Malfunction EGR Solenoid 2 Malfunction EGR Solenoid 2 Malfunction Remarks Description Communication with the ABS ECU is lost." The EGR solenoid 1 has a malfunction. There are possibilities of solenoid valve malfunction. "The EGR solenoid 1 has a malfunction. There are possibilities of solenoid valve malfunction and short circuit to +B in the harness. There are possibilities of solenoid valve malfunction and short circuit to +B in the harness. Communication with the air suspension ECU is lost. sensor COMMON2 COMMON2 TWV2 Accelerator position sensor Idle controller Boost pressure sensor VPC VPC A-GND THL A-VCC VIMC A-GND A-VCC PIM1 A-GND Case GND TWV6 Switches Actuators NOTE: Dashed lines in the illustration show shield line.[2] ECU External Wiring Diagram Power 4 relay 50 A 30 A 5A ACT power relay 15 A KEY/SW KEY/SW +BF +BF SCVHI SCVHI SCVLO SCVLO SCV Main relay 15 A +BP +BP M-REL M-REL ST/SW CANH CANL For CAN wire (Twist pair wire etc. sensor Lights TDC sensor COMMON1 COMMON1 TWV1 TWV3 TWV5 Injector L6 (x6) Accelerator position sensor Water temp.) Starter relay Battery 12 V GND GND P-GND P-GND P-GND Engine speed sensor NE [+] NE [-] NE-SLD G-VCC G G-GND A-VCC ACCP1 A-GND THW ACCP2 A-GND SCASC A-VCC TWV4 Rail pressure sensor Fuel temp. Q000441E 44 . [3] ECU Connector Diagram (1) ECU Connector Terminal Layout 34 P 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 P 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 32 P 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 35 P 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 31 P 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 Q000442E (2) Terminal Connections No. switch spare Connections 18 (CASE GND) Case ground (spare) 10 POUT1 11 POUT2 12 POUT3 13 POUT4 14 PIN1 15 PIN2 16 — 17 (BATT) 35 +BF 36 OUT5 37 OUT6 38 OUT7 39 NE-SLD 40 NE+ 41 NE42 OUT1 43 OUT2 44 OUT3 45 OUT4 46 SW1 47 OUT8 48 SW2 49 SW3 50 SW4 51 SW5 52 SW6 28 CASE GND Case ground . Pin Symbol 19 KWP2000 ISO9141-K 20 IN1 21 AD1 22 AD2 23 AD10 24 AD12 25 AD19 26 AD20 27 VS1 29 IN2 30 AD14 31 AD15 32 AD16 33 AD17 34 AD18 53 SW7 54 A-GND4 55 A-GND5 56 SW1 57 A-VCC4 58 SW8 59 SW10 60 SW12 61 SW17 62 AD21 63 AD22 64 — 65 A-VCC5 66 SW9 67 SW11 68 SW16 69 SW18 — Accelerator position sensor 1 Accelerator position sensor 2 Accelerator position sensor for operation spare spare spare Vehicle speed sensor — IMC volume spare Intake air temp. sensor (Build-in Airflow meter) spare spare Brake switch Sensor ground 4 Sensor ground 5 Key switch Sensor (Power supply) 4 Accelerator pedal switch spare Constant-speed switch Stop lamp switch spare EGR valve lift sensor 2 — Sensor (Power supply) 5 Neutral switch spare Diag. Pin Symbol 1 2 3 4 5 6 7 8 9 (GND) (GND) IN3 IN3+B +B +B TAC1 TAC2 Connections ECU ground (spare) ECU ground (spare) spare spare Power Power Power spare Tachometer signal (SINK) spare spare spare spare spare spare — — +BF Exhaust brake solenoid valve spare spare Engine RPM shield ground Engine RPM + Engine RPM spare spare Exhaust brake light Glow indicator light Key switch spare Starter switch Exhaust brake switch spare spare spare 45 No. Pin Symbol 70 OUT19 71 OUT20 72 GND 73 GND 74 OUT17 75 OUT18 76 +BF 77 SW27 78 SW 79 SW 80 SW 81 SW 82 S-OUT1 83 S-OUT2 84 S-OUT3 85 S-OUT4 102 P-GND 103 TWV1 104 TWV3 105 TWV5 Glow relay Glow relay Connections No. Pin Symbol 86 — — 87 SW31 88 SW20 89 SW21 90 SW25 91 SW26 92 SW13 93 SW28 94 SW29 95 CANH 96 CANL 97 SW32 98 SW22 99 SW23 100 SW30 120 G 121 AD4 122 AD11 123 A-VCC3 124 NE-VCC 125 A-VCC2 126 A-VCC1 127 AD13 128 AD3 129 (GND) 130 (GND) 131 G-GND 132 AD5 133 G-VCC 134 A-GND1 135 A-GND2 136 A-GND3 Connections AT identification signal PTO2 switch PTO switch spare spare Cruise switch 1 Clutch stroke switch spare CAN2 HI CAN2 LOW Hydraulic pressure switch Warm-up switch spare spare Cam angle Rail pressure sensor 1 Airflow meter Sensor (Power supply) 3 spare Sensor (Power supply) 2 Sensor (Power supply) 1 EGR valve lift sensor 1 Boost pressure sensor ECU ground (spare) ECU ground (spare) CAM angle ground Rail pressure sensor 2 Cam angle VCC (5V) Sensor ground 1 Sensor ground 2 Sensor ground 3 ECU ground ECU ground ECU main relay ECU main relay +BF Clutch switch spare Cruise switch 2 Stop lamp switch 2 spare Check engine light 1 spare spare spare Power ground Injector drive signal 1 Injector drive signal 3 Injector drive signal 5 101 CAN-SLD CAN2 Shield ground 106 COMMON1 Injector drive power 1 107 COMMON1 Injector drive power 1 108 OUT9 109 OUT10 110 OUT11 111 OUT12 112 OUT13 113 OUT14 114 OUT15 115 OUT16 116 117 — — EGR linear solenoid drive 1 EGR linear solenoid drive 2 spare spare Cruise lamp Constant-speed lamp spare spare — — Airflow ground 118 A-GND6 119 NE (MRE) 46 .No. Pin Symbol 153 PCV1 154 AD6 155 AD7 156 — 157 CAN1H 158 CAN1L 159 — — spare spare Connections Water temp.No. Pin Symbol 137 TWV2 138 TWV4 139 TWV6 140 P-GND 141 P-GND Connections Injector drive signal 2 Injector drive signal 4 Injector drive signal 6 Power ground Power ground No. sensor — CAN1 HI CAN1 LOW — — spare Fuel temp. sensor 2 — — 142 COMMON2 Injector drive power 2 143 COMMON2 Injector drive power 2 144 SCVLO 145 SCVLO 146 SCVHI 147 SCVHI 148 149 — — HP 3 or 4 pump control valve drive signal 160 HP 3 or 4 pump control valve power HP 3 or 4 pump control valve power — — spare spare spare Atmospheric air pressure sensor HP 3 or 4 pump control valve drive signal 161 (CASE GND) Case ground (spare) 162 AD8 163 AD9 164 166 — — 165 CAN1-SLD spare 167 (CASE GND) Case ground (spare) 150 PCV2 151 PCV2 152 PCV1 Built-in PATM 47 . 48 .