
Description
NumberItem Description
q1Power conditionI
This shows the condition when the system receives battery positive voltage (can
be operated).
q2Fusible link I
The double line shows that this is a fusible link.
I The open circle shows current flow in, and the shaded circle shows current flow
out.
q3Fusible link/fuse location I
This shows the location of the fusible link or fuse in the fusible link or fuse box.
For arrangement, refer to EL section (ªPOWER SUPPLY ROUTINGº).
q4Fuse I
The single line shows that this is a fuse.
I The open circle shows current flow in, and the shaded circle shows current flow
out.
q5Current rating IThis shows the current rating of the fusible link or fuse.
q6Connectors I
This shows that connector
E3is female and connectorM1is male.
I The G/R wire is located in the 1A terminal of both connectors.
I Terminal number with an alphabet (1A, 5B, etc.) indicates that the connector is
SMJ connector. Refer to GI-18.
q7Optional splice IThe open circle shows that the splice is optional depending on vehicle application.
q8Splice IThe shaded circle shows that the splice is always on the vehicle.
q9Page crossing I
This arrow shows that the circuit continues to an adjacent page.
I The A will match with the A on the preceding or next page.
q10Common connector I
The dotted lines between terminals show that these terminals are part of the same
connector.
q11Option abbreviation IThis shows that the circuit is optional depending on vehicle application.
q12Relay I
This shows an internal representation of the relay. For details, refer to EL section
(ªSTANDARDIZED RELAYº).
q13Connectors I
This shows that the connector is connected to the body or a terminal with bolt or
nut.
q14Wire color I
This shows a code for the color of the wire.
B = Black BR = Brown
W = White OR = Orange
R = Red P = Pink
G = Green PU = Purple
L = Blue GY = Gray
Y = Yellow SB = Sky Blue
LG = Light Green CH = Dark Brown
DG = Dark Green
When the wire color is striped, the base color is given first, followed by the stripe
color as shown below:
Example: L/W = Blue with White Stripe
q15Option description IThis shows a description of the option abbreviation used on the page.
q16Switch I
This shows that continuity exists between terminals 1 and 2 when the switch is in
the A position. Continuity exists between terminals 1 and 3 when the switch is in
the B position.
q17Assembly parts I
Connector terminal in component shows that it is a harness incorporated assem-
bly.
q18Cell code I
This identifies each page of the wiring diagram by section, system and wiring dia-
gram page number.
HOW TO READ WIRING DIAGRAMS
GI-12
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NumberItem Description
q19Current flow arrowI
Arrow indicates electric current flow, especially where the direction of standard
flow (vertically downward or horizontally from left to right) is difficult to follow.
I A double arrow ªF Ð
Eº shows that current can flow in either direction depending on
circuit operation.
q20System branch I
This shows that the system branches to another system identified by cell code
(section and system).
q21Page crossing I
This arrow shows that the circuit continues to another page identified by cell code.
I The C will match with the C on another page within the system other than the next
or preceding pages.
q22Shielded line IThe line enclosed by broken line circle shows shield wire.
q23Component box in wave
line I
This shows that another part of the component is also shown on another page
(indicated by wave line) within the system.
q24Component name IThis shows the name of a component.
q25Connector number I
This shows the connector number.
I The letter shows which harness the connector is located in.
Example: M: main harness. For detail and to locate the connector, refer to EL sec-
tion (ªMain Harnessº, ªHARNESS LAYOUTº). A coordinate grid is included for com-
plex harnesses to aid in locating connectors.
q26Ground (GND) I
The line spliced and grounded under wire color shows that ground line is spliced
at the grounded connector.
q27Ground (GND) IThis shows the ground connection.
q28Connector views I
This area shows the connector faces of the components in the wiring diagram on
the page.
q29Common component I
Connectors enclosed in broken line show that these connectors belong to the
same component.
q30Connector color I
This shows a code for the color of the connector. For code meaning, refer to wire
color codes, Number q14of this chart.
q31Fusible link and fuse box I
This shows the arrangement of fusible link(s) and fuse(s), used for connector
views of ªPOWER SUPPLY ROUTINGº in EL section.
The open square shows current flow in, and the shaded square shows current
flow out.
q32Reference area I
This shows that more information on the Super Multiple Junction (SMJ) and Joint
Connectors (J/C) exists on the foldout page. Refer to GI-18 for details.
HOW TO READ WIRING DIAGRAMS
Description (Cont'd)
GI-13
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Shown below are Pre-delivery Inspection items required for the new vehicle. It is recommended that
necessary items other than those listed here be added, paying due regard to the conditions in each
country.
Perform applicable items on each model. Consult text of this section for specifications.
UNDER HOOD Ð engine off
lRadiator coolant level and coolant hose connections for leaks
l Battery fluid level, specific gravity and conditions of battery terminals
l Drive belts tension
l Fuel filter for water or dust, and fuel lines and connections for leaks
l Engine oil level and oil leaks
l Brake and clutch reservoirs fluid level and fluid lines for leaks
l Windshield and rear window washer and headlamp cleaner reservoir fluid level
l Power steering reservoir fluid level and hose connections for leaks
ON INSIDE AND OUTSIDE
lRemove front spring/strut spacer (if applicable)
l Operation of all instruments, gauges, lights and accessories
l Operation of horn(s), wiper and washer
l Steering lock for operation
l Check air conditioner for gas leaks
l Front and rear seats, and seat belts for operation
l All moldings, trims and fittings for fit and alignment
l All windows for operation and alignment
l Hood, tailgate, door panels for fit and alignment
l Latches, keys and locks for operation
l Weatherstrips for adhesion and fit
l Headlamp aiming
l Tighten wheel nuts (Inc. inner nuts if applicable)
l Tire pressure (Inc. spare tire)
l Check front wheels for toe-in
l Install clock/voltmeter/room lamp fuse (if applicable)
l Install deodorizing filter to air conditioner (if applicable)
l Remove wiper blade protectors (if applicable)
UNDER BODY
lManual transmission/transaxle, transfer and differential gear oil level
l Brake and fuel lines and oil/fluid reservoirs for leaks
l Tighten bolts and nuts of steering linkage and gear box, suspension, propeller shafts and drive shafts
l Tighten rear body bolts and nuts (Models with wooden bed only)
ROAD TEST
lClutch operation
l Parking brake operation
l Service brake operation
l Automatic transmission/transaxle shift timing and kickdown (if applicable)
l Steering control and returnability
l Engine performance
l Squeaks and rattles
ENGINE OPERATING AND HOT
lAdjust idle speed
l Automatic transmission/transaxle fluid level (if applicable)
l Engine idling and stop knob operation
FINAL INSPECTION
lInstall necessary parts (outside mirror, wheel covers, seat belts, mat, carpet or mud flaps)
l Inspect for interior and exterior metal and paint damage
l Check for spare tire, jack, tools (wheel check) and literature
l Wash, clean interior and exterior
PRE-DELIVERY INSPECTION ITEMS
MA-3
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1. Warm up engine.
2. Turn ignition switch OFF.
3. Using CONSULT-II, make sure no error codes are indicated forself-diagnosis items. Refer to EC section, ªFuel Pressure
Releaseº.
I Do not disconnect CONSULT-II until the end of this operation;
it will be used to check engine rpm and for error detection at
the end of this operation.
4. Disconnect the negative battery terminal.
5. Remove the following parts.
I Intercooler
I Throttle body
I Rocker cover
6. To prevent fuel from being injected during inspection, remove fuel injection pump fuse [ENG CONT A/T (15A)] from fuse box
on the right side of engine compartment.
7. Remove glow plugs from all the cylinders.
I Before removal, clean the surrounding area to prevent
entry of any foreign materials into the engine.
I Carefully remove glow plugs to prevent any damage or
breakage.
I Handle with care to avoid applying any shock to glow
plugs.
8. Install adapter (SST) to installation holes of glow plugs and connect compression gauge for diesel engine.
:15-19N ×m (1.5 - 2.0 kg-m, 11 - 14 ft-lb)
9. Connect battery negative terminal.
10. Set the ignition switch to ªSTARTº and crank. When gauge pointer stabilizes, read compression pressure and engine rpm.
Repeat the above steps for each cylinder.
I Always use a fully-charged battery to obtain specified
engine speed.
Unit: kPa (bar, kg/cm2, psi)/rpm
Standard MinimumDifference limit between
cylinders
2,942 (29.42, 30.0, 427)/ 200 2,452 (24.52, 25.0, 356)/
200 294 (2.94, 3.0, 43)/200
I
When engine rpm is out of the specified range, check the spe-
cific gravity of battery liquid. Measure again under corrected
conditions.
I If engine rpm exceeds the limit, check valve clearance and
combustion chamber components (valves, valve seats, cylinder
head gaskets, piston rings, pistons, cylinder bores, cylinder
block upper and lower surfaces) and measure again.
11. Complete this operation as follows:
a. Turn the ignition switch to ªOFFº.
b. Disconnect battery negative terminal.
c. Replace glow plug oil seals and install glow plugs.
d. Install fuel injection pump fuse [ENG CONT A/T (15A)].
e. Connect battery negative terminal.
f. Using CONSULT-II make sure no error code is indicated for items of self-diagnosis. Refer to EC section, ªTrouble Diagno-
sis Ð Indexº.
YEM039
SEM334G
MEASUREMENT OF COMPRESSION PRESSUREZD
EM-10
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CONSULT-II
CONSULT-II INSPECTION PROCEDURE
1. Turn off ignition switch.
2. Connect ªCONSULT-IIº to data link connector for CONSULT-II.(Data link connector for CONSULT-II is located behind the fuse
box cover.)
3. Turn on ignition switch.
4. Touch ªSTARTº.
5. Touch ªENGINEº.
6. Perform each diagnostic test mode according to each service procedure.
For further information, see the CONSULT-II Operation Manual.
NRS122
YEC696A
YEC697A
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONTD27Ti
EC-350
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qA
CHECK POWER SUPPLY-III.
1. Turn ignition switch to ªONº positionand then to ªLOCKº position.
2. Check voltage between ECM connector terminals
107,108,109and engine
ground with CONSULT-II or tester.
Voltage: After turning ignition switch to
ªLOCKº position, battery voltage
will exist for a few seconds, then
drop to approximately 0V.
NG
EOK Go toqBªCHECK
GROUND CIRCUITº.
Case-1: Battery voltage does not exist.
Case-2: Battery voltage exists for more than a few
seconds.
Case-1 Case-2
EGo toªCHECK ECM
RELAYº.
CHECK HARNESS CONTINUITY
BETWEEN ECM RELAY AND ECM.
1. Disconnect ECM harness connector.
2. Disconnect ECM relay harness connec- tor.
3. Check harness continuity between ECM connector terminals
325and
ECM relay connector terminal q
2, and
ECM connector terminals
107,108,
109and ECM relay connector termi-
nal q
5. Refer to wiring diagram.
Continuity should exist.
If OK, check harness for short-circuit.
OK
ENG Check the following:
IHarness connectors
M787,F66(LHD mod-
els)
I Harness for open or
short-circuit between
ECM relay connector
and ECM connector.
If NG, repair harness or
connectors.
CHECK VOLTAGE BETWEEN ECCS
RELAY AND ENGINE GROUND.
Check voltage between ECM relay con-
nector terminals q
1,q3and engine ground
with CONSULT-II or tester.
Voltage: Battery voltage
OK
ENG Check the following:
I20A fuse
I Fuse box and battery
connections
I Harness for open or
short-circuit between
ECM relay and battery
If NG, replace fuse or
repair harness or connec-
tors.
CHECK ECM RELAY.
1. Remove ECM relay.
2. Apply 12V direct current between relay terminals q
1andq2.
3. Check continuity between relay termi- nals q
3andq5.
12V ( q
1-q2) applied:
Continuity exists.
No voltage applied: No continuity
OK
ENG Replace ECM relay.
qB
MEC944D
MEC945D
NEF350
H
H
H
H
H
TROUBLE DIAGNOSIS FOR POWER SUPPLYTD27Ti
Diagnostic Procedure (Cont'd)
EC-377
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qA
CHECK INPUT SIGNAL CIRCUIT.
1. Turn ignition switch to ªLOCKº position.
2. Disconnect accelerator work unit har- ness connector and ECM harness con-
nector.
3. Check harness continuity between accelerator work unit terminal q
3and
ECM terminal
435. Refer to wiring
diagram.
Continuity should exist.
Check harness for short-circuit.
OK
ENG Check the following:
I10A fuse in fuse box
I 75A fusible link in fusible
link box
I Harness continuity
between ECM relay and
battery positive supply
I Harness for open or
short-circuit between
ECM relay and accelera-
tor position switch.
If NG, repair harness or
connectors.
CHECK GROUND CIRCUIT.
1. Turn ignition switch to ªLOCKº position.
2. Disconnect ECM harness connector.
3. Check harness continuity between accelerator work unit connector termi-
nal q
1and ECM connector terminal
426. Refer to wiring diagram.
Continuity should exist.
If OK; check harness for short-circuit.
If OK, re-connect harness connectors.
OK
ENG Repair harness or connec-
tors.
CHECK COMPONENT.
(Accelerator position switch.)
Refer to ªCOMPONENT INSPECTIONº on
page EC-394.
OK
ENGReplace accelerator pedal.
Disconnect and reconnect harness con-
nectors in the circuits. Then retest.
Trouble is not fixed
Check ECM pin terminals for damage and
check the connection of ECM harness
connector. Reconnect ECM harness con-
nector and retest.
INSPECTION END
SEF628S
H
H
H
H
H
H
DTC P0120 ACCEL POS SENSORTD27Ti
Diagnostic Procedure (Cont'd)
EC-393
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Diagnostic Procedure
INSPECTION START
CHECK FOR AIR IN FUEL FILTER.
1. Move priming pump up and down topurge air from fuel filter.
2. Perform ªDIAGNOSTIC TROUBLE CODE CONFIRMATION PROCE-
DUREº.
CHECK POWER SUPPLY.
1. Turn ignition switch to ªLOCKº position.
2. Disconnect TVC and shut-off (injection timing control valve) harness connec-
tor.
3. Turn ignition switch to ªONº position.
4. Check voltage between TVC and shut- off (injection timing control valve) con-
nector terminal q
9and engine ground
with CONSULT-II or tester.
Voltage: Battery voltage
OK
ENG Check the following:
IHarness connector
M787,F66
I20A fuse
I ECM relay
I Harness for open or
short-circuit between
TVC and shut-off (injec-
tion timing control valve)
harness connector and
fuse box.
If NG, replace 20A fuse or
ECM relay, harness or con-
nectors.
CHECK OUTPUT SIGNAL CIRCUIT.
1. Turn ignition switch to ªLOCKº position.
2. Disconnect ECM harness connector.
3. Check harness continuity between TVC and shut-off (injection timing control
valve) connector terminal q
8and ECM
terminals
202. Refer to wiring dia-
gram.
Continuity should exist.
If OK, check harness for short-circuit.
OK
ENG Check the following:
IHarness for open or
short-circuit between
TVC and shut-off (injec-
tion timing control valve)
and ECM
If NG, repair harness or
connectors.
CHECK GROUND CIRCUIT.
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM connector terminal
349and TVC
and shut-off (injection timing control
valve) connector terminal q
10. Refer to
wiring diagram.
Continuity should exist.
If OK, check harness of short-circuit.
OK
ENG Repair harness or connec-
tors
qA
YEC256A
NEF463
MEC947D
H
H
H
H
H
DTC P0216 INJ TIMING CONT/V, DTC P1246 F/INJ TIMG F/BTD27Ti
EC-406
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