EC-1008
[YD (WITH EURO-OBD)]
TROUBLE DIAGNOSIS
WORK FLOW
*1 If time data of “SELF-DIAG
RESULTS” is other than “0”, per-
form EC-1045, "
TROUBLE DIAG-
NOSIS FOR INTERMITTENT
INCIDENT" .*2 If the incident cannot be verified, per-
form EC-1045, "
TROUBLE DIAG-
NOSIS FOR INTERMITTENT
INCIDENT" .*3 If the on board diagnostic system
cannot be performed, check main
power supply and ground circuit.
Refer to EC-1046, "POWER SUP-
PLY AND GROUND CIRCUIT" .
*4 If malfunctioning part cannot be
detected, perform EC-1045, "
TROU-
BLE DIAGNOSIS FOR INTERMIT-
TENT INCIDENT" .
PBIB2047E
TROUBLE DIAGNOSIS
EC-1009
[YD (WITH EURO-OBD)]
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Description for Work Flow
DIAGNOSTIC WORK SHEET
There are many operating conditions that lead to the malfunction of
engine components. A good grasp of such conditions can make trou-
bleshooting faster and more accurate.
In general, each customer feels differently about an incident. It is
important to fully understand the symptoms or conditions for a cus-
tomer complaint.
Utilize a diagnostic worksheet like the one shown below in order to
organize all the information for troubleshooting.
STEP DESCRIPTION
STEP IGet detailed information about the conditions and the environment when the incident/symptom occurred using the
EC-1009, "
DIAGNOSTIC WORK SHEET" .
STEP IIBefore confirming the concern, check and write down (print out using CONSULT-II or GST) the (1st/2nd trip) DTC and
the freeze frame data (When 1st/2nd trip DTC is detected, Freeze Frame Data is not recorded.), then erase the DTC
and the data. (Refer to EC-999
.) The (1st/2nd trip) DTC and the freeze frame data can be used when duplicating the
incident at STEP III & IV.
If the incident cannot be verified, perform EC-1045, "
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
Study the relationship between the cause, specified by (1st/2nd trip) DTC, and the symptom described by the cus-
tomer. (The Symptom Matrix Chart will be useful. See EC-1016
.)
Also check related service bulletins for information.
STEP IIITry to confirm the symptom and under what conditions the incident occurs.
The DIAGNOSTIC WORK SHEET and the freeze frame data are useful to verify the incident. Connect CONSULT-II
to the vehicle in “DATA MONITOR (AUTO TRIG)” mode and check real time diagnosis results.
If the incident cannot be verified, perform EC-1045, "
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
If the malfunction code is detected, skip STEP IV and perform STEP V.
STEP IVTry to detect the (1st/2nd trip) DTC by driving in (or performing) the DTC Confirmation Procedure. Check and read
the (1st/2nd trip) DTC and freeze frame data by using CONSULT-II or GST.
During the (1st/2nd trip) DTC verification, be sure to connect CONSULT-II to the vehicle in “DATA MONITOR (AUTO
TRIG)” mode and check real time diagnosis results.
If the incident cannot be verified, perform EC-1045, "
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
In case the DTC Confirmation Procedure is not available, perform the Overall Function Check instead. The (1st/2nd
trip) DTC cannot be displayed by this check, however, this simplified check is an effective alternative.
The NG result of the Overall Function Check is the same as the (1st/2nd trip) DTC detection.
STEP VTake the appropriate action based on the results of STEP I through IV.
If the malfunction code is indicated, proceed to TROUBLE DIAGNOSIS FOR DTC PXXXX.
If the normal code is indicated, proceed to the BASIC INSPECTION. (Refer to EC-1012
.)Then perform inspections
according to the Symptom Matrix Chart. (Refer to EC-1016
.)
STEP VIIdentify where to begin diagnosis based on the relationship study between symptom and possible causes. Inspect the
system for mechanical binding, loose connectors or wiring damage using (tracing) Harness Layouts.
Gently shake the related connectors, components or wiring harness with CONSULT-II set in “DATA MONITOR
(AUTO TRIG)” mode.
Check the voltage of the related ECM terminals or monitor the output data from the related sensors with CONSULT-II.
Refer to EC-1027
, EC-1042 .
The Diagnostic Procedure in EC section contains a description based on open circuit inspection. A short circuit
inspection is also required for the circuit check in the Diagnostic Procedure. For details, refer to Circuit Inspection in
GI-23, "
How to Perform Efficient Diagnosis for an Electrical Incident" .
Repair or replace the malfunction parts.
If malfunctioning part cannot be detected, perform EC-1045, "
TROUBLE DIAGNOSIS FOR INTERMITTENT INCI-
DENT" .
STEP VIIOnce you have repaired the circuit or replaced a component, you need to run the engine in the same conditions and
circumstances which resulted in the customer's initial complaint.
Perform the DTC Confirmation Procedure and confirm the normal code [DTC No. P0000] is detected. If the incident is
still detected in the final check, perform STEP VI by using a method different from the previous one.
Before returning the vehicle to the customer, be sure to erase the unnecessary (already fixed) (1st/2nd trip) DTC in
ECM. (Refer to EC-999, "
HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" .)
SEF907L
EC-1012
[YD (WITH EURO-OBD)]
TROUBLE DIAGNOSIS
Basic InspectionEBS0117A
Precaution:
Perform Basic Inspection without electrical or mechanical loads applied;
Headlamp switch is OFF.
On vehicles equipped with daytime light systems, set lighting switch to the 1st position to light
only small lamps.
Air conditioner switch is OFF.
Rear defogger switch is OFF.
Steering wheel is in the straight-ahead position, etc.
1. INSPECTION START
1. Check service records for any recent repairs that may indicate a related malfunction.
2. Check the current need for scheduled maintenance, especially for fuel filter and air cleaner filter. Refer to
MA-7, "
PERIODIC MAINTENANCE" .
3. Open engine hood and check the following:
–Harness connectors for improper connections
–Vacuum hoses for splits, kinks, or improper connections
–Wiring for improper connections, pinches, or cuts
4. Start engine and warm it up to the normal operating tempera-
ture.
>> GO TO 2.
2. PREPARATION FOR CHECKING IDLE SPEED
With CONSULT-II
Connect CONSULT-II to the data link connector.
Without CONSULT-II
Install diesel tacho tester to the vehicle.
>> GO TO 3.
SEF142I
TROUBLE DIAGNOSIS
EC-1013
[YD (WITH EURO-OBD)]
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3. CHECK IDLE SPEED
With CONSULT-II
1. Select “CKPS·RPM (TDC)” in “DATA MONITOR” mode with CONSULT-II.
2. Read idle speed.
Without CONSULT-II
Read idle speed.
OK or NG
OK >>INSPECTION END
NG >> GO TO 4.
4. CHECK FOR INTAKE AIR LEAK
Listen for an intake air leak after the mass air flow sensor.
OK or NG
OK >> GO TO 5.
NG >> Repair or replace.
5. BLEED AIR FROM FUEL SYSTEM
1. Stop engine.
2. Use priming pump to bleed air from fuel system. Refer to EC-994, "
AIR BLEEDING" .
>> GO TO 6. 725±25 rpm
SEF817Y
725±25 rpm
EC-1014
[YD (WITH EURO-OBD)]
TROUBLE DIAGNOSIS
6. CHECK IDLE SPEED AGAIN
With CONSULT-II
1. Start engine and let it idle.
2. Select “CKPS·RPM (TDC)” in “DATA MONITOR” mode with CONSULT-II.
3. Read idle speed.
Without CONSULT-II
Read idle speed.
OK or NG
OK >>INSPECTION END
NG >> GO TO 7.
7. DRAIN WATER FROM FUEL FILTER
Drain water from fuel filter. Refer to EC-994, "
WATER DRAINING" .
>> GO TO 8.
8. CHECK IDLE SPEED AGAIN
With CONSULT-II
1. Start engine and let it idle.
2. Select “CKPS·RPM (TDC)” in “DATA MONITOR” mode with CONSULT-II.
3. Read idle speed.
Without CONSULT-II
Read idle speed.
OK or NG
OK >>INSPECTION END
NG >> GO TO 9.725±25 rpm
SEF817Y
725±25 rpm
725±25 rpm
SEF817Y
725±25 rpm
TROUBLE DIAGNOSIS
EC-1015
[YD (WITH EURO-OBD)]
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9. CHECK AIR CLEANER FILTER
Check air cleaner filter for clogging or breaks.
OK or NG
OK >> GO TO 10.
NG >> Replace air cleaner filter.
10. CHECK BATTERY VOLTAGE
Check battery voltage.
OK or NG
OK >> GO TO 12.
NG >> GO TO 11.
11 . CHECK BATTERY
Refer to SC-4, "
BATTERY" .
OK or NG
OK >> Check charging system. Refer to SC-13, "CHARGING SYSTEM" .
NG >> Repair or replace.
12. CHECK COMPRESSION PRESSURE
Check compression pressure. Refer to EM-209, "
CHECKING COMPRESSION PRESSURE" .
OK or NG
OK >> GO TO 13.
NG >> Follow the instruction of “CHECKING COMPRESSION PRESSURE”.
13. CHECK IDLE SPEED AGAIN
With CONSULT-II
1. Start engine and let it idle.
2. Select “CKPS·RPM (TDC)” in “DATA MONITOR” mode with CONSULT-II.
3. Read idle speed.
Without CONSULT-II
Read idle speed.
OK or NG
OK >>INSPECTION END
NG >> 1. Replace fuel injector.
2. GO TO 3. Voltage: More than 12.13V
725±25 rpm
SEF817Y
725±25 rpm
EC-1038
[YD (WITH EURO-OBD)]
TROUBLE DIAGNOSIS
NOTE:
Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.
ACTIVE TEST MODE
EGR VOL CON/V [step]×
Indicates the EGR volume control value
computed by the ECM according to the
input signals.
The opening becomes larger as the
value increases.
INT/A VOLUME [mg/]
The intake air volume computed from the
mass air flow sensor signal is displayed.
BARO SEN [kPa]××
The barometric pressure (determined by
the signal voltage from the absolute
pressure sensor built into the ECM) is
displayed.
INT/M PRES SE [kPa]
Turbocharger boost (determined by the
signal voltage from the turbocharger
boost sensor) is displayed.
CYL COUNT [1/2/3/4]
The cylinder being injected is displayed.
1 ... Cylinder No.1 is injected.
2 ... Cylinder No.2 is injected.
3 ... Cylinder No.3 is injected.
4 ... Cylinder No.4 is injected.
SET SW
[ON/OFF]×
Indicates [ON/OFF] condition from SET/
COAST switch signal.
RESUME/ACC SW
[ON/OFF]×
Indicates [ON/OFF] condition from
RESUME/ACCELERATE switch signal.
CANCEL SW
[ON/OFF]×
Indicates [ON/OFF] condition from CAN-
CEL switch signal.
MAIN SW
[ON/OFF]×
Indicates [ON/OFF] condition from MAIN
switch signal.
Voltage [V]
Voltage, frequency, duty cycle or pulse
width measured by the probe.Only “#” is displayed if item is
unable to be measured.
Figures with “#”s are temporary
ones.
They are the same figures as an
actual piece of data which was
just previously measured. [Hz] or
[%] Frequency [msec], [Hz] or
[%]
DUTY-HI
DUTY-LOW
PLS WIDTH-HI
PLS WIDTH-LOWMONITOR ITEMECM
INPUT
SIGNALMAIN
SIG-
NALSCONDITION SPECIFICATION
TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY)
POWER BAL-
ANCE
Engine: After warming up, idle the
engine.
A/C switch: OFF
Shift lever: Neutral position
Cut off each injector signal one at
a time using CONSULT-IIEngine runs rough or dies.
Harness and connectors
Compression
Fuel injector
COOLING FAN *
Ignition switch: ON
Operate the cooling fan at LOW,
HI speed and turn OFF using
CONSULT-II.Cooling fan moves at LOW, HI
speed and stops.Harness and connector
Cooling fan motor
Cooling fan relay
TROUBLE DIAGNOSIS
EC-1039
[YD (WITH EURO-OBD)]
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*:Leaving cooling fan OFF with CONSULT-II while engine is running may cause the engine to overheat.
REAL TIME DIAGNOSIS IN DATA MONITOR MODE
CONSULT-II has two kinds of triggers and they can be selected by touching “SETTING” in “DATA MONITOR”
mode.
1. “AUTO TRIG” (Automatic trigger):
–The malfunction will be identified on the CONSULT-II screen in
real time.
In other words, DTC/1st trip DTC/2nd trip DTC will be displayed
if the malfunction is detected by ECM.
At the moment a malfunction is detected by ECM, “MONITOR”
in “DATA MONITOR” screen is changed to “Recording Data ...
xx%” as shown in the figure, and the data after the malfunction
detection is recorded. Then when the percentage reached
100%, “REAL-TIME DIAG” screen is displayed. If “STOP” is
touched on the screen during “ Recording Data ... xx%”, “REAL-
TIME DIAG” screen is also displayed.
The recording time after the malfunction detection and the recording speed can be changed by “TRIG-
GER POINT” and “Recording Speed”. Refer to CONSULT-II OPERATION MANUAL.
2. “MANU TRIG” (Manual trigger):
–DTC/1st trip DTC/2nd trip DTC will not be displayed automati-
cally on CONSULT-II screen even though a malfunction is
detected by ECM.
DATA MONITOR can be performed continuously even though a
malfunction is detected.
Use these triggers as follows:
1. “AUTO TRIG”
–While trying to detect the DTC/1st trip DTC/2nd trip DTC by per-
forming the “DTC Confirmation Procedure”, be sure to select to
“DATA MONITOR (AUTO TRIG)” mode. You can confirm the
malfunction at the moment it is detected.
–While narrowing down the possible causes, CONSULT-II should be set in “DATA MONITOR (AUTO
TRIG)” mode, especially in case the incident is intermittent.
When you are inspecting the circuit by gently shaking (or twisting) the suspicious connectors, components
and harness in the DTC Confirmation Procedure, the moment a malfunction is found the DTC/1st trip
DTC/2nd trip DTC will be displayed. Refer to GI-23, "
How to Perform Efficient Diagnosis for an Electrical
Incident" , “INCIDENT SIMULATION TESTS”.
ENG COOLANT
TEMP
Engine: Return to the original
trouble condition
Change the engine coolant tem-
perature using CONSULT-II.If trouble symptom disappears, see
CHECK ITEM.
Harness and connectors
Engine coolant temperature sen-
sor
Fuel injector
GLOW RLY
Ignition switch: ON (Engine
stopped)
Turn the glow relay ON and OFF
using CONSULT-II and listen to
operating sound.Glow relay makes the operating
sound.Harness and connector
Glow relay
EGR VOL CONT/
V
Ignition switch: ON
Change EGR volume control
valve opening step using CON-
SULT-II.EGR volume control valve makes
an operating sound.Harness and connector
EGR volume control valve
PRES REGULA-
TOR
Ignition switch: ON
Change fuel rail pressure using
CONSULT-IIFuel leaks.Fuel line
Fuel pressure relief valve
PUMP LEANT
CLEAR
This mode is used for performing Fuel Pump Learning Value Clearing. Refer to EC-994, "Fuel Pump Learning
Value Clearing" . TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY)
PBIB0480E
SEF707X