EC-950
< COMPONENT DIAGNOSIS >[MR18DE]
P2122, P2123 APP SENSOR
7.DETECT MALFUNCTIONING PART
Check the following.
Harness conector E7, M69, M25, M201 (RHD models)
Harness for open or short between ECM and APP sensor
>> Repair open circuit or short to ground or short to power in harness or connectors.
8.CHECK APP SENSOR
Refer to EC-950, "
Component Inspection".
Is the inspection result normal?
YES >> GO TO 10.
NO >> GO TO 9.
9.REPLACE ACCELERATOR PEDAL ASSEMBLY
1. Replace accelerator pedal assembly.
2. Go to EC-950, "
Special Repair Requirement".
>> INSPECTION END
10.CHECK INTERMITTENT INCIDENT
Refer to GI-55, "
Intermittent Incident".
>> INSPECTION END
Component InspectionINFOID:0000000001161936
1.CHECK ACCELERATOR PEDAL POSITION SENSOR
1. Reconnect all harness connectors disconnected.
2. Turn ignition switch ON.
3. Check the voltage between ECM harness connector terminals as follows.
Is the inspection result normal?
YES >> INSPECTION END
NO >> GO TO 2.
2.REPLACE ACCELERATOR PEDAL ASSEMBLY
1. Replace accelerator pedal assembly.
2. Go to EC-950, "
Special Repair Requirement".
>> INSPECTION END
Special Repair RequirementINFOID:0000000001161937
1.PERFORM ACCELERATOR PEDAL RELEASED POSITION LEARNING
Refer to EC-693, "
ACCELERATOR PEDAL RELEASED POSITION LEARNING : Special Repair Require-
ment".
(+) (–)
Condition Voltage
Connector Terminal Connector Terminal
E1611 0
(APP sensor 1 signal)
E16111
Accelerator pedalFully released 0.6 - 0.9V
Fully depressed 3.9 - 4.7V
103
(APP sensor 2 signal)104Fully released 0.3 - 0.6V
Fully depressed 1.95 - 2.4V
EC-962
< COMPONENT DIAGNOSIS >[MR18DE]
P2138 APP SENSOR
2. Also check harness for short to ground and short to power.
Is the inspection result normal?
YES >> GO TO 14.
NO >> GO TO 13.
13.DETECT MALFUNCTIONING PART
Check the following.
Harness conector E7, M69, M25, M201 (RHD models)
Harness for open or short between ECM and APP sensor
>> Repair open circuit or short to ground or short to power in harness or connectors.
14.CHECK APP SENSOR
Refer to EC-962, "
Component Inspection".
Is the inspection result normal?
YES >> GO TO 11.
NO >> GO TO 10.
15.REPLACE ACCELERATOR PEDAL ASSEMBLY
1. Replace accelerator pedal assembly.
2. Go to EC-963, "
Special Repair Requirement".
>> INSPECTION END
16.CHECK INTERMITTENT INCIDENT
Refer to GI-55, "
Intermittent Incident".
>> INSPECTION END
Component InspectionINFOID:0000000001161951
1.CHECK ACCELERATOR PEDAL POSITION SENSOR
1. Reconnect all harness connectors disconnected.
2. Turn ignition switch ON.
3. Check the voltage between ECM harness connector terminals as follows.
Is the inspection result normal?
YES >> INSPECTION END
NO >> GO TO 2.
2.REPLACE ACCELERATOR PEDAL ASSEMBLY
1. Replace accelerator pedal assembly.
2. Go to EC-963, "
Special Repair Requirement".
APP sensor ECM
Continuity
Connector Terminal Connector Terminal
E12 (LHD models)
M204 (RHD models)3
E1611 0
Existed
6103
(+) (–)
Condition Voltage
Connector Terminal Connector Terminal
E1611 0
(APP sensor 1 signal)
E16111
Accelerator pedalFully released 0.6 - 0.9V
Fully depressed 3.9 - 4.7V
103
(APP sensor 2 signal)104Fully released 0.3 - 0.6V
Fully depressed 1.95 - 2.4V
IGNITION SIGNAL
EC-981
< COMPONENT DIAGNOSIS >[MR18DE]
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IGNITION SIGNAL
DescriptionINFOID:0000000001161977
The ignition signal from the ECM is sent to and amplified by the power transistor. The power transistor turns
ON and OFF the ignition coil primary circuit. This ON/OFF operation induces the proper high voltage in the coil
secondary circuit.
Component Function CheckINFOID:0000000001161978
1.INSPECTION START
Turn ignition switch OFF, and restart engine.
Does the engine start?
YES-1 >> With CONSULT-III: GO TO 2.
YES-2 >> Without CONSULT-III: GO TO 3.
NO >> Go to EC-981, "
Diagnosis Procedure".
2.IGNITION SIGNAL FUNCTION
With CONSULT-III
1. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-III.
2. Make sure that each circuit produces a momentary engine speed drop.
Is the inspection result normal?
YES >> INSPECTION END
NO >> Go to EC-981, "
Diagnosis Procedure".
3.IGNITION SIGNAL FUNCTION
Without CONSULT-III
1. Let engine idle.
2. Read the voltage signal between ECM harness connector terminals as follows.
NOTE:
The pulse cycle changes depending on rpm at idle.
Is the inspection result normal?
YES >> INSPECTION END
NO >> Go to EC-981, "
Diagnosis Procedure".
Diagnosis ProcedureINFOID:0000000001161979
1.CHECK IGNITION COIL POWER SUPPLY CIRCUIT-I
1. Turn ignition switch OFF, wait at least 10 seconds and then turn ON.
2. Check the voltage between ECM harness connector terminals as follows.
ECM Ground
Voltage signal
Connector Terminal Connector Terminal
F1017
E16 108 18
21
22
JMBIA0329GB
(+) (–)
Vo l ta g e
Connector Terminal Connector Terminal
E16 105 E16 108 Battery voltage
EC-1044
< BASIC INSPECTION >[K9K]
INSPECTION AND ADJUSTMENT
2.CHECK FUEL CIRCUIT
Does the fuel circulate correctly when pumped manually?
Ye s o r N o
Ye s > > G O T O 5 .
No >> GO TO 3.
3.CHECK FOR LEAK
Look for leaks on the unions.
Are there leaks in the hoses and unions?
Yes >> Carry out the required repairs.
No >> GO TO 4.
4.CHECK FUEL FILTER
Check the correctness of the fuel filter.
Is the fuel filter correct?
Ye s > > G O T O 5 .
No >> Replace the fuel filter with a genuine part.
5.INSPECTION END
Low pressure circuit OK.
>>INSPECTION END
BASIC INSPECTION : Special Repair Requirement (TEST 2: Internal Fuel Transfer
Pump Check)
INFOID:0000000001162516
NOTE:
CONDITIONS PRIOR TO TEST
- Test 1 Low pressure fuel supply system check has been carried out previously and results are satisfactory.
CAUSE
- Fuel can be seen in the transparent supply pipe leading to the pump.
- However, fuel does not move during starting.
1.CHECK INTERNAL FUEL TRANSFER PUMP
1. Disconnect high pressure supply pump (volumetric control valve) harness connector
2. Remove fuel return pipe from the pump and block it so that it is sealed. Connect a pipe to the pump to
measure the flow of diesel.
3. To authorise a 15 second cranking engine and carry out this test it is essential to carry out the following
procedure: measure the flow of diesel.
- Turn ignition switch ON.
- Perform “SAVE DATA FOR CPU REPLC” in WORK SUPPORT mode with CONSULT-III.
- Perform “PRGRM REINITIALIZE” in WORK SUPPORT mode with CONSULT-III.
- Cranking engine for at least 15 seconds (starting speed 250 rpm)
- Check the flow rate of the fuel being collected in a graduated measuring cylinder (500 ml minimum).The
minimum flow rate must be 25 ml every 15 sec.
- Perform “WRT DATA AFTR REPLC CPU” in WORK SUPPORT mode with CONSULT-III.
Does the flow measure less than 25ml?
Yes >> Replace high pressure supply pump.
No >> GO TO 2.
2.INSPECTION END
Low pressure system OK.
>>INSPECTION END
BASIC INSPECTION : Special Repair Requirement [TEST 3: High Pressure Supply
EC-1046
< BASIC INSPECTION >[K9K]
INSPECTION AND ADJUSTMENT
Pump (Volumetric Control Valve) Check]
INFOID:0000000001162518
NOTE:
CONDITIONS PRIOR TO TEST
- The entire low pressure system must be in good condition.
- Check the sealing of the high pressure pipes and unions.
CAUSE
- Not enough or no rail pressure during starting.
- Rail reference pressure during starting, minimum 15 000 kPa (150 bar, 153 kg/cm
2, 2175 psi).
1.CHECK HIGH PRESSURE SUPPLY PUMP (VOLUMETRIC CONTROL VALVE)-I
Refer to EC-1110, "
Component Inspection".
Is the inspection result normal?
YES >> GO TO 2
NO >> Replace high pressure supply pump.
2.CHECK HIGH PRESSURE SUPPLY PUMP (VOLUMETRIC CONTROL VALVE)-II
Reconnect all harness connectors disconnected.
Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-III.
Check that the “FUEL FLOW S/V CU” indication when the cranking engine.
Is the excitation current between 0.6 - 1.0A?
YES >> GO TO 6.
NO >> GO TO 3.
3.CHECK HIGH PRESSURE SUPPLY PUMP (VOLUMETRIC CONTROL VALVE) POWER SUPPLY
1. Turn ignition switch OFF.
2. Disconnect high pressure supply pump (volumetric control valve) harness connector.
3. Turn ignition switch ON.
4. Check the voltage between high pressure supply pump (volumetric control valve) harness connector and
ground.
Is the inspection result normal?
YES >> GO TO 5.
NO >> GO TO 4.
4.DETECT MALFUNCTIONING PART
Check the following.
IPDM E/R
Harness for open or short between ECM and high pressure supply pump (volumetric control valve)
Harness for open or short between IPDM E/R and high pressure supply pump (volumetric control valve)
>> Repair open circuit or short to ground or short to power in harness or connectors.
5.CHECK HIGH PRESSURE SUPPLY PUMP (VOLUMETRIC CONTROL VALVE) OUTPUT SIGNAL CIR-
CUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check the continuity between high pressure supply pump (volumetric control valve) harness connector
and ECM harness connector.
High pressure supply pump
(volumetric control valve)
Ground Voltage
Connector Terminal
F54 1 Ground Battery voltage
EC-1048
< BASIC INSPECTION >[K9K]
INSPECTION AND ADJUSTMENT
>>INSPECTION END
BASIC INSPECTION : Special Repair Requirement (TEST 5: Rail High Pressure Reg-
ulation Check)
INFOID:0000000001162519
NOTE:
If contaminants (swarf) can be seen in the transparent return pipe, the entire fuel injection system (fuel injec-
tors, pump, rail, high pressure pipes and all return pipes) must be replaced.
CONDITIONS PRIOR TO TEST
- Engine coolant temperature between 80 - 90°C (176 - 194°F).
- All the electrical load are switched off.
- Air conditioning is switched off.
- The tank is at least half-full.
- The pipe connections and unions have been checked.
- Check the sealing of the high pressure pipes and unions.
CAUSE
- Rail pressure variations around the setpoint.
- The rail reference pressure is not reached.
- Rough idle.
- Possibly noisy combustion.
1.CHECK AIR BUBBLES
1. Start engine
2. Are there large air bubbles in the transparent supply pipe going to the pump?
Is the inspection result normal?
YES >> Check low pressure system.
NO >> GO TO 2.
2.CHECK HIGH PRESSURE SUPPLY PUMP (VOLUMETRIC CONTROL VALVE)-I
Disconnect high pressure supply pump (volumetric control valve) harness connector.
Does the engine stop?
YES >> GO TO 3.
NO >> Replace high pressure supply pump (the high pressure supply pump [volumetric control valve]
remains open mechanically).
3.CHECK HIGH PRESSURE SUPPLY PUMP (PRESSURE CONTROL VALVE)-I
1. Reconnect high pressure supply pump (volumetric control valve) harness connector.
2. Turn ignition switch OFF and wait at least 30 seconds.
3. Start engine.
4. Disconnect high pressure supply pump (pressure control valve) harness connector.
Does the engine stop?
YES >> GO TO 4.
NO >> Replace high pressure supply pump (the high pressure supply pump [pressure control valve]
remains open mechanically).
4.CHECK FUEL INJECTOR
1. Reconnect high pressure supply pump (pressure control valve) harness connector.
2. Wait at least 30 seconds.
3. Start engine and let it idle speed.
4. Select “DATA MONITOR” mode with CONSULT-III.
5. Check that the “F/FLOW CORR CYL1”, “F/FLOW CORR CYL2”, “F/FLOW CORR CYL3”, “F/FLOW
CORR CYL4” indication.
Are the reference value 0.3 - 1.9?
YES >> GO TO 6.
NO >> GO TO 5.
5.CHECK MAJOR LEAK IN FUEL INJECTOR/FUEL INJECTORS OPEN
Carry out TEST 6.
INSPECTION AND ADJUSTMENT
EC-1053
< BASIC INSPECTION >[K9K]
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YES >> GO TO 2.
NO >> Replace malfunctioning fuel injector.
2.CHECK INTERNAL FUEL TRANSFER PUMP
1. Turn ignition switch OFF.
2. Disconnect the return system connections at the fuel injectors and close off the return pipes so they are
leak-tight.
3. To authorise a 15 second cranking engine and carry out this test it is essential to carry out the following
procedure:
- Disconnect high pressure supply pump (volumetric control valve) harness connector
- Turn ignition switch ON.
- Perform “SAVE DATA FOR CPU REPLC” in WORK SUPPORT mode with CONSULT-III.
- Perform “PRGRM REINITIALIZE” in WORK SUPPORT mode with CONSULT-III.
- Cranking engine for at least 15 seconds (starting speed 250 rpm)
- Perform “WRT DATA AFTR REPLC CPU” in WORK SUPPORT mode with CONSULT-III.
Is the return volume at the fuel injectors more than 20 ml per fuel injector for the starting phase?
NOTE:
Do not repeat this procedure more than 3 times and wait 30 seconds between each 15 second cranking
engine.
Then wait 30 minutes before cranking the engine for 3 15 second cycles.
Follow this instruction so that the starter does not get damaged.
Does the flow measure more than 20ml?
Yes >> Replace malfunctioning fuel injector.
No >> GO TO 3.
3.CHECK FUEL INJECTOR-II
1. Turn ignition switch OFF.
2. Reconnect return pipes.
3. Start Engine.
4. Select “DATA MONITOR” mode with CONSULT-III.
5. Check “RAIL PRESSURE” and “RAIL PRES SET” indication.
6. Does “RAIL PRESSURE” follow “RAIL PRES SET” during the 3 second cranking engine?
Is the inspection result normal?
YES >> GO TO 5.
NO >> GO TO 4.
4.CHECK GLOW PLUG
1. Turn ignition switch OFF.
2. Remove the glow plugs and check for moisture.
3. If the glow plugs are wet with fuel, it is possible that the fuel injector is leaking.
Are the glow plugs wet with fuel?
Yes >> Replace malfunction fuel injector.
No >> Replace high pressure supply pump.
5.INSPECTION END
Fuel injector system OK.
>>INSPECTION END
BASIC INSPECTION : Special Repair Requirement (TEST 7: Incorrect Fuel Injection
Quantity)
INFOID:0000000001162521
NOTE:
CONDITIONS PRIOR TO TEST
- The entire low pressure system must be in good condition.
- Check the sealing of the high pressure pipes and unions.
- Test 3 High pressure supply pump (pressure control valve) check is OK
- Test 4 High pressure supply pump (volumetric control valve) check is OK
- Test 5 Rail high pressure regulation circuit check is OK.
EC-1054
< BASIC INSPECTION >[K9K]
INSPECTION AND ADJUSTMENT
- All the electrical loads are switched off.
- Air conditioning is switched off.
CAUSE
- The engine runs poorly at idle speed, possibly emits white smoke.
1.CHECK FUEL INJECTOR
Refer to EC-1141, "
Component Inspection".
Is the inspection result normal?
YES >> GO TO 2.
NO >> Replace malfunctioning fuel injector.
2.CHECK ENGINE COOLANT TEMPERATURE AND FUEL TEMPERATURE
1. Start engine let it idle speed.
2. Select “DATA MONITOR” mode with CONSULT-III.
3. Check “FUEL TEMP” indication is above 60°C (140°F)
4. Check “F/FLOW CORR CYL1“, “F/FLOW CORR CYL2”, “F/FLOW CORR CYL3”, “F/FLOW CORR CYL4”
indication.
Are the reference value 0.3 - 1.9?
YES >> GO TO 3.
NO >> GO TO 4.
3.CHECK INTERNAL FUEL TRANSFER PUMP
1. Turn ignition switch OFF.
2. Disconnect the return system connections at the fuel injectors and close off the return pipes so they are
leak-tight. While the engine is idling, check the return flow rate at the fuel injector. After 5 minutes the
return volume must be between 16 - 24 ml per fuel injector.
Is there more than 24 ml or less than 16 ml of return for each fuel injector?
Yes >> Replace malfunctioning fuel injector.
No >> INSPECTION END
4.CHECK COMPRESSION PRESSURE
Check compression pressure. Refer to EM-267, "
Inspection".
>> INSPECTION END
ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT
ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Description
INFOID:0000000001162522
When replacing ECM, this procedure must be performed.
ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Special Repair Re-
quirement
INFOID:0000000001162523
1.PRECONDITIONING
Connect a CONSULT-III
Connect a battery charger
Electric load switch is OFF
Wait for the engine to cool [engine coolant temperature < 60°C (140°F and air temperature < 50°C (122°F)].
NOTE:
While the ECM is being programmed the cooling fan motors are triggered automatically.
>> GO TO 2.
2.SAVE ECM DATA
Turn ignition switch ON.
Perform “SAVE DATA FOR CPU REPLC” in WORK SUPPORT mode with CONSULT-III.