ECD SYSTEM DATA LIST / ACTIVE TEST

Calculated load by ECM/

Min.: 0%, Max.: 100%

• Idling: 10 to 35%

• Running without load (2500 rpm): 10 to 35%

• Driving with the accelerator fully open at 3000 rpm: 80.3 to 99.6%

• Driving with the accelerator fully open at 4000 rpm: 96.4 to 98%

Results of real-vehicle check:

• Ignition switch ON: 0.0%

• Cranking (295 rpm): 83.0%

• Idling (warm up the engine): 15.0% (2 minutes after starting the engine)

• Running without load (2500 rpm): 16%

• Running without load (4500 rpm): 30.1%

• Driving with the accelerator fully open at 2000 rpm: 86.6%

• Driving with the accelerator fully open at 3000 rpm: 99.6%

• Driving with the accelerator fully open at 4500 rpm: 100%

Diagnostic Note:

Calculate load = (Actual inner torque / Full inner torque) x 100.

Air flow rate from MAF meter/

Min.: 0 gm/sec., Max.: 200 gm/sec.

• Idling: 3.5 to 12 g/sec.

• Running without load (2000 rpm): 10 to 40 g/sec.

• MAF meter

• MAF meter circuit

• Intake related clog or leak

• Exhaust related clog

• Turbocharger sub-assembly

• Leak or clog in passages for turbocharger

• Malfunction in which EGR valve does not close

Results of real-vehicle check:

• Ignition switch ON: 0 g/sec.

• Cranking (295 rpm): 2.72 g/sec.

• Idling (warm up the engine): 5.0 g/sec. (2 minutes after starting the vehicle and "Actual EGR Valve Pos." = 56%)

• Idling (warm up the engine): 8.5 g/sec. (2 minutes after starting the vehicle and "Actual EGR Valve Pos." = 0.3%)

• Running without load (2500 rpm): 21.2 g/sec. (at "Actual EGR Valve Pos." = 56%)

• Running without load (4500 rpm): 69.8 g/sec.

• Driving with the accelerator fully open at 2000 rpm: 43.94 g/sec.

• Driving with the accelerator fully open at 3000 rpm: 72.47 g/sec.

• Driving with the accelerator fully open at 4500 rpm: 87.8 g/sec.

Symptoms when out of range:

Rough idling

Diagnostic Note:

• Based on the MAF, the ECM controls the fuel injection volume, injection timing, EGR, etc.

• If the MAF value exceeds the normal condition when the engine is idling, the EGR passage is possibly clogged.

• If the value is always approximately 0 g/sec.:




• Mass air flow meter power source circuit is open.

• VG circuit is open or shorted.

• If the value is always 200 g/sec. or more:




• EVG circuit is open.

Engine speed/

Min.: 0 rpm, Max.: 6000 rpm

• Crankshaft position sensor

• Crankshaft position sensor circuit

Results of real-vehicle check:

Idling ("Coolant Temp" = 88°C (190°F)): 773 rpm

Symptoms when out of range:

-

Diagnostic Note:

When the crankshaft position sensor is malfunctioning, "Engine speed" is approximately 0 or varies greatly from the actual engine speed.

Absolute pressure inside intake manifold/

Min.: 0 kPa, Max.: 255 kPa

• Idling: 90 to 102 kPa (depending on barometric pressure)

• Engine running without load at 3000 rpm: 100 to 150 kPa

• Manifold absolute pressure sensor

• Intake related clog or leak

• Exhaust related clog

• Turbocharger sub-assembly

• Leak or clog in passages for turbocharger

• EGR valve stuck open

• Exhaust leak

• Throttle valve stuck closed

Results of real-vehicle check:

• Ignition switch ON: 98 kPa

• Cranking: 98 kPa

• Idling (warm up the engine): 99 kPa (2 minutes after starting the vehicle)

• Running without load (2500 rpm): 109 kPa

• Running without load (3000 rpm): 131 kPa

• Running without load (4000 rpm): 163 kPa

• Running without load (4500 rpm): 173 kPa

• Driving with the accelerator fully open at 2000 rpm: 183 kPa

• Driving with the accelerator fully open at 3000 rpm: 217 kPa

• Driving with the accelerator fully open at 4500 rpm: 205 kPa

Symptoms when out of range:

Lack of power

Diagnostic Note:

• When the ignition switch is ON or the vehicle is idling, the intake manifold absolute pressure and atmospheric pressure are approximately the same (standard atmospheric pressure = 101 kPa).

  Above approximately 1500 rpm, the turbo becomes effective, and the pressure becomes higher than atmospheric pressure.

• Inspect while comparing with "Target Booster Pressure".

• With the accelerator fully open, if the actual manifold absolute pressure (MAP) is low compared to the target booster pressure by at least 20 kPa for 5 seconds or more, a feeling of insufficient power will occur.

Vehicle speed/

Min.: 0 km/h, Max.: 255 km/h

• Speed sensor

• Speed sensor circuit

Symptoms when out of range:

-

Diagnostic Note:

-

Engine coolant temperature/

Min.: -40°C, Max.: 140°C

• Engine coolant temperature sensor

• Thermostat

Results of real-vehicle check:

After warming up engine: 88°C (190°F)

Symptoms when out of range:

Difficult starting when engine is cold, rough idle, black smoke, lack of power

Diagnostic Note:

• If the value is -30°C (-22°F) or 120°C (248°F), the sensor circuit is open or shorted.

• After a long soak, the coolant temperature, intake air temperature, and ambient air temperature are approximately equal.

Intake air temperature/

Min.: -40°C, Max.: 140°C

Results of real-vehicle check:

Idling: 35°C (95°F)

Symptoms when out of range:

-

Diagnostic Note:

• After a long soak, the engine coolant temperature, intake air temperature, and ambient air temperature are approximately equal.

• If the value is -40°C (-40°F) or 140°C (284°F), the sensor circuit is open or shorted.

Initial engine coolant temperature/

Min.: -40°C, Max.: 120°C

Diagnostic Note:

For Freeze Frame Data, this tells whether the malfunction happened at a cold start or with a warm engine.

Initial intake air temperature/

Min.: -40°C, Max.: 120°C

Diagnostic Note:

-

Intake air temperature after intercooler/

Min.: -40°C, Max.: 190°C

Results of real-vehicle check:

Idling: 59°C (138°F)

Diagnostic Note:

• Intake air temperature at the intake manifold (after intercooler).

Pre glow operation/

ON or OFF

Diagnostic Note:

-

After glow operation/

ON or OFF

Diagnostic Note:

-

Starter signal/

ON or OFF

• OFF malfunction (ignition switch is START but the starter signal is OFF and the starter is operating): Wire harness is open or shorted to ground

• ON malfunction (ignition switch is off but the starter signal is ON and the starter is not operating): Wire harness is shorted to +B

• Operation malfunction: Ignition switch malfunction, starter relay malfunction, starter malfunction, battery or battery cable is defective, or wire harness is open or shorted

Symptoms when out of range:

• Ignition switch is ON but the starter does not operate: Starting is not possible

Diagnostic Note:

• Ignition switch (START) output:




• ON: Starter is operating.

• OFF: Starter is not operating.

A/C (Air Conditioner) signal/

ON or OFF

A/C operation signal output from A/C amplifier

• ON: Operating

• OFF: Not operating

• A/C switch

• A/C amplifier

• A/C system malfunction, wire harness between A/C amplifier and ECU open or shorted

Symptoms when out of range:

• OFF malfunction (OFF even when A/C switch is turned on):




• Engine speed decreases temporarily when the A/C is operating.

Diagnostic Note:

-

Electric fan motor operation/

ON or OFF

Diagnostic Note:

-

Electrical load signal/

ON or OFF

Diagnostic Note:

-

Stop light switch/

ON or OFF

• ON: Brake pedal depressed

• OFF: Brake pedal released

• OFF malfunction: Wire harness (stop light switch to ECM, stop light switch to +B) open or shorted to ground

• ON malfunction: Wire harness (stop light switch to ECM) shorted to +B

• Stop light switch

Symptoms when out of range:

• Stop light switch malfunction DTC P0504 is stored

Diagnostic Note:

• Stop light switch (STP) operation condition:




• ON: Light is on (Brake pedal is depressed).

• OFF: Light is off (Brake pedal is released).

Immobiliser communication/

ON or OFF

• Use of a non-registered key

• Key battery is fully depleted

Symptoms when out of range:

-

Diagnostic Note:

-

Clutch switch/

ON or OFF

Symptoms when out of range:

When OFF with the clutch pedal depressed, the engine does not start.

Diagnostic Note:

-

Battery voltage/

Min.: 0 V, Max.: 15 V

Results of real-vehicle check:

• Ignition switch ON: 12.3 V

• Idling: 14.0 V

Symptoms when out of range:

If 5 V or less, starting becomes difficult

Diagnostic Note:

If 11 V or less, characteristics of some electrical components change.

Atmospheric pressure value/

Min.: 50 kPa, Max.: 120 kPa

Results of real-vehicle check:

Ignition switch ON: 99 kPa

Symptoms when out of range:

-

Diagnostic Note:

• With the ignition switch is ON, when the difference between the atmospheric pressure sensor and intake manifold absolute pressure is 7 kPa or higher, there is a malfunction in one of the sensors.

• With the ignition switch is ON, when the atmospheric pressure is 0 kPa or 140 kPa, there is a malfunction in the sensor circuit.

• Standard atmospheric pressure: 101 kPa.

• For every 100 m increase in altitude, pressure drops by 1 kPa.

  Varies by weather (high atmospheric pressure, low atmospheric pressure).

A/C cut status for Active Test/

ON or OFF

Diagnostic Note:

Active Test "Control the A/C Cut Signal" support data.

Number of codes/

Min.: 0, Max.: 255

Diagnostic Note:

Number of DTCs appearing at least once during the last 40 times the vehicle was warmed up.

MIL status/

ON or OFF

MIL on run distance/

Min.: 0 km, Max.: 65535 km

Diagnostic Note:

• Distance traveled after a DTC is stored.

• Cleared when the negative (-) battery cable is disconnected or when the DTC is cleared using the intelligent tester.

Running time from MIL on/

Min.: 0 min., Max.: 65535 min.

Diagnostic Note:

• Engine run time since the MIL illumination.

• Cleared when the negative (-) battery cable is disconnected or when the DTC is cleared using the intelligent tester.

Engine run time/

Min.: 0 sec., Max.: 65535 sec.

Diagnostic Note:

Time passed since the ignition switch was turned to ON.

Time after DTC cleared/

Min.: 0 min., Max.: 65535 min.

Diagnostic Note:

Time elapsed since the DTCs were cleared (or shipment from the factory).

Distance after DTC cleared/

Min.: 0 km, Max.: 65535 km

Diagnostic Note:

• Distance driven since the DTCs were cleared.

• (Data List's "Distance from DTC clear") - (Freeze frame data's "Distance from DTC clear") = Distance driven since the abnormality occurred.

Warmup cycle after DTC cleared/

Min.: 0, Max.: 255

Diagnostic Note:

• Number of engine warm ups since DTCs were cleared.

• (Data List "Warmup Cycle Cleared DTC") - (Freeze frame data "Warmup Cycle Cleared DTC") = Warmup cycles since the abnormality occurred.

Diagnostic Note:

-

Accelerator position status/

Min.: 0%, Max.: 100%

• Accelerator pedal released:

  0%

• Accelerator pedal fully depressed:

  100%

Results of real-vehicle check:

• Ignition switch ON: 0% (accelerator pedal released)

• Running without load (2500 rpm): 7.0%

• Running without load (4500 rpm): 14.1%

• Driving with the accelerator fully open at 2000 rpm: 99.6%

• Driving with the accelerator fully open at 4500 rpm: 99.6%

Symptoms when out of range:

-

Diagnostic Note:

• "Accel Position" is the accelerator opening angle (%) for engine control use.

• When the accelerator pedal position sensor output itself (Accel Sens. No. 1 Volt %, Accel Sens. No. 2 Volt %) is in the normal voltage range, another actuator malfunction has caused the fail-safe to restrict the accelerator.

• Without VSC requests, and without accelerator restriction by the fail-safe, this is adjusted proportionally to the depressing of the accelerator pedal by the driver.

• Accelerator fully closed: 0%

• Accelerator fully open: 100%

Engine speed for No. 1 cylinder/

Min.: 0 rpm, Max.: 6000 rpm

Symptoms when out of range:

When the engine speed of all cylinders is not equal, idling will be rough.

Diagnostic Note:

• At the beginning of engine cranking, the speed of each cylinder is measured (compression test).

• Indicates the speed of each cylinder when cranking. Example - Normal: Engine speed of all cylinders is approximately equal. When No. 1 cylinder compression is extremely low, "Engine speed of Cyl #1" is approximately 300 rpm, and "Engine speed of Cyl #2 to #4" is approximately 200 rpm.

• Usually the tester displays the value of when the engine is started.

Engine speed for No. 2 cylinder/

Min.: 0 rpm, Max.: 6000 rpm

Engine speed for No. 3 cylinder/

Min.: 0 rpm, Max.: 6000 rpm

Engine speed for No. 4 cylinder/

Min.: 0 rpm, Max.: 6000 rpm

Engine speed for all cylinders/

Min.: 0 rpm, Max.: 6000 rpm

Diagnostic Note:

• Identifying model code:

Diagnostic Note:

• Identifying engine type: 1NDTV

Cylinder number/

Min.: 0, Max.: 255

Diagnostic Note:

• Identifying cylinder number: 4

Transmission type/

MT

Diagnostic Note:

Identifying transmission type: MT (Manual transmission)

Diagnostic Note:

• Identifying destination:

Model year/

Min.: 1900, Max.: 2155

Diagnostic Note:

• Identifying model year: 200#

Diagnostic Note:

• Identifying engine type: Diesel

Target common rail pressure/

Min.: 0 kPa, Max.: 250000 kPa

Results of real-vehicle check:

• Ignition switch ON: 25000 kPa

• Cranking: 21470 kPa

• Idling (warm up the engine): 25000 kPa (2 minutes after starting the vehicle)

• Running without load (2500 rpm): 35590 kPa

• Running without load (3500 rpm): 80200 kPa

• Running without load (4500 rpm): 68200 kPa

• Driving with the accelerator fully open at 2000 rpm: 114330 kPa

• Driving with the accelerator fully open at 3000 rpm: 156460 kPa

• Driving with the accelerator fully open at 4500 rpm: 160000 kPa

Symptoms when out of range:

-

Diagnostic Note:

• Inspect the (actual) fuel pressure, comparing it against the common rail target value.

• Considered normal when the actual fuel pressure is within +/-10 MPa of the target fuel pressure under stable conditions.

Fuel pressure/

Min.: 0 kPa, Max.: 250000 kPa

Idling: 19900 to 37000 kPa

4000 rpm: 50700 to 73000 kPa

Fuel Press = Target Common Rail Pressure +/-10000 kPa at stable condition

• Fuel supply pump

• High pressure pipes

• Fuel pressure sensor

• Fuel injector

• Feed pump (fuel supply pump)

• Fuel filter

• Pressure limiter

• Air bleed to the fuel

• Lack of fuel

Results of real-vehicle check:

• Ignition switch ON: 140 kPa

• Cranking: 21920 kPa

• Idling (warm up the engine): 25430 kPa (2 minutes after starting the vehicle)

• Running without load (2500 rpm): 35550 kPa

• Running without load (4500 rpm): 68990 kPa

• Driving with the accelerator fully open at 2000 rpm: 114950 kPa

• Driving with the accelerator fully open at 3000 rpm: 154320 kPa

• Driving with the accelerator fully open at 4500 rpm: 160280 kPa

Symptoms when out of range:

• Difficult to start, poor driveability, lack of power, abnormal combustion noise

Diagnostic Note:

• Fuel pressure is the actual common rail fuel pressure.

• Inspect by comparing the fuel pressure with the target fuel pressure.

• When in a stable condition such as when idling, the fuel pressure is within +/-10 MPa of the target fuel pressure.

• The ECM uses fuel pressure for feedback control of the target fuel pressure via the supply pump.

  The injection amount is determined based on the injection timing and fuel pressure.

Pump current target final value/

Min.: 0 mA, Max.: 4000 mA

• Suction control valve malfunction

• Clogged fuel filter

Results of real-vehicle check:

• Cranking: 1052 mA

• Idling: 1167 mA

• Running without load (2500 rpm): 1300 mA

• Running without load (4500 rpm): 1188 mA

• Driving with the accelerator fully open at 2000 rpm: 1102 mA

• Driving with the accelerator fully open at 3000 rpm: 934 mA

• Driving with the accelerator fully open at 4500 rpm: 920 mA

Symptoms when out of range:

Difficult starting, lack of power, or rough idling

Diagnostic Note:

• ECU-calculated value for the suction control valve actuation target current.

• Value is large when a high fuel pressure is desired.

• Value becomes stuck at 3 A or more or operation is poor (poor movement due to deposits, etc.).

• When this deviates from the standard value, it indicates that for some reason, even though the pump is running hard, the actual fuel pressure is inconsistent with the target fuel pressure.

Injection volume/

Min.: 0 mm³/st, Max.: 1279.98 mm³/st

Idling: 2.0 to 8.0 mm³/st

Results of real-vehicle check:

• Cranking: 19.58 mm³/st

• Idling (warm up the engine): 4.19 mm³/st (at "Actual EGR Valve Pos." = 0.3%)

• Idling (warm up the engine): 4.58 mm³/st (at "Actual EGR Valve Pos." = 56%)

• Running without load (2500 rpm): 4.68 mm³/st

• Running without load (4500 rpm): 8.28 mm³/st

• Driving in 3rd gear 60 km/h (37 mph): 9.39 mm³/st

• Driving in 3rd gear 60 km/h (37 mph) during PM regeneration: 26.28 mm³/st

• Driving with the accelerator fully open at 2000 rpm: 36.48 mm³/st

• Driving with the accelerator fully open at 3000 rpm: 46.97 mm³/st

• Driving with the accelerator fully open at 4500 rpm: 37.89 mm³/st

Symptoms when out of range:

-

Diagnostic Note:

• Injection amount for each combustion.

• If injectors are clogged, fuel quality is poor, the fuel filter is clogged, or engine friction increases, then "Injection Volume" will increase.

Injection volume correction for No. 1 cylinder/

Min.: -10 mm³/st, Max.: 10 mm³/st

Idling: -2.0 to 2.0 mm³/st

• Injector clogging

• Injector deterioration

• Decrease in cylinder compression

• Injector compensation code is incorrectly set (forgot to input code after replacement or made mistake during setting of code after replacing ECM with one from another vehicle)

Results of real-vehicle check:

Idling: -0.07 mm³/st

#1 cylinder fuel cut (misfired): 7.2 mm³/st

Symptoms when out of range:

Rough idling, black smoke, white smoke, poor driveability, lack of power, abnormal combustion noise, difficult to start

Diagnostic Note:

• When idling after warm up, the injection amount for each cylinder is corrected to optimize the difference between the engine speed of each cylinder.

  Example: For cylinders that are slowing the engine speed compared to other cylinders, the injection volume is increased.

• "Injection Feedback Val" more than 2.0 mm³/st: Injector breakdown is causing injection volume deviation, or insufficient compression is causing poor combustion.

Injection volume correction for No. 2 cylinder/

Min.: -10 mm³/st, Max.: 10 mm³/st

Idling: -2.0 to 2.0 mm³/st

• Injector clogging

• Injector deterioration

• Decrease in cylinder compression

• Injector compensation code is incorrectly set (forgot to input code after replacement or made mistake during setting of code after replacing ECM with one from another vehicle)

Results of real-vehicle check:

Idling: 0.18 mm³/st

#2 cylinder fuel cut (misfired): 7.2 mm³/st

Diagnostic Note:

The intelligent tester display number and the cylinder number do not match.

Injection volume correction for No. 3 cylinder/

Min.: -10 mm³/st, Max.: 10 mm³/st

Idling: -2.0 to 2.0 mm³/st

• Injector clogging

• Injector deterioration

• Decrease in cylinder compression

• Injector compensation code is incorrectly set (forgot to input code after replacement or made mistake during setting of code after replacing ECM with one from another vehicle)

Results of real-vehicle check:

Idling: 0.06 mm³/st

#3 cylinder fuel cut (misfired): 7.2 mm³/st

Diagnostic Note:

The intelligent tester display number and the cylinder number do not match.

Injection volume correction for No. 4 cylinder/

Min.: -10 mm³/st, Max.: 10 mm³/st

Idling: -2.0 to 2.0 mm³/st

• Injector clogging

• Injector deterioration

• Decrease in cylinder compression

• Injector compensation code is incorrectly set (forgot to input code after replacement or made mistake during setting of code after replacing ECM with one from another vehicle)

Results of real-vehicle check:

Idling: -0.21 mm³/st

#4 cylinder fuel cut (misfired): 7.2 mm³/st

Diagnostic Note:

The intelligent tester display number and the cylinder number do not match.

Pilot 1 injection period/

Min.: 0 μs, Max.: 65535 μs

Results of real-vehicle check:

• Cranking: 189 μs

• Idling (warm up the engine): 228 μs

• Running without load (2500 rpm): 231 μs

• Running without load (3500 rpm): 363 μs

• Driving with the accelerator fully open at 2000 rpm: 169 μs

• Driving with the accelerator fully open at 3000 rpm: 167 μs

Symptoms when out of range:

Combustion noise, poor driveability, white smoke.

Diagnostic Note:

Check to see if "Pilot 1 Injection Period" is not zero when the symptoms occur.

Pilot 2 injection period/

Min.: 0 μs, Max.: 65535 μs

Symptoms when out of range:

Combustion noise, poor driveability, white smoke.

Diagnostic Note:

Check to see if "Pilot 2 Injection Period" is not zero when the symptoms occur.

Main injection period/

Min.: 0 μs, Max.: 65535 μs

Results of real-vehicle check:

• Cranking: 639 μs

• Idling (warm up the engine): 307 μs (2 minutes after starting the vehicle)

• Running without load (2500 rpm): 515 μs

• Driving in 3rd gear 60 km/h (37 mph): 326 μs

• Driving in 3rd gear 60 km/h (37 mph) during PM regeneration: 235 μs

• Driving with the accelerator fully open at 2000 rpm: 553 μs

• Driving with the accelerator fully open at 3000 rpm: 546 μs

• Driving with the accelerator fully open at 4500 rpm: 439 μs

Symptoms when out of range:

-

Diagnostic Note:

When the engine will not start, confirm that injection is performed.

After injection period/

Min.: 0 μs, Max.: 65535 μs

Results of real-vehicle check:

• Driving in 3rd gear 60 km/h (37 mph): 0 μs

• Driving in 3rd gear 60 km/h (37 mph) during PM regeneration: 282 μs

Symptoms when out of range:

Poor drivability, white smoke during PM regeneration.

Diagnostic Note:

-

Pilot 1 injection timing/

Min.: -70°CA, Max.: 20°CA

Results of real-vehicle check:

• Cranking: 11.5°CA

• Idling (warm up the engine): 4.9°CA

• Running without load (2500 rpm): 19.9°CA

• Driving with the accelerator fully open at 2000 rpm: 24.8°CA

• Driving with the accelerator fully open at 3000 rpm: 35.2°CA

Symptoms when out of range:

Combustion noise, poor drivability, white smoke.

Diagnostic Note:

-

Pilot 2 injection timing/

Min.: -50°CA, Max.: 20°CA

Symptoms when out of range:

Combustion noise, poor drivability, white smoke.

Diagnostic Note:

-

Main injection timing/

Min.: -90°CA, Max.: 90°CA

Results of real-vehicle check:

• Cranking: 4.9°CA

• Idling (warm up the engine): -2.1°CA

• Running without load (2500 rpm): 0°CA

• Driving with the accelerator fully open at 2000 rpm: 2.6°CA

• Driving with the accelerator fully open at 3000 rpm: 9.0°CA

• Driving with the accelerator fully open at 4500 rpm: 20.1°CA

Symptoms when out of range:

Combustion noise, poor drivability, white smoke.

Diagnostic Note:

Use "Main Injection Timing" to check poor drivability when the following symptoms are present: Bad injection timing, black smoke, and white smoke.

After injection timing/

Min.: -10°CA, Max.: 50°CA

Results of real-vehicle check:

• Driving with PM regeneration operating at 3000 rpm: -23.9°CA

Symptoms when out of range:

Poor drivability, white smoke during PM regeneration.

Diagnostic Note:

-

Fuel temperature/

Min.: -40°C, Max.: 140°C

Results of real-vehicle check:

Idling: 53°C (127°F)

Symptoms when out of range:

-

Diagnostic Note:

After fully cold soaking, the fuel temperature is the same as the outside air temperature.

Injector compensation code write status

NO error or Error

Symptoms when out of range:

-

Diagnostic Note:

-

EGR valve target opening angle/

Min.: 0%, Max.: 100%

Results of real-vehicle check:

• Ignition switch ON: 0%

• Cranking: 0%

• Idling with EGR off (warm up the engine): 0.3%

• Idling with EGR on (warm up the engine): 56%

• Running without load (2500 rpm): 57%

• Running without load (4500 rpm): 0%

• Driving with the accelerator fully open at 2000 rpm: 0%

• Driving with the accelerator fully open at 3000 rpm: 0%

• Driving with the accelerator fully open at 4500 rpm: 0%

Symptoms when out of range:

• When value is out of range and approaching 0%: MAF meter degradation, intake or exhaust system blockage

• When value is out of range and approaching 100%: EGR pipe blockage

Diagnostic Note:

• Fully open: 100%.

• Fully closed: 0%.

• Used for comparison to "Actual EGR Valve Pos.".

EGR valve position/

Min.: 0%, Max.: 100%

Results of real-vehicle check:

• Ignition switch ON: 0%

• Cranking: 0%

• Idling with EGR off (warm up the engine): 0%

• Idling with EGR on (warm up the engine): 56%

• Running without load (2500 rpm): 56%

• Running without load (4500 rpm): 0.3%

• Driving in 3rd gear 60 km/h (37 mph): 57%

• Driving in 3rd gear 60 km/h (37 mph) during PM regeneration: 0.3%

• Driving with the accelerator fully open at 2000 rpm: 0.3%

• Driving with the accelerator fully open at 3000 rpm: 0.3%

• Driving with the accelerator fully open at 4500 rpm: 0%

Symptoms when out of range:

• EGR valve stuck open: Poor starts (engine does not stop), black smoke, white smoke, lack of power

• EGR valve stuck closed: Increased turbo booster noise

Diagnostic Note:

• Fully open: 100%.

• Fully closed: 0%.

• Inspect while comparing to "Target EGR Position".

• Check the valve movement via the Active Test.

• Sometimes the malfunction only occurs around a certain temperature, so refer to the engine coolant temperature and outside temperature at the time the malfunction occurred.

EGR Active Test operation prohibit/

OK or NG

Symptoms when out of range:

-

Diagnostic Note:

• OK: "EGR Valve Control Active Test Possible" Condition.

• NG: "Not Possible" Condition.

Target throttle position

Min.: -128%, Max.: 127%

• Throttle valve fully opened: 0%

• Throttle valve fully closed: 100%

Results of real-vehicle check:

• Ignition switch ON: 0%

• Cranking: 0%

• Idling (warm up the engine): 0%

• Running without load (2500 rpm): 0%

• Running without load (4500 rpm): 0%

• Driving with the accelerator fully open at 2000 rpm: 0%

• Driving with the accelerator fully open at 4500 rpm: 0%

• Driving in 3rd gear 60 km/h (37 mph) during PM regeneration: 77%

Symptoms when out of range:

-

Diagnostic Note:

If there is a malfunction of the throttle actuator, compare the target and actual throttle position values for the troubleshooting.

Actual throttle position/

Min.: -20%, Max.: 120%

Results of real-vehicle check:

• Ignition switch ON: -1%

• Cranking: -1%

• Idling (warm up the engine): -1%

• Running without load (2500 rpm): 0%

• Running without load (4500 rpm): 0%

• Driving in 3rd gear 60 km/h (37 mph): -1%

• Driving in 3rd gear 60 km/h (37 mph) during PM regeneration: 78%

• Driving with the accelerator fully open at 2000 rpm: 0%

• Driving with the accelerator fully open at 4500 rpm: 0%

• Soon after engine running to ignition switch off: 0% → 99% → 0%

Symptoms when out of range:

• Stuck closed: Engine stall, difficult to start, lack of power, black smoke, rough idle

• Stuck open: Loud turbocharging sound, bad vibration when engine stopped

• When ECM detects a malfunction of diesel throttle (MIL on), engine power is restricted so that the vehicle can drive with a maximum speed of 80 to 120 km/h.

Diagnostic Note:

Closing percentage of the throttle valve.

• Fully closed: 100%.

• Fully open: 0%.

If there is a malfunction of the throttle actuator, compare the target and actual throttle position values for the troubleshooting.

Throttle position sensor output voltage

Min.: 0%, Max.: 100%

• Throttle valve fully opened: 0 to 15%

• Throttle valve fully closed: 90 to 100%

Results of real-vehicle check:

• Ignition switch ON: 0.0%

• Cranking: 0.0%

• Idling (warm up the engine): 0.0%

• Running without load (2500 rpm): 0.0%

• Running without load (4500 rpm): 0.0%

• Driving with the accelerator fully open at 2000 rpm: 0.0%

• Driving with PM regeneration operation at 3000 rpm: 78.0%

Symptoms when out of range:

-

Diagnostic Note:

Throttle position sensor output voltage is converted using 5 V = 100%.

Diesel throttle motor actuate duty/

Min.: 0%, Max.: 100%

Results of real-vehicle check:

• Cranking: 16.4%

• Idling (warm up the engine): 9.4%

• Running without load (2500 rpm): 10.1%

• Running without load (4500 rpm): 10.5%

• Driving with the accelerator fully open at 2000 rpm: 12.5%

• Driving with the accelerator fully open at 3000 rpm: 12.1%

• Throttle valve closing when soon after engine running to ignition switch off: 79.6%

Symptoms when out of range:

-

Diagnostic Note:

When the value of the Throttle Motor Duty increases, the moving force to open and close the diesel throttle valve increases.

Target boost pressure/

Min.: 0 kPa, Max.: 320 kPa

Idling: 84 to 121 kPa

3000 rpm: 129 to 186 kPa

4000 rpm: 142 to 204 kPa

Results of real-vehicle check:

• Ignition switch ON: 96 kPa

• Cranking: 100 kPa

• Idling (warm up the engine): 99.5 kPa

• Running without load (2500 rpm): 110 kPa

• Running without load (4500 rpm): 172 kPa

• Driving with the accelerator fully open at 2000 rpm: 216.85 kPa

• Driving with the accelerator fully open at 3000 rpm: 215.85 kPa

• Driving with the accelerator fully open at 4500 rpm: 200 kPa

Symptoms when out of range:

Lack of power

Diagnostic Note:

Inspect while comparing with "MAP".

Boost pressure deviation/

Min.: -320 kPa, Max.: 320 kPa

Diagnostic Note:

Boost Pressure Deviation = MAP (actual turbocharging pressure) - Target Booster Pressure

VN turbo command value/

Min.: 20%, Max.: 100%

Results of real-vehicle check:

• Ignition switch ON: 100%

• Cranking: 100%

• Idling (warm up the engine): 88%

• Running without load (2500 rpm): 85%

• Running without load (4500 rpm): 70%

• Driving with the accelerator fully open at 2000 rpm: 88%

• Driving with the accelerator fully open at 3000 rpm: 32%

• Driving with the accelerator fully open at 4500 rpm: 32%

Symptoms when out of range:

-

Diagnostic Note:

• "VN Turbo command" is a command value.

• 0%: Full open vanes (contraction of actuation-use rods)

• 90% or more: Full closed vanes (extension of actuation-use rods)

• When this value is large, the turbo works well.

• There is no actual opening angle data to handle the VN Turbo command value.

Lambda equivalent ratio/

Min.: 0, Max.: -

AF Lambda B1 S1 = air-fuel ratio / 14.5 (Stoichiometric A/F ratio)

Value less than 1: Rich

Value greater than 1: Lean

Air-fuel ratio = Intake air mass / (fuel injection mass)

• Air fuel ratio sensor

• Air fuel ratio sensor circuit

• Fuel injector assembly clogged

Symptoms when out of range:

-

Diagnostic Note:

• If the fuel injectors become clogged, the AF Lambda B1 S1 value will increase under all circumstances while the engine is running (The value increases regardless of whether the DPF catalyst regeneration has been performed).

• AF Lambda B1S1 is about 1.0 when driving at full load, and is about 2.5 to 3.5 when idling with warm engine.

Air-fuel ratio sensor output voltage/

Min. : 0 V Max.: 7.999 V

• Air fuel ratio sensor

• Air fuel ratio sensor circuit

• Fuel injector assembly clogged

Symptoms when out of range:

-

Diagnostic Note:

-

A/F sensor current/

Min.: -128 mA Max.: 127 mA

Symptoms when out of range:

-

Diagnostic Note:

-

A/F sensor learning value/

Min.: 0 Max.: 5 V

Symptoms when out of range:

-

Diagnostic Note:

Inspect the air fuel ratio sensor performance.

Exhaust gas temperature of CCo catalyst/

Min.: 0°C Max.: 1000°C

Idling after engine warmed-up/

80 to 300°C

During DPF catalyst regeneration/

470 to 600°C

• Exhaust gas temperature sensor B1S1

• DPF catalyst deteriorated

Results of real-vehicle check:

• Ignition switch ON: 20.0°C

• Idling (warm up the engine): 106.2°C

• Running without load (2500 rpm): 112°C

• Running without load (4500 rpm): 172°C

• Driving in 3rd gear 60 km/h (37 mph): 253°C

• Driving in 3rd gear 60 km/h (37 mph) during PM regeneration: 504°C

• Driving with the accelerator fully open at 2000 rpm: 281.2°C

• Driving with the accelerator fully open at 3000 rpm: 305.0°C

Symptoms when out of range:

-

Diagnostic Note:

• If an open occurs in an exhaust temperature sensor circuit, 20°C is displayed on the intelligent tester.

• If a short occurs in an exhaust temperature sensor circuit, 900°C is displayed on the intelligent tester.

Exhaust gas temperature of DPF catalyst/

Min.: 0°C Max.: 1000°C

Idling after engine warmed-up/

80 to 300°C

During DPF catalyst regeneration/

500 to 700°C

• Exhaust gas temperature sensor B1S2

• DPF catalyst deteriorated

Results of real-vehicle check:

• Ignition switch ON: 20.0°C

• Idling (warm up the engine): 98.1°C

• Running without load (2500 rpm): 102°C

• Running without load (4500 rpm): 148°C

• Driving in 3rd gear 60 km/h (37 mph): 255°C

• Driving in 3rd gear 60 km/h (37 mph) during PM regeneration: 589°C

• Driving with the accelerator fully open at 2000 rpm: 302.5°C

• Driving with the accelerator fully open at 3000 rpm: 302.5°C

Symptoms when out of range:

-

Diagnostic Note:

• If an open occurs in an exhaust temperature sensor circuit, 20°C is displayed on the intelligent tester.

• If a short occurs in an exhaust temperature sensor circuit, 900°C is displayed on the intelligent tester.

DPF differential pressure sensor output

Min.: -5 kPa Max.: 100 kPa

Idling/

-3 to 3 kPa

• DPF catalyst

• DPF differential pressure sensor

• Vacuum transmitting pipe clogged

• Differential pressure sensor vacuum hose clogged

Results of real-vehicle check:

• Ignition switch ON: 0.30 kPa

• Idling (warm up the engine): 0.496 kPa

• Running without load (2500 rpm): 0.898 kPa

• Running without load (4500 rpm): 2.597 kPa

• Driving in 3rd gear 60 km/h (37 mph): 1.40 kPa

• Driving in 3rd gear 60 km/h (37 mph) during PM regeneration: 3.30 kPa

• Driving with the accelerator fully open at 2000 rpm: 2.097 kPa

• Driving with the accelerator fully open at 3000 rpm: 3.097 kPa

• Driving with the accelerator fully open at 4500 rpm: 3.097 kPa

Diagnostic Note:

• When PM (Particulate Matter) builds up in the DPF catalyst, the "DPF Differential Pressure" value increases.

Standardized DPF Differential Pressure

Min.: -4 Max.: 3.9998

Results of real-vehicle check:

• Ignition switch ON: 0.0000

• Idling (warm up the engine): 0.0415

• Running without load (2500 rpm): 0.0395

• Running without load (4500 rpm): 0.0437

• Driving in 3rd gear 60 km/h (37 mph): 0.046

• Driving in 3rd gear 60 km/h (37 mph) during PM regeneration: 0.070

• Driving with the accelerator fully open at 2000 rpm: 0.0374

• Driving with the accelerator fully open at 3000 rpm: 0.0325

• Driving with the accelerator fully open at 4500 rpm: 0.0270

Symptoms when out of range:

-

Diagnostic Note:

• Catalyst Differential Press is the DPF Differential Pressure corrected in response to the MAF and other values.

• The value increases as the DPF catalytic converter becomes clogged.

• The value is large when the DPF catalytic converter is new.

DPF PM Block/

No Block / Blocked

• DPF catalyst clogged

• DPF differential pressure sensor

• Vacuum transmitting pipe clogged

• Differential pressure sensor vacuum hose clogged

• Fuel injector assembly

• Exhaust gas leak

• MAF sensor

Diagnostic Note:

• If PM (Particulate Matter) builds up in the DPF catalyst, the pressure differential from front to rear of the DPF catalyst gradually increases.

• If the calculated value of the PM accumulation becomes 20 g, "Blocked" appears on the intelligent tester display.

• In this case, clogging of the DPF catalyst, injector system malfunction, differential pressure sensor system malfunction, exhaust leaks and MAF meter malfunction are possible causes of the malfunction.

• Clogging of the DPF catalyst may be caused by the use of an oil that does not meet the specifications, such as using an engine oil that is not low-ash.

• Clogging of the DPF catalyst may also be caused by a high rate of engine oil consumption.

PM regeneration status/

Standby / Ready / Operate / Compl

During DPF catalyst regeneration/

Operate

Results of real-vehicle check:

• Driving in 3rd gear 60 km/h (37 mph): Standby

• Driving in 3rd gear 60 km/h (37 mph) during PM regeneration: Operate

Symptoms when out of range:

-

Diagnostic Note:

• Standby




• Before entering the "Activate the DPF Rejuvenate (PM)"

• Ready




• Turn the "Activate the DPF Rejuvenate (PM)" to on using the intelligent tester but the enabling condition of the Active Test is not sufficient

• Operate




• PM regeneration is performing.

• If "Activate the DPF Rejuvenate (PM)" is not finished completely, the status turns to "Ready".

• If "Activate the DPF Rejuvenate (PM)" is finished completely, the status turns to "Compl".

• Compl




• PM regeneration is successfully completed (Amount of PM is 0 g)