DIESEL FUEL
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Transcript of DIESEL FUEL
DIESEL FUEL<4D5-STEP III>
Click on the applicable bookmark to selected the required model year.
13E-1
DIESEL FUEL<4D5-STEP III>
CONTENTS
GENERAL 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Outline of Change 2. . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION 2. . . . . . . . . . . . . . . . . . .
SERVICE SPECIFICATIONS 4. . . . . . . . . . . . . . . . .
SEALANT 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 5. . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 6. . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE SERVICE 55. . . . . . . . . . . . . . . . . . . .Injection Nozzle Check and Adjustment 55. . . . . . . . .
Injection Timing Check and Adjustment 55. . . . . . . . .
Idle Speed Check and Adjustment 55. . . . . . . . . . . . .
Accelerator Pedal Position Sensor (APS)Adjustment 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Relay Continuity Check 57. . . . . . . . . . . . . . . .
Accelerator Pedal Position Sensor (APS)Check 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idle Switch Check 58. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Boost Air Temperature Sensor (Intake AirTemperature Sensor) Check 58. . . . . . . . . . . . . . . . . .
Engine Coolant Temperature Sensor Check 59. . . . .
Evacuation of Water from Fuel Filter 59. . . . . . . . . . . .
Fuel Filter Cartridge Replacement 60. . . . . . . . . . . . . .
Evacuation of Air from Fuel Line 60. . . . . . . . . . . . . . .
EGR Valve Position Sensor Check 60. . . . . . . . . . . . .
Fuel Injection Pump Check 61. . . . . . . . . . . . . . . . . . . .
Throttle Solenoid Valve Check 62. . . . . . . . . . . . . . . . .
Throttle Actuator Check 63. . . . . . . . . . . . . . . . . . . . . .
Variable Geometry Solenoid Valve Check 63. . . . . . .
EGR Control Solenoid Valve Check 63. . . . . . . . . . . .
FUEL INJECTION NOZZLE 64. . . . . . . . . . . . . . . . .
FUEL INJECTION PUMP 64. . . . . . . . . . . . . . . . . . .
CRANKSHAFT POSITION SENSOR 66. . . . . . . . .
ENGINE-ECU 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIESEL FUEL <4D5-step III> - General/General Information13E-2
GENERALOUTLINE OF CHANGEAn electronically-controlled injection pump has been added in order to comply with Regulation STEPIII. Due to this, the following service procedures have been added.
GENERAL INFORMATIONThe electronically-controlled fuel injection system consists of sensors which detect the condition of thediesel engine, an engine-ECU which controls the system based on signals from these sensors, and actuatorswhich operate according to control commands from the engine-ECU.The engine-ECU carries out operations such as fuel injection rate control, fuel injection timing controland idle up control. In addition, the engine-ECU is equipped with several self-diagnosis functions whichmake troubleshooting easier in the event that a problem develops.
FUEL INJECTION RATE CONTROLThe fuel injection completion timing is controlled by means of a solenoid-type spill valve to ensure thatthe optimum amount of fuel is supplied to the engine in accordance with gradual changes in the enginerunning condition.Before fuel injection starts, the solenoid-type spill valve is on (energized), so that the valve is closed.As the plunger turns and rises, fuel is sent out under pressure, and when the fuel flow rate reachesthe target value for fuel injection, the solenoid-type spill valve turns off. When the solenoid-type spillvalve turns off, the fuel under high pressure inside the plunger is leaked out into the pump chamberand fuel injection is completed.
FUEL INJECTION TIMING CONTROLThe position of the injection pump timer piston is controlled so that fuel injection is carried out at theoptimum timing in accordance with the engine running condition.The timer piston position is determined by duty control of the timing control solenoid valve which is locatedin the line between the high-pressure chamber and the low-pressure chamber of the timer piston.The fuel injection timing is advanced by increasing the control duty of the timing control solenoid valve.
IDLE SPEED CONTROLControlling the fuel injection rate in accordance with the engine running condition maintains the idle speedat the optimum condition.
SELF-DIAGNOSIS FUNCTIOND When an abnormality is detected in any of the sensors or actuators, the engine warning lamp illuminates
to warn the driver.D When an abnormality is detected in any of the sensors or actuators, a diagnosis code number
corresponding to the problem which occurred is output.D The RAM data relating to the sensors and actuators which is stored in the engine-ECU can be read
using the MUT-II. In addition, the actuators can be force-driven under certain conditions.
OTHER CONTROL FUNCTIONS1. Power Supply Control
When the ignition switch is turned to ON, the relay turns on and power is supplied to componentssuch as the timing control solenoid valve.
2. Intake Air Throttle ControlWhen the engine-ECU detects an abnormality in any of the sensors or actuators, the throttle valveis half opened to restrict the amount of intake air in order to prevent the vehicle from running away.
3. A/C Relay ControlTurns the compressor clutch of the A/C ON and OFF
4. Condenser Fan Motor Relay ControlControls the condenser fan motor relay based on the A/C switch, engine coolant temperature andvehicle speed input signals.
5. Glow ControlRefer to GROUP 16.
6. EGR ControlRefer to GROUP 17.
DIESEL FUEL <4D5-step III> - General Information 13E-3
CONTROL SYSTEM DIAGRAM
L1. Pump speed sensorL2. Crank angle sensorL3. Engine coolant temperature sensorL4. Boost pressure sensorL5. Fuel temperature sensorL6. Boost air temperature sensorL7. Control sleeve position sensorL8. Timer piston position sensorL9. EGR valve position sensorL10. Variable geometry control pressure sensor
D Accelerator pedal position sensor (main)D Accelerator pedal position sensor (sub)D Idle switchD Power supplyD Ignition switch-IGD Ignition switch-STD Vehicle speed sensorD A/C switchD A/C relay switchD Injection volume adjusting ROMD Barometric pressure sensor (ECU built-in)
l1. GE actuator (electronic governor)l2. Timing control valvel3. EGR control solenoid valve No. 1l4. EGR control solenoid valve No. 2l5. Throttle solenoid valvel6. Fuel cut solenoid valvel7. Variable geometry solenoid valve
D Control relayD A/C relayD Condenser fan relayD Glow indicator lampD Glow plug relayD Engine warning lampD Diagnosis output
Engine-ECU
L8 TimerpistonpositionsensorL2 Crank angle
sensor
L9 EGRvalve positionsensor
L10 Variable geometry controlpressure sensor
L6 Boost airtemperature sensor
L4 Boost pressuresensor
L3 Engine coolanttemperature sensor
L7 Controlsleevepositionsensor
l7Variable geometrysolenoid valve
l3EGR controlsolenoid valve No. 1
l1 GE actuator
l5 Throttle solenoid valve
l6 Fuel cutsolenoidvalve
Vacuum pump
Alternator
To variablegeometry actuator
l2 Timing controlvalve
Catalytic converter
Variablegeometryactuator
Variablegeometryturbocharger
Throttleactuator
EGR valve
To variable geome-try solenoid valve
L1 Pump speedsensor
L5 Fueltemperaturesensor
l4 EGR controlsolenoidvalve No. 2
DIESEL FUEL <4D5-step III> - Service Specifications/Sealant13E-4
SERVICE SPECIFICATIONSItem Standard value
Fuel injection initial pressure kPa 14,710 - 15,490
Accelerator pedal position sensor reference voltage V 0.985 - 1.085
Accelerator pedal position sensor resistance kΩ 3.5 - 6.5
Boost air temperature sensor (Intake air temperature) i t kΩ
When the temperature is 20_C 2.3 - 3.0p ( psensor) resistance kΩ When the temperature is 80_C 0.30 - 0.42
Engine coolant temperature sensor resistance kΩ When the temperature is 20_C 2.1 - 2.7g p
When the temperature is 80_C 0.26 - 0.36
Fuel cut solenoid valve resistance Ω 6.8 - 9.2
Timing control valve resistance Ω 10.8 - 11.2
Timer piston position sensor resistance Ω Connector terminals No. 1 - No. 2 160 - 168p p
Connector terminals No. 1 - No. 3 80 - 84
Connector terminals No. 2 - No. 3 80 - 84
Control sleeve position sensor resistance Ω Connector terminals No. 4 - No. 12 11.2 - 12.4p
Connector terminals No. 4 - No. 8 5.6 - 6.2
Connector terminals No. 8 - No. 12 5.6 - 6.2
GE actuator (electronic governor) resistance Ω Connector terminals No. 6 - No. 10 0.64 - 0.72
Fuel temperature sensor resistance kΩ Connector terminals No. 7 - No. 11 1.4 - 2.6
Pump speed sensor resistance kΩ 1.36 - 1.84
Throttle solenoid valve resistance Ω 36 - 44
SEALANTItem Specified sealant
Engine coolant temperature sensor 3M Nut Locking Part No. 4171 or equivalent
DIESEL FUEL <4D5-step III> - Special Tools 13E-5
SPECIAL TOOLS
Tools Number Name Application
MB991502 MUT-II subassembly
Electronically controlled fuel injection systemcheck
MB991529 Diagnosis codecheck harness
Diagnosis code reading
MB991348 Test harness set D Boost pressure sensor checkD Variable geometry control pressure sensor
check
MB991658 Test harness set D APS adjustmentD Inspection using an analyzer
MD998478 Test harness(3-pin, square)
D Crank angle sensor checkD Inspection using an analyzer
MB990767 End yoke holder Holding the fuel injection pump sprocket
MD998719 Crankshaft pulleyholder pin
MD998388 Injection pumpsprocket puller
Fuel injection pump sprocket removal
DIESEL FUEL <4D5-step III> - Troubleshooting13E-6
TROUBLESHOOTINGSTANDARD FLOW OF DIAGNOSTICTROUBLESHOOTINGRefer to GROUP 00 - How to Use Troubleshooting/InspectionService Points.
NOTEWhen replacing the engine-ECU, replace immobilizer-ECUand ignition key as well at the same time.
DIAGNOSIS FUNCTIONENGINE WARNING LAMP (CHECK ENGINE LAMP)Engine warning lamp is lit when any abnormality takes placein the item related to electronically controlled fuel injectionsystem shown in the following table.If the malfunction indicator lamp has been on and/or is litwhen the engine is in operation, check the diagnosis output.
Engine warning lamp check items
Accelerator pedal position sensor (main)
Accelerator pedal position sensor (sub)
Boost pressure sensor (Boost sensor)
Crank angle sensor
Control sleeve position sensor
Timer piston position sensor
Throttle solenoid valve
GE actuator
Variable geometry control pressure sensor
Barometric pressure sensor
Timing control valve
Idle switch
Engine-ECU
METHOD OF ERASING AND ERASING DIAGNOSISCODESRefer to GROUP 00 - How to Use Troubleshooting/InspectionService Points.
INSPECTION USING MUT-II DATA LIST ANDACTUATOR TESTING1. Carry out inspection by means of the data list and the
actuator test function.If there is an abnormality, check and repair the chassisharnesses and components.
2. After repairing, re-check using MUT-II and check thatthe abnormal input and output have returned to normalas a result of the repairs.
3. Erase the diagnosis code memory.4. Remove the MUT-II.5. Start the engine again and carry out a road test to confirm
that the problem has disappeared.
Engine warning lamp(check engine lamp)
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-7
FAIL-SAFE, BACKUP FUNCTIONSWhen abnormalities in the major sensors are detected by diagnosis functions, pre-set control logic operatesto maintain a safe driving condition for the vehicle.
Diagnosis item Control features in malfunction
Accelerator pedal position sensor D Accelerator pedal released (idle switch ON)Acceleration opening degree = 0 %
D Accelerator pedal applied (idle switch OFF)Engine controlled at low speedAcceleration opening degree = 30 % fixed
D Void EGR control
Idle switch Void idling speed control.
Engine speed sensor D Engine controlled at low speedD Void EGR controlD Void variable geometry turbocharger control
Boost air temperature sensor D Maintain the intake air temperature at 50_C.D Void EGR control
Vehicle speed sensor D Void idling speed control.D Void EGR control
Engine coolant temperature sensor D Maintain the engine coolant temperature at 80_C (However, the systemassumes the coolant temperature as 0_C).
D Void EGR control
Control sleeve position sensor D Engine controlled at low speedD Void EGR controlD Void variable geometry turbocharger control
Timer piston position sensor D Injection timing stabilizing controlD Void EGR control
Barometric pressure sensor (ECUbuilt-in)
D Keep the barometric pressure at 101 kPa.D Void EGR controlD Void variable geometry turbocharger control
Fuel temperature sensor Maintain the fuel temperature at 40_C.
Boost pressure sensor D Keep the boost pressure as barometric pressure (101 kPa).D Void EGR controlD Void variable geometry turbocharger control
Injection volume adjusting ROM Void correction.
GE actuator D Engine controlled at low speedD Void EGR controlD Void variable geometry turbocharger control
Over boost D Void variable geometry turbocharger controlD Engine controlled at low fuel injection
Timing control valve D Injection timing stabilizing controlD Void EGR control
EGR valve position sensor Void EGR control
Variable geometry control pressuresensor
D Void EGR controlD Void variable geometry turbocharger control
DIESEL FUEL <4D5-step III> - Troubleshooting13E-8
INSPECTION CHART FOR DIAGNOSIS CODESCode No. Diagnosis item Reference
page
11 Accelerator pedal position sensor (main) system 13E-9
12* Boost pressure sensor system 13E-10
13 Barometric pressure sensor (ECU built-in) system 13E-11
14 Fuel temperature sensor system 13E-11
15 Engine coolant temperature sensor system 13E-12
16 Boost air temperature sensor system 13E-12
17 Vehicle speed sensor system 13E-13
18 Pump speed sensor system 13E-14
21 Crank angle sensor system 13E-15
23 Idle switch (accelerator pedal position sensor built-in) system 13E-16
25* Timer piston position sensor system 13E-17
26* Control sleeve position sensor system 13E-18
27 Accelerator pedal position sensor (sub) system 13E-19
41* Throttle solenoid valve system 13E-20
43 Timing control valve system 13E-21
46 Injection volume adjusting ROM system 13E-22
48* GE actuator (in the middle of control sleeve position sensor inoperative) system 13E-23
49* Over boost (variable geometry control pressure sensor system malfunction) 13E-24
51 EGR valve position sensor system 13E-25
52 Variable geometry control pressure sensor system 13E-26
54 Immobilizer system 13E-27
CautionIf the above-mentioned diagnosis code numberwith the asterisks can be displayed alongwith anothercode number in parentheses simultaneously, check the other code number before replacing theengine-ECU.12 (41, 49), 26 (48), 25 (43), 41 (12, 49), 48 (26), 49 (12, 41)
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-9
INSPECTION PROCEDURE FOR DIAGNOSIS CODE
Code No. 11 Accelerator pedal position sensor (main)system
Probable cause
Range of CheckD Ignition switch: ON, accelerator pedal position sensor (sub) operative, except
for during engine crankingSet ConditionsD Accelerator pedal position sensor output voltage is as below for 1 second:
Sub side: 0.2 V or more, less than 2.5 VMain side: 4.5 V or moreorSub or main side: less than 0.2 V
Range of CheckD Ignition switch: ON, except for during engine crankingSet ConditionsD The output voltage of accelerator pedal position sensor (main and sub) for
0.2 second is 0.2 V or higher, or lower than 4.5 V and the difference insensor output voltage between the main and sub is 1 V or higher, or idleswitch: ON, and sensor main output voltage is 1.875 V or higher.
D Accelerator pedal position sensor inoperativeD Accelerator pedal position sensor open circuit,
short circuit, or connector contact inoperativeD Engine-ECU inoperative
NG
OK
OK
Measure at D-135 accelerator pedal positionsensor connectorD Disconnect the connector and measure
at the harness side.D Voltage between 2 and earth
(Ignition switch: ON)OK: 4.5 - 5.5 V
D Continuity between 1 and earthOK: Continuity
NGCheck the following connector: D-113
NGRepair
OK
OK
Repair
NGAccelerator pedal position sensor check(Refer to P.13E-57.)
Replace
Check the trouble symptoms.
Replace the engine-ECU.
NG
Check the trouble symptoms.
NG
Replace the engine-ECU.
NGRepairCheck the following connectors:
D-113, D-135
OK
NG
NG
Check the following connector: D-113NG
RepairOK
Check the harness between theengine-ECU and the accelerator pedalposition sensor connector.
OK
Measure at D-113 engine-ECU connectorD Connect the connector.D Voltage between 84 and the earth
(Ignition switch: ON)OK: 0.9 - 1.1 V
(Throttle lever idling position)4.1 V or higher(Throttle lever fully opened position)
Check the harness between theengine-ECU and the accelerator pedalposition sensor connector.
NGRepair
NGNGNGNGNG
Check the trouble symptoms.
OK
Replace the engine-ECU.
DIESEL FUEL <4D5-step III> - Troubleshooting13E-10
Code No. 12 Boost pressure sensor (boost sensor)system
Probable cause
Range of CheckD Ignition switch: ON, except for during engine crankingSet ConditionsD Sensor output voltage for 1 second is 4.5 V or higher
(boost pressure is approximately 267 kPa).orD Sensor output voltage for 1 second is 0.2 V or lower
(boost pressure is approximately 51.7 kPa or lower)Range of CheckD Engine speed is 2,000 r/min or higher, barometric pressure is 69.7 kPa or
less (equivalent to an altitude of 300 m) and under high load.Set ConditionsD Boost pressure is lower than the barometric pressure + 13 kPa for 3
seconds.
D Boost pressure sensor inoperativeD Boost pressure sensor open circuit, short circuit,
or connector contact inoperativeD Boost pressure sensor hose disconnectedD Engine-ECU inoperative
NG
Check the trouble symptoms.
Replace the engine-ECU.
Check the following connector:D-113
NG
OK
NG
Repair
RepairOK
NG
Check the trouble symptoms.
OK
OK
OK
Check the following connector:B-08
NG
Check the trouble symptoms.
NG
Repair
NG
NG
Check the vacuum hose between theboost pressure sensor and the intakemanifold.
Replace the boost pressure sensor.
OK
OK
OK
Repair
NGRepair
Check the trouble symptoms.
Check the harness between theengine-ECU and the boost pressuresensor connector, and repair ifnecessary.
NG
OK
NGRepairCheck the following connector:
B-08
NG
Measure at B-08 boost pressuresensor connectorD Connect the connector.
(Test harness: MB991348 used)D Voltage between 1 and the earth
(Engine: Idling)OK: 1.3 - 1.7 V
D Voltage between 1 and the earthOK: When the accelerator pedal
is suddenly pressed fromthe idling condition, thevoltage temporarily in-creases from 1.3 V to 1.7V.
Measure at D-113 engine-ECUconnectorD Connect the connector.D Voltage between 85 and the
earth (Engine: Idling)OK: 1.3 - 1.7 V
Check the harness between theengine-ECU and the boost pressuresensor connector.
Measure at B-08 boost pressuresensor connectorD Disconnect the connector and
measure at the harness side.D Voltage between 3 and the earth
(Ignition switch: ON)OK: 4.5 - 5.5 V
D Continuity between 2 and theearthOK: Continuity
Replace the engine-ECU.
NG
Check the harness between theengine-ECU and the boost pressuresensor connector.
Replace the engine-ECU.
OK NG
Repair
Check the following connector:D-112
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-11
Code No. 13 Barometric pressure sensor system Probable causeRange of CheckD Ignition switch: ON, except for during engine crankingSet ConditionsD The sensor output voltage is for 3 seconds is 4.5 V or higher (the
barometric pressure is approximately 114 kPa or over).orD The sensor output voltage is for 3 seconds is 1.5 V or lower (the barometric
pressure is approximately 40 kPa or under).Range of CheckD Ignition switch: OND The coolant temperature is 40_C or lowerSet conditionsD Difference between the barometric pressure and boost pressure sensors is
13.3 kPa or more
Engine-ECU inoperative
Replace the engine-ECU.NG
Check the trouble symptoms.
Code No. 14 Fuel temperature sensor system Probable causeRange of CheckD Ignition switch: ON, except for during engine crankingSet ConditionsD The sensor output voltage for 3 seconds is 0.2 V or lower (the fuel
temperature is approximately 125°C or higher).orD The sensor output voltage for 3 seconds is 4.6 V or higher (the fuel
temperature is approximately -47°C or lower).
D Fuel temperature sensor inoperativeD Fuel temperature sensor open circuit, short circuit,
or connector contact inoperativeD Engine-ECU inoperative
OK
Measure at B-38 fuel temperature sensorconnectorD Disconnect the connector and measure at
the harness side.D Voltage between 11 and the earth
(Ignition switch: ON)OK: 4.5 - 5.5 V
D Continuity between 7 and the earthOK: Continuity
NG Check the following connectors:D-112, D-113
NG Repair
OK
OK
Check the harness between theengine-ECU and the fuel temperaturesensor connector.
Repair
NG
Check the trouble symptoms.
Replace the engine-ECU.
NG
Replace the engine-ECU.
OK
NG
Replace the injection pump.
OKRepair
Check the following connector: B-38NG
NGCheck the trouble symptoms.
Fuel temperature sensor check (Refer toP.13E-61.)
DIESEL FUEL <4D5-step III> - Troubleshooting13E-12
Code No. 15 Engine coolant temperature sensor system Probable causeRange of CheckD Ignition switch: ON, except for during engine crankingSet ConditionsD The sensor output voltage for 3 seconds is 4.9 V or higher (the coolant
temperature is approximately -45_C or lower).orD The sensor output voltage for 3 seconds is 0.2 V or lower (the coolant
temperature is approximately 140_C or higher).
D Engine coolant temperature sensor inoperativeD Engine coolant temperature sensor open circuit,
short circuit, or connector contact inoperativeD Engine-ECU inoperative
OKNG NG
Repair
OK
OK
Repair
NGEngine coolant temperature sensor check(Refer to P.13E-59.)
Replace the engine-ECU.
NG
Replace the engine-ECU.
OK
NG
OKRepair
Check the following connector: B-56
NGCheck the trouble symptoms.
NG
Measure at B-56 engine coolant temperaturesensor connectorD Disconnect the connector and measure at
the harness side.D Voltage between 1 and the earth
(Ignition switch: ON)OK: 4.1 - 4.9 V
D Continuity between 2 and the earthOK: Continuity
Check the following connectors:D-112, D-113
Check the harness between theengine-ECU and the engine coolanttemperature sensor connector.
Check the trouble symptoms.
Replace
Code No. 16 Boost air temperature sensor (intake airsensor) system
Probable cause
Range of CheckD Ignition switch: ON, except for during engine crankingSet ConditionsD The sensor output voltage for 3 seconds is 4.6 V or higher (the intake air
temperature is approximately -45_C or lower).orD The sensor output voltage for 3 seconds is 0.3 V or lower (the intake air
temperature is approximately 110_C or higher).
D Boost air temperature sensor inoperativeD Boost air temperature sensor open circuit, short
circuit, or connector contact inoperativeD Engine-ECU inoperative
OK
Measure at B-49 boost air temperatureconnectorD Disconnect the connector and measure at
the harness side.D Voltage between 1 and the earth
(Ignition switch: ON)OK: 4.0 - 5.3 V
D Continuity between 2 and the earthOK: Continuity
NGCheck the following connectors:D-112, D-113
NGRepair
OK
OKRepair
NGBoost air temperature sensor check(Refer to P.13E-58.)
Check the trouble symptoms.
Replace the engine-ECU.
NG
Replace the engine-ECU.
OK
NG
OKRepair
Check the following connector: B-49
Replace
NGCheck the trouble symptoms.
NG
Check the harness between theengine-ECU and the boost air temperaturesensor connector.
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-13
Code No. 17 Vehicle speed sensor system Probable causeRange of CheckD Ignition switch: OND Engine speed: 2,800 r/min or higherD Driving with heavy loadSet ConditionsD Slower than vehicle speed of 3 km/h
D Vehicle speed sensor inoperativeD Vehicle speed sensor open circuit, short circuit, or
connector contact inoperativeD Engine-ECU inoperative
Replace the engine-ECU.
NG
OK
Check trouble symptoms.
NG
OK
Check trouble symptom.
NG
Check the following connectors:C-09, D-113, E-113
NGRepair
YES
Measure at engine-ECU connector D-113.D Disconnect the connector.D Voltage between terminal 86 and earth (Ignition switch: ON)
OK: When the vehicle is pushed to move, the cycle changeof 0.5 V is repeated.
Check the followingconnector:D-113
NGRepair
Is the speedometer working properly?NO
Check the harness wire between the engine-ECU and the vehiclespeed sensor connector, and repair if necessary.
Check the vehicle speed sensor circuit.
OK
DIESEL FUEL <4D5-step III> - Troubleshooting13E-14
Code No. 18 Pump speed sensor system Probable causeRange of CheckD Ignition switch: OND Not during the engine crankingSet ConditionsD The difference between the pump speed sensor and the crank angle sensor
output value is 500 r/min or higher for 4 seconds
D Malfunction of pump speed sensorD Open circuit or short-circuit in pump speed sensor
circuit, or poor sensor contactD Engine-ECU inoperative
NG
Replace the engine-ECU.
OK
Check trouble symptoms.
NGRepair
NG
Check the harness between theengine-ECU and the pump speed sensorconnector, and repair if necessary.
OK
Replace the injection pump.
OK
Measure at engine-ECU connector D-112.D Connect the connector.D Voltage between 51 - 61.
(Engine: idling and then raced)OK: Voltage increases from the voltage
when engine is idling
NGCheck the following connector:B-36, D-112
NGRepair
OK
NGPump speed sensor check (Refer toP.13E-62.)
Check the following connector: D-112
Check the trouble symptoms.
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-15
Code No. 21 Crank angle sensor system Probable causeRange of CheckD Engine crankingSet ConditionsD Sensor output voltage does not change for 2 seconds (no pulse signal input)
D Malfunction of crank angle sensorD Open circuit or short-circuit in crank angle sensor
circuit, or poor connector contactD Engine-ECU inoperative
Range of CheckD Ignition switch: OND Not during the engine crankingD Pump speed sensor circuit: NormalSet ConditionsD When crank angle sensor signal is being input normally, suddenly no sensor
signal is input for 0.3 seconds or more
OK
Check the harness between thecrank angle sensor and the enginecontrol relay, and repair if necessary.
OK
NG (1) NGMeasure at crank angle sensorconnector B-52.D Connect the connector.
(Test harness: MB998478 used)D Voltage between 2 (black clip)
and the earthOK: 0.4 - 4.0 V
(Engine: cranking)1.5 - 2.5 V(Engine: idling)
NG
Replace the crank angle sensor.
Replace the engine-ECU.
OKRepair
Check the following connector:D-113
NG
OKRepair
NG
Check the harness between theengine-ECU and the crank anglesensor.
NG
Check the trouble symptoms.
Replace the engine-ECU.
Check the harness between thecrank angle sensor and the earth,and repair if necessary.
OKRepair
NG
Check the following connector:B-52
Check the trouble symptoms.
Measure at crank angle sensorconnector B-52.D Disconnect the connector and
measure at the harness side.(1) Voltage between 3 and the earth
(Ignition switch: ON)OK: System voltage
(2) Continuity between 2 and theearth (Ignition switch: ON)OK: 4.6 - 5.4 V
(3) Continuity between 1 and theearthOK: Continuity
(2) NG
(3) NG
DIESEL FUEL <4D5-step III> - Troubleshooting13E-16
Code No. 23 Idle switch (accelerator pedal positionsensor built-in) system
Probable cause
Range of CheckIgnition switch: ON, accelerator pedal position sensor (main, sub) operative,except for during engine crankingSet ConditionsD Idle switch (built-in): ON for 0.8 second, accelerator pedal position sensor
(main, sub) output voltage 1.875 V or higherD Idle switch (built-in): OFF for 10 minutes, accelerator pedal position sensor
(main, sub) opening degrees less than 1.17 %
D Accelerator pedal position sensor inoperativeD Accelerator pedal position sensor open circuit,
short circuit, or connector contact inoperativeD Idle switch “ON” inoperativeD Idle switch signal line short circuitD Engine-ECU inoperative
OK
Measure at D-135 accelerator pedal positionsensor connectorD Disconnect the connector and measure at
the harness side.D Voltage between 4 and the earth
(Ignition switch: ON)OK: 4.5 - 5.5 V
D Continuity between 5 and the earthOK: Continuity
NGCheck the following connectors:D-111, D-112
NGRepair
OK
OKRepair
NGIdle switch check (Refer to P.13E-58.)
Check the trouble symptoms.
Replace the engine-ECU.
NG
Replace the engine-ECU.
OK
NG
OK
Check the following connector: D-135
Replace
NG
Check the trouble symptoms.
Check the harness between theengine-ECU and the accelerator pedalposition sensor connector.
NGRepair
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-17
Code No. 25 Timer piston position sensor system Probable causeRange of CheckD Ignition switch: OKD Not during the engine crankingSet ConditionsD The sensor output voltage for 1 second is 4.9 V* or moreorD The sensor output voltage for 1 second is 0.25 V* or less
D Timer piston position sensor inoperativeD Timer piston position sensor open circuit, short
circuit, or connector contact inoperativeD Engine-ECU inoperative
NOTE:*: This voltage is derived from the input pulse signal converted in the engine-ECU and cannot be measured.
Replace injection pump assembly (timerpiston fully closed/opened positioninoperative, etc.)
NG
NG
OK
OKNG
Check the following connector: D-113NG
Repair
OK
Repair
NGTimer piston position sensor check(Refer to P.13E-62.)
NGNG
OK
NG
Check the trouble symptoms.
Replace injection pump assembly.
Check the following connector: B-39
OK
Replace the engine-ECU.NG
MUT-II Data list19 Injection timing (command value)(Refer to P.13E-41.)
OK
Check the trouble symptoms.
Check the trouble symptoms.
Check the harness between theengine-ECU and the timer piston sensorconnector.
MUT-II Data list18 Actual injection timing (Refer toP.13E-41.)
Replace the engine-ECU.
DIESEL FUEL <4D5-step III> - Troubleshooting13E-18
Code No. 26 Control sleeve position sensor system Probable causeRange of CheckD Ignition switch: ONSet ConditionsD The sensor output voltage for 0.3 second is 4.5 V* or moreorD The sensor output voltage for 0.3 second is 0.25 V* or less
D Control sleeve position sensor inoperativeD Control sleeve position sensor open circuit, short
circuit, or connector contact inoperativeD Engine-ECU inoperative
NOTE:*: This voltage is derived from the input pulse signal converted in the engine-ECU and cannot be measured.
OKNG
Check the following connector: D-113NG
Repair
OK
Repair
NGControl sleeve position sensor check (Referto P.13E-62.)
NGNG
OK
NG
Check the trouble symptoms.
Replace injection pump assembly.
Check the following connector: B-38
OK
Replace the engine-ECU.NG
MUT-II Data list17 Control sleeve position sensor (targetvalue) (Refer to P.13E-41.)
OK
Check the trouble symptoms.
Replace injection pump assembly.
Check the trouble symptoms.
NG
NG
Check the harness between theengine-ECU and the injection pumpassembly connector.
MUT-II Data list23 Control sleeve position sensor (actualvalue) (Refer to P.13E-41.)
Replace the engine-ECU.
OK
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-19
Code No. 27 Accelerator pedal position sensor (sub)system
Probable cause
Range of CheckD Ignition switch: ON, accelerator pedal position sensor (main) operative, except
for during engine crankingSet ConditionsD Accelerator pedal position sensor output voltage for 1 second
Sub side: 0.2 V or higher, lower than 2.5 VMain side: 4.5 V or higherorSub or main: Lower than 0.2 V
Range of CheckD Ignition switch: ON, except for during engine crankingSet ConditionsD The difference in the output sensor voltage between the main and the sub
sensor is 1 V or higher, or the idle switch ON, and sensor main outputvoltage is 1.875 V or higher.
D Accelerator pedal position sensor inoperativeD Accelerator pedal position sensor open circuit,
short circuit, or connector contact inoperativeD Engine-ECU inoperative
OK
Measure at D-135 accelerator pedal positionsensor connectorD Disconnect the connector and measure at
the harness side.D Voltage between 8 and the earth
(Ignition switch: ON)OK: 4.5 - 5.5 V
D Continuity between 7 and the earthOK: Continuity
NG NGRepair
OK
OK
Repair
NGAccelerator pedal position sensor check(Refer to P.13E-57.)
NG
Replace the engine-ECU.
OK
NG
OK
Replace
NG
Check the trouble symptoms.
NGRepairCheck the following connector: D-135
Check the harness between theengine-ECU and the accelerator pedalposition sensor connector.
Check the trouble symptoms.
Replace the engine-ECU.
Check the following connector:D-112
DIESEL FUEL <4D5-step III> - Troubleshooting13E-20
Code No. 41 Throttle solenoid valve system Probable causeRange of CheckD Ignition switch: OFFD Barometric pressure is 95.4 kPa or over (equivalent to an altitude of 500 m).Set ConditionsD Boost pressure sensor output does not change.
D Throttle solenoid valve inoperativeD Throttle solenoid valve open circuit, short circuit, or
connector contact inoperativeD Engine-ECU inoperativeD Malfunction of throttle actuator
Check and repair the harness between theengine-ECU and the solenoid valveconnector.
NG
OK
Check the trouble symptoms.
OK
Check and repair the harness between thecontrol relay and the solenoid valveconnector.
NG
OK
Measure at B-62 throttle solenoid valveconnectorD Disconnect the connector and measure at
the harness side.D Voltage between 2 and the earth
(Ignition switch: ON)OK: System voltage
OK
ReplaceThrottle actuator check(Refer to P.13E-63.)
NG
OK
Throttle solenoid valve check(Refer to P.13E-62.)
Replace the engine-ECU.
OK
RepairCheck the following connector: D-110
Check the trouble symptoms.
NG
ReplaceNG
Check the following connector:B-62
NGRepairNGMeasure at D-110 engine-ECU connector
D Disconnect the connector and measure atthe harness side.
D Voltage between 14 and the earth(Ignition switch: ON)OK: System voltage
NG
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-21
Code No. 43 Timing control valve system Probable causeRange of CheckD Engine coolant temperature 80_C or higher and the engine runningSet ConditionsD Target value minus actual value is 0.64 V or more for 5 seconds
D Timing control valve inoperativeD Timing control valve open circuit, short circuit, or
connector contact inoperativeD Engine-ECU inoperativeD Blockage in fuel system
OK
OK
Check and repair the harness between thecontrol relay and the injection pumpassembly connector.
Timing control valve check(Refer to P.13E-61.)
Replace the engine-ECU.
OK
RepairCheck the following connector: D-110
Check the trouble symptoms.
NG
NG
NG
Check the following connector: B-38NG
Repair
OK
Check the trouble symptoms.
NG
NGMeasure at D-110 engine-ECU connector.D Disconnect the connector and measure at
the harness side.D Voltage between 3 and the earth
(Ignition switch: ON)OK: 11 V or higher
OK
Measure at B-38 injection pump assemblyconnector.D Disconnect the connector and measure at
the harness side.D Voltage between 5 and the earth
(Ignition switch: ON)OK: System voltage
Replace injection pump assembly.
Check and repair the harness between theengine-ECU and the injection pumpassembly connector.
Fuel system blockage checkD Fuel filter blockedD Fuel hose blocked or bentD Fuel tank filter blocked
OK
ReplaceNG
NG
DIESEL FUEL <4D5-step III> - Troubleshooting13E-22
Code No. 46 Injection volume adjusting ROM system Probable causeRange of CheckD Ignition switch: ONSet ConditionsD When communication fails
D Injection volume adjusting ROM inoperativeD Engine-ECU inoperative
Repair
OK
Replace the engine-ECU.
OK
RepairCheck the following connector: B-37
Check the trouble symptoms.
NG
NGCheck the following connector: D-112
NG Repair
OK
Check the trouble symptoms.
NG
Measure at B-37 injection volume adjustingROM connector.D Disconnect the connector and measure at
the harness side.D Voltage between 3 and the earth
(Ignition switch: ON)OK: 4.5 - 5.5 V
D Continuity between 4 and the earthOK: Continuity
Check the harness between theengine-ECU and the injection volumeadjusting ROM connector.
OK
Replace the engine-ECU.
NG
NG RepairCheck the harness between theengine-ECU and the injection volumeadjusting ROM connector.
OK
Check the trouble symptoms.
NG
Replace injection pump assembly.
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-23
Code No. 48 GE actuator (in the middle of control sleeveposition sensor inoperative) system
Probable cause
Range of CheckD Ignition switch: ONSet ConditionsD Target value minus actual value is 1 V or more for 1 second
D Control sleeve position sensor inoperativeD GE actuator inoperativeD Control sleeve position sensor open circuit, short
circuit, or connector contact inoperativeD Engine-ECU inoperative
OK
OK
Check and repair the harness between thecontrol relay and the injection pumpassembly connector.
GE actuator check (Refer to P.13E-61.)
Replace the engine-ECU.
OK
RepairCheck the following connector: D-110
Check the trouble symptoms.
NG
NG
NG
Check the following connector: B-38NG
RepairOK
Check the trouble symptoms.
NG
NGMeasure at D-110 engine-ECU connectorD Disconnect the connector and measure at
the harness side.D Voltage between 1 and the earth
(Ignition switch: ON)OK: 9 V or higher
OK
Measure at B-38 injection pump assemblyconnector.D Disconnect the connector and measure at
the harness side.D Voltage between 6 and the earth
(Ignition switch: ON)OK: System voltage
Replace injection pump assembly.
Check and repair the harness between thecontrol relay and the injection pumpassembly connector.
NG
DIESEL FUEL <4D5-step III> - Troubleshooting13E-24
Code No. 49 Over boost Probable causeRange of CheckD Ignition switch: ONSet ConditionsD Boost pressure is higher than the barometric pressure + 133 kPa
D Malfunction of the variable geometry actuatorD Malfunction of variable geometry solenoid valveD Variable geometry solenoid valve open circuit, short
circuit, or connector contact inoperativeD Engine-ECU inoperative
OK
OK
Check and repair the harness between thecontrol relay and the solenoid valveconnector.
Replace the engine-ECU.
OK
ReplaceVariable geometry solenoid valve check(Refer to GROUP 15 - On-vehicle Service.)
Check the trouble symptoms.
NG
NG
Check the following connector: B-61NG
RepairOK
Check the trouble symptoms.
NG
NGMeasure at D-110 engine-ECU connectorD Disconnect the connector and measure at
the harness side.D Voltage between 17 and earth
(Ignition switch: ON)OK: System voltage
OK
Measure at B-61 variable geometry solenoidvalve connectorD Disconnect the connector and measure at
the harness side.D Voltage between 2 and earth
(Ignition switch: ON)OK: System voltage
Check and repair the harness between theengine-ECU and the solenoid valveconnector.
ReplaceVariable geometry actuator check (Refer toGROUP 15 - On-vehicle Service.)
NG
OK
RepairCheck the following connector: D-110NG
NG
Replace the turbocharger assembly.YES
Connect a boost gauge to the boostpressure sensor hose. When the vehicle isdriven at 1st gear with full throttle, doesboost pressure exceed 133 kPamomentarily?
NO
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-25
Code No. 51 EGR valve position sensor system Probable causeRange of CheckD Ignition switch: ON, except during engine crankingSet ConditionD Output voltage of EGR valve position sensor for 3 seconds is 4.85 V or
higher, or lower than 0.15 V
D EGR valve position sensor inoperativeD EGR valve position sensor open circuit, short
circuit or connector circuit inoperativeD Engine-ECU inoperative
RepairNG
NG
OK
Check the harness between the engine-ECUand the EGR valve position sensorconnector.
Replace the engine-ECU.
RepairNG
OK
NGRepair
OK
OK
Check the harness between theengine-ECU and the EGR valve positionsensor connector.
EGR valve position sensor check(Refer to P.13E-60.)
OK
Replace
Check the following connector: D-113
Check the trouble symptoms.
NG
NG
Check the following connector: B-66NG
RepairOK
Check the trouble symptoms.
NG
NGMeasure at D-113 engine-ECU connectorD Connect the connector.D Voltage between 90 and earth.
OK: 0.4 - 0.6 V(Ignition switch: ON)
4.1 - 4.8 V(When 60 kPa of negative pressure isapplied to the EGR valve nipple and thevalve is fully open)
OK
Measure at B-66 EGR valve position sensorconnector.D Disconnect the connector and measure at
the harness side.D Voltage between 2 and earth
(Ignition switch: ON)OK: 4.5 - 5.5 V
D Continuity between 3 and earthOK: Continuity
Replace the engine-ECU.
Replace the engine-ECU.
Check the following connector: D-112NG
RepairOK
Check the trouble symptoms.NG
DIESEL FUEL <4D5-step III> - Troubleshooting13E-26
Code No. 52 Variable geometry control pressure sensorsystem
Probable cause
Range of CheckD Ignition switch: ON, except during engine crankingSet ConditionD 4.5 V or higher, or 0.2 V or lowerRange of CheckD Engine idlingSet ConditionsD The difference between target and actual negative pressures remains 10.6
kPa or more for 10 seconds.
D Variable geometry control pressure sensorinoperative
D Variable geometry control pressure sensor opencircuit, short circuit or connector contactinoperative
D Vacuum hose disconnected or rupturedD Engine-ECU inoperative
NGReplace the engine-ECU.
Check the harness between theengine-ECU and the variablegeometry control pressure sensorconnector, if necessary.
NG
Check the trouble symptoms.
OK NGRepair
Replace the variable geometrycontrol pressure sensor.
OK NGRepair
Check the vacuum hose and pipebetween the variable geometrycontrol pressure sensor andalternator.
OK NGRepair
NG
NG
Check the trouble symptoms.
OK
Repair
Check the trouble symptoms.
OK
Replace the engine-ECU.
OKRepair
NG
NG
Check the harness between theengine-ECU and the variablegeometry control pressure sensorconnector.
Check the trouble symptoms.
OK NGRepair
Check the following connector:D-111
NG
Repair
OK
OK
OK
Check the following connector:B-63
NG
NG NG
Check the following connector:B-63
Measure at B-63 variable geometrycontrol pressure sensor connector.D Connect the connector.
(Use the test harness:MB991348)
D Voltage between 1 and earth(Ignition switch: ON)OK: Altitude 0 m: 3.7 - 4.3 V
Altitude 1,200 m: 3.2 - 3.8V
OK: 0.5 - 1.2 V when 80 kPaof negative pressure is ap-plied to the sensor
Measure at D-111 engine-ECUconnectorD Connect the connector.D Voltage between 45 and earth.
(Ignition switch: ON)OK: Altitude 0 m: 3.7 - 4.3 V
Altitude 1,200 m: 3.2 - 3.8V
OK: 0.5 - 1.2 V when 80 kPaof negative pressure is ap-plied to the sensor
Measure at B-63 variable geometrycontrol pressure sensor connectorD Disconnect the connector, and
measure at the harness side.D Voltage between 3 and earth
(Ignition switch: ON)OK: 4.8 - 5.2 V
D Continuity between 2 and earthOK: Continuity
Check the following connector:D-112
Check the harness between theengine-ECU and the variablegeometry control pressure sensorconnector.
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-27
Code No. 54 Immobilizer system Probable causeRange of CheckD Ignition switch: ONSet ConditionsD Improper communication between the engine-ECU and immobilizer-ECU
D Radio interference of encrypted codesD Incorrect encrypted codeD Malfunction of harness or connectorD Malfunction of immobilizer-ECUD Engine-ECU inoperative
NOTE(1) If the ignition switches are close each other when starting the engine, radio interference may cause
this code to be displayed.(2) This code may be displayed when registering the key encrypted code.
Is there another ignition key near the ignition key that is insertedin the ignition switch?
YesRemove the extra ignition key
No
Check the following connectors:D-112, D-202, D-133, E-13
NG Repair
No
Is a diagnosis code output from the immobilizer-ECU? Yes Check the immobilizer system. (Refer to GROUP 54 - IgnitionSwitch and Immobilizer System.)
NG
OK
Check the trouble symptoms.
Check theharnessbetween theengine-ECUandimmobilizer-ECU.OK
Replace the engine-ECU and immobilizer-ECU.
Check the trouble symptoms.NG
Repair
NG
DIESEL FUEL <4D5-step III> - Troubleshooting13E-28
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble Symptom InspectionprocedureNo.
Referencepage
No communication canbe established be
No communication can be established with all systems. 1 13E-29be established be-tween MUT-II and theengine-ECU.
No communication can be established only with theengine-ECU.
2 13E-29
Engine warning lamprelated
Immediately after the ignition switch is “ON”, the enginewarning lamp does not turn on.
3 13E-30
The engine warning lamp keeps on and does not turn off. 4 13E-30
Starting performance No initial combustion (unable to start) 5 13E-31
Starting performance is bad when the engine is cold (difficult tostart)
6 13E-31
Starting performance is bad regardless of when the engine ishot or cold (difficult to start)
7 13E-32
Idling stability(idling inoperative)
Low idling speed when the engine is cold (improper idlingspeed)
8 13E-32
High idling speed (improper idling speed) 9 13E-32
Low idling speed (improper idling speed) 10 13E-33
Idling instable (rough idling, hunting) 11 13E-33
Idling stability(idling sustainment in
The engine halts after running for a while. 12 13E-33(idling sustainment in-operative) The engine halts during idling. 13 13E-34
Driveability Lack of output power 14 13E-34
Occurrence of abnormal knocking 15 13E-34
Abnormal black smoke 16 13E-35
Abnormal white smoke 17 13E-35
Hunting during driving 18 13E-35
A/C condenser fan malfunction 19 13E-36
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-29
INSPECTION PROCEDURES FOR TROUBLE SYMPTOMSINSPECTION PROCEDURE 1
No communication can be established between MUT-IIand all systems.
Probable cause
Probable cause can be found in troubles with the power supply circuit and theearth circuit to the diagnosis connector.
D Diagnosis connector inoperativeD Harness inoperative
OK
Check and repair the earth line.
OK
Replace MUT-II.
NG
Check and repair the harnessbetween the power supply anddiagnosis connector.
OK
Check the trouble symptoms.
NGRepair
NGCheck the following connectors:D-27, D-211, D-210
NG
Measure at D-23 diagnosisconnector.D Voltage between 16 and the
earthOK: System voltage
Measure at D-23 diagnosisconnector.D Continuity between 4 and the
earthD Continuity between 5 and the
earthOK: Continuity
INSPECTION PROCEDURE 2
No communication can be established between MUT-IIand the engine-ECU.
Probable cause
Probable causes are shown in the following:D The power is not supplied to the engine-ECU.D The earth circuit of the engine-ECU inoperativeD The engine-ECU inoperativeD Communication between the engine-ECU and MUT-II inoperative
D The power supply circuit of the engine-ECUinoperative
D Engine-ECU inoperativeD Open circuit at the harness between the
engine-ECU and the diagnosis connector
NG
Check the harness between the engine-ECU and diagnosisconnector.
NGRepair
OK
Check the trouble symptoms.
Check the following connectors: D-112, E-13, D-33, D-23,D-06 <Vehicles with the center display>, D-40 <Vehicles withthe RV meter>
NGRepair
OK
The engine-ECU power supply and the earth circuit check(Refer to P.13E-37, Inspection procedure 20.)
NOTEIf the trouble symptoms persist even after implementing the above - mentioned inspection procedureto the vehicle with center display, check the center display or the RV meter and replace it if necessary.(Refer to GROUP 54A - Clock or Center display.)
DIESEL FUEL <4D5-step III> - Troubleshooting13E-30
INSPECTION PROCEDURE 3
Immediately after the ignition switch is “ON”, the enginewarning lamp does not turn on.
Probable cause
The engine-ECU turns on the engine warning lamp for 5 seconds immediatelyafter turning on the ignition switch to check the bulb for being blown.If the engine warning lamp does not turn on immediately after turning the ignitionswitch ON, problems shown in the right could exist.
D The engine warning lamp blownD The engine warning lamp circuit inoperativeD Engine-ECU inoperative
NG
Replace the engine-ECU.
NGCheck and repair the harnessbetween the combination meter andthe engine-ECU connector.
NGCheck and repair the engine warninglamp power supply circuit.
OK
Check the trouble symptoms.
OK
Measure at D-01 combination meterconnector.D Disconnect the connector and
measure at the harness side.D Voltage between 62 and the
earth (Ignition switch: ON)OK: System voltage
OKCheck the following connectors:D-01, D-02, D-110, E-13
NGRepair
NG
Check bulb for being blown.
OK
Check the trouble symptoms.
OK
Measure at D-110 engine-ECUconnector.D Disconnect the connector and
measure at the harness side.D Short circuit between 8 and the
earth (Ignition switch: ON)OK: The engine warning lamp turns
on.
OKCheck the following connector:D-110
NGRepair
MUT-II Data list11 Engine-ECU power supply voltage(Refer to P.13E-41.)
NGThe engine-ECU power supply andthe earth circuit check (Refer toP.13E-37, Inspection procedure 20.)
INSPECTION PROCEDURE 4
The engine warning lamp keeps on and does not turnoff.
Probable cause
The probable causes can be found in either the engine-ECU detecting themalfunction in the sensor and/or the actuator, or the problem shown in the righttakes place.
D Short circuit at the harness between the enginewarning lamp and the engine-ECU
D Engine-ECU inoperative
Check the following connector: E-13
NO
Measure at D-02 combination meter connector.D Disconnect the connector and measure at the harness
side.D Disconnect the engine-ECU connector D-110.D Continuity between 38 and the earthOK: No continuity
NGCheck and repair the harness between the combination meterand the engine-ECU connector.
OK
MUT-II Self-Diag codeIs a diagnosis code output?
YESInspection chart for diagnosis codes (Refer to P.13E-8.)
Check the trouble symptoms.
OK
Replace the engine-ECU.NG
NGRepair
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-31
INSPECTION PROCEDURE 5
No initial combustion (unable to start) Probable causeProbable causes can be found in troubles with control system, injection pump,glow system, and power supply system.
D Control system inoperativeD Injection pump inoperativeD Intake system inoperativeD Glow system inoperativeD Engine-ECU inoperative
NG
Repair
MUT-II Self-Diag codeIs a diagnosis code output?
YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-II Data list check and an actuator test.(Refer to P.13E-40, 44.)
OKCheck the following items in order:D Glow plug, glow plug relayD BatteryD Injection nozzleD Throttle body assemblyD Injection pumpD Compression pressureD Existence of mixing foreign objects (water, kerosene) with
the fuel
INSPECTION PROCEDURE 6
Starting performance is bad when the engine is cold(unable to start)
Probable cause
Probable causes can be found in troubles with control system, injection pump,fuel system, intake system, and glow system.
D Control system inoperativeD Injection pump inoperativeD Fuel system inoperativeD Intake system inoperativeD Glow system inoperativeD Engine-ECU inoperative
NG
Repair
MUT-II Self-Diag codeIs a diagnosis code output?
YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-II Data list check and an actuator test.(Refer to P.13E-40, 44.)
OKInspect the following items in order:D Glow plug, glow plug relayD Injection nozzle, fuel filterD Throttle body assemblyD Existence of starter switch signal inputD Engine oilD Injection pumpD Existence of mixing foreign objects (water, kerosene) with
the fuel
DIESEL FUEL <4D5-step III> - Troubleshooting13E-32
INSPECTION PROCEDURE 7
Starting performance is bad regardless of whether theengine is hot or cold (unable to start)
Probable cause
Probable causes can be found in troubles with control system, injection pump,fuel system, and intake system.
D Control system inoperativeD Injection pump inoperativeD Fuel system inoperativeD Intake system inoperativeD Engine-ECU inoperative
NG
Repair
MUT-II Self-Diag codeIs a diagnosis code output?
YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-II Data list check and an actuator test.(Refer to P.13E-40, 44.)
OKInspect the following items in order:D Injection nozzle, fuel filterD Throttle body assemblyD Compression pressureD Injection pumpD Existence of mixing foreign objects (water, kerosene) with
the fuel
INSPECTION PROCEDURE 8
Low idling speed when the engine is cold (improperidling speed)
Probable cause
Probable causes can be found in troubles with control system, injection pump,and fuel system.
D Control system inoperativeD Injection pump inoperativeD Fuel system inoperativeD Engine-ECU inoperative
NG
Repair
MUT-II Self-Diag codeIs a diagnosis code output?
YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-II Data list check and an actuator test.(Refer to P.13E-40, 44.)
OKInspect the following items in order:D Injection pumpD Fuel filter
INSPECTION PROCEDURE 9
High idling speed (improper idling speed) Probable causeProbable causes can be found in troubles with control system and injectionpump.
D Control system inoperativeD Injection pump inoperativeD Engine-ECU inoperative
NG
Repair
MUT-II Self-Diag codeIs a diagnosis code output?
YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-II Data list check and an actuator test.(Refer to P.13E-40, 44.)
OKInspect the following items in order:D Injection pumpD Starter switch signal
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-33
INSPECTION PROCEDURE 10
Low idling speed (improper idling speed) Probable causeProbable causes can be found in troubles with control system, injection pump,and fuel.
D Control system inoperativeD Injection pump inoperativeD Fuel system inoperativeD Engine-ECU inoperative
NG
Repair
MUT-II Self-Diag codeIs a diagnosis code output?
YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-II Data list check and an actuator test.(Refer to P.13E-40, 44.)
OKInspect the following items in order:D Injection nozzleD Injection pump
INSPECTION PROCEDURE 11
Idling instable (rough idling, hunting) Probable causeProbable causes can be found in troubles with control system, injection pump,fuel system, glow system, intake system, and EGR system.
D Control system inoperativeD Injection pump inoperativeD Fuel system inoperativeD Intake system inoperativeD Glow system inoperativeD EGR system inoperativeD Engine-ECU inoperative
NG
Repair
MUT-II Self-Diag codeIs a diagnosis code output?
YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-II Data list check and an actuator test.(Refer to P.13E-40, 44.)
OKInspect the following items in order:D Glow plug, glow plug relayD EGR systemD Injection nozzleD Compression pressureD Valve clearanceD Throttle body assemblyD Injection timingD Fuel line bleedingD Injection pump
INSPECTION PROCEDURE 12
The engine stalls after running for a while. Probable causeProbable causes can be found in troubles with control system, injection pump,fuel system, and intake system.
D Control system inoperativeD Injection pump inoperativeD Fuel system inoperativeD Intake system inoperativeD Engine-ECU inoperative
NG
Repair
MUT-II Self-Diag codeIs a diagnosis code output?
YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-II Data list check and an actuator test.(Refer to P.13E-40, 44.)
OKInspect the following items in order:D Throttle body assemblyD Fuel filterD Injection pump
DIESEL FUEL <4D5-step III> - Troubleshooting13E-34
INSPECTION PROCEDURE 13
The engine stalls during idling. Probable causeProbable causes can be found in troubles with control system, injection pump,intake system, EGR system, and power supply.
D Control system inoperativeD Injection pump inoperativeD Fuel system inoperativeD Intake system inoperativeD EGR system inoperativeD Engine-ECU inoperative
NG
Repair
MUT-II Self-Diag codeIs a diagnosis code output?
YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-II Data list check and an actuator test.(Refer to P.13E-40, 44.)
OKInspect the following items in order:D Power supply systemD Throttle body assemblyD EGR systemD Injection pump
INSPECTION PROCEDURE 14
Lack of output power Probable causeProbable causes can be found in troubles with control system, injection pump,fuel system, intake system, and EGR system.
D Control system inoperativeD Injection pump inoperativeD Fuel system inoperativeD Intake system inoperativeD EGR system inoperativeD Engine-ECU inoperative
NG
Repair
MUT-II Self-Diag codeIs a diagnosis code output?
YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-II Data list check and an actuator test.(Refer to P.13E-40, 44.)
OKInspect the following items in order:D Injection nozzle, fuel filterD Throttle body assemblyD EGR systemD TurbochargerD Compression pressureD Injection timingD Injection pumpD Existence of mixing foreign objects (water, kerosene) with
the fuel
INSPECTION PROCEDURE 15
Occurrence of abnormal knocking Probable causeProbable causes can be found in troubles with control system, injection pump,fuel system, and EGR system.
D Control system inoperativeD Injection pump inoperativeD Fuel system inoperativeD EGR system inoperativeD Engine-ECU inoperative
NG
Repair
MUT-II Self-Diag codeIs a diagnosis code output?
YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-II Data list check and an actuator test.(Refer to P.13E-40, 44.)
OKInspect the following items in order:D Injection nozzleD Injection timingD EGR systemD Injection pump
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-35
INSPECTION PROCEDURE 16
Abnormal black smoke Probable causeProbable causes can be found in troubles with control system, injection pump,fuel system, intake system, and EGR system.
D Control system inoperativeD Injection pump inoperativeD Fuel system inoperativeD Intake system inoperativeD EGR system inoperativeD Engine-ECU inoperative
NG
Repair
MUT-II Self-Diag codeIs a diagnosis code output?
YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-II Data list check and an actuator test.(Refer to P.13E-40, 44.)
OKInspect the following items in order:D Air cleanerD Injection nozzleD Throttle body assemblyD EGR systemD TurbochargerD Injection pump
INSPECTION PROCEDURE 17
Abnormal white smoke Probable causeProbable causes can be found in troubles with control system, injection pump,fuel system, intake system, EGR system, and glow system.
D Control system inoperativeD Injection pump inoperativeD Fuel system inoperativeD Intake system inoperativeD EGR system inoperativeD Glow system inoperativeD Engine-ECU inoperative
NG
Repair
MUT-II Self-Diag codeIs a diagnosis code output?
YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-II Data list check and an actuator test.(Refer to P.13E-40, 44.)
OKInspect the following items in order:D Glow plug, glow plug relayD Injection nozzleD Throttle body assemblyD EGR systemD TurbochargerD Injection pump
INSPECTION PROCEDURE 18
Hunting during driving Probable causeProbable causes can be found in troubles with control system, injection pump,and fuel system.
D Control system inoperativeD Injection pump inoperativeD Fuel system inoperativeD Engine-ECU inoperative
NG
Repair
MUT-II Self-Diag codeIs a diagnosis code output?
YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-II Data list check and an actuator test.(Refer to P.13E-40, 44.)
OKInspect the following items in order:D Injection nozzleD Injection pump
DIESEL FUEL <4D5-step III> - Troubleshooting13E-36
INSPECTION PROCEDURE 19
A/C condenser fan operating problem Probable causeThe power transistor inside the engine-ECU turns on and off to control the A/Ccondenser fan motor relay.
D Malfunction of A/C condenser fan motor relayD Malfunction of A/C condenser fan motorD Malfunction of thermostatD Open circuit or short-circuit in circuit, or poor
connector contactD Malfunction of engine-ECU
Check the following connector: D-110
OK
Measure at engine-ECU connector D-110.D Disconnect the connector and measure at the harness
side.D Check the A/C condenser fan condition.
(Ignition switch: ON)OK: Fan stopped
D Voltage between 7 and the earth(Ignition switch: ON)OK: System voltage
D Short out 7 and the earth(Ignition switch: ON)OK: A/C condenser fan turns
NGA/C condenser fan motor circuit check(Refer to the wiring harness configuration diagram.)
OK
MUT-II Data list02 Engine coolant temperature sensorOK: When engine is idling after having warmed up, the en-
gine coolant temperature and the MUT-II display temper-ature are identical
NGEngine coolant temperature sensor check(Refer to Code 15 on P.13E-59.)
Check the trouble symptoms.
OK
Replace the engine-ECU.
NGRepair
Thermostat check
NGNG
Replace
OK
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-37
INSPECTION PROCEDURE 20
Engine-ECU power supply and earth circuit check
(5) NG
Check the trouble symptoms.
NGRepair
(2), (3) NG OK
Check the trouble symptoms.
OK
NG
Check the harness between theengine-ECU and the ignition switch.
Ignition switch check
(4) NG
Check and repair the harnessbetween the engine-ECU and theearth.
OK
Check the following connectors:D-110, D-111, D-113
NG
Replace the engine-ECU.
OK
Check the trouble symptoms.
RepairNG
NGRepairCheck the following connectors:
B-25X, D-128
NGCheck and repair the harnessbetween the engine-ECU and thecontrol relay connector.
Check and repair the harnessbetween the engine-ECU and thebattery.
Check the following connectors:D-208, D-223, E-13
NGRepairMeasure at D-110, D-111, D-113
engine-ECU connectors.D Disconnect the connector and
measure at the harness side.(1) Voltage between 82 and the
earth (Ignition switch: ON)OK: System voltage
(2) Voltage between 46 and theearthOK: System voltage
(3) Voltage between 12, 25 and theearth (Ignition switch: ON)OK: System voltage
(When terminal 38 is shortcircuited to the earth)
(4) Continuity between 13, 26 andthe earthOK: Continuity
(5) Voltage 80 and the earthOK: System voltage
(1) NG
OK
INSPECTION PROCEDURE 21
Fuel cut solenoid valve circuit inspection
NG
Check the harness between theengine-ECU and the fuel cutsolenoid valve connector.
OK
Replace the engine-ECU.
OK
Check the fuel injection pumpassembly connector B-38, and repairif necessary.
OK
Check the trouble symptoms.
OK
Measure at fuel injection pumpassembly connector B-38.D Disconnect the connector and
measure at the harness side.D Voltage between 1 and the earth
(Ignition switch: ON)OK: System voltage
OKCheck the following connector:D-110
NGRepair
Fuel cut solenoid valve check(Refer to P.13E-61.)
NGReplace the injection pump.
NGRepair
DIESEL FUEL <4D5-step III> - Troubleshooting13E-38
INSPECTION PROCEDURE 22
EGR control solenoid valve No. 1 circuit inspection
NG
Check the harness between theengine-ECU and the EGR controlsolenoid valve No. 1 connector, andrepair if necessary.
OK
Check the trouble symptoms.
OK
Measure at EGR control solenoidvalve No. 1 connector B-35.D Disconnect the connector and
measure at the harness side.D Voltage between 1 and the earth
(Ignition switch: ON)OK: System voltage
NGCheck the following connector:B-35
NGRepair
NGCheck the harness between thecontrol relay and the EGR controlsolenoid valve No. 1 connector, andrepair if necessary.
EGR control solenoid valve No. 1check (Refer to GROUP 17 -Service Adjustment Procedures.)
NGReplace
OK
Measure at engine-ECU connectorD-110.D Disconnect the connector and
measure at the harness side.D Voltage between 9 and the earth
(Ignition switch: ON)OK: System voltage
NGReplace the engine-ECU.
NG
Check the trouble symptoms.
OKRepair
Check the following connector:D-110
OK
INSPECTION PROCEDURE 23
EGR control solenoid valve No. 2 circuit inspection
NG
Check the harness between theengine-ECU and the EGR controlsolenoid valve No. 2 connector, andrepair if necessary.
OK
Check the trouble symptoms.
OK
Measure at EGR control solenoidvalve No. 2 connector B-34.D Disconnect the connector and
measure at the harness side.D Voltage between 1 and the earth
(Ignition switch: ON)OK: System voltage
NGCheck the following connector:B-34
NGRepair
NGCheck the harness between thecontrol relay and the EGR controlsolenoid valve No. 2 connector, andrepair if necessary.
EGR control solenoid valve No. 2check (Refer to GROUP 17 -Service Adjustment Procedures.)
NGReplace
OK
Measure at engine-ECU connectorD-110.D Disconnect the connector and
measure at the harness side.D Voltage between 5 and the earth
(Ignition switch: ON)OK: System voltage
NGReplace the engine-ECU.
NG
Check the trouble symptoms.
OKRepair
Check the following connector:D-110
OK
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-39
INSPECTION PROCEDURE 24
Glow plug relay inspection
NG
Replace the engine-ECU.
OK
Check the trouble symptoms.
OK
Measure at glow plug relayconnector B-42.D Disconnect the connector and
measure at the harness side.D Voltage between 1 and the earth
(Ignition switch: ON)(Engine coolant temperature:40_C or lower)
OK: System voltage (for 1 - 8 sec-onds after ignition switch isturned to ON)
NGCheck the following connector:D-110
NGRepair
Glow plug relay check. (Refer toGROUP 16 - Glow System.)
NGReplace
Check glow plug relay connectorB-42, and repair if necessary.
OK OK
Check the harness between theengine-ECU and the glow plug relayconnector.
NGRepair
INSPECTION PROCEDURE 25
A/C switch and A/C relay inspection
Replace the engine-ECU.
OK
Check the trouble symptoms.
Measure at engine-ECU connectorD-110 or D-111.D Disconnect the connector and
measure at the harness side.D Voltage between 21 and 32 and
the earth (Ignition switch: ON)OK: 0 - 3 V (A/C switch: OFF)
System voltage (A/Cswitch: ON)
D Short out 21 and the earth(Ignition switch: ON)(A/C switch: ON)OK: A/C compressor clutch
turns on
OKCheck the following connectors:D-110, D-111
NGRepair
A/C system check(Refer to GROUP 54 - ServiceAdjustment Procedures.)
NG
OK
DIESEL FUEL <4D5-step III> - Troubleshooting13E-40
DATA LIST REFERENCE TABLEItemNo.
Check item Inspection conditions Value to bedeterminedas normal
Code No.or inspec-tion proce-dure No.
Referencepage
01 Boost airtemperature
Ignition switch: ON orthe engine running
When the intake airtemperature is -20_C
-20_C Code No.16
13E-12p
sensorg g
When the intake airtemperature is 0_C
0_C
When the intake airtemperature is 20_C
20_C
When the intake airtemperature is 40_C
40_C
When the intake airtemperature is 80_C
80_C
02 Enginecoolanttemperature
Ignition switch: ON orthe engine running
When the enginecoolant temperature is-20_C
-20_C Code No.15
13E-12
psensor When the engine
coolant temperature is0_C
0_C
When the enginecoolant temperature is20_C
20_C
When the enginecoolant temperature is40_C
40_C
When the enginecoolant temperature is80_C
80_C
03 Barometric Ignition switch: ON Altitude 0 m 101 kPa Code No.13
13E-11pressuresensor
g
Altitude 600 m 95 kPa 13sensor
Altitude 1,200 m 88 kPa
Altitude 1,800 m 81 kPa
04 Boost D Engine coolantt t
Altitude 0 m 101 kPa Code No.12
13E-10pressuresensor
gtemperature:80 - 95_C
Altitude 600 m 95 kPa 12sensor 80 - 95_C
D Lamps, electrical Altitude 1,200 m 88 kPaLamps, electricalcooling fan, andaccessories: OFF
Altitude 1,800 m 81 kPaaccessories: OFF
D Transmission: Idling 81- 109 kPaD Transmission:Neutral
D Ignition switch: ONWhen sudden racing isdone
Increased
05 Fueltemperature
Ignition switch: ON orthe engine running
When the fueltemperature is -20_C
-20_C Code No.14
13E-11p
sensorg g
When the fueltemperature is 0_C
0_C
When the fueltemperature is 20_C
20_C
When the fueltemperature is 40_C
40_C
When the fueltemperature is 80_C
80_C
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-41
ItemNo.
Referencepage
Code No.or inspec-tion proce-dure No.
Value to bedeterminedas normal
Inspection conditionsCheck item
06 Vehiclespeedsensor
When driving Compare the enginespeed displayed in thespeed meter with thatin MUT-II
Matched Code No.17
13E-13
07 Pumpspeed
Engine: Cranking Compare the enginespeed displayed in the
Matched Code No.18
13E-14speedsensor Engine: Idling
speed displayed in thetachometer with that inMUT-II
18
08 Crank anglesensor
Engine: Cranking Compare the enginespeed displayed in the
Matched Code No.21
13E-15sensor
Engine: Idlingspeed displayed in thetachometer with that inMUT-II
21
09 Acceleratorpedal posi-tion sensor
Ignition switch: ON Accelerator pedal:Idling position
1,015 - 1,055mV
Code No.11
13E-9
tion sensor(main) Accelerator pedal:
Fully opened position4,035 - 4,500mV or higher
10 Acceleratorpedal posi-ti
Ignition switch: ON Accelerator pedal:Idling position
0 % Code No.11
13E-9p ption sensor(main)
Accelerator pedal:Fully opened position
99 - 100 %
11 System volt-age
Ignition switch: ON System volt-age
ProcedureNo. 20
13E-37
13 Timingt l
Engine: After warmingth i
Idling 70 - 90 % Code No.25 N
13E-17gcontrolvalve*1
g gup the engine When engine is
suddenly racedChanges 25 or No.
4313E-21
14 EGR com-d l
Engine: After warmingth i
Idling 0 - 100 %*2 – -mand value
g gup the engine When engine is
suddenly racedMomentarilydecreases
17 Controlsleeve posi-
Engine: After warmingup the engine
Idling 2.1 - 2.5 V Code No.26
13E-18sleeve position (targetvalue)
up the engine2,500 r/min (no load) 1.8 - 2.2 V
26
18 Actual injec-ti ti i
Engine: After warmingth i
Idling 0.7 - 1.2 V – –jtion timing
g gup the engine When engine is
suddenly racedIncreases
19 Injectionti i
Engine: After warmingth i
Idling 0.7 - 1.2 V – –jtiming com-mand value
g gup the engine When engine is
suddenly racedIncreases
21 GE actuator Engine: After warmingup the engine
Idling 0 % Code No.26 or No
13E-1813E 23up the engine
2,500 r/min 18 - 38 %26 or No.48
13E-23
23 Controlsleeve posi-
Engine: After warmingup the engine
Idling 2.1 - 2.5 V Code No.26
13E-18sleeve position (actuall )
up the engine2,500 r/min (no load) 1.8 - 2.2 V
26(
value)2,500 r/min (no load) 1.8 2.2 V
24 Acceleratorpedal posi-ti
Ignition switch: ON Accelerator pedal:Idling position
1,015 - 1,055mV
Code No.27
13E-19p ption sensor(sub)
Accelerator pedal:Fully opened position
4,035 - 4,500mV or higher
DIESEL FUEL <4D5-step III> - Troubleshooting13E-42
ItemNo.
Referencepage
Code No.or inspec-tion proce-dure No.
Value to bedeterminedas normal
Inspection conditionsCheck item
25 Acceleratorpedalposition
Ignition switch: ON Accelerator pedal:Idling position
0 % Code No.27
13E-19
positionsensor (sub) Accelerator pedal:
Fully opened position99 - 100 %
31 EGR valveposition
Engine: After warmingup the engine
Idling under no load 2.3 - 3.3 V Code No.51
13E-25positionsensor (tar-get value)
up the engineEngine is suddenlyraced
Momentarilydecreases(0.3 - 0.7 V)
51
32 EGR valveposition
Engine: After warmingup the engine
Idling under no load 2.3 - 3.3 V Code No.51
13E-25positionsensor (ac-tual value)
up the engineEngine is suddenlyraced
Momentarilydecreases(0.3 - 0.7 V)
51
33 Variablegeometry
Engine: After warmingup the engine
Idling 53 - 59 kPa Code No.52
13E-26geometrycontrol pres-sure sensor
up the engineEngine is suddenlyraced
Momentarilyincreases
52
NOTE*1: The opening degree of the timing control valve is converted into percentage. (0 %: timer non-advanced angle,
100 %: timer maximum advanced angle)*2: The opening degree of the EGR solenoid valve is converted into percentage.
ItemNo.
Check item Inspection conditions Value to bedeterminedas normal
Code No.or inspec-tion proce-dure No.
Referencepage
41 Idle switch Ignition switch: ON(check by repeatedaccelerator operation)
Release the foot fromthe accelerator pedal.
ON Code No.23
13E-16y
accelerator operation) Step on the acceleratorpedal slightly.
OFF
43 A/C switch Engine: Idling (TheA/C compressorshould be in operation
A/C switch: ON ON ProcedureNo. 25
13E-39
should be in operationwhen the A/C switch is“ON”)
A/C switch: OFF OFF
44 Ignitioni h ST
Ignition switch: ON Engine: Stop OFF – –gswitch-ST
gEngine: Cranking ON
45 Ignitionswitch-IG
Ignition switch: ON ON – –
46 Controlrelay
Ignition switch: ON ON – –
47 A/C relay Engine: Idling afterwarming up the engine
A/C switch: OFF OFF (A/Ccompressorclutch not inoperation)
ProcedureNo. 25
13E-39
A/C switch: ON ON (A/Ccompressorclutch inoperation)
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-43
ItemNo.
Check item Inspection conditions Value to bedeterminedas normal
Code No.or inspec-tion proce-dure No.
Referencepage
50 Condenserfan relay
Ignition switch: ON A/C switch: OFF(engine coolanttemperature at 102_Cor higher)A/C switch: ON(engine coolanttemperature at 102_Cor higher, or outsidetemperature at 15_Cor higher)
ON ProcedureNo. 19
13E-36
Condenserfan relay
Ignition switch: ON A/C switch: OFF(engine coolanttemperature at 95_Cor lower)A/C switch: ON(engine coolanttemperature at 95_Corlower, or outsidetemperature at 15_Cor lower)
OFF
52 Glow plugrelay
D Ignition switch:ON
Relay not driven OFF ProcedureNo. 24
13E-39relay ON
D Select actuatortest item No. 02.
Relay is forcibly driven ONNo. 24
53 Throttlesolenoid
Ignition switch: ON (Engine stops) OFF Code No.41
13E-20solenoidvalve Engine: main sensor or actuator is failed ON
41
55 Enginewarning
D Ignition switch:ONS
Engine warning lampoff
OFF ProcedureNo. 3
13E-30g
lamp D Select actuatortest item No. 16.
Enginewarning lamp isforced on
ON
56 Glow lamp D Ignition switch:ON
Glow lamp off OFF – –ON
D Select actuatortest item No. 15.
Glow lamp is forced on ON
60 Fuel cutrelay
D Ignition switch: OND Select actuator
Relay not driven OFF ProcedureNo 21
13E-37relay D Select actuator
test item No. 27. Relay is forcibly driven ONNo. 21
62 AT/MTswitch
Ignition switch: ON Vehicles with M/T M/T – –
73 EGR controlsolenoid
Engine: After warmingup the engine
Idling under no load(stable condition)
OFF ProcedureNo. 22
13E-38
valve No. 1p g
Engine is suddenlyraced (EGR amountdecreasing)
OFF
Engine is suddenlyraced (EGR amountincreasing)
ON (momen-tarily)
74 EGR controll id
Engine: After warmingh i
Idling (stable condition) ON ProcedureN
13E-38solenoidvalve No. 2
g gup the engine When engine is sud-
denly raced (EGRamount decreasing)
OFF (mo-mentarily)
No. 23
When engine is sud-denly raced (EGRamount increasing)
ON
DIESEL FUEL <4D5-step III> - Troubleshooting13E-44
ACTUATOR TEST TABLE
ItemNo.
Check item Drive Con-tents
Inspectionconditions
Value to be determinedas normal
Code No.or inspec-tion proce-dure No.
Referencepage
02 Glow plug relay Turning therelay from
Ignition switch:ON
Battery charge isenergized to the glow
ProcedureNo 24
13E-39relay fromOFF to ON orfrom ON to
ON energized to the glowplug when the glowplug relay is ON
No. 24
from ON toOFF
plug relay is ON.
03 A/C compressorrelay
Turning therelay from
Ignition switch:ON
The A/C compressorclutch makes an
ProcedureNo 25
13E-39relay relay from
OFF to ON orfrom ON to
ON clutch makes anaudible sound.
No. 25
from ON toOFF
11 Timing controlvalve
Turn thetiming controlvalve to ON
D Ignitionswitch: ON
D Engine:Idling
Makes an audiblesound
Code No.43
13E-21
12 Turn thetiming controlvalve to OFF
IdlingD Timer piston
positionsensor:Normal
15 Glow lamp Turn the glowlamp on or off
Ignition switch:ON
The glow lamp turnson.
– –
16 Warning lamp Turn thewarning lampon or off
Ignition switch:ON
The warning lampturns on.
ProcedureNo. 3, 4
13E-30
22 Condenser fanrelay
Turning therelay fromOFF to ON orfrom ON toOFF
Ignition switch:ON
The condenser fanrotates.
ProcedureNo. 19
13E-36
23 Throttle solenoidvalve
Turn thesolenoidvalve fromOFF to ON orfrom ON toOFF
D Ignitionswitch: ON
D Vehiclespeed:0 km/h
D Enginespeed:1,000 r/minor lower
Makes an audiblesound
Code No.41
13E-20
25 GE actuator Turn the GEactuator toON
D Ignitionswitch: ON
D Enginespeed:0 r/min or
Measure the wavepattern betweenengine-ECU connec-tor terminals No. 1and No. 15 using an
Code No.48
13E-23
26 Turn the GEactuator toOFF
0 r/min orlower
D Controlsleeve posi-tion sensor:Normal
and No. 15 using ananalyzer and checkthe change in the dutyratio.
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-45
ItemNo.
Referencepage
Code No.or inspec-tion proce-dure No.
Value to be determinedas normal
Inspectionconditions
Drive Con-tents
Check item
27 Fuel cut solenoidvalve
Turn thesolenoidvalve fromOFF to ON orfrom ON toOFF.
D Ignitionswitch: ON
D Vehiclespeed:0 km/h
Makes an audiblesound
– –
34 Middle positionof GE actuator
Hold theinjectiongovernor inits middleposition.
D Ignitionswitch: ON
When the crankshaftis turned clockwiseduring the adjustmentof the injection timing,the injection pipesspray out fuel.
Code No.48
13E-23
35 Variablegeometrysolenoid valve
Turn thesolenoidvalve to ON
Ignition switch:ON
Makes an audiblesound
Code No.49
13E-24
36 Turn thesolenoidvalve to OFF
Engine: Idling Operating sound andvibration, whichaccompany with theduty activation, cease.
37 EGR controlsolenoid valveNo. 1
Turn thesolenoidvalve fromOFF to ONfrom ON toOFF
Ignition switch:ON
Makes an audiblesound
ProcedureNo. 22
13E-38
38 EGR controlsolenoid valveNo. 2
Turn thesolenoidvalve fromOFF to ONfrom ON toOFF
Ignition switch:ON
Makes an audiblesound
ProcedureNo. 23
13E-38
DIESEL FUEL <4D5-step III> - Troubleshooting13E-46
CHECK AT THE ENGINE-ECU TERMINALSTERMINAL VOLTAGE CHECK CHARTEngine-ECU Connector Terminal Arrangement
TerminalNo.
Check item Inspection conditions (engine status) Normal condition:
1 GE actuator Ignition switch: ON (Engine stops) 9 V or higher
2 Fuel cut solenoid valve Other than below 0 - 1 V
Engine: Idling→ Stop (in about 1 - 3 second) System voltage(for 3 - 5 seconds)
3 Timing control valve Ignition switch: ON (Engine stops) 11 V or higher
4 Glow lamp Ignition switch: OFF→ ON 0 - 1 V (In few seconds)→ System voltage
5 EGR control solenoidvalve No. 2
Engine: Idling after warming up the engine(stable condition)
System voltage
When any one of the following conditions issatisfied:D Engine speed: 3,700 r/min or higherD Engine speed: 450 r/min or lowerD Vehicle speed: 176 km/h or higherD The accelerator pedal is fully depressedD The accelerator pedal is released when engine
speed is 2,700 r/min or higher and vehicle speedis 140 km/h or higher
D Engine coolant temperature: 112_C or higher
System voltage
7 Condenser fan relay Condenser fan in operation 0 - 1 V
8 Engine warning lamp Ignition switch: OFF→ ON 0 -1 V (In few seconds)→ System voltage
9 EGR control solenoidvalve No 1
Ignition switch: ON System voltagevalve No. 1
Engine: After warming up the engine, conductsudden racing from idling.
Very briefly rises fromvoltage during idling
12 Power supply Ignition switch: ON System voltage
25
14 Throttle solenoid valve Ignition switch: ON (Engine stops) System voltage
Engine: Idling after warming up the engine. 0 - 1 V
15 GE actuator powersupply
Ignition switch: ON System voltage
16 Glow plug relay D Engine coolant temperature: 40_C or lowerD Ignition switch: OFF → ON
System voltage (In about8 seconds: at 20_C)→ 0- 1 V
17 Variable geometrysolenoid valve
Engine: After warm-ing up the engine
Engine is idling 4.4 - 10.1 Vsolenoid valve ing up the engine
Engine is suddenly raced Voltage rises
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-47
TerminalNo.
Normal condition:Inspection conditions (engine status)Check item
21 A/C relay A/C switch: OFF→ ON System voltage → 0 - 1V
31 Idle switch Ignition switch: ON Release the foot from theaccelerator pedal.
0 - 1 V
Step on the acceleratorpedal slightly
3 V or higher
32 A/C switch A/C in operation (compressor in operation) System voltage
36 Selector switchbetween A/T and M/T
Ignition switch: ON System voltage (M/T)
46 Control relay Ignition switch: ON 0 - 1 V
Ignition switch: ON→ OFF (in about 8 seconds) System voltage
51 Pump speed sensor Engine: Idling (Use a digital voltagemeter to check.) 0 V↔ 5 V(repeat the change)
55 Accelerator pedalposition sensor (sub)
Ignition switch: ON Accelerator pedal: Idlingposition
0.9 - 1.1 V
Accelerator pedal: Fullyopened position
3.7 V or higher
60 Sensor power supply Ignition switch: ON 4.6 - 5.4 V
71 Ignition switch-ST Engine: Cranking 8 V or higher
80 Back-up power supply Ignition switch: OFF System voltage
81 Power supply to accel-erator pedal positionsensor (main)
Ignition switch: ON 4.6 - 5.4 V
82 Ignition switch-IG Ignition switch: ON System voltage
83 Engine coolant tem-perature sensor
Ignition switch: ON Engine coolanttemperature: 0_C
3.7 - 4.3 V
Engine coolanttemperature: 20_C
2.8 - 3.4 V
Engine coolanttemperature: 40_C
1.9 - 2.5 V
Engine coolanttemperature: 80_C
0.6 - 1.2 V
84 Accelerator pedal posi-tion sensor (main)
Ignition switch: ON Accelerator pedal: Idlingposition
0.9 - 1.1 V
Accelerator pedal: Fullyopened position
3.7 V or higher
85 Boost pressure sensor Ignition switch: ON (101 kPa) 1.0 - 1.4 V
86 Vehicle speed sensor D Ignition switch: OND Move the vehicle forward slowly
0 V↔ 8 - 12 V(repeat the change)
87 Fuel temperature sen-sor
Ignition switch: ON Fuel temperature: 0_C 3.2 - 3.6 Vsor
Fuel temperature: 20_C 2.3 - 2.7 V
Fuel temperature: 40_C 1.5 - 1.9 V
Fuel temperature: 80_C 0.4 - 0.8 V
DIESEL FUEL <4D5-step III> - Troubleshooting13E-48
TerminalNo.
Normal condition:Inspection conditions (engine status)Check item
88 Boost air temperaturesensor
Ignition switch: ON Intake air temperature:0_C
3.2 - 3.8 V
Intake air temperature:20_C
2.3 - 2.9 V
Intake air temperature:40_C
1.4 - 2.0 V
Intake air temperature:80_C
0.4 - 1.0 V
89 Crank angle sensor Engine: Idling (Use a digital voltagemeter to check.) 0 V↔ 5 V(repeat the change)
90 EGR valve positionsensor
Engine: After warm-ing up the engine
Idling under no load 2.3 - 3.3 Vsensor ing up the engine
Engine is suddenly raced Momentarily drops fromvoltage during idling
91 Parking switch Ignition switch: ON(Engine stops)
Parking brake: ON 0 - 1 V(Engine stops)
Parking brake: OFF System voltage
CHECK CHART FOR RESISTANCE AND CONTINUITYBETWEEN TERMINALS1. Turn the ignition switch to LOCK (OFF) position.2. Disconnect the engine-ECU connector.3. Measure the resistance and check for continuity between
the terminals of the engine-ECU harness-side connectorwhile referring to the check chart.
NOTE(1) When measuring resistance and checking continuity,
a harness for checking contact pin pressure shouldbe used instead of inserting a test probe.
(2) Checking need not be carried out in the order givenin the chart.
CautionIf the terminals that should be checked are mistaken,or if connector terminals are not correctly shortedto earth, damage may be caused to the vehicle wiring,sensors, engine-ECU and/or ohmmeter.Be careful to prevent this!
4. If the ohmmeter shows any deviation from the standardvalue, check the corresponding sensor, actuator andrelated electrical wiring, and then repair or replace.
5. After repair or replacement, recheck with the ohmmeterto confirm that the repair or replacement has correctedthe problem.
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-49
Engine-ECU Harness Side Connector Terminal Arrangement
Terminal No. Inspection item Normal condition (Check condition)
1 - 15 GE actuator 0.64 - 0.72 Ω
2 - Body earth Fuel cut solenoid valve 6.8 - 9.2 Ω
3 - 12 Timing control valve 10.8 - 11.2 Ω
5 - 12 EGR control solenoid valve No. 2 36 - 44 Ω (at 20_C)
9 - 12 EGR control solenoid valve No. 1 36 - 44 Ω (at 20_C)
13 - Body earth Engine-ECU earth Continuity (0 Ω)
26 - Body earth
14 - 12 Throttle solenoid valve 29 - 35 Ω (at 20_C)
31 - 61 Idle switch Continuity (Replace the foot from the acceleratorpedal)
No continuity (when accelerator pedal is fullydepressed)
51 - 61 Pump speed sensor 1.36 - 1.84 kΩ
73 - 74 Control sleeve position sensor 5.6 - 6.2 Ω
73 - 75 5.6 - 6.2 Ω
74 - 75 11.2 - 12.4 Ω
77 - 78 Timer piston position sensor 160 - 168 Ω
76 - 77 80 - 84 Ω
76 - 78 80 - 84 Ω
DIESEL FUEL <4D5-step III> - Troubleshooting13E-50
Terminal No. Normal condition (Check condition)Inspection item
83 - 61 Engine coolant temperature sensor 5.1 - 6.5 kΩ (when the engine coolant temperature is0_C)
2.1 - 2.7 kΩ (when the engine coolant temperature is20_C)
0.9 - 1.3 kΩ (when the engine coolant temperature is40_C)
0.26 - 0.36 kΩ (when the engine coolant temperatureis 80_C)
87 - 61 Fuel temperature sensor 5.1 - 6.5 kΩ (when the fuel temperature is 0_C)
2.1 - 2.7 kΩ (when the fuel temperature is 20_C)
0.9 - 1.3 kΩ (when the fuel temperature is 40_C)
0.26 - 0.36 kΩ (when the fuel temperature is 80_C)
88 - 61 Boost air temperature sensor 5.3 - 6.7 kΩ (when the intake air temperature is 0_C)
2.3 - 3.0 kΩ (when the intake air temperature is 20_C)
1.0 - 1.5 kΩ (when the intake air temperature is 40_C)
0.30 - 0.42 kΩ (when the intake air temperature is80_C)
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-51
INSPECTION PROCEDURE USING AN ANALYZERCRANK ANGLE SENSORAn analyzer can be used to observe the wave pattern in order to visually check the crankshaft rotationand abnormalities in the sensor output.
Measurement Method1. Disconnect the crank angle sensor connector and connect
the special tool (test harness: MD998478) in between.2. Connect the analyzer probe to terminal No. 2 of the crank
angle sensor connector (black clip of special tool).
NOTEWhen measuring at the engine-ECU connector, connectthe analyzer probe to terminal No. 89.
Standard Wave PatternObservation conditions
Crank angle sensor
Probe select switch × 1
TIME/DIV. 10 ms
VOLTS/DIV. 2 V
AC - GND - DC DC
Other -
Engine r/min Idle speed
Analyzer
CHI
DIESEL FUEL <4D5-step III> - Troubleshooting13E-52
Standard wave pattern
(V)
ATDC90_
1 engine revolution
BTDC35_
Crank anglesensor outputwave pattern
TDC TDC
5
0
BTDC9_ATDC12_
T
Explanation of Wave PatternThe crank angle sensor detects the rotation of a sensing plate. Accordingly, the period T (seconds) canbe measured and the engine speed can be calculated from the following formula.
Engine speed (r/min) = 24T (sec)
× 60 =30
T (sec)
Wave Pattern Observation PointsCheck that cycle time T becomes shorter and the frequency increases when the engine speed is increased.
Examples of Abnormal Wave PatternsD Example 1
Cause of problem
Sensor interface malfunction
Wave pattern characteristics
Rectangular wave pattern is output even when the engineis not started.
D Example 2
Cause of problem
Abnormality in sensor disk
Wave pattern characteristics
Wave pattern is displaced to the left or right.
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-53
PUMP SPEED SENSORAn analyzer can be used to observe the wave pattern in order to visually check the pump shaft rotationand abnormalities in the sensor output.
Measurement Method1. Disconnect the pump speed sensor connector and
connect the special tool (test harness: MD991658) inbetween. (All terminals should be connected.)
2. Connect the analyzer probe to terminal No. 1 of the pumpspeed sensor connector (black clip of special tool).
NOTEWhen measuring at the engine-ECU connector, connectthe analyzer probe to terminal No. 51.
Standard Wave PatternObservation conditions
Pump speed sensor
Probe select switch Set according to the probe.
TIME/DIV. About 10 msec
VOLTS/DIV. About 0.5 V
AC - GND - DC DC
Engine r/min Idle speed
Sensor side connectorAnalyzer
DIESEL FUEL <4D5-step III> - Troubleshooting13E-54
Standard wave pattern
(V)
T
Pump speed sensoroutput wave pattern
1 cranking
0.85
-0.85
Explanation of Wave PatternThe pump speed sensor detects the rotation of the pump shaft. Accordingly, the period T (seconds)can be measured and the engine speed can be calculated from the following formula.
Engine speed =2
4 × T (sec)× 60
Wave Pattern Observation PointsCheck that cycle time T becomes shorter and the frequency increases when the engine speed is increased.
Examples of Abnormal Wave PatternsD Example 1
Cause of problem
Malfunction or open circuit in sensor
Wave pattern characteristics
No signal is output even when engine is started.
D Example 2
Cause of problem
Incorrect gap between sensor and sensing gear plate
Wave pattern characteristics
No signal is output even when engine is started, or signalamplitude is small.
DIESEL FUEL <4D5-step III> - On-vehicle Service 13E-55
ON-VEHICLE SERVICEINJECTION TIMING CHECK ANDADJUSTMENTRefer to GROUP 11B - Engine Adjustment.
IDLE SPEED CHECK AND ADJUSTMENTRefer to GROUP 11B - Engine Adjustment.
INJECTION NOZZLE CHECK ANDADJUSTMENTCautionNever touch the injection spray that is injected from thenozzle.
FUEL INJECTION INITIAL PRESSURE CHECK1. Install the injection nozzle to a nozzle tester.2. Move the lever of the nozzle tester 2 - 3 times to inject
fuel and to bleed the air.3. Gently press down the lever of the nozzle tester, and
take a reading of the indication value on the pressuregauge at the point where the needle slowly rises andthen suddenly drops.
Standard value (Fuel injection initial pressure):14,710 - 15,490 kPa
4. If the fuel injection initial pressure is outside the standardvalue, disassembly the nozzle holder to clean it, andthen change the thickness of the shim to adjust the fuelinjection initial pressure.
NOTE(1) For disassembly, reassembly and adjustment of the
nozzle holder, refer to P.13B-8.(2) There are 10 shims for adjustment, with thicknesses
in the range of 0.10 - 0.80 mm.(3) When the shim thickness is increased by 0.1 mm,
the fuel injection initial pressure increases by 2,350kPa.
INJECTION SPRAY CONDITION CHECK1. Move the lever of the nozzle tester rapidly (4 - 6 times
per second) to eject the fuel continuously. Check to besure that the injection spray comes out evenly in a coneshape (injection spray angle is 0_). The injection spraypatterns shown in the illustration at left are wrong.A. Injection angle is tool largeB. BiasC. Intermittent fuel injection
A B C
DIESEL FUEL <4D5-step III> - On-vehicle Service13E-56
2. Check to be sure that no fuel drips after injection iscompleted.
3. If there are any drips, disassemble the nozzle, clean itand reinspect, or replace the nozzle.
NOZZLE FUEL-TIGHT CHECK1. Gently raise the lever of the nozzle tester until the pressure
inside the nozzle (value displayed on pressure gauge)becomes 12,750 - 13,730 kPa, and after holding thispressure for approximately 10 seconds, check to be surethat there are no fuel leaks from the nozzle.
2. If there are any leaks, disassemble the injection nozzle,clean it and re-inspect, or replace the nozzle.
ACCELERATOR PEDAL POSITION SENSOR(APS) ADJUSTMENTCaution(1) APS is properly adjusted in the factory. Therefore,
APS should not be moved carelessly.(2) If the adjustment is not done correctly, carry out a
new adjustment in the following procedure:
1. Remove accelerator pedal complete.
2. Connect MUT-II to the diagnosis connector. If MUT-IIis not used, the following operation should be done:(1) Disconnect APS connector and connect the special
tool (test harness: MB991658) between twoconnectors.(Be careful not to take a wrong terminal No.)
(2) Connect a digital voltmeter between APS connectorterminal No. 3 (APS main output) and terminal No.1 (APS main earth).
3. Loosen the APS mounting bolt to make it temporarilytightened.
APS
Connector at theequipment
Acceleratorpedal
APS
MB991658
DIESEL FUEL <4D5-step III> - On-vehicle Service 13E-57
4. Ensure that the accelerator pedal arm contacts the closingstopper.
5. Use the adjusting screw to make the clearance A (shownin the illustration) between 0.5 and 0.93 mm.
6. Secure the adjusting screw with the lock nut.7. Turn the ignition switch to “ON” position. (Engine does
not start.)8. Turn APS to make APS (main) output the standard value.
Standard value: 0.985 - 1.085 V
9. Tighten the APS mounting bolt securely.10. Install the accelerator pedal complete.
CONTROL RELAY CONTINUITY CHECK
Terminals to beconnected
Battery voltage Normalconation
2 - 4 Not applied Continuity
1 - 3 Not applied No continuity
Connect a positive batterycable to No.2 terminal and anegative battery cable to No.4terminal, respectively.
Continuity
ACCELERATOR PEDAL POSITION SENSOR(APS) CHECK1. Disconnect the APS connector.2. Measure the resistance between APS connector terminal
No. 2 [APS main power supply] and the terminal No.1 [APS main earth] as well as the resistance betweenterminal No. 8 [APS sub power supply] and terminal No.7 [APS sub earth].
Standard value: 3.5 - 6.5 kΩ
3. Measure the resistance between APS connector terminalNo. 2 (APS main power supply) and the terminal No.3 (APS main output) as well as the resistance betweenterminal No. 8 (APS sub power supply) and terminal No.7 (APS sub output).
Normal condition:
Step on the accelerator pedalslowly.
Resistance smoothlychanges in proportion to thetravel of the acceleratorpedal.
Acceleratorpedal arm
Fully closedstopper
Adjusting screw
APS
Clearance A
Connector at thecontrol replay
Control relay
APS
Connector at theequipment
Acceleratorpedal
DIESEL FUEL <4D5-step III> - On-vehicle Service13E-58
4. If the APS is out of the range of the standard value orthe resistance does not change smoothly, replace APS.
NOTEMake an adjustment on APS after replacement. (Referto P.13E-56.)
IDLE SWITCH CHECK1. Disconnect the accelerator pedal position sensor (APS)
connector.2. Check the continuity between the idle switch connector
terminal No. 4 (idle switch) and terminal No. 5 (earth).
Normal condition:
Accelerator pedal Continuity
Step on None
Release Yes
3. Replace APS if it is inoperative.
NOTEMake an adjustment on APS after replacement. (Referto P.13E-56.)
BOOST AIR TEMPERATURE SENSOR (INTAKEAIR TEMPERATURE SENSOR) CHECK1. Remove the boost air temperature sensor.2. Measure the resistance at the boost air temperature
sensor connector terminal.
Standard value:2.3 - 3.0 kΩ (at 20_C)0.30 - 0.42 kΩ (at 80_C)
3. Measure the resistance at the sensor part being warmedup by a hair dryer.
Normal condition:
Temperature (_C) Resistance value (kΩ)
Rising Become smaller
4. If the resistance is not within the range of the standardvalue or does not change at all, replace the boost airtemperature sensor.
Connector at theequipment
Acceleratorpedal
APS
Boost air temperaturesensor
Boost air temperaturesensor
DIESEL FUEL <4D5-step III> - On-vehicle Service 13E-59
NOTEReplace the gasket as well.
5. Tighten the boost air temperature sensor to the specifiedtorque.
Tightening torque: 14 ± 1 N·m
ENGINE COOLANT TEMPERATURE SENSORCHECK1. Remove the engine coolant temperature sensor.
2. Measure the resistance between the terminals of theconnectors while immersing the sensor part of the enginecoolant temperature sensor in the hot water.
Standard value:2.1 - 2.7 kΩ (at 20_C)0.26 - 0.36 kΩ (at 80_C)
3. If the resistance is not within the range of the standardvalue, replace the engine coolant temperature sensor.
4. Apply the sealant to the thread of the engine coolanttemperature sensor and tighten it to the specified torque.
Sealant:3M Nut Locking Part No. 4171 or equivalent
Tightening torque: 36 ± 6 N·m
EVACUATION OF WATER FROM FUEL FILTERWater is in the filter when fuel filter warning lamp illuminates.Evacuate water by the following procedure.1. Loosen the water level sensor.2. After water is evacuated by using a hand pump, tighten
the water level sensor to the specified torque.
Tightening torque: 2.5 ± 0.5 N·m
Engine coolanttemperature sensor
Hand pump
Water level sensor
DIESEL FUEL <4D5-step III> - On-vehicle Service13E-60
FUEL FILTER CARTRIDGE REPLACEMENTRefer to GROUP 13D of the 2001 PAJERO Workshop ManualPub. No. PWJE0001 (1/2)
EVACUATION OF AIR FROM FUEL LINEWhen the following service work(s) is done, refill the fueltank and then evacuate air from the fuel line.D Fuel hose is removedD Fuel filter is replacedD Fuel injection nozzle is removedD If necessary for access, fuel is drained from the fuel tank.1. Loosen the fuel filter air plug.2. Cover the circumference of the air plug hole with cloth
and use a manual pump repeatedly until no bubbles comeout of the plug hole, then tighten the air plug to the specifiedtorque.
Tightening torque: 6.0 ± 1.0 N·m
3. Repeat until the hand pump operation becomes stiff.
EGR VALVE POSITION SENSOR CHECK1. Disconnect the EGR valve position sensor connector.2. Measure the resistance between the EGR valve position
sensor side connector terminal No. 2 and terminal No.3.
Standard value: 3.5 - 6.5 kΩ
3. Install a hand vacuum pump to the EGR valve nipple.4. Measure the resistance between the EGR valve position
sensor-side connector terminal No. 1 and terminal No.3 when a negative pressure is applied.
Normal condition:
Slowly increase the negativepressure to 60 kPa.
Changes smoothly inproportion to the negativepressure
5. If the resistance is outside the standard value, or if itdoesn’t change smoothly, replace the EGR valve positionsensor.
Hand pump
Air plug
Equipmentside connector
EGR valvepositionsensor
DIESEL FUEL <4D5-step III> - On-vehicle Service 13E-61
FUEL INJECTION PUMP CHECKFUEL CUT SOLENOID VALVE CHECKOperation noise check1. Attach the sound scope to the fuel cut solenoid valve
to check for running noise when the ignition switch is“ON” position.
Coil resistance check1. Disconnect the injection pump connector (12 pin).2. Measure the resistance between terminal No. 1 (fuel cut
solenoid valve) and the injection pump body.
Standard value: 6.8 - 9.2 Ω
TIMING CONTROL VALVE CHECK1. Disconnect the injection pump connector (12 pin).2. Measure the resistance between terminal No. 5 and
terminal No. 9.
Standard value: 10.8 - 11.2 Ω
GE ACTUATOR (ELECTRONIC GOVERNOR) CHECK1. Disconnect the injection pump connector (12 pin).2. Measure the resistance between terminal No. 6 and
terminal No. 10.
Standard value: 0.64 - 0.72 Ω
FUEL TEMPERATURE SENSOR CHECK1. Disconnect the injection pump connector (12 pin).2. Measure the resistance between terminal No. 7 and
terminal No. 11.
Standard value: 1.4 - 2.6 kΩ
Fuel cutsolenoidvalve
Connector at theequipment (12 pin)
Fuel cut solenoidvalve
Timingcontrolvalve
Connector at theequipment (12 pin)
Connector at theequipment (12 pin)
Connector at theequipment (12 pin)
DIESEL FUEL <4D5-step III> - On-vehicle Service13E-62
CONTROL SLEEVE POSITION SENSOR CHECK1. Disconnect the injection pump connector (12 pin).2. Measure the resistance between the following terminals.
Standard value:
Terminal No. 4 - Terminal No. 12 11.2 - 12.4 Ω
Terminal No. 4 - Terminal No. 8 5.6 - 6.2 Ω
Terminal No. 8 - Terminal No. 12 5.6 - 6.2 Ω
TIMER PISTON POSITION SENSOR CHECK1. Disconnect the timer piston position sensor connector.2. Measure the resistance between the following terminals.
Standard value:
Terminal No. 1 - Terminal No. 2 160 - 168 Ω
Terminal No. 1 - Terminal No. 3 80 - 84 Ω
Terminal No. 2 - Terminal No. 3 80 - 84 Ω
PUMP SPEED SENSOR CHECK1. Disconnect the pump speed sensor connector.2. Measure the resistance between terminals No. 1 and
No. 2.
Standard value: 1.36 - 1.84 kΩ
THROTTLE SOLENOID VALVE CHECKINSPECTION PROCEDURE1. Disconnect the vacuum hose (black and yellow stripe)
from the solenoid valve.2. Disconnect the harness connector.
3. Install a hand vacuum pump to solenoid valve nippleB.
4. Use jumper leads to connect the solenoid valve terminalsand the battery terminals.
5. Disconnect the jumper lead from the battery ( - ) terminal,and then apply negative pressure to check theair-tightness.
Connector at theequipment (12 pin)
Connector atthe equipment
Timer piston position sensor
Pump speed sensor-sideconnector
Pump speed sensor
Throttle solenoidvalve
Battery
BA
DIESEL FUEL <4D5-step III> - On-vehicle Service 13E-63
Standard value:
Jumper lead Nipple A Normal condition
Connected Open Negative pressureleaks
Closed Negative pressuremaintained
Disconnected Open Negative pressuremaintained
COIL RESISTANCE CHECK1. Measure the resistance between the solenoid valve
terminals.
Standard value: 29 - 35 Ω (at 20_C)
THROTTLE ACTUATOR CHECK1. Remove the vacuum hose (yellow stripe) from the throttle
actuator and connect a hand vacuum pump to the throttleactuator nipple.
2. Check that the actuator rod moves smoothly whenapplying vacuum gradually.Also, check that the vacuum is maintained when applying53 kPa of vacuum.
VARIABLE GEOMETRY SOLENOID VALVECHECKRefer to GROUP 15 - On-vehicle Service.
EGR CONTROL SOLENOID VALVE CHECKRefer to GROUP 17 - Emission Control System <4D5-stepIII>.
Throttle actuator
DIESEL FUEL <4D5-step III> - Fuel Injection Nozzle/Fuel Injection Pump13E-64
FUEL INJECTION NOZZLEREMOVAL AND INSTALLATIONRefer to GROUP 13C of the 2001 PAJERO Workshop Manual Pub. No. PWJE0001 (1/2)
FUEL INJECTION PUMPREMOVAL AND INSTALLATION
Pre-removal OperationD Engine Coolant Draining.D Battery and Battery Tray RemovalD Timing Belt Removal (Refer to GROUP 11B.)D Air Pipe Removal (Refer to GROUP 15 - Intake
and Exhaust Manifold, Turbocharger <4D5>.)
Post-installation OperationD Air Pipe Installation (Refer to GROUP 15 - Intake
and Exhaust Manifold, Turbocharger <4D5>.)D Timing Belt Installation (Refer to GROUP 11B.)D Battery and Battery Tray InstallationD Engine Coolant Supplying.D Injection Timing Adjustment
(Refer to GROUP 11B - On-vehicle Service.)
1
3
4
56
72
10 ± 2 N·m
5.0 ± 1.0 N·m
5.0 ± 1.0 N·m
30 ± 7 N·m
30 ± 7 N·m
19 ± 3 N·m
23 ± 3 N·m
83 ± 5 N·m
12 ± 1 N·m
(Engine oil)
Removal steps1. Fuel injection pump connector2. Fuel hoses connection
AA" 3. Fuel injection pipe4. Engine oil level gauge guide and
oil level gauge assembly
AB" 5. Fuel injection pump sprocket6. Flange7. Fuel injection pump
DIESEL FUEL <4D5-step III> - Fuel Injection Pump 13E-65
REMOVAL SERVICE POINTSAA" INJECTION PIPE REMOVALLoosen the nuts at the end of the injection pipe with thedelivery holder (for pump side) and injection nozzle assembly(for nozzle side) retained by a spanner, etc.
AB"FUEL INJECTION PUMP SPROCKET REMOVAL1. Use the special tool to stop the fuel injection pump sprocket
from turning, and remove the fuel injection pump sprocketmounting bolt.
2. Use the special tool to remove the fuel injection pumpsprocket.
Caution(1) Do not hit pump drive shaft with hammer, etc.(2) When holding injection pump, do not allow to
dangle by holding accelerator lever or fast idlelever.Do not remove these levers. Removal will causeinjection pump malfunction.
Delivery holderNut
MB990767
MD998719
MD998388
DIESEL FUEL <4D5-step III> - Crankshaft Position Sensor/Engine-ECU13E-66
CRANKSHAFT POSITION SENSORREMOVAL AND INSTALLATION
Pre-removal and Post-installation OperationD Timing Belt Cover Removal and Installation
(Refer to GROUP 11B.)
Crankshaftposition sensor
9.0 ± 1.0 N·m
ENGINE-ECUREMOVAL AND INSTALLATIONRemoval and installation is the same as for 6G7 engine or 4M4 engine. Refer to GROUP 13A or 13Cof the 2001 PAJERO Workshop Manual Pub. No. PWJE0001 (1/2)