<4D5-STEP III>
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13E-1
DIESEL FUEL
<4D5-STEP III>
CONTENTS
GENERAL
OUTLINE OF CHANGE
An electronically-controlled injection pump has been added in order to comply with Regulation STEP
III. Due to this, the following service procedures have been added.
GENERAL INFORMATION
The electronically-controlled fuel injection system consists of sensors which detect the condition of the
diesel engine, an engine-ECU which controls the system based on signals from these sensors, and actuators
which operate according to control commands from the engine-ECU.
The engine-ECU carries out operations such as fuel injection rate control, fuel injection timing control
and idle up control. In addition, the engine-ECU is equipped with several self-diagnosis functions which
make troubleshooting easier in the event that a problem develops.
FUEL INJECTION RATE CONTROL
The fuel injection completion timing is controlled by means of a solenoid-type spill valve to ensure that
the optimum amount of fuel is supplied to the engine in accordance with gradual changes in the engine
running 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 reaches
the target value for fuel injection, the solenoid-type spill valve turns off. When the solenoid-type spill
valve turns off, the fuel under high pressure inside the plunger is leaked out into the pump chamber
and fuel injection is completed.
FUEL INJECTION TIMING CONTROL
The position of the injection pump timer piston is controlled so that fuel injection is carried out at the
optimum 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 located
in 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 CONTROL
Controlling the fuel injection rate in accordance with the engine running condition maintains the idle speed
at the optimum condition.
SELF-DIAGNOSIS FUNCTION
D 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 FUNCTIONS
1. Power Supply Control
When the ignition switch is turned to ON, the relay turns on and power is supplied to components
such as the timing control solenoid valve.
2. Intake Air Throttle Control
When the engine-ECU detects an abnormality in any of the sensors or actuators, the throttle valve
is half opened to restrict the amount of intake air in order to prevent the vehicle from running away.
3. A/C Relay Control
Turns the compressor clutch of the A/C ON and OFF
4. Condenser Fan Motor Relay Control
Controls the condenser fan motor relay based on the A/C switch, engine coolant temperature and
vehicle speed input signals.
5. Glow Control
Refer to GROUP 16.
6. EGR Control
Refer to GROUP 17.
DIESEL FUEL <4D5-step III> - General Information 13E-3
CONTROL SYSTEM DIAGRAM
L1. Pump speed sensor Engine- l1. GE actuator (electronic governor)
L2. Crank angle sensor ECU l2. Timing control valve
L3. Engine coolant temperature sensor l3. EGR control solenoid valve No. 1
L4. Boost pressure sensor l4. EGR control solenoid valve No. 2
L5. Fuel temperature sensor l5. Throttle solenoid valve
L6. Boost air temperature sensor l6. Fuel cut solenoid valve
L7. Control sleeve position sensor l7. Variable geometry solenoid valve
L8. Timer piston position sensor
L9. EGR valve position sensor D Control relay
L10. Variable geometry control pressure sensor D A/C relay
D Condenser fan relay
D Accelerator pedal position sensor (main) D Glow indicator lamp
D Accelerator pedal position sensor (sub) D Glow plug relay
D Idle switch D Engine warning lamp
D Power supply D Diagnosis output
D Ignition switch-IG
D Ignition switch-ST
D Vehicle speed sensor
D A/C switch
D A/C relay switch
D Injection volume adjusting ROM
D Barometric pressure sensor (ECU built-in)
Vacuum pump
l5 Throttle solenoid valve
l3 l7
EGR control Variable geometry Alternator
solenoid valve No. 1 solenoid valve
Throttle
actuator
To variable
geometry actuator L7 Control
Boost air sleeve
L6 l4 EGR control L4 Boost pressure
temperature sensor solenoid position L5 Fuel
sensor
valve No. 2 sensor temperature
L3 Engine coolant sensor
temperature sensor
L9 EGR L1 Pump speed
valve position l6 Fuel cut sensor
sensor solenoid
valve
EGR valve
Variable geometry
turbocharger
l1 GE actuator
L10 Variable geometry control
pressure sensor L8 Timer piston
To variable geome- l2 Timing control position
Variable try solenoid valve valve sensor
L2 Crank angle
geometry sensor
actuator
Catalytic converter
13E-4 DIESEL FUEL <4D5-step III> - Service Specifications/Sealant
SERVICE SPECIFICATIONS
Item 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 k 3.5 - 6.5
Boost air temperature
p sensor (Intake
( air temperature
p When the temperature is 20_C 2.3 - 3.0
sensor)) resistance
i t k When the temperature is 80_C 0.30 - 0.42
Engine
g coolant temperature
p sensor resistance k When the temperature is 20_C 2.1 - 2.7
When the temperature is 80_C 0.26 - 0.36
Fuel cut solenoid valve resistance 6.8 - 9.2
Timing control valve resistance 10.8 - 11.2
Timer piston
p position
p sensor resistance Connector terminals No. 1 - No. 2 160 - 168
Connector terminals No. 1 - No. 3 80 - 84
Connector terminals No. 2 - No. 3 80 - 84
Control sleeve position
p sensor resistance Connector terminals No. 4 - No. 12 11.2 - 12.4
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 Connector terminals No. 6 - No. 10 0.64 - 0.72
Fuel temperature sensor resistance k Connector terminals No. 7 - No. 11 1.4 - 2.6
Pump speed sensor resistance k 1.36 - 1.84
Throttle solenoid valve resistance 36 - 44
SEALANT
Item 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 sub Electronically controlled fuel injection system
assembly check
MB990767 End yoke holder Holding the fuel injection pump sprocket
TROUBLESHOOTING
STANDARD FLOW OF DIAGNOSTIC
TROUBLESHOOTING
Refer to GROUP 00 - How to Use Troubleshooting/Inspection
Service Points.
NOTE
When replacing the engine-ECU, replace immobilizer-ECU
and ignition key as well at the same time.
Caution
If the above-mentioned diagnosis code number with the asterisks can be displayed along with another
code number in parentheses simultaneously, check the other code number before replacing the
engine-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) Probable cause
system
Range of Check D Accelerator pedal position sensor inoperative
D Ignition switch: ON, accelerator pedal position sensor (sub) operative, except D Accelerator pedal position sensor open circuit,
for during engine cranking short circuit, or connector contact inoperative
Set Conditions D Engine-ECU inoperative
D Accelerator pedal position sensor output voltage is as below for 1 second:
Sub side: 0.2 V or more, less than 2.5 V
Main side: 4.5 V or more
or
Sub or main side: less than 0.2 V
Range of Check
D Ignition switch: ON, except for during engine cranking
Set Conditions
D 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 in
sensor output voltage between the main and sub is 1 V or higher, or idle
switch: ON, and sensor main output voltage is 1.875 V or higher.
NG
Accelerator pedal position sensor check Replace
(Refer to P.13E-57.)
OK
NG NG
Measure at D-135 accelerator pedal position Check the following connector: D-113 Repair
sensor connector OK
D Disconnect the connector and measure
at the harness side. Check the trouble symptoms.
D Voltage between 2 and earth NG
(Ignition switch: ON) NG
OK: 4.5 - 5.5 V Check the harness between the Repair
D Continuity between 1 and earth engine-ECU and the accelerator pedal
OK: Continuity position sensor connector.
OK
OK
Replace the engine-ECU.
NG NG
Measure at D-113 engine-ECU connector Check the following connectors: Repair
D Connect the connector. D-113, D-135
D Voltage between 84 and the earth OK
(Ignition switch: ON)
OK: 0.9 - 1.1 V Check the trouble symptoms.
(Throttle lever idling position) NG
4.1 V or higher
(Throttle lever fully opened position) Replace the engine-ECU.
OK
NG
Check the following connector: D-113 Repair
OK
NG
Check the harness between the Repair
engine-ECU and the accelerator pedal
position sensor connector.
OK
NG NG
Measure at B-08 boost pressure Measure at B-08 boost pressure Check the following connector:
sensor connector sensor connector D- 112
D Connect the connector. D Disconnect the connector and
(Test harness: MB991348 used) measure at the harness side. OK NG
D Voltage between 1 and the earth D Voltage between 3 and the earth Repair
(Engine: Idling) (Ignition switch: ON)
Check the trouble symptoms.
OK: 1.3 - 1.7 V OK: 4.5 - 5.5 V
D Voltage between 1 and the earth D Continuity between 2 and the NG
OK: When the accelerator pedal earth
is suddenly pressed from OK: Continuity
the idling condition, the Check
Replacethetheharness between the
engine-ECU.
OK
voltage temporarily in- engine-ECU and the boost pressure
creases from 1.3 V to 1.7 sensor connector.
V. Check the following connector: NG NG
B-08 Repair OK Repair
OK
OK
Replace the engine-ECU.
Check the trouble symptoms.
NG
NG
Check the trouble symptoms. Replace the engine-ECU.
NG
Fuel temperature sensor check (Refer to Replace the injection pump.
P.13E-61.)
OK
NG NG
Measure at B-38 fuel temperature sensor Check the following connectors: Repair
connector D-112, D-113
D Disconnect the connector and measure at OK
the harness side.
D Voltage between 11 and the earth Check the trouble symptoms.
(Ignition switch: ON) NG
OK: 4.5 - 5.5 V NG
Check the harness between the
D Continuity between 7 and the earth Repair
engine-ECU and the fuel temperature
OK: Continuity
sensor connector.
OK
OK
Check the following connector: B-38 Replace the engine-ECU.
OK NG
Repair
NG
Check the trouble symptoms. Replace the engine-ECU.
13E-12 DIESEL FUEL <4D5-step III> - Troubleshooting
NG
Engine coolant temperature sensor check Replace
(Refer to P.13E-59.)
OK
NG NG
Measure at B-56 engine coolant temperature Check the following connectors: Repair
sensor connector D-112, D-113
D Disconnect the connector and measure at OK
the harness side.
D Voltage between 1 and the earth Check the trouble symptoms.
(Ignition switch: ON) NG
OK: 4.1 - 4.9 V NG
D Continuity between 2 and the earth Check the harness between the Repair
OK: Continuity engine-ECU and the engine coolant
temperature sensor connector.
OK
OK
Check the following connector: B-56 Replace the engine-ECU.
OK NG
Repair
NG
Check the trouble symptoms. Replace the engine-ECU.
Code No. 16 Boost air temperature sensor (intake air Probable cause
sensor) system
Range of Check D Boost air temperature sensor inoperative
D Ignition switch: ON, except for during engine cranking D Boost air temperature sensor open circuit, short
Set Conditions circuit, or connector contact inoperative
D The sensor output voltage for 3 seconds is 4.6 V or higher (the intake air D Engine-ECU inoperative
temperature is approximately - 45_C or lower).
or
D The sensor output voltage for 3 seconds is 0.3 V or lower (the intake air
temperature is approximately 110_C or higher).
NG
Boost air temperature sensor check Replace
(Refer to P.13E-58.)
OK
NG NG
Measure at B-49 boost air temperature Check the following connectors: Repair
connector D-112, D-113
D Disconnect the connector and measure at
OK
the harness side.
D Voltage between 1 and the earth Check the trouble symptoms.
(Ignition switch: ON)
OK: 4.0 - 5.3 V NG
D Continuity between 2 and the earth
OK: Continuity NG
Check the harness between the Repair
OK engine-ECU and the boost air temperature
sensor connector.
OK
NO
Is the speedometer working properly? Check the vehicle speed sensor circuit.
YES
OK NG
Measure at engine-ECU connector D-113. Check the following Repair
D Disconnect the connector. connector:
D Voltage between terminal 86 and earth (Ignition switch: ON) D- 113
OK: When the vehicle is pushed to move, the cycle change OK
of 0.5 V is repeated.
Check trouble symptoms.
NG
NG
NG
Check the following connectors: Repair Replace the engine-ECU.
C-09, D-113, E-113
OK
NG
Check trouble symptom. Check the harness wire between the engine-ECU and the vehicle
speed sensor connector, and repair if necessary.
13E-14 DIESEL FUEL <4D5-step III> - Troubleshooting
NG
Pump speed sensor check (Refer to Replace the injection pump.
P.13E-62.)
OK
NG NG
Measure at engine-ECU connector D-112. Check the following connector: Repair
D Connect the connector. B-36, D-112
D Voltage between 51 - 61. OK
(Engine: idling and then raced)
OK: Voltage increases from the voltage Check the trouble symptoms.
when engine is idling
NG
OK
Check the harness between the
Check the following connector: D-112 engine-ECU and the pump speed sensor
OK NG connector, and repair if necessary.
Repair
Check trouble symptoms.
NG
NG (1) NG
Measure at crank angle sensor Measure at crank angle sensor Check the harness between the
connector B-52. connector B-52. crank angle sensor and the engine
D Connect the connector. D Disconnect the connector and control relay, and repair if necessary.
(Test harness: MB998478 used) measure at the harness side.
D Voltage between 2 (black clip) (1) Voltage between 3 and the earth (2) NG
Check the following connector:
and the earth (Ignition switch: ON)
D-113
OK: 0.4 - 4.0 V OK: System voltage
(Engine: cranking) (2) Continuity between 2 and the OK NG
1.5 - 2.5 V earth (Ignition switch: ON) Repair
(Engine: idling) OK: 4.6 - 5.4 V
(3) Continuity between 1 and the Check the trouble symptoms.
OK earth NG
OK: Continuity
Check the harness between the
Replace the engine-ECU. (3) NG engine-ECU and the crank angle
sensor.
OK OK NG
Repair
Check the following connector:
B-52 Replace the engine-ECU.
OK NG
Repair
Check the harness between the
Check the trouble symptoms. crank angle sensor and the earth,
and repair if necessary.
NG
Replace the crank angle sensor.
13E-16 DIESEL FUEL <4D5-step III> - Troubleshooting
NG
Idle switch check (Refer to P.13E-58.) Replace
OK
NG NG
Measure at D-135 accelerator pedal position Check the following connectors: Repair
sensor connector D-111, D-112
D Disconnect the connector and measure at
the harness side. OK
D Voltage between 4 and the earth Check the trouble symptoms.
(Ignition switch: ON)
OK: 4.5 - 5.5 V NG
D Continuity between 5 and the earth NG
OK: Continuity Check the harness between the Repair
engine-ECU and the accelerator pedal
OK position sensor connector.
Check the following connector: D-135 OK
OK NG Replace the engine-ECU.
Repair
Check the trouble symptoms.
NG
NOTE:
*: This voltage is derived from the input pulse signal converted in the engine-ECU and cannot be measured.
NG
Timer piston position sensor check Replace injection pump assembly.
(Refer to P.13E-62.)
OK
NG NG
Check the following connector: B-39 Check the following connector: D-113 Repair
OK OK
NG
MUT-II Data list Replace the engine-ECU.
19 Injection timing (command value)
(Refer to P.13E-41.)
OK
OK
MUT-II Data list Replace the engine-ECU.
18 Actual injection timing (Refer to
P.13E-41.)
NG Check the trouble symptoms.
NG
NOTE:
*: This voltage is derived from the input pulse signal converted in the engine-ECU and cannot be measured.
NG
Control sleeve position sensor check (Refer Replace injection pump assembly.
to P.13E-62.)
OK
NG NG
Check the following connector: B-38 Check the following connector: D-113 Repair
OK OK
NG
Accelerator pedal position sensor check Replace
(Refer to P.13E-57.)
OK
NG NG
Measure at D-135 accelerator pedal position Check the following connector: Repair
sensor connector D-112
D Disconnect the connector and measure at
the harness side. OK
D Voltage between 8 and the earth Check the trouble symptoms.
(Ignition switch: ON)
OK: 4.5 - 5.5 V NG
D Continuity between 7 and the earth NG
Check the harness between the Repair
OK: Continuity
engine-ECU and the accelerator pedal
OK position sensor connector.
OK
NG
Check the following connector: D-135 Repair
OK
Check the trouble symptoms.
NG
NG
Throttle solenoid valve check Replace
(Refer to P.13E-62.)
OK
NG
Throttle actuator check Replace
(Refer to P.13E-63.)
OK
NG
Measure at B-62 throttle solenoid valve Check and repair the harness between the
connector control relay and the solenoid valve
D Disconnect the connector and measure at connector.
the harness side.
D Voltage between 2 and the earth
(Ignition switch: ON)
OK: System voltage
OK
NG NG
Measure at D-110 engine-ECU connector Check the following connector: Repair
D Disconnect the connector and measure at B-62
the harness side.
D Voltage between 14 and the earth OK
(Ignition switch: ON)
OK: System voltage Check the trouble symptoms.
OK NG
NG
Timing control valve check Replace injection pump assembly.
(Refer to P.13E-61.)
OK
NG
Measure at B-38 injection pump assembly Check and repair the harness between the
connector. control relay and the injection pump
D Disconnect the connector and measure at assembly connector.
the harness side.
D Voltage between 5 and the earth
(Ignition switch: ON)
OK: System voltage
OK
NG NG
Measure at D-110 engine-ECU connector. Check the following connector: B-38 Repair
D Disconnect the connector and measure at
OK
the harness side.
D Voltage between 3 and the earth
Check the trouble symptoms.
(Ignition switch: ON)
OK: 11 V or higher NG
OK
Check and repair the harness between the
engine-ECU and the injection pump
assembly connector.
NG
Check the following connector: D-110 Repair
OK
NG
Fuel system blockage check Replace
D Fuel filter blocked
D Fuel hose blocked or bent
D Fuel tank filter blocked
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
13E-22 DIESEL FUEL <4D5-step III> - Troubleshooting
NG NG
Measure at B-37 injection volume adjusting Check the following connector: D-112 Repair
ROM connector.
OK
D Disconnect the connector and measure at
the harness side.
Check the trouble symptoms.
D Voltage between 3 and the earth
(Ignition switch: ON) NG
OK: 4.5 - 5.5 V NG
D Continuity between 4 and the earth Check the harness between the Repair
OK: Continuity engine-ECU and the injection volume
adjusting ROM connector.
OK
OK
NG
GE actuator check (Refer to P.13E-61.) Replace injection pump assembly.
OK
NG
Measure at B-38 injection pump assembly Check and repair the harness between the
connector. control relay and the injection pump
D Disconnect the connector and measure at assembly connector.
the harness side.
D Voltage between 6 and the earth
(Ignition switch: ON)
OK: System voltage
OK
NG NG
Measure at D-110 engine-ECU connector Check the following connector: B-38 Repair
D Disconnect the connector and measure at OK
the harness side.
D Voltage between 1 and the earth Check the trouble symptoms.
(Ignition switch: ON)
OK: 9 V or higher NG
OK Check and repair the harness between the
control relay and the injection pump
assembly connector.
NG
Check the following connector: D-110 Repair
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
13E-24 DIESEL FUEL <4D5-step III> - Troubleshooting
NG
Variable geometry actuator check (Refer to Replace
GROUP 15 - On-vehicle Service.)
OK
NG
Variable geometry solenoid valve check Replace
(Refer to GROUP 15 - On-vehicle Service.)
OK
NG
Measure at B-61 variable geometry solenoid Check and repair the harness between the
valve connector control relay and the solenoid valve
D Disconnect the connector and measure at connector.
the harness side.
D Voltage between 2 and earth
(Ignition switch: ON)
OK: System voltage
OK
NG NG
Measure at D-110 engine-ECU connector Check the following connector: B-61 Repair
D Disconnect the connector and measure at OK
the harness side.
D Voltage between 17 and earth Check the trouble symptoms.
(Ignition switch: ON)
OK: System voltage NG
OK Check and repair the harness between the
engine-ECU and the solenoid valve
connector.
NG
Check the following connector: D-110 Repair
OK
YES
Connect a boost gauge to the boost Replace the turbocharger assembly.
pressure sensor hose. When the vehicle is
driven at 1st gear with full throttle, does
boost pressure exceed 133 kPa
momentarily?
NO
NG
NG
EGR valve position sensor check Replace
(Refer to P.13E-60.)
OK
NG NG
Measure at B-66 EGR valve position sensor Check the following connector: D-112 Repair
connector.
OK
D Disconnect the connector and measure at
the harness side.
Check the trouble symptoms.
D Voltage between 2 and earth
(Ignition switch: ON) NG
OK: 4.5 - 5.5 V NG
D Continuity between 3 and earth Check the harness between the Repair
OK: Continuity engine-ECU and the EGR valve position
sensor connector.
OK
OK
NG NG
Measure at B-63 variable geometry Measure at B-63 variable geometry Check the following connector:
control pressure sensor connector. control pressure sensor connector D-112
D Connect the connector. D Disconnect the connector, and OK NG
(Use the test harness: measure at the harness side. Repair
MB991348) D Voltage between 3 and earth Check the trouble symptoms.
D Voltage between 1 and earth (Ignition switch: ON)
(Ignition switch: ON) OK: 4.8 - 5.2 V NG
OK: Altitude 0 m: 3.7 - 4.3 V D Continuity between 2 and earth
Check the harness between the
Altitude 1,200 m: 3.2 - 3.8 OK: Continuity
engine-ECU and the variable
V
OK geometry control pressure sensor
OK: 0.5 - 1.2 V when 80 kPa
connector.
of negative pressure is ap-
plied to the sensor OK NG
Repair
OK
Replace the engine-ECU.
NG
Check the following connector: Repair
B-63
OK
NG
Check the trouble symptoms. Check the harness between the
engine-ECU and the variable
NG geometry control pressure sensor
Measure at D-111 engine-ECU Check the following connector: connector.
connector B-63
D Connect the connector. OK NG
OK NG Repair
D Voltage between 45 and earth.
Repair
(Ignition switch: ON) Check the vacuum hose and pipe
OK: Altitude 0 m: 3.7 - 4.3 V Check the trouble symptoms. between the variable geometry
Altitude 1,200 m: 3.2 - 3.8 control pressure sensor and
NG
V alternator.
OK: 0.5 - 1.2 V when 80 kPa Check the harness between the OK NG
of negative pressure is ap- engine-ECU and the variable Repair
plied to the sensor geometry control pressure sensor Replace the variable geometry
OK connector, if necessary. control pressure sensor.
NG
Check the following connector:
Repair
D-111
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-27
Code No. 54 Immobilizer system Probable cause
Range of Check D Radio interference of encrypted codes
D Ignition switch: ON D Incorrect encrypted code
Set Conditions D Malfunction of harness or connector
D Improper communication between the engine-ECU and immobilizer-ECU D Malfunction of immobilizer-ECU
D 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.
Yes
Is there another ignition key near the ignition key that is inserted Remove the extra ignition key
in the ignition switch?
No NG
Check the trouble symptoms.
OK
Check the harness between the engine-ECU and immobilizer-ECU. Replace the engine-ECU and immobilizer-ECU.
NG
Repair
13E-28 DIESEL FUEL <4D5-step III> - Troubleshooting
Engine warning lamp Immediately after the ignition switch is ON, the engine 3 13E-30
related warning lamp does not turn on.
The engine warning lamp keeps on and does not turn off. 4 13E-30
Idling stability Low idling speed when the engine is cold (improper idling 8 13E-32
(idling inoperative) speed)
Idling stability The engine halts after running for a while. 12 13E-33
(idling sustainment in-
in
operative) The engine halts during idling. 13 13E-34
NG NG
Measure at D-23 diagnosis Check the following connectors: Repair
connector. D-27, D-211, D-210
D Voltage between 16 and the
earth OK
OK: System voltage
Check the trouble symptoms.
OK NG
NG
Measure at D-23 diagnosis Check and repair the earth line.
connector.
D Continuity between 4 and the
earth
D Continuity between 5 and the
earth
OK: Continuity
OK
Replace MUT-II.
INSPECTION PROCEDURE 2
No communication can be established between MUT-II Probable cause
and the engine-ECU.
Probable causes are shown in the following: D The power supply circuit of the engine-ECU
D The power is not supplied to the engine-ECU. inoperative
D The earth circuit of the engine-ECU inoperative D Engine-ECU inoperative
D The engine-ECU inoperative D Open circuit at the harness between the
D Communication between the engine-ECU and MUT-II inoperative engine-ECU and the diagnosis connector
NOTE
If the trouble symptoms persist even after implementing the above - mentioned inspection procedure
to 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.)
13E-30 DIESEL FUEL <4D5-step III> - Troubleshooting
INSPECTION PROCEDURE 3
Immediately after the ignition switch is ON, the engine Probable cause
warning lamp does not turn on.
The engine-ECU turns on the engine warning lamp for 5 seconds immediately D The engine warning lamp blown
after turning on the ignition switch to check the bulb for being blown. D The engine warning lamp circuit inoperative
If the engine warning lamp does not turn on immediately after turning the ignition D Engine-ECU inoperative
switch ON, problems shown in the right could exist.
NG
MUT-II Data list The engine-ECU power supply and
11 Engine-ECU power supply voltage the earth circuit check (Refer to
(Refer to P.13E-41.) P.13E-37, Inspection procedure 20.)
OK
OK NG
Measure at D-110 engine-ECU Check the following connector: Repair
connector. D-110
D Disconnect the connector and OK
measure at the harness side.
D Short circuit between 8 and the Check the trouble symptoms.
earth (Ignition switch: ON)
OK: The engine warning lamp turns NG
on.
NG Replace the engine-ECU.
INSPECTION PROCEDURE 4
The engine warning lamp keeps on and does not turn Probable cause
off.
The probable causes can be found in either the engine-ECU detecting the D Short circuit at the harness between the engine
malfunction in the sensor and/or the actuator, or the problem shown in the right warning lamp and the engine-ECU
takes place. D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
NG
Measure at D-02 combination meter connector. Check and repair the harness between the combination meter
D Disconnect the connector and measure at the harness and the engine-ECU connector.
side.
D Disconnect the engine-ECU connector D-110.
D Continuity between 38 and the earth
OK: No continuity
OK
NG
Check the following connector: E-13 Repair
OK
NG
Check the trouble symptoms. Replace the engine-ECU.
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-31
INSPECTION PROCEDURE 5
No initial combustion (unable to start) Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
glow system, and power supply system. D Injection pump inoperative
D Intake system inoperative
D Glow system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Check the following items in order:
(Refer to P.13E-40, 44.) D Glow plug, glow plug relay
D Battery
NG D Injection nozzle
D Throttle body assembly
Repair D Injection pump
D Compression pressure
D Existence of mixing foreign objects (water, kerosene) with
the fuel
INSPECTION PROCEDURE 6
Starting performance is bad when the engine is cold Probable cause
(unable to start)
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, intake system, and glow system. D Injection pump inoperative
D Fuel system inoperative
D Intake system inoperative
D Glow system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Glow plug, glow plug relay
D Injection nozzle, fuel filter
NG D Throttle body assembly
D Existence of starter switch signal input
Repair D Engine oil
D Injection pump
D Existence of mixing foreign objects (water, kerosene) with
the fuel
13E-32 DIESEL FUEL <4D5-step III> - Troubleshooting
INSPECTION PROCEDURE 7
Starting performance is bad regardless of whether the Probable cause
engine is hot or cold (unable to start)
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, and intake system. D Injection pump inoperative
D Fuel system inoperative
D Intake system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Injection nozzle, fuel filter
D Throttle body assembly
NG D Compression pressure
D Injection pump
Repair D Existence of mixing foreign objects (water, kerosene) with
the fuel
INSPECTION PROCEDURE 8
Low idling speed when the engine is cold (improper Probable cause
idling speed)
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
and fuel system. D Injection pump inoperative
D Fuel system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Injection pump
D Fuel filter
NG
Repair
INSPECTION PROCEDURE 9
High idling speed (improper idling speed) Probable cause
Probable causes can be found in troubles with control system and injection D Control system inoperative
pump. D Injection pump inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Injection pump
D Starter switch signal
NG
Repair
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-33
INSPECTION PROCEDURE 10
Low idling speed (improper idling speed) Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
and fuel. D Injection pump inoperative
D Fuel system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Injection nozzle
D Injection pump
NG
Repair
INSPECTION PROCEDURE 11
Idling instable (rough idling, hunting) Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, glow system, intake system, and EGR system. D Injection pump inoperative
D Fuel system inoperative
D Intake system inoperative
D Glow system inoperative
D EGR system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Glow plug, glow plug relay
D EGR system
NG D Injection nozzle
D Compression pressure
Repair D Valve clearance
D Throttle body assembly
D Injection timing
D Fuel line bleeding
D Injection pump
INSPECTION PROCEDURE 12
The engine stalls after running for a while. Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, and intake system. D Injection pump inoperative
D Fuel system inoperative
D Intake system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Throttle body assembly
D Fuel filter
NG D Injection pump
Repair
13E-34 DIESEL FUEL <4D5-step III> - Troubleshooting
INSPECTION PROCEDURE 13
The engine stalls during idling. Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
intake system, EGR system, and power supply. D Injection pump inoperative
D Fuel system inoperative
D Intake system inoperative
D EGR system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Power supply system
D Throttle body assembly
NG D EGR system
D Injection pump
Repair
INSPECTION PROCEDURE 14
Lack of output power Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, intake system, and EGR system. D Injection pump inoperative
D Fuel system inoperative
D Intake system inoperative
D EGR system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Injection nozzle, fuel filter
D Throttle body assembly
NG D EGR system
D Turbocharger
Repair D Compression pressure
D Injection timing
D Injection pump
D Existence of mixing foreign objects (water, kerosene) with
the fuel
INSPECTION PROCEDURE 15
Occurrence of abnormal knocking Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, and EGR system. D Injection pump inoperative
D Fuel system inoperative
D EGR system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Injection nozzle
D Injection timing
NG
D EGR system
D Injection pump
Repair
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-35
INSPECTION PROCEDURE 16
Abnormal black smoke Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, intake system, and EGR system. D Injection pump inoperative
D Fuel system inoperative
D Intake system inoperative
D EGR system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Air cleaner
D Injection nozzle
NG D Throttle body assembly
D EGR system
Repair D Turbocharger
D Injection pump
INSPECTION PROCEDURE 17
Abnormal white smoke Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
fuel system, intake system, EGR system, and glow system. D Injection pump inoperative
D Fuel system inoperative
D Intake system inoperative
D EGR system inoperative
D Glow system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Glow plug, glow plug relay
D Injection nozzle
NG D Throttle body assembly
D EGR system
Repair D Turbocharger
D Injection pump
INSPECTION PROCEDURE 18
Hunting during driving Probable cause
Probable causes can be found in troubles with control system, injection pump, D Control system inoperative
and fuel system. D Injection pump inoperative
D Fuel system inoperative
D Engine-ECU inoperative
YES
MUT-II Self-Diag code Inspection chart for diagnosis codes (Refer to P.13E-8.)
Is a diagnosis code output?
NO
OK
Conduct MUT-II Data list check and an actuator test. Inspect the following items in order:
(Refer to P.13E-40, 44.) D Injection nozzle
D Injection pump
NG
Repair
13E-36 DIESEL FUEL <4D5-step III> - Troubleshooting
INSPECTION PROCEDURE 19
A/C condenser fan operating problem Probable cause
The power transistor inside the engine-ECU turns on and off to control the A/C D Malfunction of A/C condenser fan motor relay
condenser fan motor relay. D Malfunction of A/C condenser fan motor
D Malfunction of thermostat
D Open circuit or short-circuit in circuit, or poor
connector contact
D Malfunction of engine-ECU
NG
Measure at engine-ECU connector D-110. A/C condenser fan motor circuit check
D Disconnect the connector and measure at the harness (Refer to the wiring harness configuration diagram.)
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
OK
NG
Check the following connector: D-110 Repair
OK
(1) NG NG
Measure at D-110, D-111, D-113 Check the following connectors: Repair
engine-ECU connectors. D-208, D-223, E-13
D Disconnect the connector and
(2), (3) NG OK
measure at the harness side.
(1) Voltage between 82 and the
earth (Ignition switch: ON) Check the trouble symptoms.
OK: System voltage NG
(2) Voltage between 46 and the NG
earth Check the harness between the Repair
OK: System voltage engine-ECU and the ignition switch.
(3) Voltage between 12, 25 and the (4) NG
OK
earth (Ignition switch: ON)
OK: System voltage
Ignition switch check
(When terminal 38 is short
circuited to the earth) (5) NG
(4) Continuity between 13, 26 and NG
Check the following connectors: Repair
the earth
B-25X, D-128
OK: Continuity
(5) Voltage 80 and the earth OK
OK: System voltage NG
OK Check the trouble symptoms. Check and repair the harness
between the engine-ECU and the
control relay connector.
Check the following connectors:
Check and repair the harness
D-110, D-111, D-113
between the engine-ECU and the
OK NG earth.
Repair
INSPECTION PROCEDURE 21
Fuel cut solenoid valve circuit inspection
NG
Fuel cut solenoid valve check Replace the injection pump.
(Refer to P.13E-61.)
OK
OK NG
Measure at fuel injection pump Check the following connector: Repair
assembly connector B-38. D-110
D Disconnect the connector and OK
measure at the harness side.
D Voltage between 1 and the earth Check the trouble symptoms.
(Ignition switch: ON)
OK: System voltage NG
OK NG
Check the harness between the Repair
engine-ECU and the fuel cut
Check the fuel injection pump solenoid valve connector.
assembly connector B-38, and repair OK
if necessary.
Replace the engine-ECU.
13E-38 DIESEL FUEL <4D5-step III> - Troubleshooting
INSPECTION PROCEDURE 22
EGR control solenoid valve No. 1 circuit inspection
NG
EGR control solenoid valve No. 1 Replace
check (Refer to GROUP 17 -
Service Adjustment Procedures.)
OK
NG
Measure at EGR control solenoid Check the harness between the
valve No. 1 connector B-35. control relay and the EGR control
D Disconnect the connector and solenoid valve No. 1 connector, and
measure at the harness side. repair if necessary.
D Voltage between 1 and the earth
(Ignition switch: ON)
OK: System voltage
OK
NG NG
Measure at engine-ECU connector Check the following connector: Repair
D-110. B-35
D Disconnect the connector and OK
measure at the harness side.
D Voltage between 9 and the earth Check the trouble symptoms.
(Ignition switch: ON)
OK: System voltage NG
OK
Check the harness between the
Check the following connector: engine-ECU and the EGR control
D-110 solenoid valve No. 1 connector, and
repair if necessary.
OK NG
Repair
NG
Check the trouble symptoms. Replace the engine-ECU.
INSPECTION PROCEDURE 23
EGR control solenoid valve No. 2 circuit inspection
NG
EGR control solenoid valve No. 2 Replace
check (Refer to GROUP 17 -
Service Adjustment Procedures.)
OK
NG
Measure at EGR control solenoid Check the harness between the
valve No. 2 connector B-34. control relay and the EGR control
D Disconnect the connector and solenoid valve No. 2 connector, and
measure at the harness side. repair if necessary.
D Voltage between 1 and the earth
(Ignition switch: ON)
OK: System voltage
OK
NG NG
Measure at engine-ECU connector Check the following connector: Repair
D-110. B-34
D Disconnect the connector and OK
measure at the harness side.
D Voltage between 5 and the earth Check the trouble symptoms.
(Ignition switch: ON)
OK: System voltage NG
OK
Check the harness between the
Check the following connector: engine-ECU and the EGR control
D-110 solenoid valve No. 2 connector, and
repair if necessary.
OK NG
Repair
NG
Check the trouble symptoms. Replace the engine-ECU.
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-39
INSPECTION PROCEDURE 24
Glow plug relay inspection
NG
Glow plug relay check. (Refer to Replace
GROUP 16 - Glow System.)
OK
NG NG
Measure at glow plug relay Check the following connector: Repair
connector B-42. D-110
D Disconnect the connector and
OK
measure at the harness side.
D Voltage between 1 and the earth
Check the trouble symptoms.
(Ignition switch: ON)
(Engine coolant temperature: NG
40_C or lower) NG
OK: System voltage (for 1 - 8 sec- Check the harness between the Repair
onds after ignition switch is engine-ECU and the glow plug relay
turned to ON) connector.
OK OK
Check glow plug relay connector Replace the engine-ECU.
B-42, and repair if necessary.
INSPECTION PROCEDURE 25
A/C switch and A/C relay inspection
OK NG
Measure at engine-ECU connector Check the following connectors: Repair
D-110 or D-111. D-110, D-111
D Disconnect the connector and
OK
measure at the harness side.
D Voltage between 21 and 32 and
Check the trouble symptoms.
the earth (Ignition switch: ON)
OK: 0 - 3 V (A/C switch: OFF) OK
System voltage (A/C
switch: ON) Replace the engine-ECU.
D Short out 21 and the earth
(Ignition switch: ON)
(A/C switch: ON)
OK: A/C compressor clutch
turns on
NG
31 EGR valve Engine: After warming Idling under no load 2.3 - 3.3 V Code No. 13E-25
position up the engine 51
sensor (tar- Engine is suddenly Momentarily
get value) raced decreases
(0.3 - 0.7 V)
32 EGR valve Engine: After warming Idling under no load 2.3 - 3.3 V Code No. 13E-25
position up the engine 51
sensor (ac- Engine is suddenly Momentarily
tual value) raced decreases
(0.3 - 0.7 V)
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.
02 Glow plug relay Turning the Ignition switch: Battery charge is Procedure 13E-39
relay from ON energized to the glow No 24
No.
OFF to ON or plug when the glow
from ON to plug relay is ON.
ON
OFF
03 A/C compressor Turning the Ignition switch: The A/C compressor Procedure 13E-39
relay relay from ON clutch makes an No 25
No.
OFF to ON or audible sound.
from ON to
OFF
11 Timing control Turn the D Ignition Makes an audible Code No. 13E-21
valve timing control switch: ON sound 43
valve to ON D Engine:
Idling
12 Turn the D Timer piston
timing control position
valve to OFF sensor:
Normal
15 Glow lamp Turn the glow Ignition switch: The glow lamp turns
lamp on or off ON on.
16 Warning lamp Turn the Ignition switch: The warning lamp Procedure 13E-30
warning lamp ON turns on. No. 3, 4
on or off
22 Condenser fan Turning the Ignition switch: The condenser fan Procedure 13E-36
relay relay from ON rotates. No. 19
OFF to ON or
from ON to
OFF
23 Throttle solenoid Turn the D Ignition Makes an audible Code No. 13E-20
valve solenoid switch: ON sound 41
valve from D Vehicle
OFF to ON or speed:
from ON to 0 km/h
OFF D Engine
speed:
1,000 r/min
or lower
25 GE actuator Turn the GE D Ignition Measure the wave Code No. 13E-23
actuator to switch: ON pattern between 48
ON D Engine engine-ECU connec-
speed: tor terminals No. 1
0 r/min or and No. 15 using an
lower analyzer and check
26 Turn the GE
D Control the change in the duty
actuator to
sleeve posi- ratio.
OFF
tion sensor:
Normal
DIESEL FUEL <4D5-step III> - Troubleshooting 13E-45
Item Check item Drive Con- Inspection Value to be determined Code No. Reference
No. tents conditions as normal or inspec- page
tion proce-
dure No.
34 Middle position Hold the D Ignition When the crankshaft Code No. 13E-23
of GE actuator injection switch: ON is turned clockwise 48
governor in during the adjustment
its middle of the injection timing,
position. the injection pipes
spray out fuel.
35 Variable Turn the Ignition switch: Makes an audible Code No. 13E-24
geometry solenoid ON sound 49
solenoid valve valve to ON
37 EGR control Turn the Ignition switch: Makes an audible Procedure 13E-38
solenoid valve solenoid ON sound No. 22
No. 1 valve from
OFF to ON
from ON to
OFF
38 EGR control Turn the Ignition switch: Makes an audible Procedure 13E-38
solenoid valve solenoid ON sound No. 23
No. 2 valve from
OFF to ON
from ON to
OFF
13E-46 DIESEL FUEL <4D5-step III> - Troubleshooting
26 - Body earth
73 - 75 5.6 - 6.2
74 - 75 11.2 - 12.4
76 - 77 80 - 84
76 - 78 80 - 84
13E-50 DIESEL FUEL <4D5-step III> - Troubleshooting
83 - 61 Engine coolant temperature sensor 5.1 - 6.5 k (when the engine coolant temperature is
0_C)
87 - 61 Fuel temperature sensor 5.1 - 6.5 k (when the fuel temperature is 0_C)
88 - 61 Boost air temperature sensor 5.3 - 6.7 k (when the intake air temperature is 0_C)
Measurement Method
Analyzer
1. Disconnect the crank angle sensor connector and connect
the special tool (test harness: MD998478) in between.
CHI 2. Connect the analyzer probe to terminal No. 2 of the crank
angle sensor connector (black clip of special tool).
NOTE
When measuring at the engine-ECU connector, connect
the analyzer probe to terminal No. 89.
TIME/DIV. 10 ms
VOLTS/DIV. 2V
AC - GND - DC DC
Other -
1 engine revolution
(V)
T
Crank angle
sensor output ATDC BTDC9_
wave pattern 90_ BTDC35_ ATDC
12_
5
TDC TDC
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 SENSOR
An analyzer can be used to observe the wave pattern in order to visually check the pump shaft rotation
and abnormalities in the sensor output.
Measurement Method
Analyzer
1. Disconnect the pump speed sensor connector and
Sensor side connector
connect the special tool (test harness: MD991658) in
between. (All terminals should be connected.)
2. Connect the analyzer probe to terminal No. 1 of the pump
speed sensor connector (black clip of special tool).
NOTE
When measuring at the engine-ECU connector, connect
the analyzer probe to terminal No. 51.
AC - GND - DC DC
(V)
0.85
- 0.85 T
1 cranking
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 signal
amplitude is small.
DIESEL FUEL <4D5-step III> - On-vehicle Service 13E-55
ON-VEHICLE SERVICE
INJECTION TIMING CHECK AND
ADJUSTMENT
Refer to GROUP 11B - Engine Adjustment.
IDLE SPEED CHECK AND ADJUSTMENT
Refer to GROUP 11B - Engine Adjustment.
Accelerator
pedal arm
Connector at the
CONTROL RELAY CONTINUITY CHECK
control replay
Terminals to be Battery voltage Normal
connected conation
2-4 Not applied Continuity
1-3 Not applied No continuity
Control relay
Connect a positive battery Continuity
cable to No.2 terminal and a
negative battery cable to No.4
terminal, respectively.
Connector at the
Coil resistance check
Fuel cut solenoid
equipment (12 pin) valve 1. 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
Throttle solenoid
valve
Battery
DIESEL FUEL <4D5-step III> - On-vehicle Service 13E-63
Standard value:
Jumper lead Nipple A Normal condition
Connected Open Negative pressure
leaks
Closed Negative pressure
maintained
Disconnected Open Negative pressure
maintained
30 7 Nm
5.0 1.0 Nm
5.0 1.0 Nm
3
30 7 Nm 12 1 Nm
7
2
4
10 2 Nm
1 (Engine oil)
5
6 23 3 Nm
19 3 Nm
83 5 Nm
Removal steps
1. Fuel injection pump connector AB" 5. Fuel injection pump sprocket
2. Fuel hoses connection 6. Flange
AA" 3. Fuel injection pipe 7. Fuel injection pump
4. Engine oil level gauge guide and
oil level gauge assembly
DIESEL FUEL <4D5-step III> - Fuel Injection Pump 13E-65
REMOVAL SERVICE POINTS
AA" INJECTION PIPE REMOVAL
Loosen the nuts at the end of the injection pipe with the
delivery holder (for pump side) and injection nozzle assembly
(for nozzle side) retained by a spanner, etc.
Nut
Delivery holder
MD998719
Crankshaft
position sensor
9.0 1.0 Nm
ENGINE-ECU
REMOVAL AND INSTALLATION
Removal and installation is the same as for 6G7 engine or 4M4 engine. Refer to GROUP 13A or 13C
of the 2001 PAJERO Workshop Manual {Pub. No. PWJE0001 (1/2)}