Go to SUP9 1st Rev.
ENGINE CONTROL SYSTEM
MODIFICATION NOTICE:
• Wiring diagrams have been modified.
• ZD30DDTi with common rail engine has been added.
CONTENTS
ZD30DDTi WITHOUT COMMON RAIL
ENGINE AND EMISSION CONTROL OVERALL
SYSTEM ..................................................................... 7
Circuit Diagram ........................................................ 7
DTC 0208 OVER HEAT .............................................. 8
Wiring Diagram ........................................................ 8
Diagnostic Procedure ............................................... 9
Component Inspection ........................................... 14
ZD30DDTi WITH COMMON RAIL
INDEX FOR DTC ...................................................... 15
DTC No. Index ....................................................... 15
Alphabetical Index .................................................. 19
PRECAUTIONS ........................................................ 23
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-
TENSIONER” ......................................................... 23
On Board Diagnostic (OBD) System of Engine and
A/T .......................................................................... 23
Precautions ............................................................ 23
PREPARATION ........................................................ 26
Special Service Tools ............................................. 26
Commercial Service Tools ..................................... 26
ENGINE CONTROL SYSTEM .................................. 27
System Diagram ..................................................... 27
Vacuum Hose Drawing .......................................... 28
System Chart ......................................................... 29
Fuel Injection Control System ................................ 29
Fuel Injection Timing Control System .................... 31
Air Conditioning Cut Control ................................... 31
Fuel Cut Control (At No Load & High Engine Speed)... 31
Crankcase Ventilation System ............................... 32
CAN Communication .............................................. 33
BASIC SERVICE PROCEDURE .............................. 34
Fuel Filter ............................................................... 34
Injector Adjustment Value Registration .................. 34
EGR Volume Control Valve Closed Position
Learning Value Clear ............................................. 37
EGR Volume Control Valve Closed Position
EC-1
SECTION
EC
Learning .................................................................. 37
Throttle Valve Closed Position Learning Value
Clear ....................................................................... 39
Throttle Valve Closed Position Learning ................ 39
Injection Tube And Common Rail Assembly .......... 40
Fuel Injector ............................................................ 44
Fuel Pump .............................................................. 46
ON BOARD DIAGNOSTIC (OBD) SYSTEM ............ 48
Introduction ............................................................. 48
Three Trip Detection Logic and One Trip Detection
Logic ....................................................................... 48
Emission-related Diagnostic Information ................ 48
NATS (Nissan Anti-theft System) ........................... 55
Malfunction Indicator (MI) ....................................... 55
OBD System Operation Chart ................................ 56
TROUBLE DIAGNOSIS ............................................ 59
Trouble Diagnosis Introduction ............................... 59
DTC Inspection Priority Chart ................................. 63
Basic Inspection ..................................................... 65
Symptom Matrix Chart ............................................ 69
Engine Control Component Parts Location ............ 74
Circuit Diagram ....................................................... 78
ECM Harness Connector Terminal Layout ............. 80
ECM Terminals And Reference Value .................... 80
CONSULT-II Function (ENGINE) ........................... 87
Generic Scan Tool (GST) Function ........................ 94
CONSULT-II Reference Value in Data Monitor
Mode ....................................................................... 96
Major Sensor Reference Graph in Data Monitor
Mode ....................................................................... 99
TROUBLE DIAGNOSIS FOR INTERMITTENT
INCIDENT ................................................................ 100
Description ............................................................ 100
Diagnostic Procedure ........................................... 100
POWER SUPPLY AND GROUND CIRCUIT .......... 101
Wiring Diagram ..................................................... 101
Diagnostic Procedure ........................................... 103
Component Inspection .......................................... 107
Ground Inspection ................................................ 107
DTC U1000, U1001 CAN COMMUNICATION LINE. 108
Description ............................................................ 108
On Board Diagnosis Logic .................................... 108
DTC Confirmation Procedure ............................... 108
Wiring Diagram ..................................................... 109
Diagnostic Procedure ........................................... 110
DTC U1010 CAN COMMUNICATION ..................... 111
Description ............................................................ 111
On Board Diagnosis Logic .................................... 111
DTC Confirmation Procedure ............................... 111
Diagnostic Procedure ........................................... 112
DTC P0016 CKP - CMP CORRELATION ............... 113
On Board Diagnosis Logic .................................... 113
DTC Confirmation Procedure ............................... 113
Diagnostic Procedure ........................................... 113
DTC P0045 TC BOOST CONTROL SOLENOID
VALVE ..................................................................... 115
Description ............................................................ 115
On Board Diagnosis Logic .................................... 115
DTC Confirmation Procedure ............................... 116
Wiring Diagram ..................................................... 117
Diagnostic Procedure ........................................... 119
Component Inspection .......................................... 120
DTC P0078 EXHAUST GAS CONTROL VALVE
CONTROL SOLENOID VALVE .............................. 121
Component Description ........................................ 121
On Board Diagnosis Logic .................................... 121
DTC Confirmation Procedure ............................... 121
Wiring Diagram ..................................................... 122
Diagnostic Procedure ........................................... 124
Component Inspection .......................................... 127
DTC P0087 FUEL SYSTEM .................................... 128
On Board Diagnosis Logic .................................... 128
DTC Confirmation Procedure ............................... 128
Diagnostic Procedure ........................................... 128
Component Inspection .......................................... 129
DTC P0088 FUEL SYSTEM .................................... 131
On Board Diagnosis Logic .................................... 131
DTC Confirmation Procedure ............................... 131
Diagnostic Procedure ........................................... 131
DTC P0090 FUEL PUMP ........................................ 133
On Board Diagnosis Logic .................................... 133
DTC Confirmation Procedure ............................... 133
Wiring Diagram ..................................................... 134
Diagnostic Procedure ........................................... 135
Component Inspection .......................................... 136
DTC P0091, P0092 FUEL PUMP ............................ 138
On Board Diagnosis Logic .................................... 138
DTC Confirmation Procedure ............................... 138
Wiring Diagram ..................................................... 139
Diagnostic Procedure ........................................... 140
Component Inspection .......................................... 141
DTC P0093 FUEL SYSTEM .................................... 143
On Board Diagnosis Logic .................................... 143
Overall Function Check ........................................ 143
Diagnostic Procedure ........................................... 144
Component Inspection .......................................... 144
DTC P0100 MAF SENSOR ..................................... 145
Component Description ........................................ 145
EC-2
On Board Diagnosis Logic .................................... 145
DTC Confirmation Procedure ................................ 145
Wiring Diagram ..................................................... 146
Diagnostic Procedure ............................................ 147
Component Inspection ..........................................149
DTCP0110INTAKEAIRTEMPERATURESENSOR
.150
Component Description ........................................ 150
On Board Diagnosis Logic .................................... 150
DTC Confirmation Procedure ................................ 150
Wiring Diagram ..................................................... 152
Diagnostic Procedure ............................................ 153
Component Inspection ..........................................154
DTC P0115 ECT SENSOR ...................................... 155
Description ............................................................ 155
On Board Diagnosis Logic .................................... 155
DTC Confirmation Procedure ................................ 156
Wiring Diagram ..................................................... 157
Diagnostic Procedure ............................................ 158
Component Inspection ..........................................159
DTC P0120 ACCELERATOR PEDAL POSITION
SENSOR .................................................................. 160
Description ............................................................ 160
CONSULT-II Reference Value in Data Monitor
Mode ..................................................................... 160
On Board Diagnosis Logic .................................... 160
DTC Confirmation Procedure ................................ 160
Wiring Diagram ..................................................... 162
Diagnostic Procedure ............................................ 164
Component Inspection ..........................................166
DTC P0190 FRP SENSOR ...................................... 167
Description ............................................................ 167
CONSULT-II Reference Value in Data Monitor
Mode ..................................................................... 167
On Board Diagnosis Logic .................................... 167
DTC Confirmation Procedure ................................ 167
Wiring Diagram ..................................................... 168
Diagnostic Procedure ............................................ 169
Component Inspection ..........................................171
DTC P0201 - P0204 FUEL INJECTOR ................... 172
Component Description ........................................ 172
CONSULT-II Reference Value in Data Monitor
Mode ..................................................................... 172
On Board Diagnosis Logic .................................... 172
DTC Confirmation Procedure ................................ 173
Wiring Diagram ..................................................... 174
Diagnostic Procedure ............................................ 176
Component Inspection ..........................................177
DTC P0217 ENGINE OVER TEMPERATURE ........ 178
On Board Diagnosis Logic .................................... 178
Overall Function Check ......................................... 178
Wiring Diagram ..................................................... 180
Diagnostic Procedure ............................................ 181
Main 12 Causes of Overheating ........................... 184
Component Inspection ..........................................185
DTC P0220 APP SENSOR ...................................... 186
Description ............................................................ 186
CONSULT-II Reference Value in Data Monitor
Mode ..................................................................... 186
 On Board Diagnosis Logic ................................... 186
DTC Confirmation Procedure ............................... 186
Wiring Diagram .................................................... 188
Diagnostic Procedure ........................................... 190
Component Inspection ......................................... 192
DTC P0234 TC SYSTEM ........................................ 193
Description ........................................................... 193
On Board Diagnosis Logic ................................... 193
Overall Function Check ........................................ 194
Wiring Diagram .................................................... 195
Diagnostic Procedure ........................................... 196
Component Inspection ......................................... 199
DTC P0235 TC BOOST SENSOR .......................... 200
Component Description ........................................ 200
CONSULT-II Reference Value in Data Monitor
Mode .................................................................... 200
On Board Diagnosis Logic ................................... 200
DTC Confirmation Procedure ............................... 200
Wiring Diagram .................................................... 202
Diagnostic Procedure ........................................... 203
Component Inspection ......................................... 205
DTCP0262,P0265,P0268,P0271FUELINJECTOR
. 206
Component Description ........................................ 206
CONSULT-II Reference Value in Data Monitor
Mode .................................................................... 206
On Board Diagnosis Logic ................................... 206
DTC Confirmation Procedure ............................... 207
Wiring Diagram .................................................... 208
Diagnostic Procedure ........................................... 210
Component Inspection ......................................... 210
DTC P0299 TC SYSTEM ........................................ 211
Description ........................................................... 211
On Board Diagnosis Logic ................................... 211
Overall Function Check ........................................ 212
Wiring Diagram .................................................... 213
Diagnostic Procedure ........................................... 214
Component Inspection ......................................... 217
DTC P0335 CKP SENSOR ..................................... 218
Description ........................................................... 218
CONSULT-II Reference Value in Data Monitor
Mode .................................................................... 218
On Board Diagnosis Logic ................................... 218
DTC Confirmation Procedure ............................... 218
Wiring Diagram .................................................... 220
Diagnostic Procedure ........................................... 221
Component Inspection ......................................... 222
DTC P0340 CMP SENSOR .................................... 224
Description ........................................................... 224
CONSULT-II Reference Value in Data Monitor
Mode .................................................................... 224
On Board Diagnosis Logic ................................... 224
DTC Confirmation Procedure ............................... 224
Wiring Diagram .................................................... 226
Diagnostic Procedure ........................................... 227
Component Inspection ......................................... 229
DTC P0380 GLOW RELAY .................................... 231
On Board Diagnosis Logic ................................... 231
DTC Confirmation Procedure ............................... 231
EC-3
Wiring Diagram ..................................................... 232
Diagnostic Procedure ........................................... 233
Component Inspection .......................................... 235
DTC P0400 EGR FUNCTION ................................. 236
Description ............................................................ 236
On Board Diagnosis Logic .................................... 237
DTC Confirmation Procedure ............................... 237
Wiring Diagram ..................................................... 239
Diagnostic Procedure ........................................... 241
Component Inspection .......................................... 242
DTC P0401 EGR FUNCTION ................................. 244
Description ............................................................ 244
On Board Diagnosis Logic .................................... 245
DTC Confirmation Procedure ............................... 245 EC
Wiring Diagram ..................................................... 246
Diagnostic Procedure ........................................... 248
Component Inspection .......................................... 252
DTC P0403 EGR VOLUME CONTROL VALVE ..... 253
Description ............................................................ 253
On Board Diagnosis Logic .................................... 253
DTC Confirmation Procedure ............................... 253
Diagnostic Procedure ........................................... 254
DTC P0404 EGR VOLUME CONTROL VALVE ..... 255
Description ............................................................ 255
On Board Diagnosis Logic .................................... 256
DTC Confirmation Procedure ............................... 256
Wiring Diagram ..................................................... 257
Diagnostic Procedure ........................................... 258
Component Inspection .......................................... 260
DTC P0409 EGR VOLUME CONTROL VALVE
CONTROL POSITION SENSOR ............................ 261
Description ............................................................ 261
On Board Diagnosis Logic .................................... 262
DTC Confirmation Procedure ............................... 262
Wiring Diagram ..................................................... 263
Diagnostic Procedure ........................................... 264
Component Inspection .......................................... 266
DTC P0480 COOLING FAN RELAY ...................... 268
System Description ............................................... 268
CONSULT-II Reference Value in Data Monitor
Mode ..................................................................... 268
On Board Diagnosis Logic .................................... 268
DTC Confirmation Procedure ............................... 269
Wiring Diagram ..................................................... 270
Diagnostic Procedure ........................................... 271
Component Inspection .......................................... 272
DTC P0500 VSS ...................................................... 273
Description ............................................................ 273
On Board Diagnosis Logic .................................... 273
DTC Confirmation Procedure ............................... 273
Overall Function Check ........................................ 273
Diagnostic Procedure ........................................... 274
DTC P0504 ASCD BRAKE SWITCH ...................... 275
Component Description ........................................ 275
CONSULT-II Reference Value in Data Monitor
Mode ..................................................................... 275
On Board Diagnosis Logic .................................... 275
DTC Confirmation Procedure ............................... 276
Wiring Diagram ..................................................... 277
 Diagnostic Procedure ........................................... 278
Component Inspection .......................................... 283
DTC P0520 ENGINE OIL PRESSURE SENSOR ... 284
Component Description ........................................ 284
CONSULT-II Reference Value in Data Monitor
Mode ..................................................................... 284
On Board Diagnosis Logic .................................... 284
DTC Confirmation Procedure ............................... 285
Wiring Diagram ..................................................... 286
Diagnostic Procedure ........................................... 287
Component Inspection .......................................... 289
DTC P0581 ASCD STEERING SWITCH ................ 290
Component Description ........................................ 290
CONSULT-II Reference Value in Data Monitor
Mode ..................................................................... 290
On Board Diagnosis Logic .................................... 291
DTC Confirmation Procedure ............................... 291
Wiring Diagram ..................................................... 292
Diagnostic Procedure ........................................... 293
Component Inspection .......................................... 296
DTC P0606 ECM ..................................................... 297
Description ............................................................ 297
On Board Diagnosis Logic .................................... 297
DTC Confirmation Procedure ............................... 297
Diagnostic Procedure ........................................... 298
DTC P0607 ECM ..................................................... 299
Description ............................................................ 299
On Board Diagnosis Logic .................................... 299
DTC Confirmation Procedure ............................... 299
Diagnostic Procedure ........................................... 300
DTC P0611 ECM ..................................................... 301
Description ............................................................ 301
On Board Diagnosis Logic .................................... 301
DTC Confirmation Procedure ............................... 301
Diagnostic Procedure ........................................... 302
DTC P0638 ELECTRIC THROTTLE CONTROL
ACTUATOR FUNCTION ......................................... 303
Component Description ........................................ 303
On Board Diagnosis Logic .................................... 303
DTC Confirmation Procedure ............................... 303
Wiring Diagram ..................................................... 304
Diagnostic Procedure ........................................... 305
Component Inspection .......................................... 308
DTC P0641 SENSOR POWER SUPPLY ................ 309
On Board Diagnosis Logic .................................... 309
DTC Confirmation Procedure ............................... 309
Wiring Diagram ..................................................... 310
Diagnostic Procedure ........................................... 312
DTC P0645 A/C CLUTCH RELAY .......................... 315
CONSULT-II Reference Value in Data Monitor
Mode ..................................................................... 315
On Board Diagnosis Logic .................................... 315
DTC Confirmation Procedure ............................... 315
Wiring Diagram ..................................................... 316
Diagnostic Procedure ........................................... 317
Component Inspection .......................................... 318
DTC P0651 SENSOR POWER SUPPLY ................ 319
On Board Diagnosis Logic .................................... 319
DTC Confirmation Procedure ............................... 319
EC-4
Wiring Diagram ..................................................... 320
Diagnostic Procedure ............................................ 321
DTC P0660 SWIRL CONTROL VALVE CONTROL
SOLENOID VALVE ................................................. 324
Description ............................................................ 324
On Board Diagnosis Logic .................................... 325
DTC Confirmation Procedure ................................ 325
Wiring Diagram ..................................................... 326
Diagnostic Procedure ............................................ 327
Component Inspection ..........................................328
DTC P0661, P0662 SWIRL CONTROL VALVE
CONTROL SOLENOID VALVE .............................. 330
Description ............................................................ 330
On Board Diagnosis Logic .................................... 331
DTC Confirmation Procedure ................................ 331
Wiring Diagram ..................................................... 332
Diagnostic Procedure ............................................ 333
Component Inspection ..........................................334
DTC P0697 SENSOR POWER SUPPLY ................ 336
On Board Diagnosis Logic .................................... 336
DTC Confirmation Procedure ................................ 336
Wiring Diagram ..................................................... 337
Diagnostic Procedure ............................................ 339
DTC P1089 FUEL PUMP ........................................ 342
On Board Diagnosis Logic .................................... 342
DTC Confirmation Procedure ................................ 342
Diagnostic Procedure ............................................ 342
Component Inspection ..........................................343
DTC P1090 FUEL PUMP ........................................ 345
On Board Diagnosis Logic .................................... 345
DTC Confirmation Procedure ................................ 345
Diagnostic Procedure ............................................ 345
Component Inspection ..........................................346
DTC P1276, P1277 FUEL INJECTOR .................... 347
Component Description ........................................ 347
CONSULT-II Reference Value in Data Monitor
Mode ..................................................................... 347
On Board Diagnosis Logic .................................... 347
DTC Confirmation Procedure ................................ 347
Wiring Diagram ..................................................... 349
Diagnostic Procedure ............................................ 351
DTC P1409 EGR FUNCTION .................................. 352
Description ............................................................ 352
On Board Diagnosis Logic .................................... 353
DTC Confirmation Procedure ................................ 353
Diagnostic Procedure ............................................ 354
DTC P1603 ECM ..................................................... 355
Description ............................................................ 355
On Board Diagnosis Logic .................................... 355
DTC Confirmation Procedure ................................ 355
Diagnostic Procedure ............................................ 356
DTC P1625 INJECTOR ADJUSTMENT VALUE .... 357
Description ............................................................ 357
On Board Diagnosis Logic .................................... 357
DTC Confirmation Procedure ................................ 357
Diagnostic Procedure ............................................ 358
DTC P2100 THROTTLE CONTROL MOTOR ......... 359
Component Description ........................................ 359
CONSULT-II Reference Value in Data Monitor
 Mode .................................................................... 359
On Board Diagnosis Logic ................................... 359
DTC Confirmation Procedure ............................... 359
Wiring Diagram .................................................... 361
Diagnostic Procedure ........................................... 362
Component Inspection ......................................... 364
DTC P2101 THROTTLE CONTROL MOTOR ........ 365
Component Description ........................................ 365
CONSULT-II Reference Value in Data Monitor
Mode .................................................................... 365
On Board Diagnosis Logic ................................... 365
DTC Confirmation Procedure ............................... 365
Wiring Diagram .................................................... 367
Diagnostic Procedure ........................................... 368
Component Inspection ......................................... 370
DTC P2118 THROTTLE CONTROL MOTOR ........ 371
Component Description ........................................ 371
CONSULT-II Reference Value in Data Monitor
Mode .................................................................... 371
On Board Diagnosis Logic ................................... 371
DTC Confirmation Procedure ............................... 371
Wiring Diagram .................................................... 373
Diagnostic Procedure ........................................... 374
Component Inspection ......................................... 377
DTC P2119 ELECTRIC THROTTLE CONTROL
ACTUATOR ............................................................ 378
Component Description ........................................ 378
On Board Diagnosis Logic ................................... 378
DTC Confirmation Procedure ............................... 378
Diagnostic Procedure ........................................... 379
DTC P2135 APP SENSOR ..................................... 380
Description ........................................................... 380
CONSULT-II Reference Value in Data Monitor
Mode .................................................................... 380
On Board Diagnosis Logic ................................... 380
DTC Confirmation Procedure ............................... 381
Wiring Diagram .................................................... 382
Diagnostic Procedure ........................................... 384
Component Inspection ......................................... 386
DTC P2146, P2149 FUEL INJECTOR POWER
SUPPLY .................................................................. 387
Component Description ........................................ 387
CONSULT-II Reference Value in Data Monitor
Mode .................................................................... 387
On Board Diagnosis Logic ................................... 387
DTC Confirmation Procedure ............................... 388
Wiring Diagram .................................................... 389
Diagnostic Procedure ........................................... 391
DTC P2226 BARO SENSOR .................................. 392
Description ........................................................... 392
On Board Diagnosis Logic ................................... 392
DTC Confirmation Procedure ............................... 392
Diagnostic Procedure ........................................... 393
DTC P2620 TP SENSOR ........................................ 394
Description ........................................................... 394
CONSULT-II Reference Value in Data Monitor
Mode .................................................................... 394
On Board Diagnosis Logic ................................... 394
DTC Confirmation Procedure ............................... 394
EC-5
Wiring Diagram ..................................................... 396
Diagnostic Procedure ........................................... 397
Component Inspection .......................................... 399
ASCD INDICATOR ................................................. 401
Component Description ........................................ 401
Wiring Diagram ..................................................... 402
Diagnostic Procedure ........................................... 403
AUTOMATIC SPEED CONTROL DEVICE (ASCD). 404
System Description ............................................... 404
Component Description ........................................ 405
ASCD BRAKE SWITCH ......................................... 406
Component Description ........................................ 406
CONSULT-II Reference Value in Data Monitor
Mode ..................................................................... 406 EC
Wiring Diagram ..................................................... 407
Diagnostic Procedure ........................................... 408
Component Inspection .......................................... 413
HEAT UP SWITCH .................................................. 414
Component Description ........................................ 414
CONSULT-II Reference Value in Data Monitor
Mode ..................................................................... 414
ECM Terminals And Reference Value .................. 414
Wiring Diagram ..................................................... 415
Diagnostic Procedure ........................................... 416
GLOW CONTROL SYSTEM ................................... 419
Description ............................................................ 419
Wiring Diagram ..................................................... 420
Diagnostic Procedure ........................................... 422
Component Inspection .......................................... 426
CLUTCH SWITCH ................................................... 427
Wiring Diagram ..................................................... 427
Diagnostic Procedure ........................................... 428
Component Inspection .......................................... 430
PNP SWITCH .......................................................... 431
Description ............................................................ 431
CONSULT-II Reference Value in Data Monitor
Mode ..................................................................... 431
Wiring Diagram ..................................................... 432
Diagnostic Procedure ........................................... 433
Component Inspection .......................................... 434
START SIGNAL ...................................................... 436
Wiring Diagram ..................................................... 436
Diagnostic Procedure ........................................... 437
MI & DATA LINK CONNECTORS .......................... 439
Wiring Diagram ..................................................... 439
SERVICE DATA AND SPECIFICATIONS (SDS) ... 441
General Specifications .......................................... 441
Mass Air Flow Sensor ........................................... 441
Intake Air Temperature Sensor ............................ 441
Engine Coolant Temperature Sensor ................... 441
Fuel Rail Pressure Sensor .................................... 441
Fuel Injector .......................................................... 441
Glow Plug ............................................................. 441
EGR Volume Control Valve Motor ........................ 441
Crankshaft Position Sensor .................................. 441
Camshaft Position Sensor .................................... 442
Fuel Pump ............................................................ 442
Throttle Control Motor ........................................... 442
When you read wiring diagrams:
• Read GI section, “HOW TO READ WIRING DIAGRAMS”.
• See EL section, “POWER SUPPLY ROUTING” for power distribution circuit.
When you perform trouble diagnoses, read GI section, “HOW TO FOLLOW FLOW CHART IN
TROUBLE DIAGNOSES” and “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL
INCIDENT”.

EC-6
 ENGINE AND EMISSION CONTROL OVERALL SYSTEM
[ZD30DDTi WITHOUT COMMON RAIL]
ENGINE AND EMISSION CONTROL OVERALL SYSTEM PFP:00024

Circuit Diagram B99998

EC

TEC645M

EC-7
 DTC 0208 OVER HEAT
[ZD30DDTi WITHOUT COMMON RAIL]
DTC 0208 OVER HEAT PFP:00024

Wiring Diagram B99996

TEC646M

EC-8
 DTC 0208 OVER HEAT
[ZD30DDTi WITHOUT COMMON RAIL]
Diagnostic Procedure B99995

1. INSPECTION START
Do you have CONSULT-II?
Yes or No
Yes >> GO TO 2.
No >> GO TO 3.

2. CHECK COOLING FAN OPERATION

With CONSULT-II
1. Turn ignition switch “ON”.
2. Perform “COOLING FAN” in “ACTIVE TEST” mode with CON- EC
SULT-II.
3. Make sure that cooling fan-1 operate.
OK or NG
OK >> GO TO 12.
NG >> GO TO 4.

SEF646X

3. CHECK COOLING FAN OPERATION

Without CONSULT-II
1. Turn ignition switch “OFF”.
2. Disconnect engine coolant temperature sensor harness connector.
3. Connect 150Ω resistor to engine coolant temperature sensor harness connector.
4. Restart engine and make sure that cooling fan operate.
OK or NG
OK >> GO TO 12.
NG >> GO TO 4.

SEF023R

EC-9
 DTC 0208 OVER HEAT
[ZD30DDTi WITHOUT COMMON RAIL]
4. CHECK COOLING FAN POWER SUPPLY CIRCUIT
1. Turn ignition switch “OFF”.
2. Disconnect cooling fan relay-1.
3. Turn ignition switch “ON”.
4. Check voltage between cooling fan relay-1 terminals 1, 5 and
ground with CONSULT-II or tester.

SEF690V

SEC065E

OK or NG
OK >> GO TO 6.
NG >> GO TO 5.

5. DETECT MALFUNCTIONING PART

Check the following.
● Fuse block (J/B) connector E112
● 10A fuse or 20A fuse
● 40A fusible link
● Harness for open or short between cooling fan relay-1 and fuse
● Harness for open or short between cooling fan relay-1 and battery

>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK COOLING FAN GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch “OFF”.

2. Disconnect cooling fan motor-1 harness connector.
3. Check harness continuity between cooling fan relay-1 terminal 3
and cooling fan motor-1 terminal 1, cooling fan motor-1 terminal
2 and body ground. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 7.
NG >> Repair open circuit or short to ground or short to power
in harness or connectors. SEF691V

EC-10
 DTC 0208 OVER HEAT
[ZD30DDTi WITHOUT COMMON RAIL]
7. CHECK COOLING FAN OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT

1. Disconnect ECM harness connector.

2. Check harness continuity between ECM terminal 14 and cooling fan relay-1 terminal 2. Refer to Wiring Di-
agram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 9.
NG >> GO TO 8.

8. DETECT MALFUNCTIONING PART EC

Check the following.
● Harness connectors E127, M21
● Harness connectors M52, F7
● Harness for open or short between cooling fan relay-1 and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

9. CHECK COOLING FAN RELAY-1

Refer to EC-14, "Component Inspection" .
OK or NG
OK >> GO TO 10.
NG >> Replace cooling fan relay.

10. CHECK COOLING FAN MOTOR-1

Refer to EC-14, "Component Inspection" .
OK or NG
OK >> GO TO 11.
NG >> Replace cooling fan motor-1.

11. CHECK INTERMITTENT INCIDENT

Perform “TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT”.

>> INSPECTION END

EC-11
 DTC 0208 OVER HEAT
[ZD30DDTi WITHOUT COMMON RAIL]
12. CHECK COOLING SYSTEM FOR LEAK
Apply pressure to the cooling system with a tester, and check if the pressure drops.
Testing pressure: 98 kPa (0.98 bar, 1.0 kg/cm2, 14 psi)
CAUTION:
Higher than the specified pressure may cause radiator damage.
Pressure should not drop.
OK or NG
OK >> GO TO 14.
NG >> GO TO 13.

SLC754A

13. DETECT MALFUNCTIONING PART

Check the following for leak.
● Hose
● Radiator
● Water pump (Refer to LC section, “Water Pump”.)

>> Repair or replace.

14. CHECK RADIATOR CAP

Apply pressure to cap with a tester and check radiator cap relief pres-
sure.
Radiator cap relief pressure:
59 - 98 kPa (0.59 - 0.98 bar, 0.6 - 1.0 kg/cm2, 9 - 14 psi)
OK or NG
OK >> GO TO 15.
NG >> Replace radiator cap.

SLC755A

EC-12
 DTC 0208 OVER HEAT
[ZD30DDTi WITHOUT COMMON RAIL]
15. CHECK THERMOSTAT
1. Remove thermostat.
2. Check valve seating condition at normal room temperatures.
It should seat tightly.
3. Check valve opening temperature and valve lift.
Valve opening temperature:
82°C (180°F) [standard] (Models for cold areas)
76.5°C (170°F) [standard] (Models for except cold areas)
Valve lift:
More than 10 mm/95°C (0.394 in/203°F)
EC
4. Check if valve is closed at 5°C (9°F) below valve opening tem-
perature. For details, refer to LC section, “Thermostat”.
SLC343
OK or NG
OK >> GO TO 16.
NG >> Replace thermostat.

16. CHECK ENGINE COOLANT TEMPERATURE SENSOR

1. Remove engine coolant temperature sensor.

2. Check resistance between engine coolant temperature sensor terminals 1 and 2 as shown in the figure.

SEF304X

OK or NG
OK >> GO TO 17.
NG >> Replace engine coolant temperature sensor.

17. CHECK MAIN 12 CAUSES

If the cause cannot be isolated, go to “MAIN 12 CAUSES OF OVERHEATING”, EC-538 in the Service Manual
(Publication No. SM2E-Y61FG1).

>> INSPECTION END

EC-13
 DTC 0208 OVER HEAT
[ZD30DDTi WITHOUT COMMON RAIL]
Component Inspection B99994

COOLING FAN RELAY-1

Check continuity between terminals 3 and 5.
Conditions Continuity
12V direct current supply between terminals 1 and 2 Yes
No current supply No

If NG, replace relay.

SEF497Y

COOLING FAN MOTOR-1

1. Disconnect cooling fan motor-1 harness connector.
2. Supply cooling fan motor-1 terminal with battery voltage and
check operation.

Terminals
(+) (-)
Cooling fan motor-1 1 2

Cooling fan motor should operate.

If NG, replace cooling fan motor.
PBIB1834E

EC-14
 INDEX FOR DTC
[ZD30DDTi WITH COMMON RAIL]
INDEX FOR DTC PFP:00024

DTC No. Index BBS00CEJ

NOTE:
● If DTC U1000 or U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC
U1000, U1001. Refer to EC-108, "DTC U1000, U1001 CAN COMMUNICATION LINE" .
● If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer
to EC-111, "DTC U1010 CAN COMMUNICATION" .

DTC*1
Items Reference
CONSULT-II
3 (CONSULT-II screen item) page
GST*
ID FLAG*2
U1000 4 U1000 CAN COMM CIRCUIT EC-108 EC
U1001 4 U1001 CAN COMM CIRCUIT EC-108
U1010 4 U1010 CONTROL UNIT(CAN) EC-111
NO DTC IS DETECTED.
P0000 — P0000 FURTHER TESTING —
MAY BE REQUIRED.
P0016 1 P0016 CMP/CKP RELATION EC-113
1 P0048
2 P0047
P0045 TC BOOST SOL/CIRC EC-115
4 P0045
8 P0046
1 P0080
2 P0079
P0078 EXH GAS CONT/V EC-121
4 P0078
8 P0078
P0087 1 P0087 LOW FUEL PRES EC-128
P0088 1 P0088 HIGH FUEL PRES EC-131
4
P0090 P0090 FUEL PUMP EC-133
8
P0091 2 P0091 FUEL PUMP EC-138
P0092 1 P0092 FUEL PUMP EC-138
P0093 1 P0093 FUEL LEAK EC-143
1 P0103
P0100 MAS AIR FLOW SEN EC-145
2 P0102
1 P0113
P0110 INTAIR TEMP SEN EC-150
2 P0112
1 P0118
P0115 COOLANT TEMP SEN EC-155
2 P0117
1 P0123
P0120 ACCEL POS SENSOR EC-160
2 P0122
1 P0193
P0190 CR PRES SEN EC-167
2 P0192
P0201 4 P0201 CYL1 INJECTOR EC-172
P0202 4 P0202 CYL2 INJECTOR EC-172
P0203 4 P0203 CYL3 INJECTOR EC-172
P0204 4 P0204 CYL4 INJECTOR EC-172

EC-15
 INDEX FOR DTC
[ZD30DDTi WITH COMMON RAIL]
DTC*1
Items Reference
CONSULT-II
(CONSULT-II screen item) page
GST*3
ID FLAG*2
P0217 1 P0217 ENG OVER TEMP EC-178
1 P0223
P0220 ACCEL POS SENSOR EC-186
2 P0222
P0234 2 P0234 TC SYSTEM EC-193
1 P0238
P0235 TC BOOST SEN/CIRC EC-200
2 P0237
1
P0262 P0262 CYL1 INJECTOR EC-206
4
1
P0265 P0265 CYL2 INJECTOR EC-206
4
1
P0268 P0268 CYL3 INJECTOR EC-206
4
1
P0271 P0271 CYL4 INJECTOR EC-206
4
P0299 1 P0299 TC SYSTEM EC-211
1 P0335
P0335 CKP SEN/CIRCUIT EC-218
2 P0336
1 P0340
P0340 CMP SEN/CIRCUIT EC-224
2 P0341
1
2
P0380 P0380 GLOW RELAY EC-231
4
8
P0400 1 P0400 EGR SYSTEM EC-236
P0401 1 P0401 EGR SYSTEM EC-244
P0403 8 P0403 EGR SYSTEM EC-253
1 P0490
P0404 2 P0489 EGR VALVE EC-255
4 P0404
1 P0406
P0409 EGR SYSTEM EC-261
2 P0405
1 P0692
2 P0691
P0480 COOLING FAN RELAY EC-268
4 P0480
8 P0480
P0500 8 P0500 VEHICLE SPEED EC-273
8
P0504 P0504 BRAKE SW/CIRCUIT EC-275
8
1 P0523
P0520 OIL PRESS SEN EC-284
2 P0522
1 P0578
P0581 STRG SW/CIRC EC-290
1 P0581

EC-16
 INDEX FOR DTC
[ZD30DDTi WITH COMMON RAIL]
DTC*1
Items Reference
CONSULT-II
(CONSULT-II screen item) page
GST*3
ID FLAG*2
P0606 — P0606 ECM EC-297
P0607 — P0607 ECM EC-299
1
2
P0611 P0611 ECM EC-301
4
8
P0638 8 P0638 ETC ACTR EC-303
1 P0643 EC
P0641 SENSOR PWR/CIRC1 EC-309
2 P0642
1 P0647
2 P0646
P0645 A/C RELAY EC-315
4 P0645
8 P0645
1 P0653
P0651 SENSOR PWR/CIRC2 EC-319
2 P0652
4
P0660 P0660 SWIRL CONT VALVE EC-324
8
P0661 2 P0661 SWIRL CONT VALVE EC-330
P0662 1 P0662 SWIRL CONT VALVE EC-330
1 P0699
P0697 SENSOR PWR/CIRC3 EC-336
2 P0698
P0705 4 P0705 PNP SW/CIRC AT section
P0710 4 P0710 ATF TEMP SEN/CIRC AT section
P0720 4 P0720 VEH SPD SE/CIR A/T AT section
P0725 4 P0725 ENG SPEED SIG AT section
P0731 4 P0731 A/T 1ST GR FNCTN AT section
P0732 4 P0732 A/T 2ND GR FNCTN AT section
P0733 4 P0733 A/T 3RD GR FNCTN AT section
P0734 4 P0734 A/T 4TH GR FNCTN AT section
P0740 4 P0740 TCC SOLENID/CIRC AT section
P0745 4 P0745 L/PRESS SOL/CIRC AT section
P0750 4 P0750 SFT SOL A/CIRC AT section
P0755 4 P0755 SFT SOL B/CIRC AT section
P1089 1 P0089 FUEL PUMP EC-342
P1090 1 P0089 FUEL PUMP EC-345
P1276 1 P1276 CYL1 CYL4 INJECTOR EC-347
P1277 1 P1277 CYL 2 CYL3 INJECTOR EC-347
P1409 1 P1409 EGR VALVE EC-352
2
P1603 P0603 ECM EC-355
4

EC-17
 INDEX FOR DTC
[ZD30DDTi WITH COMMON RAIL]
DTC*1
Items Reference
CONSULT-II
(CONSULT-II screen item) page
GST*3
ID FLAG*2
1
P1610 - P1616 2 P1610 - P1616 NATS MALFUNCTION EL section
4
P1625 4 P1625 INJ ADJ VAL EC-357
P1760 4 P1760 O/R CLTCH SOL/CIRC AT section
1 P2103
2 P2102
P2100 ETC CONT CIR EC-359
4 P2100
4 P2101
P2101 8 P2101 ETC CONT CIR EC-365
P2118 1 P2118 ETC MOT EC-371
P2119 1 P2119 ETC ACTR EC-378
P2135 8 P2135 APP SENSOR EC-380
1 P2146
P2146 INJ PWR/CIRC EC-387
8 P0200
1 P2149
P2149 INJ PWR/CIRC EC-387
8 P0200
1 P2229
P2226 BARO SENSOR EC-392
2 P2228
1 P2622
P2620 TP SEN/CIRCUIT EC-394
2 P2621
*1: 1st trip DTC No. and 2nd trip DTC No. are the same as DTC No.
*2: This item is displayed in Freeze Frame Data of CONSULT-II.
*3: This number is prescribed by ISO 15031-6.

EC-18
 INDEX FOR DTC
[ZD30DDTi WITH COMMON RAIL]
Alphabetical Index BBS00CEK

NOTE:
● If DTC U1000 or U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC
U1000, U1001. Refer to EC-108, "DTC U1000, U1001 CAN COMMUNICATION LINE" .
● If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer
to EC-111, "DTC U1010 CAN COMMUNICATION" .

DTC*1

Items CONSULT-II Reference page

(CONSULT-II screen item) GST*3
ID FLAG*2
1 P0647
2 P0646
A/C RELAY P0645 EC-365 EC
4 P0645
8 P0645
A/T 1ST GR FNCTN P0731 4 P0731 AT section
A/T 2ND GR FNCTN P0732 4 P0732 AT section
A/T 3RD GR FNCTN P0733 4 P0733 AT section
A/T 4TH GR FNCTN P0734 4 P0734 AT section
1 P0123
ACCEL POS SENSOR P0120 EC-160
2 P0122
1 P0223
ACCEL POS SENSOR P0220 EC-186
2 P0222
APP SENSOR P2135 8 P2135 EC-380
ATF TEMP SEN/CIRC P0710 4 P0710 AT section
1 P2229
BARO SENSOR P2226 EC-392
2 P2228
8
BRAKE SW/CIRCUIT P0504 P0504 EC-275
8
CAN COMM CIRCUIT U1000 4 U1000 EC-108
CAN COMM CIRCUIT U1001 4 U1001 EC-108
1 P0335
CKP SEN/CIRCUIT P0335 EC-218
2 P0336
1 P0340
CMP SEN/CIRCUIT P0340 EC-224
2 P0341
CMP/CKP RELATION P0016 1 P0016 EC-113
1 P0118
COOLANT TEMP SEN P0115 EC-155
2 P0117
CONTROL UNIT(CAN) U1010 4 U1010 EC-111
1 P0193
CR PRES SEN P0190 EC-167
2 P0192
CYL1 CYL4 INJECTOR P1276 1 P1276 EC-347
CYL1 INJECTOR P0201 4 P0201 EC-172
1
CYL1 INJECTOR P0262 P0262 EC-206
4
CYL2 CYL3 INJECTOR P1277 1 P1277 EC-347
CYL2 INJECTOR P0202 4 P0202 EC-172

EC-19
 INDEX FOR DTC
[ZD30DDTi WITH COMMON RAIL]
DTC*1

Items CONSULT-II Reference page

GST*3
(CONSULT-II screen item) ID FLAG* 2

1
CYL2 INJECTOR P0265 P0265 EC-206
4
CYL3 INJECTOR P0203 4 P0203 EC-172
1
CYL3 INJECTOR P0268 P0268 EC-206
4
CYL4 INJECTOR P0204 4 P0204 EC-172
1
CYL4 INJECTOR P0271 P0271 EC-206
4
ECM P0606 — P0606 EC-297
ECM P0607 — P0607 EC-299
1
2
ECM P0611 P0611 EC-301
4
8
2
ECM P1603 P0603 EC-355
4
EGR SYSTEM P0400 1 P0400 EC-236
EGR SYSTEM P0401 1 P0401 EC-244
EGR SYSTEM P0403 8 P0403 EC-253
1 P0406
EGR SYSTEM P0409 EC-261
2 P0405
1 P0490
EGR VALVE P0404 2 P0489 EC-255
4 P0404
EGR VALVE P1409 1 P1409 EC-352
ENG OVER TEMP P0217 1 P0217 EC-178
ENG SPEED SIG P0725 4 P0725 AT section
ETC ACTR P0638 8 P0638 EC-303
ETC ACTR P2119 1 P2119 EC-378
1 P2103
2 P2102
ETC MOT P2100 EC-359
4 P2100
4 P2101
ETC MOT P2101 8 P2101 EC-365
ETC MOT P2118 1 P2118 EC-371
1 P2622
TP SEN/CIRCUIT P2620 EC-394
2 P2621
1 P0080
2 P0079
EXH GAS CONT/V P0078 EC-121
4 P0078
8 P0078

EC-20
 INDEX FOR DTC
[ZD30DDTi WITH COMMON RAIL]
DTC*1

Items CONSULT-II Reference page

GST*3
(CONSULT-II screen item) ID FLAG*2

1 P0692
2 P0691
COOLING FAN RELAY P0480 EC-268
4 P0480
8 P0480
FUEL LEAK P0093 1 P0093 EC-143
4
FUEL PUMP P0090 P0090 EC-133
8
FUEL PUMP P0091 2 P0091 EC-138 EC
FUEL PUMP P0092 1 P0092 EC-138
FUEL PUMP P1089 1 P0089 EC-342
FUEL PUMP P1090 1 P0089 EC-345
1
2
GLOW RELAY P0380 P0380 EC-231
4
8
HIGH FUEL PRES P0088 1 P0088 EC-131
INJ ADJ VAL P1625 4 P1625 EC-357
1 P2146
INJ PWR/CIRC P2146 EC-387
8 P0200
1 P2149
INJ PWR/CIRC P2149 EC-387
8 P0200
1 P0113
INTAIR TEMP SEN P0110 EC-150
2 P0112
L/PRESS SOL/CIRC P0745 4 P0745 AT section
LOW FUEL PRES P0087 1 P0087 EC-128
1 P0103
MAS AIR FLOW SEN P0100 EC-145
2 P0102
1
P1610 -
NATS MALFUNCTION P1610 - P1616 2 EL section
P1616
4
NO DTC IS DETECTED.
FURTHER TESTING P0000 — P0000 —
MAY BE REQUIRED.
O/R CLTCH SOL/CIRC P1760 4 P1760 AT section
1 P0523
OIL PRESS SEN P0520 EC-284
2 P0522
PNP SW/CIRC P0705 4 P0705 AT section
1 P0643
SENSOR PWR/CIRC1 P0641 EC-309
2 P0642
1 P0653
SENSOR PWR/CIRC2 P0651 EC-319
2 P0652
1 P0699
SENSOR PWR/CIRC3 P0697 EC-336
2 P0698

EC-21
 INDEX FOR DTC
[ZD30DDTi WITH COMMON RAIL]
DTC*1

Items CONSULT-II Reference page

GST*3
(CONSULT-II screen item) ID FLAG* 2

SFT SOL A/CIRC P0750 4 P0750 AT section

SFT SOL B/CIRC P0755 4 P0755 AT section
1 P0578
STRG SW/CIRC P0581 EC-290
1 P0581
4
SWIRL CONT VALVE P0660 P0660 EC-324
8
SWIRL CONT VALVE P0661 2 P0661 EC-330
SWIRL CONT VALVE P0662 1 P0662 EC-330
1 P0048
2 P0047
TC BOOST SOL/CIRC P0045 EC-115
4 P0045
8 P0046
1 P0238
TC BOOST SEN/CIRC P0235 EC-200
2 P0237
TC SYSTEM P0234 2 P0234 EC-193
TC SYSTEM P0299 1 P0299 EC-211
TCC SOLENID/CIRC P0740 4 P0740 AT section
VEH SPD SE/CIR A/T P0720 4 P0720 AT section
VEHICLE SPEED P0500 8 P0500 EC-273
*1: 1st trip DTC No. and 2nd trip DTC No. are the same as DTC No.
*2: This item is displayed in Freeze Frame Data of CONSULT-II.
*3: This number is prescribed by ISO 15031-6.

EC-22
 PRECAUTIONS
[ZD30DDTi WITH COMMON RAIL]
PRECAUTIONS PFP:00001

Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT
BELT PRE-TENSIONER” BBS001VW

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with
a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types
of collision. Information necessary to service the system safely is included in the SRS and SB section of this
Service Manual.
WARNING:
● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN/INFINITI dealer.
● Improper maintenance, including incorrect removal and installation of the SRS, can lead to person-
al injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag EC
Module, see the SRS section.
● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or har-
ness connectors.
On Board Diagnostic (OBD) System of Engine and A/T BBS00CEM

The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver of
a malfunction causing emission deterioration.
CAUTION:
● Be sure to turn the ignition switch OFF and disconnect the battery negative cable before any repair
or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc. will
cause the MI to light up.
● Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will
cause the MI to light up due to the open circuit. (Be sure the connector is free from water, grease,
dirt, bent terminals, etc.)
● Certain systems and components, especially those related to OBD, may use a new style slide-lock-
ing type harness connector. For description and how to disconnect, refer to EL section.
● Be sure to route and secure the harnesses properly after work. The interference of the harness with
a bracket, etc. may cause the MI to light up due to the short circuit.
● Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube
may cause the MI to light up due to the malfunction of the fuel system, etc.
● Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM before
returning the vehicle to the customer.
Precautions BBS00CEN

● Always use a 12 volt battery as power source.

● Do not attempt to disconnect battery cables while engine is
running.
● Before connecting or disconnecting the ECM harness con-
nector, turn ignition switch OFF and disconnect battery
negative cable. Failure to do so may damage the ECM be-
cause battery voltage is applied to ECM even if ignition
switch is turned off.
● Before removing parts, turn ignition switch OFF and then
disconnect battery negative cable.
SEF289H

EC-23
 PRECAUTIONS
[ZD30DDTi WITH COMMON RAIL]
● Do not disassemble ECM.

MBIB0625E

● When connecting ECM harness connector, fasten it securely

with levers as far as they will go as shown in the figure.
– Levers (1)
– ECM (2)
– Fasten (A)
– Loosen (B)

MBIB1645E

● When connecting or disconnecting pin connectors into or

from ECM, take care not to damage pin terminals (bend or
break).
Make sure that there are not any bends or breaks on ECM pin
terminal, when connecting pin connectors.
● Securely connect ECM harness connectors.
A poor connection can cause an extremely high (surge) volt-
age to develop in coil and condenser, thus resulting in dam-
age to IC's.
● Keep engine control system harness at least 10cm (4 in)
away from adjacent harness, to prevent engine control sys- PBIB0090E

tem malfunctions due to receiving external noise, degraded

operation of IC's, etc.
● Keep engine control system parts and harness dry.

● Before replacing ECM, perform ECM Terminals and Refer-

ence Value inspection and make sure ECM functions prop-
erly. Refer to EC-80, "ECM Terminals And Reference Value" .
● Handle mass air flow sensor carefully to avoid damage.
● Do not disassemble mass air flow sensor.
● Do not clean mass air flow sensor with any type of deter-
gent.
● Even a slight leak in the air intake system can cause serious
incidents.
● Do not shock or jar the camshaft position sensor, crankshaft MEF040D
position sensor.

EC-24
 PRECAUTIONS
[ZD30DDTi WITH COMMON RAIL]
● After performing each TROUBLE DIAGNOSIS, perform DTC
Confirmation Procedure or Overall Function Check.
The DTC should not be displayed in the DTC Confirmation
Procedure if the repair is completed. The Overall Function
Check should be a good result if the repair is completed.

SAT652J

● When measuring ECM signals with a circuit tester, never al-

low the two tester probes to contact.
EC
Accidental contact of probes will cause a short circuit and
damage the ECM power transistor.
● Do not use ECM ground terminals when measuring input/
output voltage. Doing so may result in damage to the ECM's
transistor. Use a ground other than ECM terminals, such as
the ground.
● Do not disassemble fuel pump.
If NG, take proper action.
● Do not disassemble fuel injector.
If NG, replace fuel injector.

SEF348N

● Do not depress accelerator pedal when starting.

● Immediately after starting, do not rev up engine unnecessar-
ily.
● Do not rev up engine just prior to shutdown.

SEF709Y

● When installing C.B. ham radio or a mobile phone, be sure

to observe the following as it may adversely affect electronic
control systems depending on installation location.
– Keep the antenna as far as possible from the electronic con-
trol units.
– Keep the antenna feeder line more than 20 cm (8 in) away
from the harness of electronic controls.
Do not let them run parallel for a long distance.
– Adjust the antenna and feeder line so that the standingwave
radio can be kept smaller.
SEF708Y
– Be sure to ground the radio to vehicle body.
EC-25
 PREPARATION
[ZD30DDTi WITH COMMON RAIL]
PREPARATION PFP:00002

Special Service Tools BBS00CEO

Tool number
Description
Tool name
EG17550000 Measuring ECM signals with a circuit tester
Break-out box

ZZA1194D

EG17550500 Measuring the ECM signals with a circuit tester

Y-cable adapter

MBIB1825E

Commercial Service Tools BBS00CEP

Tool name Description

Socket wrench Removing and installing engine coolant tempera-
ture sensor

S-NT705

EC-26
 ENGINE CONTROL SYSTEM
[ZD30DDTi WITH COMMON RAIL]
ENGINE CONTROL SYSTEM PFP:23710

System Diagram BBS00CEQ

EC

SEC079E

EC-27
 ENGINE CONTROL SYSTEM
[ZD30DDTi WITH COMMON RAIL]
Vacuum Hose Drawing BBS00CER

SEC127E

: Vehicle front
1. Rocker cover 2. Mass air flow sensor 3. Turbocharger boost control sole-
noid valve
4. Turbocharger control actuator
NOTE: Do not use soapy water or any type of solvent while installing vacuum hose.

Refer to EC-27, "System Diagram" for Vacuum Control System.

EC-28
 ENGINE CONTROL SYSTEM
[ZD30DDTi WITH COMMON RAIL]
System Chart BBS00CES

Input (Sensor) ECM Function Output (Actuator)

● Accelerator pedal position sensor Fuel injection control Fuel injector and Fuel pump
● Fuel rail pressure sensor Fuel injection timing control Fuel injector and Fuel pump
● Engine coolant temperature sensor Fuel cut control Fuel injector and Fuel pump
● Engine oil pressure sensor
Glow control system Glow relay and glow indicator lamp*2
● Mass air flow sensor
● Intake air temperature sensor On board diagnostic system Malfunction indicator (MI)*2
● Crankshaft position sensor EGR volume control EGR volume control valve
● Camshaft position sensor Turbocharger boost control Turbocharger boost control solenoid valve
● Turbocharger boost sensor
Swirl control valve control Swirl control valve solenoid valve
● Wheel sensor*1 EC
ASCD vehicle speed control Fuel injector and Fuel pump
● Ignition switch
Cooling fan control Cooling fan relay
● Stop lamp switch
Air conditioning cut control Air conditioner relay*2
● Air conditioner switch*1
● Park/neutral position switch Idle speed control Fuel injector and Fuel pump
● ASCD brake switch
● Clutch switch (M/T models)
● EGR volume control valve control position Exhaust gas control valve control sole-
Engine warm-up control
sensor noid valve
● Heat up switch
● Battery voltage
*1: The input signal is sent to the ECM through CAN communication line.
*2: The output signal is sent from the ECM through CAN communication line.

Fuel Injection Control System BBS00CET

SYSTEM DESCRIPTION
Three types of fuel injection control are provided to accommodate engine operating conditions; normal control,
idle control and start control. The ECM determines the appropriate fuel injection control. Under each control,
the amount of fuel injected is adjusted to improve engine performance.
Pulse signals are sent to fuel injectors according to the input signals to adjust the amount of fuel injected to
preset value.
START CONTROL
Input/Output Signal Chart
Sensor Input Signal to ECM ECM Function Actuator
Engine coolant temperature sensor Engine coolant temperature
Crankshaft position sensor Engine speed
Fuel injection
Fuel injector
Camshaft position sensor Piston position control (start
Fuel pump
control)
Ignition switch Start signal
Fuel rail pressure sensor Fuel rail pressure

When the ECM receives a start signal from the ignition switch, the
ECM adapts the fuel injection system for the start control. The amount
of fuel injected at engine starting is a preset program value in the
ECM. The program is determined by the engine speed, engine cool-
ant temperature and fuel rail pressure.
For better startability under cool engine conditions, the lower the cool-
ant temperature becomes, the greater the amount of fuel injected.
The ECM ends the start control when the engine speed reaches the
specific value, and shifts the control to the normal or idle control.

SEF648S

EC-29
 ENGINE CONTROL SYSTEM
[ZD30DDTi WITH COMMON RAIL]
IDLE CONTROL
Input/Output Signal Chart
Sensor Input Signal to ECM ECM Function Actuator
Engine coolant temperature sensor Engine coolant temperature
Crankshaft position sensor Engine speed
Battery Battery voltage
Accelerator pedal position sensor Accelerator pedal position Fuel injection
Fuel injector
control (idle
Fuel rail pressure sensor Fuel rail pressure Fuel pump
control)
Wheel sensor Vehicle speed*
Air conditioner switch Air conditioner ON signal*
Heat up switch Heat up switch signal
*: The input signal is sent to the ECM through CAN communication line.

When the ECM determines that the engine speed is at idle, the fuel injection system is adapted for the idle con-
trol. The ECM regulates the amount of fuel injected corresponding to changes in load applied to the engine to
keep engine speed constant. The ECM also provides the system with a fast idle control in response to the en-
gine coolant temperature signal.
NORMAL CONTROL
Input/Output Signal Chart
Sensor Input Signal to ECM ECM Function Actuator
Crankshaft position sensor Engine speed
Fuel injection
Fuel injector
Accelerator pedal position sensor Accelerator position control (normal
Fuel pump
control)
Fuel rail pressure sensor Fuel rail pressure

The amount of fuel injected under normal driving conditions is deter-

mined according to sensor signals. The crankshaft position sensor
detects engine speed, the accelerator pedal position sensor detects
accelerator pedal position and fuel rail pressure sensor detects fuel
rail pressure. These sensors send signals to the ECM.
The fuel injection data, predetermined by correlation between various
engine speeds, accelerator pedal positions and fuel rail pressure are
stored in the ECM memory, forming a map. The ECM determines the
optimal amount of fuel to be injected using the sensor signals in com-
parison with the map.
SEF649S

MAXIMUM AMOUNT CONTROL

Input/Output Signal Chart
Sensor Input Signal to ECM ECM Function Actuator
Mass air flow sensor Amount of intake air
Fuel injection
Engine coolant temperature sensor Engine coolant temperature control (maxi-
Fuel injector
Crankshaft position sensor Engine speed mum amount
control)
Accelerator pedal position sensor Accelerator pedal position

The maximum injection amount is controlled to an optimum by the engine speed, intake air amount, engine
coolant temperature, and accelerator opening in accordance with the driving conditions.
This prevents the oversupply of the injection amount caused by decreased air density at a high altitude or during
a system failure.

EC-30
 ENGINE CONTROL SYSTEM
[ZD30DDTi WITH COMMON RAIL]
DECELERATION CONTROL
Input/Output Signal Chart
Sensor Input Signal to ECM ECM Function Actuator
Accelerator pedal position sensor Accelerator pedal position Fuel injection
Fuel injector
control (decel-
Crankshaft position sensor Engine speed Fuel pump
eration control)

The ECM sends a fuel cut signal to the fuel injectors and fuel pump during deceleration for better fuel efficiency.
The ECM determines the time of deceleration according to signals from the accelerator pedal position sensor
and crankshaft position sensor.
Fuel Injection Timing Control System BBS00CEU

DESCRIPTION
The target fuel injection timing in accordance with the engine speed and the fuel injection amount are recorded EC
as a map in the ECM beforehand. The ECM determines the optimum injection timing using sensor signals ac-
cordance with the map.
Air Conditioning Cut Control BBS00CEV

INPUT / OUTPUT SIGNAL CHART

Sensor Input Signal to ECM ECM Function Actuator
Air conditioner switch 1
Air conditioner ON signal*
Accelerator pedal position sensor Accelerator pedal opening angle Air conditioner
cut control Air conditioner relay*2
Wheel sensor 1
Vehicle speed*
Engine coolant temperature sensor Engine coolant temperature
*1: The input signal is sent to the ECM through CAN communication line.
*2: The output signal is sent from the ECM through CAN communication line.

SYSTEM DESCRIPTION
This system improves acceleration when the air conditioner is used.
When the accelerator pedal is fully depressed, the air conditioner is turned off for a few seconds.
When engine coolant temperature becomes excessively high, the air conditioner is turned off. This continues
until the engine coolant temperature returns to normal.
Fuel Cut Control (At No Load & High Engine Speed) BBS00CEW

INPUT/OUTPUT SIGNAL CHART

Sensor Input Signal to ECM ECM Function Actuator
Wheel sensor Vehicle speed*
Accelerator pedal position sensor Accelerator pedal position Fuel cut control Fuel injector
Crankshaft position sensor Engine speed
*: The input signal is sent to the ECM through CAN communication line.

If the engine speed is above 2,800 rpm under no load (for example, the shift position is neutral and engine
speed is over 2,800 rpm) fuel will be cut off after some time. The exact time when the fuel is cut off varies based
on engine speed. Fuel cut will be operated until the engine speed reaches 1,500 rpm, then fuel cut will be can-
celled.
NOTE:
This function is different from deceleration control listed under EC-29, "Fuel Injection Control System" .

EC-31
 ENGINE CONTROL SYSTEM
[ZD30DDTi WITH COMMON RAIL]
Crankcase Ventilation System BBS00CEX

DESCRIPTION
In this system, blow-by gas is sucked into the air duct after oil separation by oil separator in the rocker cover.

PBIB0590E

INSPECTION
Ventilation Hose
1. Check hoses and hose connections for leaks.
2. Disconnect all hoses and clean with compressed air. If any hose
cannot be freed of obstructions, replace.

SEC692

EC-32
 ENGINE CONTROL SYSTEM
[ZD30DDTi WITH COMMON RAIL]
CAN Communication BBS00CEY

SYSTEM DESCRIPTION
CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul-
tiplex communication line with high data communication speed and excellent error detection ability. Many elec-
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.
Refer to EL section, about CAN communication for detail.

EC

EC-33
 BASIC SERVICE PROCEDURE
[ZD30DDTi WITH COMMON RAIL]
BASIC SERVICE PROCEDURE PFP:00018

Fuel Filter BBS00CEZ

DESCRIPTION
A water draining cock is on the lower side and a priming pump for bleeding air is on the upper side.
AIR BLEEDING
After fuel filter is replaced and after fuel system components are removed/installed, bleed air from fuel line as
follows:
1. Prime the circuit using the priming pump (1).
2. Perform engine cranking with repeating several times until en-
gine starting.
CAUTION:
● Crank engine until it starts. Do not crank engine for more
than 30 seconds.
● Prepare a tray to collect fuel. Prevent fuel from adhering to
rubber parts, especially the engine mounting insulator.

SEC102E

WATER DRAINING
1. Prepare a tray at the drain plug open end.
2. Loosen drain plug (2), and operate priming pump to drain water
from fuel filter (1).
CAUTION:
● Water in filter is drained with fuel. Prepare larger capacity
pan than fuel filter volume.
● Drained water is mixed with fuel. Prevent fuel from adher-
ing to rubber parts such as engine mounting insulator.
3. After draining, close drain plug by hand.
CAUTION:
If drain plug is tightened excessively, it may be damaged MBIB1627E
and fuel will leak. Do not use tools to tighten drain cock.
4. Bleed air in fuel piping. Refer to EC-34, "AIR BLEEDING" .
5. Start engine and make sure there is no fuel leakage.
Injector Adjustment Value Registration BBS00CF0

DESCRIPTION
Injector adjustment value indicates manufacturing tolerance and the value is printed on the top of fuel injector.
The injector adjustment value which is correctly stored in ECM is needed for precise fuel injection control.
A performance of emission control and a drivability may effect when there is a mismatch between the following
two values.
● The injector adjustment value stored in ECM
● The injector adjustment value of the injector which is installed on the vehicle
Injector Adjustment Value Registration must be performed after the following cases.
● Fuel injector(s) are replaced.
● ECM is replaced.
For the first case, Injector Adjustment Value Registration for the replaced fuel injector must be performed. And
for the second case, Injector Adjustment Value Registration for all the fuel injectors must be performed.

EC-34
 BASIC SERVICE PROCEDURE
[ZD30DDTi WITH COMMON RAIL]

MBIB1648E

1. Injector adjustment value

Example: Injector adjustment value = C1TGMA
EC
OPERATION PROCEDURE
NOTE:
Before performing this procedure, record injector adjustment value printed on a fuel injector.
1. Turn ignition switch ON (engine stopped).
2. Select “ENTER INJECTOR CALIB DATA” in “WORK SUPPORT” mode with CONSULT-II.
3. Touch “START”.
NOTE:
When touching “START”, CONSULT-II reads injector adjustment values stored in ECM.
4. Select the number of the cylinder which needs Injector Adjustment Value Registration.
5. Input injector adjustment value, and touch “ENTER”.
NOTE:
Input injector adjustment value is stored in CONSULT-II.
6. Repeat step 4 - 5 till there is no cylinder which needs Injector Adjustment Value Registration, and touch
“START”.
NOTE:
When touching “START”, injector adjustment values stored in CONSULT-II are written onto ECM memory.
7. After “CMND FINISHED” is displayed, make sure that the following values are same for each cylinder.
● Injector adjustment value which is printed on a fuel injector.

● Injector adjustment value which is displayed on CONSULT-II screen.

NOTE:
● In this step, CONSULT-II reads injector adjustment values stored in ECM and displays the values on the
CONSULT-II screen. This is for checking if injector adjustment values are written onto ECM memory cor-
rectly.
● If DTC is detected, perform DTC Confirmation Procedure for the DTC, and check if the same DTC is
detected again.

EC-35
 BASIC SERVICE PROCEDURE
[ZD30DDTi WITH COMMON RAIL]
8. Turn ignition switch OFF and wait at least 10 seconds.

MBIB1628E

EC-36
 BASIC SERVICE PROCEDURE
[ZD30DDTi WITH COMMON RAIL]
EGR Volume Control Valve Closed Position Learning Value Clear BBS00CPJ

EGR volume control valve closed position learning value should be cleared under the following cases.
● EGR volume control valve is removed.
● EGR volume control valve is replaced.
OPERATION PROCEDURE
1. Start engine and warm it up to normal operating temperature.
2. Turn ignition switch OFF and wait at least 30 seconds.
3. Turn ignition switch ON.
4. Select “EGR/V LEARN CLR” in “WORK SUPPORT” mode with
CONSULT-II.

EC

MBIB1629E

5. Touch “CLEAR” and wait a few seconds.

MBIB1630E

6. Make sure the “CMPLT” is displayed on CONSULT-II screen.

MBIB1631E

EGR Volume Control Valve Closed Position Learning BBS00CPK

EGR Volume Control Valve Closed Position Learning is an operation to learn the fully closed position of the
EGR volume control valve by monitoring the EGR volume control valve control position sensor output signal. It
must be performed under any of the following conditions:
● EGR volume control valve is removed.
● EGR volume control valve is replaced.
● ECM is replaced.
OPERATION PROCEDURE
1. Start engine and warm it up to normal operating temperature.
2. Turn ignition switch OFF and wait at least 10 seconds.

EC-37
 BASIC SERVICE PROCEDURE
[ZD30DDTi WITH COMMON RAIL]
Make sure that EGR volume control valve moves during above 10 seconds by confirming the operating
sound.

EC-38
 BASIC SERVICE PROCEDURE
[ZD30DDTi WITH COMMON RAIL]
Throttle Valve Closed Position Learning Value Clear B88888

Throttle valve closed position learning value should be cleared under the following cases.
● Electric throttle control actuator is removed.
● Electric throttle control actuator is replaced.
OPERATION PROCEDURE
1. Start engine and warm it up to normal operating temperature.
2. Turn ignition switch OFF and wait at least 30 seconds.
3. Turn ignition switch ON.
4. Select “TP POS LEARN CLR” in “WORK SUPPORT” mode with
CONSULT-II.

EC

SEC080E

5. Touch “CLEAR” and wait a few seconds.

SEC081E

6. Make sure the “CMPLT” is displayed on CONSULT-II screen.

SEC082E

Throttle Valve Closed Position Learning B88886

Throttle Valve Closed Position Learning is an operation to learn the fully closed position of the throttle valve by
monitoring the throttle position sensor output signal. It must be performed each time harness connector of elec-
tric throttle control actuator or ECM is disconnected.
● Electric throttle control actuator is removed.
● Electric throttle control actuator is replaced.
● ECM is replaced.
OPERATION PROCEDURE
1. Make sure that accelerator pedal is fully released.
2. Turn ignition switch ON.

EC-39
 BASIC SERVICE PROCEDURE
[ZD30DDTi WITH COMMON RAIL]
3. Turn ignition switch OFF and wait at least 10 seconds.
Make sure that throttle valve moves during above 10 seconds by confirming the operating sound.
Injection Tube And Common Rail Assembly B88884

REMOVAL AND INSTALLATION

MBIB9138E

1. Injector tube No. 1 2. Injector tube No. 2 3. Injector tube No. 3

4. Injector tube No. 4 5. Fuel tube 6. Fuel injector No. 1*
7. Fuel injector No. 2* 8. Fuel injector No. 3* 9. Fuel injector No. 4*
10. Common rail assembly 11. Injection tube clamp (Upper) 12. Injection tube clamp (Lower)
13. Eye connector 14. Fuel hose 15. Check valve**
16. Spill tube 17. Spill tube bracket (Lower) 18. Fuel return tube
19. Fuel feed tube 20. Fuel pump feed hose 21. Fuel pump return hose
22. Spill hose 23. Rubber 24. Spill tube bracket (Upper)
25. Copper washer 26. Eye bolt
A. From injector B. From fuel pump C. To fuel pump
D. Flow of fuel E. To tank F. From tank
G. Refer to text for tightening order
: Flow of fuel
*: Refer to GI section for symbol marks in the figure.
**: Refer to text
Refer to GI-9 for symbol marks in the figure.

CAUTION:
● Make sure that no foreign materials attach and enter into the paths when disassembling fuel piping.
● Do not disassemble common rail assembly.

EC-40
 BASIC SERVICE PROCEDURE
[ZD30DDTi WITH COMMON RAIL]
● Except eye bolt and eye connector, do not remove any part such fuel pressure sensor, plugs, etc
from the common rail assembly.
● Injector tube and fuel tube are not reusable. Replace by new ones if removed.
● Handle common rail carefully and avoid impacts.
Removal
1. For all injectors 1 to 4 proceed as follow:
a. Disconnect injector harness connectors (1) from injector.
b. Pull up to release injector cover (2) from injector.
c. Remove each injection tube.
● Loosen injection tubes at fuel injector side retaining inlet con-
nector of fuel injector with a spanner to prevent it from loosing.
2. Remove all spill tube, spill hose connector with the following pro- EC
cedure:
a. Disconnect spill hose on common rail assembly side.

MBIB9104E

b. Push and pull fuel injector fixing clip to release the spill tube con-
nector from the injector.
CAUTION:
● Do not remove the clip

● Replace the clip if it has been removed.

● Remove spill tube.

3. Disconnect spill hose from return tube.

KBIA2319E

4. Using two spanners, loose fuel tube (1) on fuel pump (2).
5. Loose the fuel supply tube on the common rail assembly.

MBIB9101E

6. Remove mountings bolts and remove common rail assembly

from the cylinder head.

MBIB9106E

EC-41
 BASIC SERVICE PROCEDURE
[ZD30DDTi WITH COMMON RAIL]
Installation
CAUTION:
While tightening injector tubes or fuel tube, prevent partner part to move by meaning of a spanner, so
as not to stress or loose the part.
1. Use a new copper washer and install eye connector and eye bolt to the common rail assembly.
2. Install common rail to cylinder head and tighten mountings bolts
to the specified torque.
: 29.5 N·m (3.0 kg-m, 22 ft-lb)

MBIB9106E

3. Finger tightens fuel injector connections (1), common rail con-

nections (2) and fuel pump connection (3).

MBIB9134E

4. Finger tightens injection tubes clamp (Lower) bolt.

5. Finger tightens injection tubes clamp (Upper) bolt.

MBIB9135E

6. Tighten connections (1) and (3) to the specified torque.

: 29.5 N·m (3.0 kg-m, 22 ft-lb)

MBIB9136E

EC-42
 BASIC SERVICE PROCEDURE
[ZD30DDTi WITH COMMON RAIL]
7. Tighten connections (2) to the specified torque.
: 29.5 N·m (3.0 kg-m, 22 ft-lb)

MBIB9137E

8. Tighten injection tubes clamp (Lower) bolt.

: 28.0 N·m (2.9 kg-m, 21 ft-lb) EC

9. Tighten injection tubes clamp (Upper) bolt.

: 28.0 N·m (2.9 kg-m, 21 ft-lb)

MBIB9135E

10. Install check valve of fuel hose between common rail assembly
and spill tube, then the side of large diameter (in the direction of
the arrow) need to be at the side of common rail.
CAUTION:
Fuel hose is not reusable. Replace by a new one if removed
from the check valve.
11. Apply diesel fuel around O-ring spill tube connector.

PBIC1797E

12. Open fuel injector head clip with clip pushed.

CAUTION:
● Do not remove the clip.

● Replace the clip if it is removed.

13. Insert spill tube to fuel injector.

14. Release the clip to original position and fix it.
CAUTION:
Replace O-ring of spill tube connector.
15. Pull up spill tube connector by hand, and make sure that it does
not disconnect. KBIA2320E

16. Connect fuel hose to common rail assembly.

Inspection After Installation
Start engine, increase the engine speed, and make sure that there is no fuel leakage.

EC-43
 BASIC SERVICE PROCEDURE
[ZD30DDTi WITH COMMON RAIL]
Fuel Injector B88880

REMOVAL AND INSTALLATION

KBIA2266E

1. Fuel injector 2. O-ring 3. Nozzle gasket

4. Cylinder head bolt 5. Fuel injector support 6. Washer

CAUTION:
Make sure that no foreign materials attach and enter into the paths when disassembling fuel piping.
Removal
1. Remove rocker cover. Refer to EM section.
2. Remove fuel injector support bolt.
3. Remove fuel injector from cylinder head.
● Remove fuel injector support while removing.

CAUTION:
● Handle fuel injector carefully and avoid impacts.

● Identify installation position of fuel injector. Arrange re-

moved parts to prevent mixing them up.
● Do not disassemble fuel injector.

4. Remove O-ring from fuel injector.

5. Remove nozzle gasket from fuel injector. PBIC2214E

● Remove nozzle gasket from cylinder head mounting hole if it is not at top of fuel injector.

Installation
NOTE:
In this section, information about non-reusable parts is shown in the text considering these parts' characteris-
tics. (In other sections, information about non-reusable parts is shown in Component Parts Location.)

EC-44
 BASIC SERVICE PROCEDURE
[ZD30DDTi WITH COMMON RAIL]
1. Record “IMA DATA (ALPHA NUM CODE)” on the top surface
when replacing fuel injector.
● Refer to EM section for use of “IMA DATA (ALPHA NUM
CODE)”.

KBIA2268E

2. Assemble O-ring and nozzle gasket to fuel injector.

● Apply grease around the O-ring. EC
● Install fuel injector in its original position.

CAUTION:
Replace O-ring and nozzle gasket.
3. Insert fuel injector to cylinder head.
● Install fuel injector support while inserting.

● Set one side of fuel injector support to the top of cylinder head
bolt.
4. Tighten fuel injector support bolt. PBIC2214E

● Install washer so that the curved surface side faces downward (fuel injector support side).

5. Reinstall removed parts in the reverse order of removal.

Inspection After Installation
Input “IMA DATA (ALPHA NUM CODE)” to ECM after installing to the
vehicle when replacing fuel injector.

KBIA2268E

EC-45
 BASIC SERVICE PROCEDURE
[ZD30DDTi WITH COMMON RAIL]
Fuel Pump B88876

REMOVAL AND INSTALLATION

MBIB9090E

1. Fuel pump 2. Fuel pump mounting 3. Gasket

4. O-ring 5. Oldham coupling 6. Stud
7. Gear case 8. Rear plate 9. Washer
Refer to GI section for symbol marks in the figure.

Removal
1. Remove fuel supply tube from fuel pump supply and common rail assembly. Refer to EM section.
2. Disconnect fuel feed and return hoses from the fuel pump.
3. Remove fuel pump mounting bolts.
4. Remove fuel taking care to not drop the Oldham coupling from the fuel pump.
5. If removal of fuel mounting is requires, proceed as follow:
● Remove chain cover. Refer to EM section.

● Remove fuel pump sprocket, and fuel pump gear.

● Remove oil feed eye bolt.

● Remove bolts securing the fuel pump mounting on the front

plate and remove the fuel pump mounting.

MBIB9098E

EC-46
 BASIC SERVICE PROCEDURE
[ZD30DDTi WITH COMMON RAIL]
Installation
Install in the reverse order of removal paying attention to the followings points:
● Replace fuel supply pump O-ring by a new one.
● Before installation of the fuel, rotate the engine so, the thin notch-
es on the inner bearing of fuel pump bracket (3) are in the vertical
position.
● In this position, center the position of the Oldham coupling (1) on
the fuel supply (2) in the manner to obtain the same gap "a" on
both sides.
● Tighten fuel pump and fuel mounting to the specified torque.
● Replace old fuel pump tube by a new one. Refer to EM section.
● For assembling order of oil feed tubes, refer to EM section.
EC

MBIB9057E

Inspection After Installation

Start engine, and increase engine speed to check for fuel leakage.

EC-47
 ON BOARD DIAGNOSTIC (OBD) SYSTEM
[ZD30DDTi WITH COMMON RAIL]
ON BOARD DIAGNOSTIC (OBD) SYSTEM PFP:00028

Introduction BBS00CF1

The ECM has an on board diagnostic system, which detects malfunctions related to engine sensors or actua-
tors. The ECM also records various emission-related diagnostic information including:
Emission-related diagnostic information ISO Standard
Diagnostic Trouble Code (DTC) Service $03 of ISO 15031-5
Freeze Frame data Service $02 of ISO 15031-5
1st/2nd Trip Diagnostic Trouble Code (1st/2nd Trip DTC) Service $07 of ISO 15031-5
1st/2nd Trip Freeze Frame data
Calibration ID Service $09 of ISO 15031-5

The above information can be checked using procedures listed in the table below.
×: Applicable —: Not applicable
DTC 1st trip DTC 2nd trip DTC Freeze Frame data
CONSULT-II × × × ×
GST × × × ×

The malfunction indicator (MI) on the instrument panel lights up when the same malfunction is detected in three
consecutive trips (Three trip detection logic).
Three Trip Detection Logic and One Trip Detection Logic BBS00CF2

On board diagnosis (OBD) system of this vehicle has “Three Trip Detection Logic” and “One Trip Detection Log-
ic”. For which logic each self-diagnosis corresponds with, refer to EC-48, "EMISSION-RELATED DIAGNOSTIC
INFORMATION ITEMS" .
“Trip” of “Three Trip Detection Logic” means a driving mode in which the self-diagnosis is performed while driv-
ing.
THREE TRIP DETECTION LOGIC
When a malfunction is detected for the first time, 1st trip DTC and 1st trip Freeze Frame Data are stored in the
ECM memory. MI does not illuminate at this stage. <1st trip>
When the same malfunction is detected again during the next driving, 2nd trip DTC and 2nd trip Freeze Frame
Data are stored in the ECM memory and 1st trip DTC and 1st trip Freeze Frame Data are cleared from the ECM
memory. MI does not illuminate at this stage. <2nd trip>
When the same malfunction is detected again at the third driving, DTC and Freeze Frame Data are stored in
the ECM memory and 2nd trip DTC and 2nd trip Freeze Frame Data are cleared from the ECM memory. MI
illuminates at the same time when DTC is stored. <3rd trip>
In other words, DTC and Freeze Frame Data are stored and MI illuminates when the same malfunction occurs
in 3 consecutive trips.
This is called “Three Trip Detection Logic”.
ONE TRIP DETECTION LOGIC
When a malfunction is detected for the first time, DTC and Freeze Frame Data are stored in the ECM memory
and MI lights up. This is called “One Trip Detection Logic”. Some self-diagnoses will not illuminate MI when DTC
is stored. (Refer to EC-48, "Emission-related Diagnostic Information" .) 1st/2nd trip DTC is not stored for one
trip detection logic.
Emission-related Diagnostic Information BBS00CF3

EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS

X: Applicable —: Not applicable

Items DTC*1 MI lighting Reference

Trip
(CONSULT-II screen item) 2 up page
CONSULT-II ID FLAG* GST*3
CAN COMM CIRCUIT U1000 4 U1000 3 × EC-108
CAN COMM CIRCUIT U1001 4 U1001 1 — EC-108
1 (M/T) — (M/T)
CONTROL UNIT(CAN) U1010 4 U1010 EC-111
3 (A/T) × (A/T)

EC-48
 ON BOARD DIAGNOSTIC (OBD) SYSTEM
[ZD30DDTi WITH COMMON RAIL]

Items DTC*1 MI lighting Reference

Trip
(CONSULT-II screen item) up page
CONSULT-II ID FLAG*2 GST*3
NO DTC IS DETECTED.
FURTHER TESTING P0000 — P0000 — — —
MAY BE REQUIRED.
CMP/CKP RELATION P0016 1 P0016 3 × EC-113
1 P0048
2 P0047
TC BOOST SOL/CIRC P0045 3 × EC-115
4 P0045
8 P0046
1 P0080 1 —
EC
2 P0079 1 —
EXH GAS CONT/V P0078 EC-121
4 P0078 1 —
8 P0078 1 —
LOW FUEL PRES P0087 1 P0087 3 × EC-128
HIGH FUEL PRES P0088 1 P0088 3 × EC-131
4
FUEL PUMP P0090 P0090 3 × EC-133
8
FUEL PUMP P0091 2 P0091 3 × EC-138
FUEL PUMP P0092 1 P0092 3 × EC-138
FUEL LEAK P0093 1 P0093 3 × EC-143
1 P0103
MAS AIR FLOW SEN P0100 3 × EC-145
2 P0102
1 P0113
INTAIR TEMP SEN P0110 3 × EC-150
2 P0112
1 P0118
COOLANT TEMP SEN P0115 3 × EC-155
2 P0117
1 P0123
ACCEL POS SENSOR P0120 3 × EC-160
2 P0122
1 P0193
CR PRES SEN P0190 3 × EC-167
2 P0192
CYL1 INJECTOR P0201 4 P0201 3 × EC-172
CYL2 INJECTOR P0202 4 P0202 3 × EC-172
CYL3 INJECTOR P0203 4 P0203 3 × EC-172
CYL4 INJECTOR P0204 4 P0204 3 × EC-172
ENG OVER TEMP P0217 1 P0217 1 × EC-178
1 P0223
ACCEL POS SENSOR P0220 3 × EC-186
2 P0222
TC SYSTEM P0234 2 P0234 1 — EC-193
1 P0238
TC BOOST SEN/CIRC P0235 3 × EC-200
2 P0237
1
CYL1 INJECTOR P0262 P0262 3 × EC-206
4
1
CYL2 INJECTOR P0265 P0265 3 × EC-206
4

EC-49
 ON BOARD DIAGNOSTIC (OBD) SYSTEM
[ZD30DDTi WITH COMMON RAIL]

Items DTC*1 MI lighting Reference

Trip
(CONSULT-II screen item) up page
CONSULT-II ID FLAG*2 GST*3
1
CYL3 INJECTOR P0268 P0268 3 × EC-206
4
1
CYL4 INJECTOR P0271 P0271 3 × EC-206
4
TC SYSTEM P0299 1 P0299 1 — EC-211
1 P0335
CKP SEN/CIRCUIT P0335 3 × EC-218
2 P0336
1 P0340
CMP SEN/CIRCUIT P0340 3 × EC-224
2 P0341
1
2
GLOW RELAY P0380 P0380 3 × EC-231
4
8
EGR SYSTEM P0400 1 P0400 3 × EC-236
EGR SYSTEM P0401 1 P0401 3 × EC-244
EGR SYSTEM P0403 8 P0403 3 × EC-253
1 P0490
EGR VALVE P0404 2 P0489 3 × EC-255
4 P0404
1 P0406
EGR SYSTEM P0409 3 × EC-261
2 P0405
1 P0692 1 —
2 P0691 1 —
COOLING FAN RELAY P0480 EC-268
4 P0480 1 —
8 P0480 1 —
VEHICLE SPEED P0500 8 P0500 1 — EC-273
8 —
BRAKE SW/CIRCUIT P0504 P0504 1 EC-275
8 —
1 P0523 1 —
OIL PRESS SEN P0520 EC-284
2 P0522 1 —
1 P0578 1 —
STRG SW/CIRC P0581 EC-290
1 P0581 1 —
ECM P0606 — P0606 3 × EC-297
ECM P0607 — P0607 1 — EC-299
1
2
ECM P0611 P0611 3 × EC-301
4
8
ETC ACTR P0638 8 P0638 1 — EC-303
1 P0643
SENSOR PWR/CIRC1 P0641 3 × EC-309
2 P0642

EC-50
 ON BOARD DIAGNOSTIC (OBD) SYSTEM
[ZD30DDTi WITH COMMON RAIL]

Items DTC*1 MI lighting Reference

Trip
(CONSULT-II screen item) up page
CONSULT-II ID FLAG*2 GST*3
1 P0647 1 —
2 P0646 1 —
A/C RELAY P0645 EC-315
4 P0645 1 —
8 P0645 1 —
1 P0653
SENSOR PWR/CIRC2 P0651 3 × EC-319
2 P0652
4
SWIRL CONT VALVE P0660 P0660 3 × EC-324
8
SWIRL CONT VALVE P0661 2 P0661 3 × EC-330 EC
SWIRL CONT VALVE P0662 1 P0662 3 × EC-330
1 P0699
SENSOR PWR/CIRC3 P0697 3 × EC-336
2 P0698
PNP SW/CIRC P0705 4 P0705 3 × AT section
ATF TEMP SEN/CIRC P0710 4 P0710 3 × AT section
VEH SPD SE/CIR A/T P0720 4 P0720 3 × AT section
ENG SPEED SIG P0725 4 P0725 3 × AT section
A/T 1ST GR FNCTN P0731 4 P0731 3 × AT section
A/T 2ND GR FNCTN P0732 4 P0732 3 × AT section
A/T 3RD GR FNCTN P0733 4 P0733 3 × AT section
A/T 4TH GR FNCTN P0734 4 P0734 3 × AT section
TCC SOLENID/CIRC P0740 4 P0740 3 × AT section
L/PRESS SOL/CIRC P0745 4 P0745 3 × AT section
SFT SOL A/CIRC P0750 4 P0750 3 × AT section
SFT SOL B/CIRC P0755 4 P0755 3 × AT section
FUEL PUMP P1089 1 P0089 3 × EC-342
FUEL PUMP P1090 1 P0089 3 × EC-345
CYL1 CYL4 INJECTOR P1276 1 P1276 3 × EC-347
CYL 2 CYL3 INJECTOR P1277 1 P1277 3 × EC-347
EGR VALVE P1409 1 P1409 3 × EC-352
2
ECM P1603 P0603 3 × EC-355
4
1
P1610 -
NATS MALFUNCTION P1610 - P1616 2 1 — EL section
P1616
4
INJ ADJ VAL P1625 4 P1625 3 × EC-357
O/R CLTCH SOL/CIRC P1760 4 P1760 3 × AT section
1 P2103 1 —
2 P2102 1 —
ETC MOT P2100 EC-359
4 P2100 1 —
4 P2101 1 —
ETC MOT P2101 8 P2101 1 — EC-365
ETC MOT P2118 1 P2118 1 — EC-371
ETC ACTR P2119 1 P2119 1 — EC-378

EC-51
 ON BOARD DIAGNOSTIC (OBD) SYSTEM
[ZD30DDTi WITH COMMON RAIL]

Items DTC*1 MI lighting Reference

Trip
(CONSULT-II screen item) up page
CONSULT-II ID FLAG*2 GST*3
APP SENSOR P2135 8 P2135 3 × EC-380
1 P2146
INJ PWR/CIRC P2146 3 × EC-387
8 P0200
1 P2149
INJ PWR/CIRC P2149 3 × EC-387
8 P0200
1 P2229
BARO SENSOR P2226 3 × EC-392
2 P2228
1 P2622 3 ×
TP SEN/CIRCUIT P2620 EC-394
2 P2621 3 ×
*1: 1st trip DTC No. and 2nd trip DTC No. are the same as DTC No.
*2: This item is displayed in Freeze Frame Data of CONSULT-II.
*3: This number is prescribed by ISO 15031-6.

DTC AND 1ST/2ND TRIP DTC

The number of 1st/2nd trip DTC is the same as the number of DTC.
When a malfunction is detected during 1st trip, 1st trip DTC is stored in the ECM memory. MI does not illuminate
at this time. When the same malfunction is detected in the next trip (2nd trip), 2nd trip DTC is stored in the ECM
memory and 1st trip DTC is cleared from the ECM memory. MI does not illuminate at this time. In addition, DTC
is stored in the ECM memory and MI lights up when the same malfunction is detected during the following con-
secutive trip (3rd trip).
The procedure for erasing DTC, 1st trip DTC, and 2nd trip DTC from the ECM memory is described in EC-48,
"EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS" .
For malfunctions in which 1st/2nd trip DTC are displayed, Refer to EC-48, "Emission-related Diagnostic Infor-
mation" .
1st/2nd trip DTC is specified in Service $07 of ISO15031-5. 1st/2nd trip DTC detection occurs without lighting
up MI and therefore does not warn the driver of a malfunction.
When 1st/2nd trip DTC is detected, check, print out or write down, and erase 1st/2nd trip DTC as specified with
step II of Work Flow, refer to EC-60, "WORK FLOW" . Then perform DTC Confirmation Procedure or Overall
Function Check to try to duplicate the malfunction. If the malfunction is duplicated, it is necessary to investigate
the cause again.
How to Read DTC and 1st/2nd Trip DTC
DTC and 1st/2nd trip DTC can be read by the following procedures.
With CONSULT-II
With GST
CONSULT-II or GST (Generic Scan Tool): Examples: P0016, P0335, P1409, etc.
These numbers are prescribed by ISO 15031-6.
(CONSULT-II also displays the malfunctioning parts and systems.)
A sample of CONSULT-II display for DTC and 1st/2nd trip DTC is
shown in the figure. DTC and 1st/2nd trip DTC are displayed in the
“SELF-DIAG RESULTS” mode of CONSULT-II.
“TIME” data shows how many times the vehicle was driven after the
last detection of DTC or 1st/2nd trip DTC. When DTC or 1st/2nd trip
DTC has been detected currently, “TIME” becomes “CRNT” or “1t”.
● CONSULT-II displays for DTC and 1st/2nd trip DTC become the
same.
● The output of a DTC indicates a malfunction. However, GST
does not indicate whether the malfunction is still occurring or has
occurred in the past and has returned to normal. CONSULT-II PBIB2022E

can identify the malfunction status. Therefore the use of CON-

SULT-II (If available) is recommended.

EC-52
 ON BOARD DIAGNOSTIC (OBD) SYSTEM
[ZD30DDTi WITH COMMON RAIL]
FREEZE FRAME DATA
ECM records driving conditions such as calculated load value, engine coolant temperature, engine speed, ve-
hicle speed, and intake manifold pressure at the moment a malfunction is detected.
The data stored together with DTC is called Freeze Frame Data, and is displayed on CONSULT-II or GST.
Only a set of Freeze Frame Data can be stored in the ECM memory. When ECM records Freeze Frame Data,
and another Freeze Frame Data is generated after that, the first (original) Freeze Frame Data is not updated in
ECM and it remains.
When the DTC is erased from ECM memory, Freeze Frame Data is erased with DTC. The procedure for erasing
DTC is described in EC-53, "How to Erase DTC" .
HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION
How to Erase DTC
With CONSULT-II
The emission related diagnostic information in the ECM can be erased by selecting “ERASE” in the “SELF- EC
DIAG RESULTS” mode with CONSULT-II.
If DTCs are displayed for both ECM and TCM (Transmission control module), they need to be erased individ-
ually from the ECM and TCM (Transmission control module).
NOTE:
If the DTC is not for A/T related items (see EC-15, "INDEX FOR DTC" ), skip steps 2 through 4.
1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least 5
seconds and then turn it ON (engine stopped) again.
2. Turn CONSULT-II ON and touch “A/T”.
3. Touch “SELF-DIAG RESULTS”.
4. Touch “ERASE”. [The DTC in the TCM (Transmission control module) will be erased.] Then touch “BACK”
twice.
5. Touch “ENGINE”.
6. Touch “SELF-DIAG RESULTS”.

EC-53
 ON BOARD DIAGNOSTIC (OBD) SYSTEM
[ZD30DDTi WITH COMMON RAIL]
7. Touch “ERASE”. (The DTC in the ECM will be erased.)

SCIA5671E

With GST
The emission related diagnostic information in the ECM can be erased by selecting Service $04 with GST.
NOTE:
If the DTC is not for A/T related items (see EC-15, "INDEX FOR DTC" ), skip steps 2 through 4.
1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least 5
seconds and then turn it ON (engine stopped) again.
2. Perform AT section. (The DTC in the TCM will be erased.)
3. Select Service $04 with GST (Generic Scan Tool).
● If the battery is disconnected, the emission-related diagnostic information will be lost within 24
hours.
● The following data are cleared when the ECM memory is erased.
– Diagnostic trouble codes
– 1st trip diagnostic trouble codes
– 2nd trip diagnostic trouble codes
– Freeze frame data
– 1st trip freeze frame data
– 2nd trip freeze frame data
Actual work procedures are explained using a DTC as an example. Be careful so that not only the DTC, but all
of the data listed above, are cleared from the ECM memory during work procedures.

EC-54
 ON BOARD DIAGNOSTIC (OBD) SYSTEM
[ZD30DDTi WITH COMMON RAIL]
NATS (Nissan Anti-theft System) BBS00CF4

● If the security indicator lights up with the ignition switch in

the ON position or “NATS MALFUNCTION” is displayed on
“SELF-DIAG RESULTS” screen, perform self-diagnostic re-
sults mode with CONSULT-II using NATS program card. Re-
fer to NATS (Nissan Anti-Theft System) in EL section.
● Confirm no self-diagnostic results of NATS is displayed be-
fore touching “ERASE” in “SELF-DAIG RESULTS” mode
with CONSULT-II.
● When replacing ECM, initialization of NATS system and reg-
istration of all NATS ignition key IDs must be carried out with
CONSULT-II using NATS program card. SEF543X

Therefore, be sure to receive all keys from vehicle owner.

Regarding the procedure of NATS initialization and all NATS ignition key ID registration, refer to EC
CONSULT-II operation manual, NATS.
Malfunction Indicator (MI) BBS00CF5

DESCRIPTION
The MI is located on the instrument panel.
1. The MI will light up when the ignition switch is turned ON without
the engine running. This is a bulb check.
If the MI does not light up, refer to EC-439, "MI & DATA LINK
CONNECTORS" .
2. When the engine is started, the MI should go off.
If the MI remains on, the on board diagnostic system has detect-
ed an engine system malfunction.

SAT652J

EC-55
 ON BOARD DIAGNOSTIC (OBD) SYSTEM
[ZD30DDTi WITH COMMON RAIL]
ON BOARD DIAGNOSTIC SYSTEM FUNCTION
The on board diagnostic system has the following two functions.
Diagnostic Test KEY and ENG. Function Explanation of Function
Mode Status
Mode I Ignition switch in BULB CHECK This function checks the MI bulb for damage (blown, open
ON position circuit, etc.).
If the MI does not come on, check MI circuit. (See EC-439,
"MI & DATA LINK CONNECTORS" .)

Engine stopped

Engine running MALFUNCTION This is a usual driving condition. When ECM detects a mal-
WARNING function, the MI will light up to inform the driver that a mal-
function has been detected.

DIAGNOSTIC TEST MODE I — BULB CHECK

In this mode, the MI on the instrument panel should stay ON. If it remains OFF, check the bulb. Refer to EC-
439, "MI & DATA LINK CONNECTORS" .
DIAGNOSTIC TEST MODE I — MALFUNCTION WARNING
MI Condition
ON When the malfunction is detected.
OFF No malfunction.
These DTC numbers are clarified in Diagnostic Test Mode II (SELF-DIAGNOSTIC RESULTS)

OBD System Operation Chart BBS00CF6

RELATIONSHIP BETWEEN MI, 1ST/2ND TRIP DTC, DTC, AND DETECTABLE ITEMS
● When the malfunction is detected for the first time, 1st trip DTC and 1st trip Freeze Frame Data are stored
in the ECM memory.
● When the same malfunction is detected during 2nd consecutive trip, 2nd trip DTC and 2nd trip Freeze
Frame Data are stored and 1st trip DTC and 1st trip Freeze Frame Data are cleared.
● When the same malfunction is detected during 3rd consecutive trip, DTC and Freeze Frame Data are
stored and MI illuminates. Refer to EC-48, "Three Trip Detection Logic and One Trip Detection Logic" for
details.1st/2nd trip DTC and 1st/2nd trip Freeze Frame Data are cleared from the ECM memory.
● MI will go off after the vehicle is driven 5 consecutive times with no malfunction (Driving pattern A).
● 1st/2nd trip DTC, DTC, and 1st/2nd trip Freeze Frame Data, Freeze Frame Data will be stored until the
vehicle is driven 41 times (Driving pattern B) without the same malfunction recurring. “TIME” data displayed
in the “SELF-DIAG RESULTS” mode of CONSULT-II shows the number of times the vehicle is driven with-
out the same malfunction recurring.
SUMMARY CHART
Items Trip Counter Driving Pattern
MI (goes off) 5 0 A
DTC, Freeze Frame Data (clear) 41 0 B
1st/2nd Trip DTC, 1st/2nd Freeze Frame Data
41 0 B
(clear)
Refer to EC-58 for details of pattern A and B.

EC-56
 ON BOARD DIAGNOSTIC (OBD) SYSTEM
[ZD30DDTi WITH COMMON RAIL]
RELATIONSHIP BETWEEN MI, DTC, 1ST/ 2NDTRIP DTC AND DRIVING PATTERNS

EC

MBIB1647E

EC-57
 ON BOARD DIAGNOSTIC (OBD) SYSTEM
[ZD30DDTi WITH COMMON RAIL]
*1: When the ECM satisfies driving pat- *2: When the ECM satisfies driving pat- *3: When the ECM satisfies driving pat-
tern A and detects the NG detec- tern A and detects OK detection, the tern A and detects OK detection,
tion, the NG detection counter is NG detection counter is increment. the healing counter is decrement.
decrement.
*4: When the ECM detects OK detec- *5: When the ignition switch OFF after *6: When the ECM detects OK detec-
tion and elapses 4 driving cycles, the ECM satisfies driving pattern B tion and elapses 40 driving pattern
the healing counter will be reached and detects OK detection, the B, the delete counter will be
to 0. delete counter is decrement. reached to 0.
*7: When the malfunction is detected *8: When the sam malfunction is *9: When the ECM detects NG detec-
for the first time, 1st trip DTC and detected during 2nd consecutive tion, DTC and Freeze Frame Data
1st trip Freeze Frame Data are trip, 2nd trip DTC and 2nd trip are stored.
stored in the ECM memory. Freeze Frame Data are stored and
1st trip DTC and 1st trip Freeze
Frame Data are cleared.
*10: When the detect counter is reached *11: When the same malfunction is *12: MI will go off after vehicle is driven
to 0, DTC and Freeze Frame Data detected in 3 consecutive trips, MI 5 times (driving pattern A) without
are cleared. will light up. any malfunctions.
*13: When the ECM detects 1st/2nd trip *14: When the ECM detects 3rd trip NG *15: When the healing counter is 4, the
NG detection, the time “1t” will be detection, the time “CRNT” will be time “1” will be displayed in the
displayed in the CONSULT-II Self displayed in the CONSULT-II Self CONSULT-II Self diagnostic screen.
diagnostic screen. diagnostic screen.
*16: When the healing counter is 0 and *17: The 1st/2nd trip DTC (pending DTC)
the delete counter is 40, the time is displayed in Service $07 of GST.
“5” will be displayed in the CON-
SULT-II Self diagnostic screen.

<Driving Pattern A>

Driving pattern A means the vehicle operation as follows:
Engine speed should go over 500 rpm at least 5 seconds and the DTC Confirmation Procedure is performed.
● The healing counter will be set when the malfunction is detected.
● The healing counter will be decrement when the same malfunction is not detected.
● The MI will go off when the healing counter reaches 0.
<Driving Pattern B>
Driving pattern B means the vehicle operation as follows:
Driving pattern A and (1)-(3) are satisfied.

PBIB2049E

● The delete counter will be cleared when the malfunction is detected.

● The delete counter will be decrement when the same malfunction is not detected.
● The DTC will not be displayed after the delete counter reaches 0.

EC-58
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
TROUBLE DIAGNOSIS PFP:00004

Trouble Diagnosis Introduction BBS00CF7

INTRODUCTION
The engine has an ECM to control major systems such as fuel injec-
tion control, fuel injection timing control, glow control system, etc. The
ECM accepts input signals from sensors and instantly actuators. It is
essential that both input and output signals are proper and stable. At
the same time, it is important that there are no malfunctions such as
vacuum leaks, or other malfunctions with the engine.

EC
MEF036D

It is much more difficult to diagnose a malfunction that occurs inter-

mittently rather than continuously. Most intermittent malfunctions are
caused by poor electric connections or improper wiring. In this case,
careful checking of suspected circuits may help prevent the replace-
ment of good parts.

SEF233G

A visual check only may not find the cause of the incidents. A road
test with CONSULT-II (or GST) or a circuit tester connected should
be performed. Follow the EC-60, "WORK FLOW" .
Before undertaking actual checks, take a few minutes to talk with a
customer who approaches with a driveability complaint. The custom-
er can supply good information about such incidents, especially inter-
mittent ones. Find out what symptoms are present and under what
conditions they occur. A Diagnostic Worksheet like the example on
next page should be used.
Start your diagnosis by looking for “conventional” incidents first. This
will help troubleshoot driveability incidents on an electronically con-
SEF234G
trolled engine vehicle.

EC-59
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
WORK FLOW

PBIB0477E

*1 If time data of “SELF-DIAG *2 If the incident cannot be verified, per- *3 If the on board diagnostic system
RESULTS” is other than [CRNT] or form EC-100, "TROUBLE DIAGNO- cannot be performed, check main
[1t], perform EC-100, "TROUBLE SIS FOR INTERMITTENT power supply and ground circuit.
DIAGNOSIS FOR INTERMITTENT INCIDENT" . Refer to EC-101, "POWER SUPPLY
INCIDENT" . AND GROUND CIRCUIT" .
*4 If malfunctioning part cannot be
detected, perform EC-100, "TROU-
BLE DIAGNOSIS FOR INTERMIT-
TENT INCIDENT" .

EC-60
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
Description for Work Flow
STEP DESCRIPTION
Get detailed information about the conditions and the environment when the incident/symptom occurred using the
STEP I
EC-61, "DIAGNOSTIC WORK SHEET" .
Before confirming the concern, check and write down (print out using CONSULT-II) the DTC and the freeze frame
data, then erase the DTC. The DTC and the freeze frame data can be used when duplicating the incident at STEP III
& IV. Refer to EC-48 .
STEP II
If the incident cannot be verified, perform EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
Study the relationship between the cause, specified by DTC, and the symptom described by the customer. (The
“Symptom Matrix Chart” will be useful. Refer to EC-69 .) Also check related service bulletins for information.
Try to confirm the symptom and under what conditions the incident occurs.
The “DIAGNOSTIC WORK SHEET” and the freeze frame data are useful to verify the incident. Connect CONSULT-II
STEP III to the vehicle in DATA MONITOR (AUTO TRIG) mode and check real time diagnosis results.
If the incident cannot be verified, perform EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . EC
If the malfunction code is detected, skip STEP IV and perform STEP V.
Try to detect the DTC by driving in (or performing) the DTC Confirmation Procedure. Check and read the DTC and the
freeze frame data by using CONSULT-II.
During the DTC verification, be sure to connect CONSULT-II to the vehicle in DATA MONITOR (AUTO TRIG) mode
and check real time diagnosis results.
STEP IV
If the incident cannot be verified, perform EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
In case the DTC Confirmation Procedure is not available, perform the Overall Function Check instead. The DTC can-
not be displayed by this check, however, this simplified “check” is an effective alternative.
The “NG” result of the Overall Function Check is the same as the DTC detection.
Take the appropriate action based on the results of STEP I through IV.
If the malfunction code is indicated, proceed to Trouble Diagnosis for DTC PXXXX.
STEP V
If the normal code is indicated, proceed to the Basic Inspection, EC-65 . Then perform inspections according to the
Symptom Matrix Chart. Refer to EC-69 .
Identify where to begin diagnosis based on the relationship study between symptom and possible causes. Inspect the
system for mechanical binding, loose connectors or wiring damage using (tracing) Harness Layouts.
Gently shake the related connectors, components or wiring harness with CONSULT-II set in “DATA MONITOR (AUTO
TRIG)” mode.
Check the voltage of the related ECM terminals or monitor the output data from the related sensors with CONSULT-II.
STEP VI Refer to EC-80 or EC-96 .
The Diagnostic Procedure in EC section contains a description based on open circuit inspection. A short circuit
inspection is also required for the circuit check in the Diagnostic Procedure. For details, refer to , “Circuit Inspection”.
Repair or replace the malfunction parts.
If the malfunctioning part cannot be detected, perform EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCI-
DENT" .
Once you have repaired the circuit or replaced a component, you need to run the engine in the same conditions and
circumstances which resulted in the customer's initial complaint.
Perform the DTC Confirmation Procedure and confirm the normal code (DTC P0000) is detected. If the incident is still
STEP VII
detected in the final check, perform STEP VI by using a different method from the previous one.
Before returning the vehicle to the customer, be sure to erase the unnecessary (already fixed) DTC in ECM and TCM.
(Refer to EC-53 and AT section.)

DIAGNOSTIC WORK SHEET

There are many operating conditions that lead to the malfunction of
engine components. A good grasp of such conditions can make trou-
bleshooting faster and more accurate.
In general, each customer feels differently about an incident. It is im-
portant to fully understand the symptoms or conditions for a customer
complaint.
Utilize a diagnostic worksheet like the one shown below in order to or-
ganize all the information for troubleshooting.

SEF907L

EC-61
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
Worksheet Sample

MTBL0533

EC-62
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
DTC Inspection Priority Chart BBS00CF8

If some DTCs are displayed at the same time, perform inspections one by one based on the following priority
chart.
NOTE:
● If DTC U1000 or U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC
U1000, U1001. Refer to EC-108, "DTC U1000, U1001 CAN COMMUNICATION LINE" .
● If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer
to EC-111, "DTC U1010 CAN COMMUNICATION" .
WITH CONSULT-II
Priority Detected items (DTC)
1 ● U1000 CAN communication line
● U1001 CAN communication line EC
● U1010 CAN communication
● P0016 Crankshaft position - camshaft position correlation
● P0100 Mass air flow sensor
● P0110 Intake air temperature sensor
● P0115 Engine coolant temperature sensor
● P0120 P0220 P2135 Accelerator pedal position sensor
● P0190 Fuel rail pressure sensor
● P0235 Turbocharger boost sensor
● P0335 Crankshaft position sensor
● P0340 Camshaft position sensor
● P0403 P0606 P0607 P0611 P1603 ECM
● P0409 EGR volume control valve control position sensor
● P0500 Vehicle speed sensor
● P0520 Engine oil pressure sensor
● P0641 P0651 P0697 Sensor power supply
● P1610 - P1616 NATS
● P1625 Injector adjustment value
● P2226 Barometric pressure sensor
● P2620 Throttle position sensor
2 ● P0045 Turbocharger boost control solenoid valve
● P0078 Exhaust gas control valve control solenoid valve
● P0090 P0091 P0092 P1089 P1090 Fuel pump
● P0201 P0202 P0203 P0204 P0262 P0265 P0268 P0271 P1276 P1277 P2146 P2149 Fuel injector
● P0380 Glow relay
● P0400 P0404 P1409 EGR volume control valve
● P0480 Cooling fan relay
● P0645 A/C relay
● P0638 P2100 P2101 P2118 P2119 Electric throttle control actuator
● P0660 P0661 P0662 Swirl control solenoid valve
● P0705 P0710 P0720 P0725 P0731 P0732 P0733 P0734 P0740 P0750 P0755 P1760 A/T related sensors, solenoid
valves and switches
3 ● P0087 P0088 P0093 Fuel system
● P0217 Engine over temperature (OVERHEAT)
● P0234 P0299 Turbocharger system
● P0401 EGR function
● P0504 ASCD brake switch
● P0581 ASCD steering switch

EC-63
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
WITH GST
Priority Detected items (DTC)
1 ● U1000 CAN communication line
● U1001 CAN communication line
● U1010 CAN communication
● P0016 Crankshaft position - camshaft position correlation
● P0102 P0103 Mass air flow sensor
● P0112 P0113 Intake air temperature sensor
● P0117 P0118 Engine coolant temperature sensor
● P0122 P0123 P0222 P0223 P2135 Accelerator pedal position sensor
● P0192 P0193 Fuel rail pressure sensor
● P0237 P0238 Turbocharger boost sensor
● P0335 P0336 Crankshaft position sensor
● P0340 P0341 Camshaft position sensor
● P0403 P0603 P0606 P0607 P0611 ECM
● P0405 P0406 EGR volume control valve control position sensor
● P0500 Vehicle speed sensor
● P0522 P0523 Engine oil pressure sensor
● P0642 P0643 P0652 P0653 P0698 P0699 Sensor power supply
● P1610 - P1616 NATS
● P1625 Injector adjustment value
● P2228 P2229 Barometric pressure sensor
● P2621 P2622 Throttle position sensor
2 ● P0045 P0046 P0047 P0048 Turbocharger boost control solenoid valve
● P0078 P0079 P0080 Exhaust gas control valve control solenoid valve
● P0089 P0090 P0091 P0092 Fuel pump
● P0200 P0201 P0202 P0203 P0204 P0262 P0265 P0268 P0271 P1276 P1277 P2146 P2149 Fuel injector
● P0380 Glow relay
● P0400 P0404 P0489 P0490 P1409 EGR volume control valve
● P0480 P0691 P0692 Cooling fan relay
● P0645 P0646 P0647 A/C relay
● P0638 P2100 P2101 P2102 P2103 P2118 P2119 Electric throttle control actuator
● P0660 P0661 P0662 Swirl control solenoid valve
● P0705 P0710 P0720 P0725 P0731 P0732 P0733 P0734 P0740 P0750 P0755 P1760 A/T related sensors, solenoid
valves and switches
3 ● P0087 P0088 P0093 Fuel system
● P0217 Engine over temperature (OVERHEAT)
● P0234 P0299 Turbocharger system
● P0401 EGR function
● P0504 ASCD brake switch
● P0578 P0581 ASCD steering switch

EC-64
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
Basic Inspection BBS00CF9

Precaution:
Perform Basic Inspection without electrical or mechanical loads applied;
● Headlamp switch is OFF.
● On vehicles equipped with daytime light systems, set lighting switch to the 1st position to light only
small lamps.
● Air conditioner switch is OFF.
● Heat up switch is OFF.
● Rear defogger switch is OFF.
● Steering wheel is in the straight-ahead position, etc.

1. INSPECTION START EC

1. Check service records for any recent repairs that may indicate a related incident.
2. Check the current need for scheduled maintenance, especially for fuel filter and air cleaner filter. Refer to
EM section.
3. Open engine hood and check the following:
– Harness connectors for improper connections
– Vacuum hoses for splits, kinks, or improper connections
– Wiring for improper connections, pinches, or cuts
4. Start engine and warm it up to the normal operating temperature.

>> GO TO 2.

SEF142I

2. PREPARATION FOR CHECKING IDLE SPEED

With CONSULT-II
Connect CONSULT-II to the data link connector.
Without CONSULT-II
Install diesel tacho tester to the vehicle.

>> GO TO 3.

EC-65
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
3. CHECK IDLE SPEED
With CONSULT-II
1. Select “CKPS·RPM (TDC)” in “DATA MONITOR” mode with
CONSULT-II.
2. Read idle speed.
750±25 rpm

SEF817Y

Without CONSULT-II
Read idle speed.
750±25 rpm (in Neutral position)
OK or NG
OK >> INSPECTION END
NG >> GO TO 4.

4. CHECK FOR INTAKE AIR LEAK

1. Stop engine.
2. Listen for an intake air leak after the mass air flow sensor.
OK or NG
OK >> GO TO 5.
NG >> Repair or replace.

5. BLEED AIR FROM FUEL SYSTEM

Use priming pump to bleed air from fuel system. Refer to EC-34, "AIR BLEEDING" .

>> GO TO 6.

6. CHECK IDLE SPEED AGAIN

With CONSULT-II
1. Start engine and let it idle.
2. Select “CKPS·RPM (TDC)” in “DATA MONITOR” mode with CONSULT-II.
3. Read idle speed.
750±25 rpm
Without CONSULT-II
Read idle speed.
750±25 rpm
OK or NG
OK >> INSPECTION END
NG >> GO TO 7.

EC-66
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
7. DRAIN WATER FROM FUEL FILTER
1. Stop engine.
2. Drain water from fuel filter. Refer to EC-34, "WATER DRAINING" .

>> GO TO 8.

8. CHECK IDLE SPEED AGAIN

With CONSULT-II
1. Start engine and let it idle.
2. Select “CKPS·RPM (TDC)” in “DATA MONITOR” mode with CONSULT-II.
3. Read idle speed. EC

750±25 rpm
Without CONSULT-II
Read idle speed.
750±25 rpm
OK or NG
OK >> INSPECTION END
NG >> GO TO 9.

9. CHECK AIR CLEANER FILTER

1. Stop engine.
2. Check air cleaner filter for clogging or breaks.
OK or NG
OK >> GO TO 10.
NG >> Replace air cleaner filter.

10. CHECK BATTERY VOLTAGE

Check battery voltage.
Voltage: More than 12.13V
OK or NG
OK >> GO TO 12.
NG >> GO TO 11.

11. CHECK BATTERY

Refer to EL section.
OK or NG
OK >> Check charging system.
NG >> Repair or replace.

12. CHECK COMPRESSION PRESSURE

Check compression pressure. Refer to EM section.
OK or NG
OK >> GO TO 13.
NG >> Follow the instruction of “CHECKING COMPRESSION PRESSURE”.

EC-67
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
13. CHECK IDLE SPEED AGAIN
With CONSULT-II
1. Start engine and let it idle.
2. Select “CKPS·RPM (TDC)” in “DATA MONITOR” mode with CONSULT-II.
3. Read idle speed.
750±25 rpm
Without CONSULT-II
Read idle speed.
750±25 rpm
OK or NG
OK >> INSPECTION END
NG >> 1. Replace fuel injector.
2. GO TO 3.

EC-68
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
Symptom Matrix Chart BBS00CFA

SYMPTOM

HARD/NO START/RESTART (EXCP. HA)

ENGINE STALL
EC

SYSTEM — Basic engine control system HARD TO START WHEN ENGINE IS COLD Reference
page
HARD TO START WHEN ENGINE IS HOT

HESITATION/SURGING/FLAT SPOT
NO START (without first firing)
NO START (with first firing)

WHEN DECELERATING

POOR ACCELERATION
KNOCK/DETONATION
DURING DRIVING

LACK OF POWER

LOW IDLE
AT IDLE

Warranty symptom code AA AB AC AD AE HI IDLE AF

Fuel pump 5 5 5 5 5 5 5 5 5 5 5 —
Fuel injector 3 3 3 3 3 3 3 3 3 4 4 3 3 EC-172
Glow control system 1 1 1 1 1 EC-419
Engine body 3 3 3 3 3 3 3 3 4 4 3 EM section
EC-236,
EC-244 ,
EC-253 ,
EGR system 3 3
EC-255 ,
EC-261 ,
EC-352
Air cleaner and duct 3 3 EM section
Fuel rail pressure relief valve 3 3 3 3 3 3 3 3 3 3 3 EC-143

EC-69
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
SYMPTOM

HARD/NO START/RESTART (EXCP. HA)

ENGINE STALL
SYSTEM — Basic engine control system Reference
HARD TO START WHEN ENGINE IS COLD
page

HARD TO START WHEN ENGINE IS HOT

HESITATION/SURGING/FLAT SPOT
NO START (without first firing)
NO START (with first firing)

WHEN DECELERATING

POOR ACCELERATION
KNOCK/DETONATION
DURING DRIVING

LACK OF POWER

LOW IDLE
AT IDLE

HI IDLE
Warranty symptom code AA AB AC AD AE AF
EC-133,
EC-138 ,
Fuel pump circuit 4 4 4 4 4 4 4 4 4 4 4
EC-342 ,
EC-345
Fuel injector circuit 1 1 1 1 1 1 1 1 1 1 1 1 1 EC-172
Fuel injector adjustment value 1 1 1 1 EC-34
Mass air flow sensor circuit 1 1 1 EC-145
ENGINE CONTROL

Engine coolant temperature circuit 1 1 1 1 EC-155

Engine oil pressure sensor circuit EC-284
Vehicle speed signal circuit 1 EC-273
EC-160,
EC-186,
Accelerator pedal position sensor circuit 1 1 1 EC-309,
EC-336,
EC-380
Fuel rail pressure sensor circuit EC-167
Heat up switch circuit 1 1 EC-414
Exhaust gas control valve solenoid
1 1 EC-121
valve circuit

EC-70
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
SYMPTOM

HARD/NO START/RESTART (EXCP. HA)

ENGINE STALL
EC
SYSTEM — Basic engine control system Reference
HARD TO START WHEN ENGINE IS COLD
page

HARD TO START WHEN ENGINE IS HOT

HESITATION/SURGING/FLAT SPOT
NO START (without first firing)
NO START (with first firing)

WHEN DECELERATING

POOR ACCELERATION
KNOCK/DETONATION
DURING DRIVING

LACK OF POWER

LOW IDLE
AT IDLE

HI IDLE
Warranty symptom code AA AB AC AD AE AF
Crankshaft position sensor circuit 1 1 1 1 1 1 1 1 1 1 EC-218
Camshaft position sensor circuit 3 3 EC-224
Turbocharger boost sensor circuit 1 1 1 EC-200
EC-115,
Turbocharger boost control solenoid
1 1 1 EC-193 ,
valve circuit
EC-211
Start signal circuit 1 1 1 1 1 1 1 1 1 EC-436
Ignition switch circuit 1 1 1 1 EC-101
ENGINE CONTROL

Power supply for ECM circuit 1 1 1 1 EC-101

EC-324,
Swirl control valve circuit 1 1 1 1
EC-330
EC-236,
EC-244 ,
EGR volume control valve circuit 1 1 1
EC-255 ,
EC-261
Glow relay circuit 1 1 1 EC-419
ECM relay (Self shut-off) circuit 1 1 1 1 EC-101
EC-253,
EC-297,
ECM 2 2 2 2 2 2 2 2 2 2 2 2 2 EC-299,
EC-301,
EC-355
NATS (Nissan Anti-theft System) 1 EL section
1 - 5: The numbers refer to the order of inspection.
(continued on next page)

EC-71
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
SYMPTOM

OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE

ABNORMAL SMOKE COLOR

DEAD BATTERY (UNDER CHARGE)

EXCESSIVE FUEL CONSUMPTION

EXCESSIVE OIL CONSUMPTION

SYSTEM — Basic engine control system Reference

SLOW/NO RETURN TO IDLE

Can be detected by CONSULT-II?

Malfunction indicator illuminates.
page

ROUGH IDLE/HUNTING

IDLING VIBRATION

BLACK SMOKE

WHITE SMOKE
Warranty symptom code AG AH AJ AK AL AM AP HA
Fuel pump 5 5 5 5 1 1 —
Fuel injector 3 3 3 4 3 3 1 1 EC-172
Glow control system 1 EC-419
Engine body 3 3 3 3 1 3 EM section
EC-236,
EC-244 ,
EC-253 ,
EGR system 3 1 1
EC-255 ,
EC-261 ,
EC-352
Air cleaner and duct 3 EM section
Fuel rail pressure relief valve 3 3 3 3 EC-143
EC-133,
EC-138 ,
Fuel pump circuit 4 4 4 4 1 1
EC-342 ,
EC-345
Fuel injector circuit 1 1 1 1 1 1 1 1 EC-172
Fuel injector adjustment value 1 1 1 1 1 1 1 EC-34
ENGINE CONTROL

Mass air flow sensor circuit 1 1 1 EC-145

Engine coolant temperature circuit
Engine oil pressure sensor circuit
Vehicle speed signal circuit
Accelerator pedal position sensor circuit
Fuel rail pressure sensor circuit
1 1 1 1 1 EC-155
1 EC-284
1 EC-273
EC-160,
EC-186,
1 1 1 EC-309,
EC-336,
EC-380
1 1 EC-167

EC-72
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
SYMPTOM

OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE

ABNORMAL SMOKE COLOR

DEAD BATTERY (UNDER CHARGE)

EXCESSIVE FUEL CONSUMPTION

EXCESSIVE OIL CONSUMPTION

SYSTEM — Basic engine control system Reference

SLOW/NO RETURN TO IDLE

Can be detected by CONSULT-II?

Malfunction indicator illuminates.
page

ROUGH IDLE/HUNTING

IDLING VIBRATION
EC

BLACK SMOKE

WHITE SMOKE
Warranty symptom code AG AH AJ AK AL AM AP HA
Heat up swtich control circuit 1 EC-414
Exhaust gas control valve control solenoid
1 1 EC-121
valve circuit
Crankshaft position sensor circuit 1 1 1 1 EC-218
Camshaft position sensor circuit 1 1 EC-224
Turbocharger boost sensor circuit 1 1 EC-200
EC-115,
Turbocharger boost control solenoid valve cir-
1 1 1 1 EC-193 ,
cuit
EC-211
ENGINE CONTROL

Start signal circuit EC-436

Ignition switch circuit EC-101
Power supply for ECM circuit 1 1 EC-101
EC-324,
Swirl control valve circuit 1 1 1 1 1
EC-330
EC-236,
EC-244 ,
EGR volume control valve circuit 1 1 1
EC-255 ,
EC-261
Glow relay circuit 1 1 1 EC-419
ECM relay (Self shut-off) circuit EC-101
EC-253,
EC-297,
ECM 2 2 2 2 2 2 2 2 2 2 2 EC-299,
EC-301,
EC-355
NATS (Nissan Anti-theft System) 1 EL section
1 - 5: The numbers refer to the order of inspection.

EC-73

Engine Control Component Parts Location
1. Glow relay
4. Engine oil pressure sensor
7. Fuel injector
10. Mass air flow sensor (with built in
intake air temperature sensor)
13. Engine coolant temperature sensor
16. EGR volume control valve
19. A/C relay
TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
2. Swirl control valve solenoid valve
5. Turbocharger boost sensor
8. Turbocharger boost control actuator
11. Exhaust gas control valve control
solenoid valve
14. Crankshaft position sensor
17. Electric throttle control actuator (with
built in throttle position sensor, throt-
tle control motor)
EC-74
BBS00CFB
SEC083E
3. Swirl control valve actuator
6. Fuel rail pressure sensor
9. Turbocharger boost control solenoid
valve
12. Cooling fan harness connector
15. Camshaft position sensor
18. Cooling fan relay-1
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]

EC

SEC107E

1. Electric throttle control actuator (with 2. Crankshaft position sensor 3. Camshaft position sensor
built in throttle position sensor, throt-
tle control motor)
4. Engine coolant temperature sensor 5. Fuel rail pressure sensor 6. Fuel injector
7. Turbocharger boost sensor
: Vehicle front

EC-75
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]

SEC108E

1. Mass air flow sensor (with built in 2. Turbocharger boost control solenoid 3. Battery
intake air temperature sensor) valve
4. Swirl control valve actuator 5. Engine oil pressure sensor 6. Starter motor
7. Swirl control valve control solenoid 8. EGR volume control valve harness 9. Glow relay
valve connector
10. Cooling fan motor harness connec-
tor
: Vehicle front

EC-76
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]

EC

SEC109E

1. Cooling fan relay-1 2. A/C relay 3. Battery

4. Exhaust gas control valve control 5. Brake fluid reservoir tank 6. Exhaust gas control valve actuator
solenoid valve
7. ECM 8. Clutch pedal 9. Stop lamp switch
10. ASCD brake switch 11. Accelerator pedal position sensor 12. Accelerator pedal
13. Clutch switch
: Vehicle front

EC-77
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
Circuit Diagram BBS00CFC

TEC651M

EC-78
TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]

EC

TEC652M

EC-79
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
ECM Harness Connector Terminal Layout BBS00CFD

SEC117E

ECM Terminals And Reference Value BBS00CFE

PREPARATION
1. ECM (1) located as shown in the figure.
● Accelerator pedal (2)

● : Vehicle front
2. Remove ECM harness connector.

SEC097E

3. When disconnecting ECM harness connector, loosen it with le-

vers as far as they will go as shown in the figure.
● Levers (1)

● ECM (2)

● Fasten (A)

● Loosen (B)

4. Connect a break-out box (SST) and Y-cable adapter (SST) be-

tween the ECM and ECM harness connector.
● Use extreme care not to touch 2 pins at one time.

● Data is for comparison and may not be exact.

MBIB1645E

ECM INSPECTION TABLE

Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.

EC-80
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.

0 - 14V
[Engine is running]
● Warm-up condition
● Idle speed
NOTE:
The pulse cycle changes depending on rpm
101 R Fuel injector No. 3 at idle.
102 G Fuel injector No. 2 MBIB1632E

125 BR Fuel injector No. 1

0 - 14V
126 OR Fuel injector No. 4
EC
[Engine is running]
● Warm-up condition
● Engine speed: 2,000 rpm

MBIB1633E

[Engine is running]
Sensor ground
108 OR/L ● Warm-up condition Approximately 0V
(Fuel rail pressure sensor)
● Idle speed
Sensor power supply
109 B (Electric throttle control actu- [Igniton switch ON] Approximately 5V
ator position sensor)
Sensor power supply
110 W [Igniton switch ON] Approximately 5V
(Engine oil pressure sensor)
Sensor power supply
111 G (Accelerator pedal position [Ignition switch ON] Approximately 5V
sensor 1)
[Engine is running]
Sensor ground
112 B/R ● Warm-up condition Approximately 0V
(Crankshaft position sensor)
● Idle speed
Sensor power supply
113 R [Ignition switch ON] Approximately 5V
(Turbocharger boost sensor)

Sensor ground [Engine is running]

115 OR/L (Accelerator pedal position ● Warm-up condition Approximately 0V
sensor 2) ● Idle speed

Sensor ground [Engine is running]

117 R (Electric throttle control actu- ● Warm-up condition Approximately 0V
ator position sensor) ● Idle speed
[Engine is running]
Sensor ground
121 G/W ● Warm-up condition Approximately 0V
(ASCD steering switch)
● Idle speed
[Engine is running]
Sensor ground
122 B ● Warm-up condition Approximately 0V
(Engine oil pressure sensor)
● Idle speed

EC-81
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.

0 - 14V

[Engine is running]
● Warm-up condition
● Idle speed

SEC113E
Turbocharger boost control
123 R/B
solenoid valve
0 - 14V

[Engine is running]
● Warm-up condition
● Engine speed: 2,000 rpm

SEC114E

[Engine is running]
Sensor ground
129 L ● Warm-up condition Approximately 0V
(Camshaft position sensor)
● Idle speed
[Engine is running]
Sensor ground
131 B ● Warm-up condition Approximately 0V
(Sensors shield circuit)
● Idle speed
[Engine is running]
Sensor ground
132 B ● Warm-up condition Approximately 0V
(Turbocharger boost sensor)
● Idle speed
Sensor power supply
135 W/L (Accelerator pedal position [Ignition switch ON] Approximately 5V
sensor 2)

0 - 6V
[Engine is running]
● Warm-up condition
● Idle speed
NOTE:
The pulse cycle changes depending on rpm
at idle.
MBIB1635E
136 BR Crankshaft position sensor
0 - 14V

[Engine is running]
● Warm-up condition
● Engine speed: 2,000 rpm

MBIB1636E

Sensor power supply

137 L/G [Ignition switch ON] Approximately 5V
(Fuel rail pressure sensor)
Sensor power supply
138 OR/L [Ignition switch ON] Approximately 5V
(EGR volume control valve)

EC-82
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.
[Ignition switch OFF]
● For a few seconds after the following con- 1 - 14V
ditions are met and ignition switch is turned
OFF.
EGR volume control valve
139 G/B – Warm-up condition
(DC motor)
– Start engine and let it idle for 3 minutes.
NOTE:
The duty cycle changes depending on MBIB1822E
EGR volume control valve operation.

Sensor ground [Engine is running]

140 Y (Accelerator pedal position ● Warm-up condition Approximately 0V EC
sensor 1) ● Idle speed

Sensor ground [Engine is running]

147 B (Intake air temperature sen- ● Warm-up condition Approximately 0V
sor) ● Idle speed

0 - 14V
[Engine is running]
● Warm-up condition
● Idle speed
NOTE:
The pulse cycle changes depending on rpm
149 G/W Fuel injector No. 2 at idle.
MBIB1637E
151 L Fuel injector No. 4
173 R/W Fuel injector No. 3
0 - 14V
174 BR/Y Fuel injector No. 1

[Engine is running]
● Warm-up condition
● Engine speed: 2,000 rpm

MBIB1638E

[Ignition switch ON] 0.3 - 1.0V

[Engine is running]
● Warm-up condition 1.6 - 2.3V
● Idle speed
155 Y/G Mass air flow sensor
[Engine is running] 1.6 - 2.3V to Approximately 3.4V
● Warm-up condition (Check for liner voltage rise in
● Engine is revving from idle to about 4,000 response to engine being
rpm. increased to about 4,000 rpm)

[Engine is running]
● Warm-up condition 1.7 - 2.3V
● Idle speed
158 W Turbocharger boost sensor
[Engine is running]
● Warm-up condition 1.7 - 2.6V
● Engine speed: 2,000 rpm

Sensor ground [Engine is running]

159 L/B (Engine coolant tempera- ● Warm-up condition Approximately 0V
ture sensor) ● Idle speed

[Engine is running] Approximately 0.2 - 4.8V

Intake air temperature sen-
160 P Output voltage varies with intake
sor ● Warm-up condition air temperature

EC-83
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.
[Engine is running]
● Warm-up condition 1.0 - 1.6V
● Idle speed
161 W/L Fuel rail pressure sensor
[Engine is running]
● Warm-up condition 2.0 - 2.7V
● Engine speed: 2,000 rpm
Approximately 4.2V
[Ignition switch OFF] ↓
Approximately 0.5V
Electric throttle control actu- ● When the engine is stopped ↓
163 W
ator position sensor Approximately 4.2V
[Ignition switch ON]
Approximately 4.2V
[Engine is running]
[Ignition switch ON]
● Engine stopped 0.4 - 1.05V
Accelerator pedal position ● Accelerator pedal: Fully released
164 L
sensor 1 [Ignition switch ON]
3.1 - 4.7V (RHD)
● Engine stopped
3.3 - 4.7V (LHD)
● Accelerator pedal: Fully depressed
[Engine is running]
● Engine speed: Below 1,200 rpm
(More than 1 minute after starting engine)
● Shift lever: P or N (A/T), Neutral (M/T)
Approximately 0.1V
Exhaust gas control valve ● Engine coolant temperature: Below 75°C
172 BR/Y (167°F)
control solenoid valve
● Stop the vehicle
● Heat up switch: ON
[Engine is running] BATTERY VOLTAGE
● Except above condition (11 - 14V)

0 - 14V

[Engine is running]
● Warm-up condition
● Idle speed

MBIB1639E
176 R Fuel pump
0 - 14V

[Engine is running]
● Warm-up condition
● Engine speed: 2,000 rpm

MBIB1640E

EC-84
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.

0 - 14V
[Engine is running]
● Warm-up condition
● Idle speed
NOTE:
The pulse cycle changes depending on rpm
at idle.
MBIB1641E
177 W Camshaft position sensor
0 - 14V

[Engine is running]
EC
● Warm-up condition
● Engine speed: 2,000 rpm

MBIB1642E

[Engine is running]
Sensor ground
178 W/L ● Warm-up condition Approximately 0V
(EGR volume control valve)
● Idle speed
[Engine is running]
180 R Engine oil pressure sensor ● Warm-up condition Approximately 1.2V
● Idle speed
[Engine is running]
Sensor ground
182 Y/L ● Warm-up condition Approximately 0V
(Mass air flow sensor)
● Idle speed

EGR volume control valve [Ignition switch ON]

184 L/G (EGR volume control valve ● Warm-up condition 1 - 4.2V
control position sensor) ● Idle speed

[Engine is running] Approximately 0.2 - 4.8V

Engine coolant temperature
185 G/R Output voltage varies with engine
sensor ● Warm-up condition coolant temperature
[Igniton switch ON]
Approximately 4.3V
● ASCD steering switch: OFF
[Igniton switch ON]
Approximately 0.3V
● MAIN switch: Pressed
[Igniton switch ON]
187 GY/R ASCD steering switch Approximately 1.3V
● CANCEL switch: Pressed
[Igniton switch ON]
Approximately 3.3V
● RESUME/ACCELERATE switch: Pressed
[Igniton switch ON]
Approximately 2.3V
● SET/COAST switch: Pressed
[Ignition switch ON]
● Engine stopped 0.2 - 0.53V
Accelerator pedal position ● Accelerator pedal: Fully released
189 L/G
sensor 2 [Ignition switch ON]
1.56 - 2.35V (RHD)
● Engine stopped
1.66 - 2.35V (LHD)
● Accelerator pedal: Fully depressed

EC-85
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.
[Ignition switch ON] Approximately 0V
192 R/W Start signal BATTERY VOLTAGE
[Ignition switch START]
(11 - 14V)
[Ignition switch ON]
Approximately 0V
● Heat up switch: OFF
194 BR/W Heat up switch
[Ignition switch ON] BATTERY VOLTAGE
● Heat up switch: ON (11 - 14V)

[Engine is running]
● Warm-up condition
● Engine speed: Below 2,600 rpm
NOTE: Approximately 0V
If the engine continues idle for more than
Swirl control valve solenoid
195 L/B 40 seconds, swirl control valve is OFF. So
valve
please depress the accelerator pedal
slightly before measurement.
[Engine is running]
BATTERY VOLTAGE
● Warm-up condition
(11 - 14V)
● Engine speed: Above 2,600 rpm
[Ignition switch OFF]
● For a few seconds after the following con-
EGR volume control valve ditions are met and ignition switch is turned
196 G/W OFF. 0V or Battery voltage (11 - 14V)
(DC motor)
– Warm-up condition
– Start engine and let it idle for 3 minutes.
201 W
BATTERY VOLTAGE
203 W Power supply for ECM [Ignition switch ON]
(11 - 14V)
205 W

202 B [Engine is running]

204 B ECM ground ● Warm-up condition Approximately 0V
206 B ● Idle speed
[Ignition switch ON] BATTERY VOLTAGE
● Clutch pedal: Slightly depressed (11 - 14V)
207 BR Clutch switch
[Ignition switch ON]
Approximately 0V
● Clutch pedal: Fully released
[Igniton switch ON] BATTERY VOLTAGE
● Brake pedal: Fully released (11 - 14V)
208 R ASCD brake switch
[Igniton switch ON]
Approximatery 0V
● Brake pedal: Slightly depressed
[Ignition switch ON]
Approximately 0V
● Shift lever: Neutral (M/T), P or N (A/T)
209 P/B Park/Neutral position switch
[Ignition switch ON] BATTERY VOLTAGE
● Shift lever: Except above (11 - 14V)

BATTERY VOLTAGE
219 B/Y Ignition switch [Ignition switch ON]
(11 - 14V)
[Ignition switch OFF]
Approximately 0V
● Brake pedal: Fully released
221 G/Y Stop lamp switch
[Ignition switch OFF] BATTERY VOLTAGE
● Brake pedal: Slightly depressed (11 - 14V)

235 W/R CAN communication line — —

EC-86
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.
236 G/B CAN communication line — —
[Engine is running] BATTERY VOLTAGE
● Cooling fan: Not operating (11 - 14V)
242 L Cooling fan relay-1
[Engine is running]
Approximatery 0.1V
● Cooling fan: Operating
[Ignition switch ON]
[Ignition switch OFF]
Approximately 1.2V
● For a few seconds after turning ignition
245 B/Y ECM relay (self-shutoff) switch OFF
[Ignition switch OFF] EC
BATTERY VOLTAGE
● More than a few seconds after turning igni- (11 - 14V)
tion switch OFF

Throttle control motor [Ignition switch OFF]

246 W 0V or Battery voltage (11 - 14V)
(DC motor) ● When the engine is stopped

0 - 14V

Throttle control motor [Ignition switch OFF]

253 PU
(DC motor) ● When the engine is stopped

SEC115E

254 LG/B Glow relay Refer to EC-419, "GLOW CONTROL SYSTEM" .

[Engine is running] BATTERY VOLTAGE
● Air conditioner switch: OFF (11 - 14V)
255 Y/L Air conditioner relay [Engine is running]
● Both air conditioner switch and blower fan Approximatery 0.1V
switch: ON (Compressor is operating)

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

CONSULT-II Function (ENGINE) BBS00CFF

FUNCTION
Diagnostic test mode Function
This mode enables a technician to adjust some devices faster and more accurately by following
Work support
the indications on the CONSULT-II unit.
Self-diagnostic results Self-diagnostic results such as DTC and freeze frame data can be read and erased quickly.*
Data monitor Input/Output data in the ECM can be read.
CAN diagnostic support monitor The results of transmit/receive diagnosis of CAN communication can be read.
Diagnostic Test Mode in which CONSULT-II drives some actuators apart from the ECMs and also
Active test
shifts some parameters in a specified range.
This mode is used to inform customers when their vehicle condition requires periodic mainte-
Function test
nance.
ECM part number ECM part number can be read.
*: The following emission-related diagnostic information is cleared when the ECM memory is erased.
● Diagnostic trouble codes
● 1st trip diagnostic trouble codes
● 2nd trip diagnostic trouble codes
● Freeze frame data
● 1st trip freeze frame data

EC-87
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
● 2nd trip freeze frame data

ENGINE CONTROL COMPONENT PARTS/CONTROL SYSTEMS APPLICATION

DIAGNOSTIC TEST MODE
SELF-DIAG RESULTS
Item DATA
WORK FREEZE ACTIVE
MONITOR
SUPPORT DTC FRAME TEST
DATA
Crankshaft position sensor × × ×
Camshaft position sensor ×
Engine coolant temperature sensor × × × ×
Vehicle speed signal × × ×
Accelerator pedal position sensor 1 × × ×
Accelerator pedal position sensor 2 × × ×
Fuel rail pressure sensor × × ×
Mass air flow sensor × × ×
Intake air temperature sensor × ×
Turbocharger boost sensor × × ×
INPUT
Throttle position sensor × × × ×
Battery voltage × ×
Park/neutral position (PNP) switch ×
Stop lamp switch × ×
Engine oil pressure sensor ×
Heat up switch × ×
Barometric pressure sensor (built-into ECM) × ×
ASCD steering switch × ×
ASCD brake switch × ×
ENGINE CONTROL COMPONENT PARTS

Clutch switch ×
Fuel pump × ×
Fuel injector × × × ×
Glow relay × ×
Cooling fan relay ×
A/C relay × ×
OUTPUT
Throttle control motor × × ×
Turbocharger boost control solenoid valve × ×
Swirl control valve control solenoid valve × × ×
EGR volume control valve × × × ×
Exhaust gas valve control valve solenoid valve × ×
X: Applicable

INSPECTION PROCEDURE
Refer to GI section.

EC-88
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
WORK SUPPORT MODE
Work Item
WORK ITEM DESCRIPTION USAGE
ENTER INJCTR CALIB DATA ● Injector adjustment value is written onto ECM memory. When performing Injector Adjust-
ment Value Registration.
EGR volume control valve closed
position learning value should be
cleared under the following cases.
● EGR volume control valve learning value stored in ECM is
EGR/V LEARN CLR ● EGR volume control valve is
cleared.
removed.
● EGR volume control valve is
replaced.
Electric throttle control actuator EC
closed position learning value
should be cleared under the fol-
● Electric throttle control actuator learning value stored in lowing cases.
TP POS LEARN CLR
ECM is cleared. ● Electric throttle control actuator
is removed.
● Electric throttle control actuator
is replaced.

SELF-DIAGNOSTIC MODE
Self Diagnostic Item
Regarding items detected in “SELF-DIAG RESULTS” mode, refer to — EC-48, "EMISSION-RELATED DIAG-
NOSTIC INFORMATION ITEMS" .
Freeze Frame Data
Freeze frame data item Description
DIAG TROUBLE CODE ● The engine control component part/control system has a trouble code, it is displayed as “PXXXX”.
[PXXXX] (Refer to EC-15, "INDEX FOR DTC" .)
CAL/LD VALUE [%] ● The calculated load value at the moment a malfunction is detected is displayed.
COOLANT TEMP [°C] or [°F] ● The engine coolant temperature at the moment a malfunction is detected is displayed.
ENGINE SPEED [rpm] ● The engine speed at the moment a malfunction is detected is displayed.
VEHICL SPEED
● The vehicle speed at the moment a malfunction is detected is displayed.
[km/h] or [mph]
INT MANI PRES [kPa] ● The intake manifold pressure at the moment a malfunction is detected is displayed.
INT/A TEMP SE [°C] or [°F] ● The intake air temperature at the moment a malfunction is detected is displayed.
FUEL/R PRESS [kPa] ● The fuel rail pressure at the moment a malfunction is detected is displayed.
MASS AIRFLOW [g/s] ● The mass air flow at the moment a malfunction is detected is displayed.
ACCEL POS SEN [mV] ● The accelerator pedal position at the moment a malfunction is detected is displayed.
TRG INJ QTY [mg/st] ● The target injection quantity at the moment a malfunction is detected is displayed.
ETC OPEN ANGL [%] ● The Electric Throttle Control Open Angle at the moment a mulfunction is detected is displayed.
● The EGR volume control valve opening angle at the moment a malfunction is detected is dis-
EGR/V ANGLE [%]
played.
● The turbocharger boost control valve position at the moment a malfunction is detected is dis-
TC V/N CONT/V [%]
played.
INFO CODE ● The ECM information code is displayed.
ID FLAG ● The DTC identification flag is displayed.

EC-89
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
DATA MONITOR MODE
ECM
MAIN
INPUT
MONITOR ITEM SIG- CONDITION SPECIFICATION
SIG-
NALS
NAL
● The engine speed computed from the
CKPS·RPM (TDC) [rpm] × × crankshaft position sensor signal is
displayed.
● The engine speed computed from the
CMPS-RPM [rpm] × × camshaft position sensor signal is dis-
played.
When the engine coolant temperature
● The engine coolant temperature
circuit is open or short, ECM enters fail-
COOLAN TEMP/S (determined by the signal voltage of
× × safe mode. The engine coolant tempera-
[°C] or [°F] the engine coolant temperature sen-
ture determined by the ECM is dis-
sor) is displayed.
played.
VHCL SPEED SE ● The vehicle speed computed form the
× ×
[km/h] or [mph] vehicle speed signal is displayed.
This signal is converted by ECM inter-
● The accelerator pedal position sensor
ACCEL POS SEN [V] × × nally. Thus, these differ from ECM termi-
1 signal voltage is displayed.
nals voltage.
This signal is converted by ECM inter-
● The accelerator pedal position sensor
ACCEL SEN 2 [V] × × nally. Thus, these differ from ECM termi-
2 signal voltage is displayed.
nals voltage.
● The Fuel rail pressure (determined by
ACT CR PRESS [MPa] × × the signal voltage of the fuel rail pres-
sure sensor) is displayed.
● The power supply voltage of ECM is
BATTERY VOLT [V] × ×
displayed.
● Indicates [ON/OFF] condition from the
P/N POSI SW [ON/OFF] × ×
park/neutral position switch signal.
● Indicates [ON/OFF] condition from the
START SIGNAL [ON/OFF] × ×
starter signal.
● Indicates [ON/OFF] condition of the air
AIR COND SIG [ON/OFF] × × conditioner switch as determined by
the air conditioner signal.
● Indicates [ON/OFF] condition from the
BRAKE SW [ON/OFF] × ×
stop lamp switch signal.
● Indicates [ON/OFF] condition from the
BRAKE SW2 [ON/OFF] × × ASCD brake switch and ASCD clutch
switch signal.
● Indicates [ON/OFF] condition from
IGN SW [ON/OFF] × ×
ignition switch signal.
● Indicates [ON/OFF] condition from
WARM UP SW [ON/OFF] ×
heat up switch signal.
● Indicates the control condition of the
AIR COND RLY [ON/OFF] × air conditioner relay (determined by
ECM according to the input signals).
● The glow relay control condition
GLOW RLY [ON/OFF] × (determined by ECM according to the
input signal) is displayed.
● Indicates the control condition of the
cooling fans (determined by ECM
COOLING FAN
× according to the input signal).
[ON/OFF]
ON ... Operates
OFF ... Stopped

EC-90
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
ECM
MAIN
INPUT
MONITOR ITEM SIG- CONDITION SPECIFICATION
SIG-
NALS
NAL
● The turbocharger boost control valve
TC V/N CONT/V [%]
position is displayed.
● The intake air volume computed from
INT/A VOLUME [mg/] the mass air flow sensor signal is dis-
played.
● The target injection quantity is dis-
TRG INJ QTY [mg/] ×
played.
● The barometric pressure (determined
by the signal voltage from the absolute
BARO SEN [kPa] × ×
pressure sensor built into the ECM) is EC
displayed.
● The control condition of the swirl con-
trol valve control solenoid valve (deter-
SWRL CON S/V1 [ON/ mined by ECM according to the input
×
OFF] signals) is indicated.
ON: Swirl control valve is closed
OFF: Swirl control valve is opened
● Indicates [ON/OFF] condition from
SET SW [ON/OFF]
SET/COAST switch signal.
● The throttle position sensor signal volt-
THRTL SEN [mV]
age is displayed.
● Indicates [ON/OFF] condition from
RESUME/ACC SW [ON/
× RESUME/ACCELERATE switch sig-
OFF]
nal.
● Indicates [ON/OFF] condition from
CANCEL SW [ON/OFF] ×
CANCEL switch signal.
● Indicates [ON/OFF] condition from
MAIN SW [ON/OFF] ×
MAIN switch signal.
● The EGR volume control valve control
EGR V/POS SEN [mV] position sensor signal voltage is dis-
played.
● Indicates [ON/OFF] condition from
SET LAMP [ON/OFF] SET lamp determined by the ECM
according to the input signals.
● Indicates [ON/OFF] condition from
CRUISE LAMP [ON/OFF] CRUISE lamp determined by the ECM
according to the input signals.
● Indicates [ON/OFF] condition from
CLUTCH SW [ON/OFF]
clutch switch signal.
● The turbocharger boost (determined
TURBO BST SEN [kPa] by the signal voltage of the turbo-
charger boost sensor) is displayed.
● The opening angle of Electric throttle
ETC OPEN ANGL [%]
control actuator is displayed.
● Indicates the EGR volume control
valve computed by the ECM according
EGR/V ANGLE [%] to the input signals.
● The opening becomes larger as the
value increases
● The signal voltage of engine oil pres-
OIL PRESS SEN [V]
sure sensor is displayed.
SET VHCL SPD [km/h] or
● The preset vehicle speed is displayed.
[mph]

EC-91
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
ECM
MAIN
INPUT
MONITOR ITEM SIG- CONDITION SPECIFICATION
SIG-
NALS
NAL
● The control condition of the exhaust
gas control valve control solenoid
valve (computed by ECM according to
EXH/GAS REG V [ON/ the input signals) is indicated.
OFF] ON: Exhaust gas control valve is
closed.
OFF: Exhaust gas control valve is
opened.
● Indicates the vehicle cruise condition.
NON: Vehicle speed is mantained at
the ASCD set speed.
LO SPEED CUT [NON/
CUT: Vehicle speed decreased to
CUT]
excessively low compared with the
ASCD set speed, and ASCD operation
is cut off.
● Indicates the vehicle cruise condition.
NON: Vehicle speed is mantained at
the ASCD set speed.
VHCL SPD CUT [NON/
CUT: Vehicle speed decreased to
CUT]
excessively high compared with the
ASCD set speed, and ASCD operation
is cut off.
Voltage [V]
Frequency Only “#” is displayed if item is unable to
[msec], [Hz] or [%] be measured.
DUTY-HI Voltage, frequency, duty cycle or pulse Figures with “#”s are temporary ones.
width measured by the probe. They are the same figures as an actual
DUTY-LOW piece of data which was just previously
PLS WIDTH-HI measured. [Hz] or [%]

PLS WIDTH-LOW
NOTE:
Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.

ACTIVE TEST MODE

TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY)
● Ignition switch: ON
● Turn turbocharger boost control Turbocharger boost control sole- ● Harness and connector
TC BOOST CONT/V solenoid valve ON and OFF with noid valve makes an operating
sound. ● Turbocharger boost control valve
the CONSULT-II and listen to
operation sound.
● Ignition switch: ON
The opening angle of electric throt- ● Harness and connector
THRTL POSITION ● Change electric throttle control tle control actuator is changed
actuator opening angle using properly. ● Electric throttle control actuator
CONSULT-II.
● Ignition switch: ON
● Change EGR volume control The opening angle of EGR volume ● Harness and connector
EGR/V ANGLE
valve opening angle using CON- control valve is changed properly. ● EGR volume control valve
SULT-II
● Ignition switch: ON
● Turn swirl control valve solenoid Swirl control valve solenoid valve ● Harness and connector
SWIRL CONT S/V 1 valve ON and OFF with the makes an operating sound. ● Swirl control solenoid valve
CONSULT-II and listen to opera-
tion sound.

EC-92
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY)
● Ignition switch: ON (Engine
stopped)
Glow relay makes the operating ● Harness and connector
GLOW RLY ● Turn the glow relay ON and OFF sound. ● Glow relay
using CONSULT-II and listen to
operating sound.
● Ignition switch: ON
TEARGET ETC ● Change electric throttle control The opening angle of throttle valve ● Harness and connectors
ANGLE actuator opening angle using is changed properly. ● Electric throttle control actuator
CONSULT-II.

REAL TIME DIAGNOSIS IN DATA MONITOR MODE

CONSULT-II has two kinds of triggers and they can be selected by touching “SETTING” in “DATA MONITOR”
mode. EC
1. “AUTO TRIG” (Automatic trigger):
– The malfunction will be identified on the CONSULT-II screen in
real time.
In other words, DTC will be displayed if the malfunction is detect-
ed by ECM.
At the moment a malfunction is detected by ECM, “MONITOR” in
“DATA MONITOR” screen is changed to “Recording Data... xx%”
as shown in the figure, and the data after the malfunction detec-
tion is recorded. Then when the percentage reached 100%, “RE-
AL-TIME DIAG” screen is displayed. If “STOP” is touched on the
screen during “ Recording Data... xx%”, “REAL-TIME DIAG” PBIB0480E
screen is also displayed.
The recording time after the malfunction detection and the recording speed can be changed by “TRIGGER
POINT” and “Recording Speed”. Refer to CONSULT-II OPERATION MANUAL.
2. “MANU TRIG” (Manual trigger):
– DTC will not be displayed automatically on CONSULT-II screen
even though a malfunction is detected by ECM.
DATA MONITOR can be performed continuously even though a
malfunction is detected.
Use these triggers as follows:
1. “AUTO TRIG”
– While trying to detect the DTC by performing the DTC Confirma-
tion Procedure, be sure to select to “DATA MONITOR (AUTO
TRIG)” mode. You can confirm the malfunction at the moment it SEF707X
is detected.
– While narrowing down the possible causes, CONSULT-II should be set in “DATA MONITOR (AUTO TRIG)”
mode, especially in case the incident is intermittent.
When you are inspecting the circuit by gently shaking (or twisting) the suspicious connectors, components
and harness in the DTC Confirmation Procedure, the moment a malfunction is found the DTC will be dis-
played. Refer to , “INCIDENT SIMULATION TESTS”.
2. “MANU TRIG”

EC-93
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
– If the malfunction is displayed as soon as “DATA MONITOR” is selected, reset CONSULT-II to “MANU
TRIG”. By selecting “MANU TRIG” you can monitor and store the data. The data can be utilized for further
diagnosis, such as a comparison with the value for the normal operating condition.

SEF720X

Generic Scan Tool (GST) Function BBS00CFG

DESCRIPTION
Generic Scan Tool (OBDII scan tool) complying with ISO 15031-4
has 7 different functions explained below.
ISO9141 is used as the protocol.
The name “GST” or “Generic Scan Tool” is used in this service man-
ual.

SEF139P

FUNCTION
Diagnostic test mode Function
This diagnostic service gains access to current emission-related data values, including
Service $01 READINESS TESTS
analog inputs and outputs, digital inputs and outputs, and system status information.
This diagnostic service gains access to emission-related data value which were stored by
Service $02 (FREEZE DATA)
ECM during the freeze frame. For details, refer to EC-53, "FREEZE FRAME DATA" .
This diagnostic service gains access to emission-related power train trouble codes which
Service $03 DTCs
were stored by ECM.

EC-94
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
Diagnostic test mode Function
This diagnostic service can clear all emission-related diagnostic information. This
includes:
● Clear number of diagnostic trouble codes (Service $01)
● Clear diagnostic trouble codes (Service $03)
Service $04 CLEAR DIAG INFO
● Clear trouble code for freeze frame data (Service $01)
● Clear freeze frame data (Service $02)
● Reset status of system monitoring test (Service $01)
● Clear on board monitoring test results (Service $07)
Service $06 (ON BOARD TESTS) This diagnostic service is not applicable on this vehicle.
This diagnostic service enables the off board test drive to obtain test results for emission-
Service $07 (ON BOARD TESTS) related powertrain components/systems that are continuously monitored during normal
driving conditions. EC
This diagnostic service enables the off-board test device to request specific vehicle infor-
Service $09 (CALIBRATION ID)
mation such as Vehicle Identification Number (VIN) and Calibration IDs.

INSPECTION PROCEDURE
1. Turn ignition switch OFF.
2. Connect “GST” to data link connector (1), which is located under
drivers side dash panel near the fuse box cover.
● Hood opener handle (2)

3. Turn ignition switch ON.

SEC100E

4. Enter the program according to instruction on the screen or in the

operation manual.
(*: Regarding GST screens in this section, sample screens are
shown.)

SEF398S

5. Perform each diagnostic mode according to each service proce-

dure.
For further information, see the GST Operation Manual of the
tool maker.

SEF416S

EC-95
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
CONSULT-II Reference Value in Data Monitor Mode BBS00CFH

Remarks:
● Specification data are reference values.
● Specification data are output/input values which are detected or supplied by the ECM at the connector.
* Specification data may not be directly related to their components signals/values/operations.
MONITOR ITEM CONDITION SPECIFICATION
● Run engine and compare CONSULT-II value with the tachometer indica- Almost the same speed as the
CKPS-RPM (TDC)
tion. tachometer indication
● Run engine and compare CONSULT-II valve with the tachometer indica- Almost the same as half of the
CMPS-RPM
tion. tachometer indication
COOLAN TEMP/S ● Engine: After warming up More than 70°C (158°F)
● Turn drive wheels and compare CONSULT-II value with the speedome- Almost the same speed as the
VHCL SPEED SE
ter indication speedometer indication
Accelerator pedal: Fully released 0.4 - 1.05V
1 ● Ignition switch: ON
ACCEL POS SEN* (Engine stopped) 3.1 - 4.7V (RHD)
Accelerator pedal: Fully depressed
3.3 - 4.7V (LHD)
Accelerator pedal: Fully released 0.4 - 1.05V
● Ignition switch: ON
ACCEL SEN 2*1 (Engine stopped) 3.1 - 4.7V (RHD)
Accelerator pedal: Fully depressed
3.3 - 4.7V (LHD)
● Engine: After warming up Idle 30 - 40 MPa
● Air conditioner switch: OFF
ACT CR PRESS ● Shift lever: Neutral (M/T), P or N
2,000 rpm 80 - 90 MPa
(A/T)
● No load
BATTERY VOLT ● Ignition switch: ON (Engine stopped) 11 - 14V
Shift lever: P or N (A/T), Neutral (M/
ON
P/N POSI SW ● Ignition switch: ON T)
Except above OFF
START SIGNAL ● Ignition switch: ON → START → ON OFF → ON → OFF
Air conditioner switch: OFF OFF
● Engine: After warming up, idle
AIR COND SIG Air conditioner switch: ON
the engine ON
(Compressor operates.)
Brake pedal: Fully released OFF
BRAKE SW ● Ignition switch: ON
Brake pedal: Slightly depressed ON
Brake pedal: Fully released OFF
BRAKE SW2 ● Ignition switch: ON
Brake pedal: Slightly depressed ON
IGN SW ● Ignition switch: ON → OFF ON → OFF
Heat up switch: ON ON
WARM UP SW ● Ignition switch: ON
Heat up switch: OFF OFF
Air conditioner switch: OFF OFF
● Engine: After warming up, idle
AIR COND RLY Air conditioner switch: ON
the engine ON
(Compressor operates.)
● Cooling fan: Stopped OFF
COOLING FAN
● Cooling fan: Operates ON
GLOW RLY Refer to EC-419, "GLOW CONTROL SYSTEM" .
● Engine: After warming up Idle 50 - 60%
● Air conditioner switch: OFF
TC V/N CONT/V ● Shift lever: Neutral (M/T), P or N
2,000 rpm 50 - 60%
(A/T)
● No load
INT/A VOLUME ● Engine: After warming up, idle the engine 350 - 450 mg/st

EC-96
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
MONITOR ITEM CONDITION SPECIFICATION
● Engine: After warming up Idle 5 - 10 mg/st
● Air conditioner switch: OFF
TRG INJ QTY ● Shift lever: Neutral (M/T), P or N
2,000 rpm 5 - 10 mg/st
(A/T)
● No load
Altitude
Approx. 0m: Approx. 100.62 kPa
(1.0062 bar, 1.026 kg/cm2 , 14.59
psi)
Approx. 1,000 m: Approx. 88.95
kPa (0.8895 bar, 0.907 kg/cm2 ,
BARO SEN ● Ignition switch: ON 12.90 psi)
Approx. 1,500 m: Approx. 83.16 EC
kPa (0.8316 bar, 0.848 kg/cm2 ,
12.06 psi)
Approx. 2,000 m: Approx. 78.36
kPa (0.7836 bar, 0.799 kg/cm2 ,
11.36 psi)
SET/COAST switch: Released OFF
SET SW ● Ignition switch: ON
SET/COAST switch: Pressed ON
Approximately 4.2V
● Ignition switch: OFF ↓
THRTL SEN Approximately 0.5V
● When the engine is stopped ↓
Approximately 4.2V
RESUME/ACC switch: Released OFF
RESUME/ACC SW ● Ignition switch: ON
RESUME/ACC switch: Pressed ON
CANCEL switch: Released OFF
CANCEL SW ● Ignition switch: ON
CANCEL switch: Pressed ON
MAIN switch: Released OFF
MAIN SW ● Ignition switch: ON
MAIN switch: Pressed ON
● Engine: After warming up Engine speed: Below 2,600 rpm*2 ON
● Air conditioner switch: OFF
SWRL CON S/V1 ● Shift lever: Neutral (M/T), P or N
(A/T) Engine speed: Above 2,600 rpm OFF
● No load

● Engine: After warming up, idle the engine*3

● Air conditioner switch: OFF
EGR V/POS SEN 3,800 - 4,200 mV
● Shift lever: Neutral (M/T), P or N (A/T)
● No load
● MAIN switch: ON ASCD: Operating ON
● When vehicle speed: Between
SET LAMP 48 km/h (30 MPH) and 130km/h
(81 MPH) (For Australia models), ASCD: Not operating OFF
150 km/h (93 MPH) (Except for
Australia models)
MAIN switch: Press at the 1st time →
CRUISE LAMP ● Ignition switch: ON ON → OFF
at the 2nd time
Clutch pedal: Fully released OFF
CLUTCH SW ● Ignition switch: ON
Clutch pedal: Slightly depressed ON
● Engine: After warming up Idle speed Approx. Atmospheric pressure
TURBO BST SEN ● Shift lever: Neutral (M/T), P or N
Engine speed: 2,000 rpm 100 - 110 kPa
(A/T)

EC-97
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
MONITOR ITEM CONDITION SPECIFICATION
● Ignition switch: OFF
ETC OPEN ANGL 0%
● When the engine is stopped
● Engine: After warming up, idle the engine
● Air conditioner switch: OFF
EGR/V ANGLE Approximately 100%
● Shift lever: Neutral (M/T), P or N (A/T)
● No load
OIL PRESS SEN ● Engine: After warming up, idle the engine Approximatetely 1.2V
● Vehicle stopped
● Engine speed: Below 1,200 rpm
● Engine coolant temperature: Below 87°C (189°F) ON
EXH/GAS REG V
● Stop the vehicle
● Heat up switch: ON
● Except above condition OFF
NOTE:
Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.
*1: This signal is converted by ECM internally. Thus, it differs from ECM terminal voltage.
*2: If the engine continues idle for more than 40 seconds, “SWRL CON S/V1” is OFF.
*3: If the engine continues idle for more than 40 seconds, EGR volume control valve is OFF. So please depress the accelerator pedal
slightly before measurement.

EC-98
 TROUBLE DIAGNOSIS
[ZD30DDTi WITH COMMON RAIL]
Major Sensor Reference Graph in Data Monitor Mode BBS00CFI

The following are the major sensor reference graphs in “DATA MONITOR” mode.
“ACCEL POS SEN” AND “CKPS·RPM (TDC)”
Below is the data for “ACCEL POS SEN” and “CKPS·RPM (TDC)” when revving engine quickly up to 3,000 rpm
under no load after warming up engine to the normal operating temperature.
Each value is for reference, the exact value may vary.

EC

MBIB1649E

EC-99
 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT
[ZD30DDTi WITH COMMON RAIL]
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT PFP:00006

Description BBS00CFJ

Intermittent incidents may occur. In many cases, the incident resolves itself (the part or circuit function returns
to normal without intervention). It is important to realize that the symptoms described in the customer's com-
plaint often do not recur on (1st/2nd trip) DTC visits. Realize also that the most frequent cause of intermittent
incidents occurrences is poor electrical connections. Because of this, the conditions under which the incident
occurred may not be clear. Therefore, circuit checks made as part of the standard diagnostic procedure may
not indicate the specific malfunctioning area.
COMMON INTERMITTENT INCIDENT REPORT SITUATIONS
STEP in Work Flow Situation
II The CONSULT-II is used. The SELF-DIAG RESULTS screen shows time data other than [CRNT] or [1t].
III The symptom described by the customer does not recur.
IV DTC does not appear during the (1st/2nd trip) DTC Confirmation Procedure.
VI The Diagnostic Procedure for XXXX does not indicate the malfunctioning area.

Diagnostic Procedure BBS00CFK

1. INSPECTION START
Erase DTCs. Refer to EC-53, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" .

>> GO TO 2.

2. CHECK GROUND TERMINALS

Check ground terminals for corroding or loose connection.
Refer to EC-107, "Ground Inspection" .
OK or NG
OK >> GO TO 3.
NG >> Repair or replace.

3. SEARCH FOR ELECTRICAL INCIDENT

Perform “INCIDENT SIMULATION TESTS”.
OK or NG
OK >> INSPECTION END
NG >> Repair or replace.

EC-100
 POWER SUPPLY AND GROUND CIRCUIT
[ZD30DDTi WITH COMMON RAIL]
POWER SUPPLY AND GROUND CIRCUIT PFP:24110

Wiring Diagram BBS00CFM

EC

TEC653M

EC-101
POWER SUPPLY AND GROUND CIRCUIT
[ZD30DDTi WITH COMMON RAIL]

TEC654M

EC-102
 POWER SUPPLY AND GROUND CIRCUIT
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage)
NO.
201 W
BATTERY VOLTAGE
203 W Power supply for ECM [Ignition switch ON]
(11 - 14V)
205 W

202 B [Engine is running]

204 B ECM ground ● Warm-up condition Approximately 0V
206 B ● Idle speed
EC
BATTERY VOLTAGE
219 B/Y Ignition switch [Ignition switch ON]
(11 - 14V)
[Ignition switch ON]
[Ignition switch OFF]
Approximately 1.2V
● For a few seconds after turning ignition
245 B/Y ECM relay (self-shutoff) switch OFF
[Ignition switch OFF]
BATTERY VOLTAGE
● More than a few seconds after turning igni- (11 - 14V)
tion switch OFF

Diagnostic Procedure BBS00CFN

1. INSPECTION START
Start engine.
Is engine running?
Yes or No
Yes >> GO TO 6.
No >> GO TO 2.

2. CHECK ECM POWER SUPPLY CIRCUIT-I

1. Turn ignition switch OFF and then ON.
2. Check voltage between ECM terminal 219 and ground with CON-
SULT-II or tester.
Voltage: Battery voltage
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.

MBIB1650E

3. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M51, F6
● Fuse block (J/B) connector M2
● 10A fuse
● Harness for open or short between ECM and fuse

>> Repair harness or connectors.

EC-103
 POWER SUPPLY AND GROUND CIRCUIT
[ZD30DDTi WITH COMMON RAIL]
4. CHECK GROUND CONNECTIONS-I
1. Turn ignition switch OFF.
2. Loosen and retighten ground screws.
Refer to EC-107, "Ground Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 5.
NG >> Repair or replace ground connections.
SEC119E

5. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-I

1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminals 202, 204, 206 and ground.
Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to power.
OK or NG
OK >> GO TO 6.
NG >> Repair open circuit or short to power in harness or connectors.

6. CHECK ECM POWER SUPPLY CIRCUIT-II

1. Turn ignition switch OFF.
2. Reconnect ECM harness connector.
3. Turn ignition switch ON and then OFF.
4. Check voltage between ECM terminals 201, 203, 205 and
ground with CONSULT-II or tester.
Voltage: After turning ignition switch OFF, battery
voltage will exist for a few seconds, then
drop approximately 0V.
OK or NG
OK >> GO TO 15.
NG (Battery voltage does not exist.)>>GO TO 7.
NG (Battery voltage exists for more than a few seconds.)>>GO TO
12. MBIB1651E

7. CHECK ECM POWER SUPPLY CIRCUIT-III

1. Turn ignition switch OFF and wait at least 30 seconds.
2. Check voltage between ECM terminals 245 and ground with
CONSULT-II or tester.
Voltage: Battery voltage
OK or NG
OK >> GO TO 8.
NG >> GO TO 11.

MBIB1652E

EC-104
 POWER SUPPLY AND GROUND CIRCUIT
[ZD30DDTi WITH COMMON RAIL]
8. CHECK ECM POWER SUPPLY CIRCUIT-IV
1. Disconnect ECM harness connector.
2. Disconnect ECM relay.
3. Check harness continuity between ECM terminal 201, 203, 205 and ECM relay terminal 5.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 10.
NG >> GO TO 9.

9. DETECT MALFUNCTIONING PART EC

Check the following.
● Harness connectors M50, F5
● Harness for open or short between ECM relay and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

10. CHECK ECM POWER SUPPLY CIRCUIT-V

1. Check voltage between ECM relay terminal 1, 3 and ground with
CONSULT-II or tester.
Voltage: Battery voltage
OK or NG
OK >> GO TO 17.
NG >> GO TO 11.

SEF073U

11. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors E127, M21
● 20A fuse
● Harness for open or short between ECM relay and battery

>> Repair open circuit or short to ground or short to power in harness or connectors.

12. CHECK ECM POWER SUPPLY CIRCUIT-VI

1. Disconnect ECM harness connector.
2. Disconnect fuse block (J/B) harness connector.
3. Check harness continuity between ECM terminals 245 and ECM relay terminal 2.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 14.
NG >> GO TO 13.

EC-105
 POWER SUPPLY AND GROUND CIRCUIT
[ZD30DDTi WITH COMMON RAIL]
13. DETECT MALFUNCTIONING PART
Check the following.
● Harness connectors M52, F7
● Harness for open or short between ECM relay and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

14. CHECK ECM RELAY

Refer to EC-107, "Component Inspection" .
OK or NG
OK >> GO TO 15.
NG >> Replace ECM relay.

15. CHECK GROUND CONNECTIONS-II

1. Turn ignition switch OFF.
2. Loosen and retighten ground screws.
Refer to EC-107, "Ground Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 16.
NG >> Repair or replace ground connections.
SEC119E

16. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-II

1. Check harness continuity between ECM terminals 202, 204, 206 and ground.
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to power.
OK or NG
OK >> GO TO 17.
NG >> Repair open circuit or short to power in harness or connectors.

17. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

EC-106
 POWER SUPPLY AND GROUND CIRCUIT
[ZD30DDTi WITH COMMON RAIL]
Component Inspection BBS0023F

ECM RELAY
1. Apply 12V direct current between ECM relay terminals 1 and 2.
2. Check continuity between relay terminals (1) and (2).
Condition Continuity
12V direct current supply between ter-
Yes
minals (1) and (2)
OFF No
3. If NG, replace ECM relay.

SEF090M

EC
Ground Inspection BBS00CFO

Ground connections are very important to the proper operation of electrical and electronic circuits. Ground con-
nections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an
unwanted resistance. This unwanted resistance can change the way a circuit works.
Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drasti-
cally affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit. Even when
the ground connection looks clean, there can be a thin film of rust on the surface.
When inspecting a ground connection follow these rules:
● Remove the ground bolt or screw.
● Inspect all mating surfaces for tarnish, dirt, rust, etc.
● Clean as required to assure good contact.
● Reinstall bolt or screw securely.
● Inspect for “add-on” accessories which may be interfering with the ground circuit.
● If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the
wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one
eyelet make sure no ground wires have excess wire insulation.
For detailed ground distribution information, refer to EL section.

PBIB1870E

EC-107
 DTC U1000, U1001 CAN COMMUNICATION LINE
[ZD30DDTi WITH COMMON RAIL]
DTC U1000, U1001 CAN COMMUNICATION LINE PFP:23710

Description BBS00CFP

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul-
tiplex communication line with high data communication speed and excellent error detection ability. Many elec-
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.
On Board Diagnosis Logic BBS00CFQ

This self-diagnosis has the one trip detection logic.

The MI will not light up for this self-diagnosis.
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
● When ECM is not transmitting or receiv-
● Harness or connectors
CAN communi- ing CAN communication signal other than
U1001 4 U1001 (CAN communication line is open or
cation line OBD (emission-related diagnosis) for 2
shorted)
seconds or more.
● ECM can not communicate to other con-
trol unit. ● Harness or connectors
CAN communi-
U1000 4 U1000 (CAN communication line is open or
cation line ● ECM can not communicate for more than shorted)
the specified time.

DTC Confirmation Procedure BBS00CFR

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON and wait at least 3 seconds.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. If DTC is detected, go to EC-110, "Diagnostic Procedure" .

SEF817Y

EC-108
 DTC U1000, U1001 CAN COMMUNICATION LINE
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CFS

EC

TEC655M

EC-109
 DTC U1000, U1001 CAN COMMUNICATION LINE
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure BBS00CFT

Go to EL section.

EC-110
 DTC U1010 CAN COMMUNICATION
[ZD30DDTi WITH COMMON RAIL]
DTC U1010 CAN COMMUNICATION PFP:23710

Description BBS00CFU

CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul-
tiplex communication line with high data communication speed and excellent error detection ability. Many elec-
tronic control units are equipped onto a vehicle, and each control unit shares information and links with other
control units during operation (not independent). In CAN communication, control units are connected with 2
communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring.
Each control unit transmits/receives data but selectively reads required data only.
On Board Diagnosis Logic BBS00CFV

This self-diagnosis has the one trip detection logic.

The MI will not light up for this diagnosis.
DTC No.
EC

CONSULT-II Trouble diagno-

DTC detecting condition Possible cause
GST sis name
ID
FLAG
CAN communi- When detecting error during the initial diag-
U1010 4 U1010 ● ECM
cation bus nosis for CAN controller of ECM.

DTC Confirmation Procedure BBS00CFW

WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. If DTC is detected, go to EC-112, "Diagnostic Procedure" .

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-111
 DTC U1010 CAN COMMUNICATION
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure BBS00CFX

1. INSPECTION START
With CONSULT-II
1. Turn ignition switch ON.
2. Select “SELF-DIAG RESULTS” mode with CONSULT-II.
3. Touch “ERASE”.
4. Perform DTC Confirmation Procedure.
See EC-111, "DTC Confirmation Procedure" .
5. Is the DTC U1010 displayed again?
With GST
1. Turn ignition switch ON.
2. Select “Service $04” with GST.
3. Perform DTC Confirmation Procedure.
See EC-111, "DTC Confirmation Procedure" .
4. Is the DTC U1010 displayed again?
Yes or No
Yes >> GO TO 2.
No >> INSPECTION END

2. REPLACE ECM
1. Replace ECM.
2. Perform initialization of NATS system and registration of all NATS ignition key IDs.
Refer to EL section.
3. Perform Injector Adjustment Value Registration.
Refer to EC-34, "Injector Adjustment Value Registration" .
4. Perform EGR Volume Control Valve Closed Position Learning Value Clear.
Refer to EC-37, "EGR Volume Control Valve Closed Position Learning Value Clear" .
5. Perform EGR Volume Control Valve Closed Position Learning.
Refer to EC-37, "EGR Volume Control Valve Closed Position Learning" .
6. Perform Throttle Valve Closed Position Learning Value Clear.
Refer to EC-39, "Throttle Valve Closed Position Learning Value Clear" .
7. Perform Throttle Valve Closed Position Learning.
Refer to EC-39, "Throttle Valve Closed Position Learning" .

>> INSPECTION END

EC-112
 DTC P0016 CKP - CMP CORRELATION
[ZD30DDTi WITH COMMON RAIL]
DTC P0016 CKP - CMP CORRELATION PFP:10328

On Board Diagnosis Logic BBS00CFY

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
● Harness or connectors
Crankshaft posi- ● Camshaft position sensor
● The correlation between crankshaft posi-
tion - camshaft
P0016 1 P0016 tion sensor signal and camshaft position ● Crankshaft position sensor
position correla-
sensor signal is out of the normal range. ● Timing chain
tion
● Signal plate
EC
DTC Confirmation Procedure BBS00CFZ

NOTE:
● If DTC P0016 is displayed with DTC P0335 (GST: P0335, P0336), first perform trouble diagnosis for
DTC P0335 (GST: P0335, P0336). Refer to EC-218, "DTC P0335 CKP SENSOR" .
● If DTC P0016 is displayed with DTC P0340 (GST: P0340, P0341), first perform trouble diagnosis for
DTC P0340 (GST: P0340, P0341). Refer to EC-224, "DTC P0340 CMP SENSOR" .
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Start engine and let it idle for at least 5 seconds.
If engine can not start, keep ignition switch at START position for
5 seconds.
4. If 1st trip DTC is detected, go to EC-113, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above
Diagnostic Procedure BBS00CG0

1. CHECK CAMSHAFT POSITION SENSOR

Refer to EC-229, "Component Inspection" .
OK or NG
OK >> GO TO 2.
NG >> Replace camshaft position sensor.

2. CHECK SPROCKET
Visually check for chipping signal plate gear tooth.
OK or NG
OK >> GO TO 3.
NG >> Remove debris and clean the signal plate or replace sprocket.

EC-113
 DTC P0016 CKP - CMP CORRELATION
[ZD30DDTi WITH COMMON RAIL]
3. CHECK CRANKSHAFT POSITION SENSOR
Refer to EC-222, "Component Inspection" .
OK or NG
OK >> GO TO 4.
NG >> Replace crankshaft position sensor.

4. CHECK GEAR TOOTH

Visually check for chipping signal plate gear tooth.
OK or NG
OK >> GO TO 5.
NG >> Replace the signal plate.

5. CHECK TIMING CHAIN

Refer to EM section.
OK or NG
OK >> GO TO 6.
NG >> Replace timing chain.

6. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
For Wiring Diagram, refer to EC-220, "Wiring Diagram" for CKP sensor and EC-226, "Wiring Diagram" for CMP
sensor.

>> INSPECTION END

EC-114
 DTC P0045 TC BOOST CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
DTC P0045 TC BOOST CONTROL SOLENOID VALVE PFP:14956

Description BBS00CG1

The turbocharger boost control solenoid valve controls vacuum signal

to the turbocharger boost control actuator. By changing the variable
nozzle vane opening through the rods, the intake air volume is adjust-
ed.

MBIB0626E EC

The turbocharger boost control solenoid valve (2) is moved by ON/

OFF pulse from the ECM. The longer the ON pulse, the charge air
pressure rises.
● Mass air flow sensor (1)
● Battery
● : Vehicle front

SEC089E

On Board Diagnosis Logic BBS00CG2

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Turbocharger
boost control
1 P0048
solenoid valve
circuit high input
Turbocharger
boost control
2 P0047
solenoid valve ● Harness or connectors
circuit low input (The solenoid valve circuit is open or
An improper voltage is sent to ECM through shorted.)
P0045 Turbocharger turbocharger boost control solenoid valve.
boost control ● Turbocharger boost control solenoid
4 P0045
solenoid valve valve
circuit/open
Turbocharger
boost control
8 P0046 solenoid valve
circuit range/per-
formance

EC-115
 DTC P0045 TC BOOST CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
DTC Confirmation Procedure BBS00CG3

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-119, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-116
 DTC P0045 TC BOOST CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CG4

EC

TEC656M

EC-117
 DTC P0045 TC BOOST CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference valves, and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.

0 - 14V

[Engine is running]
● Warm-up condition
● Idle speed

SEC113E
Turbocharger boost control
123 R/B
solenoid valve
0 - 14V

[Engine is running]
● Warm-up condition
● Engine speed: 2,000 rpm

SEC114E

201 W
BATTERY VOLTAGE
203 W Power supply for ECM [Ignition switch ON]
(11 - 14V)
205 W
[Ignition switch ON]
[Ignition switch OFF]
Approximately 1.2V
● For a few seconds after turning ignition
245 B/Y ECM relay (self-shutoff) switch OFF
[Ignition switch OFF]
BATTERY VOLTAGE
● More than a few seconds after turning igni- (11 - 14V)
tion switch OFF

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-118
 DTC P0045 TC BOOST CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure BBS00CG5

1. CHECK TURBOCHARGER BOOST CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT

1. Disconnect turbocharger boost control solenoid valve (2) har-
ness connector.
– Mass air flow sensor (1)
– Battery (3)
– : Vehicle front
2. Turn ignition switch ON.

SEC089E EC

3. Check voltage between turbocharger boost control solenoid

valve terminal 2 and ground with CONSULT-II or tester.
Voltage: Battery voltage
OK or NG
OK >> GO TO 3.
NG >> GO TO 2.

PBIB2605E

2. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M50, F5
● Harness for open and short between turbocharger boost control solenoid valve and ECM relay
● Harness for open and short between turbocharger boost control solenoid valve and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

3. CHECK TURBOCHARGER BOOST CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR
OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminal 123 and turbocharger boost control solenoid valve termi-
nal 1. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 4.
NG >> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK TURBOCHARGER BOOST CONTROL SOLENOID VALVE

Refer to EC-120, "Component Inspection" .
OK or NG
OK >> GO TO 5.
NG >> Replace turbocharger boost control solenoid valve.

EC-119
 DTC P0045 TC BOOST CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
5. CHECK INTERMITTENT INCIDENT
Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection BBS00CG6

TURBOCHARGER BOOST CONTROL SOLENOID VALVE

1. Disconnect turbocharger boost control solenoid valve (2) har-
ness connector.
● Mass air flow sensor (1)

● Battery (3)

● : Vehicle front
2. Apply 12V direct current between turbocharger boost control so-
lenoid valve terminals.

SEC089E

3. Check air passage continuity of turbocharger boost control sole-

noid valve under the following conditions.
Air passage continuity Air passage continuity
CONDITIONS
between (A) and (B) between (A) and (C)
12V direct current supply
between terminals (1) and Yes No
(2)
No supply No Yes
Operation takes less than 1 second.
MBIB0996E
If NG, replace turbocharger boost control solenoid valve.

EC-120
 DTC P0078 EXHAUST GAS CONTROL VALVE CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
DTC P0078 EXHAUST GAS CONTROL VALVE CONTROL SOLENOID VALVE
PFP:14411

Component Description BBS00200

With the heat up switch ON, engine speed is increased and the ex-
haust gas control valve is closed, which helps to promote heating and
improve heating performance.
The exhaust gas control valve control solenoid valve (1) responds to
signals from the ECM. When the ECM sends an ON (ground) signal,
the solenoid valve is bypassed to apply vacuum pump vacuum to the
exhaust gas control valve actuator. This operation closes the exhaust
gas control valve. When the ECM sends an OFF signal, the vacuum
signal is cut and the exhaust gas control valve opens.
● Brake fluid reservoir tank
EC
● : Vehicle front SEC096E

On Board Diagnosis Logic BBS00201

DTC No.
CONSULT-II
Trouble diagnosis name DTC detecting condition Possible cause
ID GST
FLAG
ECM detects exhaust gas control
Exhaust gas control valve control
1 P0080 valve control solenoid valve circuit
solenoid valve circuit high
is short to power.
ECM detects exhaust gas control ● Harness or connectors
Exhaust gas control valve control
2 P0079 valve control solenoid valve circuit (Exhaust gas control valve
solenoid valve circuit low
is short to ground. control solenoid valve cir-
P0078 cuit is open or shorted.)
ECM detects exhaust gas control
4 valve control solenoid valve circuit ● Exhaust gas control valve
Exhaust gas control valve control is open. control solenoid valve
P0078
solenoid valve circuit ECM detects exhaust gas control
8 valve control solenoid valve inter-
nal circuit is open or short.

DTC Confirmation Procedure BBS00202

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If DTC is detected, go to EC-124, "Diagnostic Procedure" .

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-121
 DTC P0078 EXHAUST GAS CONTROL VALVE CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00203

TEC693M

EC-122
 DTC P0078 EXHAUST GAS CONTROL VALVE CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference valves, and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may damage the
ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.
[Engine is running]
● Engine speed: Below 1,200 rpm
(More than 1 minute after starting engine)
● Shift lever: P or N (A/T), Neutral (M/T)
Approximately 0.1V
Exhaust gas control valve ● Engine coolant temperature: Below 75°C
172 BR/Y (167°F) EC
control solenoid valve
● Stop the vehicle
● Heat up switch: ON
[Engine is running] BATTERY VOLTAGE
● Except above condition (11 - 14V)

201 W
BATTERY VOLTAGE
203 W Power supply for ECM [Ignition switch ON]
(11 - 14V)
205 W
[Ignition switch ON]
[Ignition switch OFF]
Approximately 1.2V
● For a few seconds after turning ignition
245 B/Y ECM relay (self-shutoff) switch OFF
[Ignition switch OFF]
BATTERY VOLTAGE
● More than a few seconds after turning igni- (11 - 14V)
tion switch OFF

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-123
 DTC P0078 EXHAUST GAS CONTROL VALVE CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure BBS00204

1. CHECK VACUUM SOURCE

1. Turn ignition switch ON.
2. Select “COOLANT TEMP/S” in “DATA MONITOR” mode with CONSULT-II.
3. Check that the “COOLANT TEMP/S” indication is below 87°C (189°F).
If “COOLANT TEMP/S” indication is within the specified value, go to following step.
If “COOLANT TEMP/S” indication is out of the specified value, cool down engine and go to step 1.
4. Turn ignition switch OFF.
5. Disconnect vacuum hose connected to exhaust gas control valve actuator.
6. Start engine and let it idle.
7. Check vacuum hose for vacuum existence under the following conditions.

SEF318Z

OK or NG
OK >> GO TO 9.
NG >> GO TO 2.

2. CHECK VACUUM HOSES AND VACUUM GALLERY

1. Turn ignition switch OFF.
2. Check vacuum hoses and vacuum gallery for clogging, cracks or improper connection.
Refer to EC-28, "Vacuum Hose Drawing" .
OK or NG
OK >> GO TO 3.
NG >> Repair or replace vacuum hoses and vacuum gallery.

SEF109L

EC-124
 DTC P0078 EXHAUST GAS CONTROL VALVE CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
3. CHECK EXHAUST GAS CONTROL VALVE CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT
1. Disconnect exhaust gas control valve control solenoid valve (1)
harness connector.
– Brake fluid reservoir tank (2)
– : Vehicle front
2. Turn ignition switch ON.

SEC096E

EC
3. Check voltage between exhaust gas control valve control sole-
noid valve terminals 2 and ground with CONSULT-II or tester.
Voltage: Battery voltage
OK or NG
OK >> GO TO 5.
NG >> GO TO 4.

PBIB0192E

4. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M21, E127
● Harness connectors M50, F5
● Harness for open or short between exhaust gas control valve control solenoid valve and ECM relay
● Harness for open or short between exhaust gas control valve control solenoid valve and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK EXHAUST GAS CONTROL VALVE CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT
FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminal 172 and exhaust gas control valve control solenoid valve
terminal 1.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 7.
NG >> GO TO 6.

EC-125
 DTC P0078 EXHAUST GAS CONTROL VALVE CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
6. DETECT MALFUNCTIONING PART
Check the following.
● Harness connectors E127, M21 (LHD models)
● Harness connectors E105, M87 (RHD models)
● Harness connectors M50, F5
● Harness for open or short between exhaust gas control valve control solenoid valve and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

7. CHECK EXHAUST GAS CONTROL VALVE CONTROL SOLENOID VALVE

Refer to EC-127, "Component Inspection".
OK or NG
OK >> GO TO 8.
NG >> Replace exhaust gas control valve control solenoid valve.

8. CHECK VACUUM PUMP

Refer to EM section.
OK or NG
OK >> GO TO 9.
NG >> Replace vacuum pump assembly.

9. CHECK EXHAUST GAS CONTROL VALVE CONTROL ACTUATOR

1. Turn ignition switch OFF.
2. Remove exhaust gas control valve actuator from exhaust tube.
3. Install a vacuum pump to exhaust gas control valve actuator.
4. Make sure that the exhaust gas control valve moves smoothly
when applying vacuum of −86.6 to −93.3 kPa (−866 to −933
mbar, −650 to −700 mmHg, −25.59 to −27.56 inHg) and releasing
it.
OK or NG
OK >> GO TO 10.
NG >> Replace turbocharger assembly.

SEF319Z

10. CHECK EXHAUST GAS CONTROL VALVE SENSOR

Refer to EC-289, "Component Inspection" .
OK or NG
OK >> GO TO 11.
NG >> Replace turbocharger boost sensor.

11. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

EC-126
 DTC P0078 EXHAUST GAS CONTROL VALVE CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
Component Inspection BBS00205

EXHAUST GAS CONTROL VALVE CONTROL SOLENOID VALVE

1. Disconnect exhaust gas control valve control solenoid valve harness connector.
2. Apply 12V direct current between exhaust gas control valve control solenoid valve terminals.
3. Check air passage continuity of exhaust gas control valve control
solenoid valve under the following conditions.
Air passage continuity Air passage continuity
CONDITIONS
between (A) and (B) between (A) and (C)
12V direct current supply
Yes No
between terminals (1) and (2)
No supply No Yes
Operation takes less than 1 second.
EC
If NG, replace exhaust gas control valve control solenoid valve. SEF822R

EC-127
 DTC P0087 FUEL SYSTEM
[ZD30DDTi WITH COMMON RAIL]
DTC P0087 FUEL SYSTEM PFP:22693

On Board Diagnosis Logic BBS00CG7

NOTE:
If DTC P0087 is displayed with DTC P0651 (GST: P0652, P0653), first perform the trouble diagnosis for
DTC P0651 (GST: P0652, P0653). Refer to EC-319, "DTC P0651 SENSOR POWER SUPPLY" .
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
● Fuel pump
● Fuel injector
● Fuel rail pressure sensor
Fuel rail pres- Fuel pressure is lower than the specified ● Air mixed with fuel
P0087 1 P0087
sure too low value. ● Lack of fuel
● Fuel rail pressure relief valve
● Fuel line
● Harness or connectors

DTC Confirmation Procedure BBS00CG8

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Start engine.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Keep engine speed more than 700 rpm for at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-128, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.
Diagnostic Procedure BBS00CG9

1. CHECK FUEL LINE FOR LEAK

1. Start engine.
2. Visually check the following for fuel leak.
– Fuel tube from fuel pump to fuel rail
– Fuel rail
– Fuel tube from fuel rail to fuel injector
3. Also check for improper connection or pinches.
OK or NG
OK >> GO TO 2.
NG >> Repair malfunctioning part.

EC-128
 DTC P0087 FUEL SYSTEM
[ZD30DDTi WITH COMMON RAIL]
2. CHECK FUEL RAIL PRESSURE SENSOR
Refer to EC-171, "Component Inspection" .
OK or NG
OK >> GO TO 3.
NG >> Replace fuel rail.

3. CHECK FUEL INJECTOR

Refer to EC-177, "Component Inspection" .
OK or NG
OK >> GO TO 5.
NG >> GO TO 4.
EC
4. REPLACE FUEL INJECTOR
1. Replace fuel injector of malfunctioning cylinder.
2. Perform Injector Adjustment Value Registration. Refer to EC-34, "Injector Adjustment Value Registration" .

>> INSPECTION END

5. CHECK FUEL PUMP

Refer to EC-136, "Component Inspection" .
OK or NG
OK >> GO TO 6.
NG >> Replace fuel pump.

6. CHECK FUEL RAIL PRESSURE RELIEF VALVE

Refer to EC-129, "Component Inspection" .
OK or NG
OK >> GO TO 7.
NG >> Replace fuel rail.

7. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
For Wiring Diagram, refer to EC-134, "Wiring Diagram" for fuel pump, EC-174, "Wiring Diagram" for fuel injec-
tor and EC-168, "Wiring Diagram" for fuel rail pressure sensor.

>> INSPECTION END

Component Inspection BBS00CRD

FUEL RAIL PRESSURE RELIEF VALVE

WARNING:
● Confirm that the engine is cooled down and there are no fire hazards near the vehicle.
● Prepare pans or saucers under the disconnected fuel line because the fuel may spill out.
1. Turn ignition switch OFF.

EC-129
 DTC P0087 FUEL SYSTEM
[ZD30DDTi WITH COMMON RAIL]
2. Remove fuel hose from fuel rail pressure relief valve.
3. Attach a blind cap or plug to removed hose.
4. Start engine and keep engine speed more than 2,000 rpm for at
least 5 seconds.
5. Confirm that the fuel does not come out from the fuel rail pressure
relief valve.
WARNING:
● Be careful not to allow leaked fuel to contaminate engine
compartment. Especially, ensure to keep engine mount
insulator clear of fuel. SEC103E
● If the fuel comes out, stop the engine immediately.

EC-130
 DTC P0088 FUEL SYSTEM
[ZD30DDTi WITH COMMON RAIL]
DTC P0088 FUEL SYSTEM PFP:17520

On Board Diagnosis Logic BBS00CGB

NOTE:
If DTC P0088 is displayed with DTC P0651 (GST: P0652, P0653), first perform the trouble diagnosis for
DTC P0651 (GST: P0652, P0653). Refer to EC-319, "DTC P0651 SENSOR POWER SUPPLY" .
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
● Fuel pump
● Fuel injector
Fuel rail pres- Fuel pressure is higher than the specified EC
P0088 1 P0088 ● Fuel rail pressure sensor
sure too high value.
● Fuel line
● Harness or connectors

DTC Confirmation Procedure BBS00CGC

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Start engine.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Let engine idle for at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-131, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.
Diagnostic Procedure BBS00CGD

1. CHECK FUEL LINE FOR LEAK

1. Start engine.
2. Visually check the following for fuel leak.
– Fuel tube from fuel pump to fuel rail
– Fuel rail
– Fuel tube from fuel rail to fuel injector
3. Also check for improper connection or pinches.
OK or NG
OK >> GO TO 2.
NG >> Repair malfunctioning part.

EC-131
 DTC P0088 FUEL SYSTEM
[ZD30DDTi WITH COMMON RAIL]
2. CHECK FUEL RAIL PRESSURE SENSOR
Refer to EC-171, "Component Inspection" .
OK or NG
OK >> GO TO 3.
NG >> Replace fuel rail.

3. CHECK FUEL INJECTOR

Refer to EC-177, "Component Inspection" .
OK or NG
OK >> GO TO 5.
NG >> GO TO 4.

4. REPLACE FUEL INJECTOR

1. Replace fuel injector of malfunctioning cylinder.
2. Perform Injector Adjustment Value Registration. Refer to EC-34, "Injector Adjustment Value Registration" .

>> INSPECTION END

5. CHECK FUEL PUMP

Refer to EC-136, "Component Inspection" .
OK or NG
OK >> GO TO 6.
NG >> Replace fuel pump.

6. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
For Wiring Diagram, refer to EC-134, "Wiring Diagram" for fuel pump, EC-174, "Wiring Diagram" for fuel injec-
tor and EC-168, "Wiring Diagram" for fuel rail pressure sensor.

>> INSPECTION END

EC-132
 DTC P0090 FUEL PUMP
[ZD30DDTi WITH COMMON RAIL]
DTC P0090 FUEL PUMP PFP:16700

On Board Diagnosis Logic BBS00CGF

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
The fuel pump signal is not detected by
4 ● Harness or connectors
Fuel pump con- ECM.
P0090 P0090 (The fuel pump circuit is open.)
trol circuit An improper voltage is sent to ECM through
8 ● Fuel pump
fuel pump.

DTC Confirmation Procedure BBS00CGG EC

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-135, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-133
 DTC P0090 FUEL PUMP
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CGH

TEC692M

EC-134
 DTC P0090 FUEL PUMP
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.

0 - 14V

[Engine is running]
● Warm-up condition
● Idle speed EC

MBIB1639E
176 R Fuel pump
0 - 14V

[Engine is running]
● Warm-up condition
● Engine speed: 2,000 rpm

MBIB1640E

201 W
BATTERY VOLTAGE
203 W Power supply for ECM [Ignition switch ON]
(11 - 14V)
205 W
[Ignition switch ON]
[Ignition switch OFF]
Approximately 1.2V
● For a few seconds after turning ignition
245 B/Y ECM relay (self-shutoff) switch OFF
[Ignition switch OFF]
BATTERY VOLTAGE
● More than a few seconds after turning igni- (11 - 14V)
tion switch OFF

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure BBS00CGI

1. CHECK FUEL PUMP POWER SUPPLY CIRCUIT

1. Turn ignition switch OFF.
2. Disconnect fuel pump harness connector.
3. Turn ignition switch ON.
4. Check voltage between fuel pump terminal 1 and ground with
CONSULT-II or tester.
Voltage: Battery voltage
OK or NG
OK >> GO TO 3.
NG >> GO TO 2.

SEF101S

EC-135
 DTC P0090 FUEL PUMP
[ZD30DDTi WITH COMMON RAIL]
2. DETECT MALFUNCTIONING PART
Check the following.
● Harness connectors M21, E127
● Harness connectors E69, E202
● Harness for open between fuel pump and ECM relay
● Harness for open between fuel pump and ECM

>> Repair open circuit in harness or connectors.

3. CHECK FUEL PUMP OUTPUT SIGNAL CIRCUIT FOR OPEN

1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between fuel pump terminal 2 and ECM terminal 176.
Refer to Wiring Diagram.
Continuity should exist.
OK or NG
OK >> GO TO 5.
NG >> Repair open circuit.

4. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors E272, F34
● Harness for open between fuel pump and ECM

>> Repair open circuit in harness or connectors.

5. CHECK FUEL PUMP

Refer to EC-136, "Component Inspection" .
OK or NG
OK >> GO TO 6.
NG >> Replace fuel pump.

6. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection BBS00D1U

FUEL PUMP
1. Disconnect fuel pump harness connector.

EC-136
 DTC P0090 FUEL PUMP
[ZD30DDTi WITH COMMON RAIL]
2. Check resistance between fuel pump terminals 1 and 2.
Resistance: 2.6 - 3.5 Ω [at 20 - 40°C (68 - 104°F)]
3. If NG, replace fuel pump.

SEC066E

EC

EC-137
 DTC P0091, P0092 FUEL PUMP
[ZD30DDTi WITH COMMON RAIL]
DTC P0091, P0092 FUEL PUMP PFP:16700

On Board Diagnosis Logic BBS00CGK

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Fuel pump circuit An excessively low voltage from the sensor
P0091 2 P0091 ● Harness or connectors
low input is sent to ECM.
(The fuel pump circuit is shorted.)
Fuel pump circuit An excessively high voltage from the sensor
P0092 1 P0092 ● Fuel pump
high input is sent to ECM.

DTC Confirmation Procedure BBS00CGL

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-140, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-138
 DTC P0091, P0092 FUEL PUMP
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CGM

EC

TEC692M

EC-139
 DTC P0091, P0092 FUEL PUMP
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.

0 - 14V

[Engine is running]
● Warm-up condition
● Idle speed

MBIB1639E
176 R Fuel pump
0 - 14V

[Engine is running]
● Warm-up condition
● Engine speed: 2,000 rpm

MBIB1640E

201 W
BATTERY VOLTAGE
203 W Power supply for ECM [Ignition switch ON]
(11 - 14V)
205 W
[Ignition switch ON]
[Ignition switch OFF]
Approximately 1.2V
● For a few seconds after turning ignition
245 B/Y ECM relay (self-shutoff) switch OFF
[Ignition switch OFF]
BATTERY VOLTAGE
● More than a few seconds after turning igni- (11 - 14V)
tion switch OFF

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure BBS00CGN

1. CHECK FUEL PUMP POWER SUPPLY CIRCUIT

1. Turn ignition switch OFF.
2. Disconnect fuel pump harness connector.
3. Turn ignition switch ON.
4. Check voltage between fuel pump terminal 1 and ground with
CONSULT-II or tester.
Voltage: Battery voltage
OK or NG
OK >> GO TO 3.
NG >> GO TO 2.

SEF101S

EC-140
 DTC P0091, P0092 FUEL PUMP
[ZD30DDTi WITH COMMON RAIL]
2. DETECT MALFUNCTIONING PART
Check the following.
● Harness connectors M21, E127
● Harness connectors M69, E202
● Harness for short between fuel pump and ECM relay
● Harness for short between fuel pump and ECM

>> Repair short to ground or short to power in harness or connectors.

3. CHECK FUEL PUMP OUTPUT SIGNAL CIRCUIT FOR SHORT

1. Turn ignition switch OFF. EC
2. Disconnect ECM harness connector.
3. Check harness continuity between fuel pump terminal 2 and ECM terminal 176.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 5.
NG >> GO TO 4.

4. DETECT MALFUNCTION
Check the following.
● Harness connectors E272, F34
● Harness for short between fuel pump and ECM

>> Repair short to ground or short to power in harness or connectors.

5. CHECK FUEL PUMP

Refer to EC-141, "Component Inspection" .
OK or NG
OK >> GO TO 6.
NG >> Replace fuel pump.

6. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection BBS00D1V

FUEL PUMP
1. Disconnect fuel pump harness connector.

EC-141
 DTC P0091, P0092 FUEL PUMP
[ZD30DDTi WITH COMMON RAIL]
2. Check resistance between fuel pump terminals 1 and 2.
Resistance: 2.6 - 3.5 Ω [at 20 - 40°C (68 - 104°F)]
3. If NG, replace fuel pump.

SEC066E

EC-142
 DTC P0093 FUEL SYSTEM
[ZD30DDTi WITH COMMON RAIL]
DTC P0093 FUEL SYSTEM PFP:17520

On Board Diagnosis Logic BBS00CGP

NOTE:
If DTC P0093 is displayed with DTC P1089 (GST: P0089), first perform the trouble diagnosis for DTC
P1089 (GST: P0089). Refer to EC-342, "DTC P1089 FUEL PUMP" .
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
● Fuel pump
● Fuel rail
ECM detects a fuel system leak. EC
(The relation between the output voltage to ● Fuel line
P0093 1 P0093 Fuel system leak the fuel pump and input voltage from the ● Fuel rail pressure relief valve
fuel rail pressure sensor is out of the normal ● Air mixed with fuel
range.)
● Lack of fuel
● Fuel injector

Overall Function Check BBS00D6L

Use this procedure to check the overall function of the turbocharger. During this check, a 1st trip DTC might not
be confirmed.
NOTE:
● Make sure that there is no fire hazard near the vehicle.
● Before performing the following procedure, cool down engine.
WITH CONSULT-II
1. Open engine hood and check if there are any signs of fuel leakage or not.
If there are any signs, go to EC-144, "Diagnostic Procedure" .
If there is no signs, go to next step.
2. Check oil level.
If oil level is above the proper range, go to EC-144, "Diagnostic Procedure" .
If oil level is within the proper range, go to next step.
3. Start engine and check fuel leakage in the engine room.
If fuel leakage is found, go to EC-144, "Diagnostic Procedure" .
If fuel leakage is not found, go to next step.
4. Select “DATA MONITOR” mode with CONSULT-II.
5. Check the fuel rail pressure at the idle speed.
Fuel rail pressure: 30 - 40 MPa
6. If NG, go to EC-144, "Diagnostic Procedure" .

MBIB1821E

WITH GST
1. Open engine hood and check if there are any signs of fuel leakage or not.
If there are any signs, go to EC-144, "Diagnostic Procedure" .
If there is no signs, go to next step.
2. Check oil level.
If oil level is above the proper range, go to EC-144, "Diagnostic Procedure" .
If oil level is within the proper range, go to next step.
3. Start engine and check fuel leakage in the engine room.
If fuel leakage is found, go to EC-144, "Diagnostic Procedure" .

EC-143
 DTC P0093 FUEL SYSTEM
[ZD30DDTi WITH COMMON RAIL]
If fuel leakage is not found, go to next step.
4. Select Service $1 mode with GST.
5. Check the fuel rail pressure at the idle speed.
Fuel rail pressure: 30 - 40 MPa
6. If NG, go to EC-144, "Diagnostic Procedure" .
Diagnostic Procedure BBS00CGR

1. CHECK FUEL LINE FOR LEAK

1. Start engine.
2. Visually check the following for fuel leak.
– Fuel tube from fuel pump to fuel rail
– Fuel rail
– Fuel tube from fuel rail to fuel injector
3. Also check for improper connection or pinches.
OK or NG
OK >> GO TO 2.
NG >> Repair malfunctioning part.

2. CHECK FUEL RAIL PRESSURE RELIEF VALVE

Refer to EC-144, "Component Inspection" .
OK or NG
OK >> GO TO 3.
NG >> Replace fuel rail.

3. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
OK or NG
OK >> Replace fuel pump.
NG >> Repair or replace.
Component Inspection BBS00CGS

FUEL RAIL PRESSURE RELIEF VALVE

WARNING:
● Confirm that the engine is cooled down and there are no fire hazards near the vehicle.
● Prepare pans or saucers under the disconnected fuel line because the fuel may spill out.
1. Turn ignition switch OFF.
2. Remove fuel hose from fuel rail pressure relief valve.
3. Attach a blind cap or plug to removed hose.
4. Start engine and keep engine speed more than 2,000 rpm for at
least 5 seconds.
5. Confirm that the fuel does not come out from the fuel rail pressure
relief valve.
WARNING:
● Be careful not to allow leaked fuel to contaminate engine
compartment. Especially, ensure to keep engine mount
insulator clear of fuel. SEC103E
● If the fuel comes out, stop the engine immediately.

EC-144
 DTC P0100 MAF SENSOR
[ZD30DDTi WITH COMMON RAIL]
DTC P0100 MAF SENSOR PFP:22693

Component Description BBS00CGU

The mass air flow sensor (1) is placed in the stream of intake air. It
measures the intake flow rate by measuring a part of the entire intake
flow. The mass air flow sensor controls the temperature of the hot
wire to a certain amount. The heat generated by the hot wire is re-
duced as the intake air flows around it. The more air, the greater the
heat loss.
Therefore, the electric current supplied to hot wire is changed to
maintain the temperature of the hot wire as air flow increases. The
ECM detects the air flow by means of this current change.

PBIA9559J EC
On Board Diagnosis Logic BBS00CGV

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Mass air flow
An excessively high voltage from the sensor ● Harness or connectors
1 P0103 sensor circuit
is sent to ECM. (The sensor circuit is open or
high input
P0100 shorted.)
Mass air flow ● Mass air flow sensor
An excessively low voltage from the sensor
2 P0102 sensor circuit low
is sent to ECM. ● Intake air leaks
input

DTC Confirmation Procedure BBS00CGW

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-147, "Diagnostic Procedure"
.
If 1st trip DTC is not detected, go to next step.
5. Start engine and wait at least 5 seconds.
6. If 1st trip DTC is detected, go to EC-147, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Following the procedure “WITH CONSULT-II” above.

EC-145
 DTC P0100 MAF SENSOR
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CGX

TEC657M

EC-146
 DTC P0100 MAF SENSOR
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values, and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage)
NO.
[Engine is running]
Sensor ground
131 B ● Warm-up condition Approximately 0V
(Sensors shield circuit)
● Idle speed
[Ignition switch ON] 0.3 - 1.0V
[Engine is running]
● Warm-up condition 1.6 - 2.3V EC
155 Y/G Mass air flow sensor ● Idle speed

[Engine is running] 1.6 - 2.3V to Approximately 3.4V

(Check for liner voltage rise in
● Warm-up condition
response to engine being
● Engine is revving from idle to about 4,000 rpm. increased to about 4,000 rpm)
[Engine is running]
Sensor ground
182 Y/L ● Warm-up condition Approximately 0V
(Mass air flow sensor)
● Idle speed
201 W
BATTERY VOLTAGE
203 W Power supply for ECM [Ignition switch ON]
(11 - 14V)
205 W

Diagnostic Procedure BBS00CGY

1. CHECK INTAKE SYSTEM

Check the following for connection.
● Air duct
● Vacuum hoses
● Intake air passage between air duct and intake manifold
OK or NG
OK >> GO TO 2.
NG >> Reconnect the parts.

2. CHECK GROUND CONNECTIONS

1. Turn ignition switch OFF.
2. Loosen and retighten ground screws.
Refer to EC-107, "Ground Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 3.
NG >> Repair or replace ground connections.
SEC119E

EC-147
 DTC P0100 MAF SENSOR
[ZD30DDTi WITH COMMON RAIL]
3. CHECK MAFS POWER SUPPLY CIRCUIT
1. Disconnect mass air flow (MAF) sensor (1) harness connector.
– Turbocharger boost control solenoid valve (2)
– Battery (3)
– : Vehicle front
2. Turn ignition switch ON.

SEC089E

3. Check voltage between MAF sensor terminal 2 and ground with

CONSULT-II or tester.
Voltage: Battery voltage
OK or NG
OK >> GO TO 5.
NG >> GO TO 4.

PBIB1168E

4. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M50, F5
● Harness for open or short between ECM relay and mass air flow sensor
● Harness for open or short between ECM and mass air flow sensor

>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK MAFS GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between MAF sensor terminal 3 and ECM terminal 182.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 6.
NG >> Repair open circuit or short to ground or short to power in harness or connectors.

EC-148
 DTC P0100 MAF SENSOR
[ZD30DDTi WITH COMMON RAIL]
6. CHECK MAFS INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Check harness continuity between MAF sensor terminal 4 and ECM terminal 155.
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 7.
NG >> Repair open circuit or short to ground or short to power in harness or connectors.

7. CHECK MASS AIR FLOW SENSOR

Refer to EC-149, "Component Inspection" . EC
OK or NG
OK >> GO TO 8.
NG >> Replace mass air flow sensor.

8. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection BBS00CGZ

MASS AIR FLOW SENSOR

1. Reconnect all harness connectors disconnected.
2. Start engine and warm it up to normal operating temperature.
3. Check voltage between ECM terminal 155 (Mass air flow sensor
signal) and ground.
Condition Voltage V
Ignition switch ON (Engine stopped.) 0.3 - 1.0V
Idle (Engine is warmed-up to normal
1.6 - 2.3
operating temperature.)
Idle to about 4,000 rpm 1.6 - 2.3 to Approx. 3.4*
*: Check for linear voltage rise in response to engine being increased to about
4,000 rpm.
MBIB1654E
4. If the voltage is out of specification, proceed the following.
a. Check for the cause of uneven air flow through mass air flow sensor. Refer to following.
● Crushed air ducts

● Malfunctioning seal of air cleaner element

● Uneven dirt of air cleaner element

● Improper specification of intake air system parts

b. If NG, repair or replace malfunctioning part and perform step 2 to 3 again.

If OK, go to next step.
5. Turn ignition switch OFF.
6. Disconnect mass air flow sensor harness connector and reconnect it again.
7. Perform step 2 and 3 again.
8. If NG, clean or replace mass air flow sensor.

EC-149
 DTC P0110 INTAKE AIR TEMPERATURE SENSOR
[ZD30DDTi WITH COMMON RAIL]
DTC P0110 INTAKE AIR TEMPERATURE SENSOR PFP:22630

Component Description BBS00CH1

The intake air temperature sensor is built into mass air flow sensor
(1). The sensor detects intake air temperature and transmits a signal
to the ECM.
The temperature sensing unit uses a thermistor which is sensitive to
the change in temperature. Electrical resistance of the thermistor de-
creases in response to the temperature rise.

PBIA9559J

<Reference data>
Intake air
Voltage* V Resistance kΩ
temperature °C (°F)
25 (77) 2.4 1.800 - 2.200
80 (176) 0.8 0.283 - 0.359
*: This data is reference values and is measured between ECM terminal 160 (Intake
air temperature sensor) and ground.

CAUTION:
Do not use ECM ground terminals when measuring input/output SEF012P
voltage. Doing so may result in damage to the ECM's transistor.
Use a ground other than ECM terminals, such as the ground.
On Board Diagnosis Logic BBS00CH2

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Intake air tem-
An excessively high voltage from the sensor
1 P0113 perature sensor ● Harness or connectors
is sent to ECM.
circuit high input (The sensor circuit is open or
P0110 shorted.)
Intake air tem-
An excessively low voltage from the sensor
2 P0112 perature sensor ● Intake air temperature sensor
is sent to ECM.
circuit low input

DTC Confirmation Procedure BBS00CH3

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.

EC-150
 DTC P0110 INTAKE AIR TEMPERATURE SENSOR
[ZD30DDTi WITH COMMON RAIL]
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-153, "Diagnostic Procedure".

SEF817Y

WITH GST
Following the procedure “WITH CONSULT-II” above.
EC

EC-151
 DTC P0110 INTAKE AIR TEMPERATURE SENSOR
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CH4

TEC658M

EC-152
 DTC P0110 INTAKE AIR TEMPERATURE SENSOR
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure BBS00CH5

1. CHECK GROUND CONNECTIONS

1. Turn ignition switch OFF.
2. Loosen and retighten ground screws.
Refer to EC-107, "Ground Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 2.
NG >> Repair or replace ground connections.
SEC119E EC

2. CHECK INTAKE AIR TEMPERATURE SENSOR POWER SUPPLY CIRCUIT

1. Disconnect mass air flow sensor (intake air temperature sensor
is built-into) (1) harness connector.
– Turbocharger boost control solenoid valve (2)
– Battery (3)
– : Vehicle front
2. Turn ignition switch ON.

SEC089E

3. Check voltage between MAF sensor terminal 5 and ground with

CONSULT-II or tester.
Voltage: Approximately 5V
OK or NG
OK >> GO TO 3.
NG >> Repair open circuit or short to ground or short to power
in harness or connectors.

PBIB1169E

3. CHECK INTAKE AIR TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between MAF sensor terminal 6 and ECM terminal 147.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 4.
NG >> Repair open circuit or short to ground or short to power in harness or connectors.

EC-153
 DTC P0110 INTAKE AIR TEMPERATURE SENSOR
[ZD30DDTi WITH COMMON RAIL]
4. CHECK INTAKE AIR TEMPERATURE SENSOR
Refer to EC-154, "Component Inspection" .
OK or NG
OK >> GO TO 5.
NG >> Replace mass air flow sensor (with intake air temperature sensor).

5. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection BBS00CH6

INTAKE AIR TEMPERATURE SENSOR

1. Check resistance between mass air flow sensor (1) terminals 3
and 4 under the following conditions.
Intake air temperature °C (°F) Resistance kΩ
25 (77) 1.800 - 2.200

2. If NG, replace mass air flow sensor (with intake air temperature
sensor).

PBIA9559J

SEF012P

EC-154
 DTC P0115 ECT SENSOR
[ZD30DDTi WITH COMMON RAIL]
DTC P0115 ECT SENSOR PFP:22693

Description BBS00CH8

The engine coolant temperature sensor is used to detect the engine

coolant temperature. The sensor modifies a voltage signal from the
ECM. The modified signal returns to the ECM as the engine coolant
temperature input. The sensor uses a thermistor which is sensitive to
the change in temperature. The electrical resistance of the thermistor
decreases as temperature increases.

SEF594K EC

<Reference data>
Engine coolant tempera-
Voltage* (V) Resistance (kΩ)
ture °C (°F)
−10 (14) 4.7 7.0 - 11.4
20 (68) 3.8 2.1 - 2.9
50 (122) 2.6 0.68 - 1.00
90 (194) 1.3 0.236 - 0.260
*: This data is reference values and is measured between ECM terminal 185 (Engine
coolant temperature sensor) and ground. SEF012P

CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
On Board Diagnosis Logic BBS00CH9

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Engine coolant
temperature sen- An excessively high voltage from the sensor
1 P0118
sor circuit high is sent to ECM. ● Harness or connectors
input (The sensor circuit is open or
P0115 shorted.)
Engine coolant
temperature sen- An excessively low voltage from the sensor ● Engine coolant temperature sensor
2 P0117
sor circuit low is sent to ECM.
input

EC-155
 DTC P0115 ECT SENSOR
[ZD30DDTi WITH COMMON RAIL]
DTC Confirmation Procedure BBS00CHA

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-158, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-156
 DTC P0115 ECT SENSOR
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CHB

EC

TEC659M

EC-157
 DTC P0115 ECT SENSOR
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure BBS00CHC

1. CHECK GROUND CONNECTIONS

1. Turn ignition switch OFF.
2. Loosen and retighten ground screws.
Refer to EC-107, "Ground Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 2.
NG >> Repair or replace ground connections.
SEC119E

2. CHECK ECT SENSOR POWER SUPPLY CIRCUIT

1. Disconnect engine coolant temperature (ECT) sensor (2) har-
ness connector.
– Camshaft position sensor (1)
– : Vehicle front
2. Turn ignition switch ON.

SEC086E

3. Check voltage between ECT sensor terminal 1 and ground with

CONSULT-II or tester.
Voltage: Approximately 5V
OK or NG
OK >> GO TO 3.
NG >> Repair open circuit or short to ground or short to power
in harness or connectors.

PBIB2245E

3. CHECK ECT SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECT sensor terminal 2 and ECM terminal 159. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 4.
NG >> Repair open circuit or short to ground or short to power in harness or connectors.

EC-158
 DTC P0115 ECT SENSOR
[ZD30DDTi WITH COMMON RAIL]
4. CHECK ENGINE COOLANT TEMPERATURE SENSOR
Refer to EC-159, "Component Inspection" .
OK or NG
OK >> GO TO 5.
NG >> Replace engine coolant temperature sensor.

5. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection BBS00CHD EC
ENGINE COOLANT TEMPERATURE SENSOR
1. Check resistance between engine coolant temperature sensor
terminals 1 and 2 as shown in the figure.

SEC120E

<Reference data>
Engine coolant temperature °C (°F) Resistance kΩ
20 (68) 2.1 - 2.9
50 (122) 0.68 - 1.00
90 (194) 0.236 - 0.260

2. If NG, replace engine coolant temperature sensor.

SEF012P

EC-159
 DTC P0120 ACCELERATOR PEDAL POSITION SENSOR
[ZD30DDTi WITH COMMON RAIL]
DTC P0120 ACCELERATOR PEDAL POSITION SENSOR PFP:18002

Description BBS00CHF

The accelerator pedal position sensor is installed on the upper end of

the accelerator pedal assembly. The sensors detect the accelerator
pedal position and sends a signal to the ECM. The ECM uses the sig-
nal to determine the amount of fuel to be injected.

PBIB1741E

CONSULT-II Reference Value in Data Monitor Mode BBS00CHG

Specification data are reference values.

MONITOR ITEM CONDITION SPECIFICATION
Accelerator pedal: Fully released 0.4 - 1.05V
● Ignition switch: ON
ACCEL POS SEN* 3.1 - 4.7V (RHD)
(Engine stopped) Accelerator pedal: Fully depressed
3.3 - 4.7V (LHD)
Accelerator pedal: Fully released 0.4 - 1.05V
● Ignition switch: ON
ACCEL SEN 2* 3.1 - 4.7V (RHD)
(Engine stopped) Accelerator pedal: Fully depressed
3.3 - 4.7V (LHD)
*: This signal is converted by ECM internally. Thus, it differs from ECM terminal voltage.

On Board Diagnosis Logic BBS00CHH

NOTE:
If DTC P0120 is displayed with DTC P0641 (GST: P0642, P0643), first perform the trouble diagnosis for
DTC P0641 (GST: P0642, P0643). Refer to EC-309, "DTC P0641 SENSOR POWER SUPPLY" .
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Accelerator
pedal position An excessively high voltage from the APP
1 P0123 ● Harness or connectors
sensor 1 circuit sensor 1 is sent to ECM.
(APP sensor 1 circuit is open or
high input
P0120 shorted.)
Accelerator ● Accelerator pedal position sensor
pedal position An excessively low voltage from the APP (APP sensor 1)
2 P0122
sensor 1 circuit sensor 1 is sent to ECM.
low input

DTC Confirmation Procedure BBS00CHI

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.

EC-160
 DTC P0120 ACCELERATOR PEDAL POSITION SENSOR
[ZD30DDTi WITH COMMON RAIL]
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-164, "Diagnostic Procedure".

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.
EC

EC-161
 DTC P0120 ACCELERATOR PEDAL POSITION SENSOR
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CHJ

LHD MODELS

TEC660M

EC-162
 DTC P0120 ACCELERATOR PEDAL POSITION SENSOR
[ZD30DDTi WITH COMMON RAIL]
RHD MODELS

EC

TEC661M

EC-163
 DTC P0120 ACCELERATOR PEDAL POSITION SENSOR
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage)
NO.
Sensor power supply
111 G (Accelerator pedal posi- [Ignition switch ON] Approximately 5V
tion sensor 1)

Sensor ground [Engine is running]

115 OR/L (Accelerator pedal posi- ● Warm-up condition Approximately 0V
tion sensor 2) ● Idle speed
[Engine is running]
Sensor ground
131 B ● Warm-up condition Approximately 0V
(Sensors shield circuit)
● Idle speed
Sensor power supply
135 W/L (Accelerator pedal posi- [Ignition switch ON] Approximately 5V
tion sensor 2)

Sensor ground [Engine is running]

140 Y (Accelerator pedal posi- ● Warm-up condition Approximately 0V
tion sensor 1) ● Idle speed
[Ignition switch ON]
● Engine stopped 0.4 - 1.05V
Accelerator pedal position ● Accelerator pedal: Fully released
164 L
sensor 1 [Ignition switch ON]
3.1 - 4.7V (RHD)
● Engine stopped
3.3 - 4.7V (LHD)
● Accelerator pedal: Fully depressed
[Ignition switch ON]
● Engine stopped 0.2 - 0.53V
Accelerator pedal position ● Accelerator pedal: Fully released
189 L/G
sensor 2 [Ignition switch ON]
1.56 - 2.35V (RHD)
● Engine stopped
1.66 - 2.35V (LHD)
● Accelerator pedal: Fully depressed

Diagnostic Procedure BBS00CHK

1. CHECK GROUND CONNECTIONS

1. Turn ignition switch OFF.
2. Loosen and retighten ground screws.
Refer to EC-107, "Ground Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 2.
NG >> Repair or replace ground connections.
SEC119E

EC-164
 DTC P0120 ACCELERATOR PEDAL POSITION SENSOR
[ZD30DDTi WITH COMMON RAIL]
2. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT
1. Disconnect accelerator pedal position (APP) sensor harness
connector (3).
2. Turn ignition switch ON.
– Stop lamp switch (1)
– ASCD brake switch (2)
– Accelerator pedal (4)

SEC098E

EC
3. Check voltage between APP sensor terminal 3 and ground with
CONSULT-II or tester.
Voltage: Approximately 5V
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.

SEC067E

3. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M51, E6 (RHD models)
● Harness for open or short between APP sensor and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK APP SENSOR 1 GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between APP sensor terminal 5 and ECM terminal 140.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 6.
NG >> GO TO 5.

5. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M52, F7 (RHD models)
● Harness for open or short between APP sensor and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-165
 DTC P0120 ACCELERATOR PEDAL POSITION SENSOR
[ZD30DDTi WITH COMMON RAIL]
6. CHECK APP SENSOR 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Check harness continuity between ECM terminal 164 and APP sensor terminal 4.
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 8.
NG >> GO TO 7.

7. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M52, F7 (RHD models)
● Harness for open or short between APP sensor and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK APP SENSOR

Refer to EC-166, "Component Inspection" .
OK or NG
OK >> GO TO 9.
NG >> Replace accelerator pedal assembly.

9. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection BBS00CHL

ACCELERATOR PEDAL POSITION SENSOR

1. Reconnect all harness connectors disconnected.
2. Turn ignition switch ON.
3. Check voltage between ECM terminals 164 (APP sensor 1 sig-
nal), 189 (APP sensor 2 signal) and ground under the following
conditions.
Terminal Accelerator pedal Voltage

164 Fully released 0.4 - 1.05V

(Accelerator pedal position 3.1 - 4.7V (RHD)
sensor 1) Fully depressed
3.3 - 4.7V (LHD)

189 Fully released 0.4 - 1.05V

(Accelerator pedal position 3.1 - 4.7V (RHD)
sensor 2) Fully depressed MBIB1656E
3.3 - 4.7V (LHD)
4. If NG, replace accelerator pedal assembly.

EC-166
 DTC P0190 FRP SENSOR
[ZD30DDTi WITH COMMON RAIL]
DTC P0190 FRP SENSOR PFP:22693

Description BBS00CHN

The fuel rail pressure (FRP) sensor is placed to the fuel rail. It measures the fuel pressure in the fuel rail. The
sensor sends voltage signal to the ECM. As the pressure increases, the voltage rises.
The ECM controls the fuel pressure in the fuel rail. The ECM uses the signal from fuel rail pressure sensor as
a feedback signal.
CONSULT-II Reference Value in Data Monitor Mode BBS00CHO

Specification data are reference values.

MONITOR CONDITION SPECIFICATOIN
● Engine: After warming up Idle 30 - 40 MPa
● Air conditioner switch: OFF
ACT CR PRESS EC
● Shift lever: Neutral (M/T), P or N (A/T) 2,000 rpm 80 - 90 MPa
● No load

On Board Diagnosis Logic BBS00CHP

NOTE:
If DTC P0190 is displayed with DTC P0651 (GST: P0652, P0653), first perform the trouble diagnosis for
DTC P0651 (GST: P0652, P0653). Refer to EC-319, "DTC P0651 SENSOR POWER SUPPLY" .
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Fuel rail pres-
An excessively high voltage from the sensor
1 P0193 sure sensor cir- ● Harness or connectors
is sent to ECM.
cuit high input (The sensor circuit is open or
P0190 shorted.)
Fuel rail pres-
An excessively low voltage from the sensor Fuel rail pressure sensor
2 P0192 sure sensor cir- ●
is sent to ECM.
cuit low input

DTC Confirmation Procedure BBS00CHQ

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-169, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-167
 DTC P0190 FRP SENSOR
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CHR

TEC662M

EC-168
 DTC P0190 FRP SENSOR
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage)
NO.
[Engine is running]
Sensor ground
108 OR/L ● Warm-up condition Approximately 0V
(Fuel rail pressure sensor)
● Idle speed
[Engine is running]
Sensor ground
131 B ● Warm-up condition Approximately 0V
(Sensors shield circuit)
● Idle speed EC
Sensor power supply
137 L/G [Ignition switch ON] Approximately 5V
(Fuel rail pressure sensor)
[Engine is running]
● Warm-up condition 1.0 - 1.6V
● Idle speed
161 W/L Fuel rail pressure sensor
[Engine is running]
● Warm-up condition 2.0 - 2.7V
● Engine speed: 2,000 rpm

Diagnostic Procedure BBS00CHS

1. CHECK GROUND CONNECTION

1. Turn ignition switch OFF.
2. Loosen and retighten ground screws.
Refer to EC-107, "Ground Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 2.
NG >> Repair or replace ground connections.
SEC119E

EC-169
 DTC P0190 FRP SENSOR
[ZD30DDTi WITH COMMON RAIL]
2. CHECK FUEL RAIL PRESSURE SENSOR POWER SUPPLY CIRCUIT
1. Disconnect fuel rail pressure sensor (1) harness connector.
– : Vehicle front
2. Turn ignition switch ON.

SEC087E

3. Check voltage between fuel rail pressure sensor terminal 1 and

ground with CONSULT-II or tester.
Voltage: Approximately 5V
OK or NG
OK >> GO TO 3.
NG >> Repair open circuit or short to ground or short to power
in harness or connectors.

PBIB0405E

3. CHECK FUEL RAIL PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between fuel rail pressure sensor terminal 3 and ECM terminal 108.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 4.
NG >> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK FUEL RAIL PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Check harness continuity between ECM terminal 161 and fuel rail pressure sensor terminal 2.
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 5.
NG >> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK FUEL RAIL PRESSURE SENSOR

Refer to EC-171, "Component Inspection" .
OK or NG
OK >> GO TO 6.
NG >> Replace fuel rail.

EC-170
 DTC P0190 FRP SENSOR
[ZD30DDTi WITH COMMON RAIL]
6. CHECK INTERMITTENT INCIDENT
Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection BBS00CHT

FUEL RAIL PRESSURE SENSOR

1. Reconnect harness connector disconnected.
2. Start engine and warm it up to normal operating temperature.
3. Check voltage between ECM terminal 161 (fuel rail pressure sen-
sor signal) and ground under the following conditions.
Condition Voltage V EC
Idle 1.0 - 1.6
2,000 rpm 2.0 - 2.7

4. If the voltage is out of specification, disconnect fuel rail pressure

sensor harness connector and connect it again. Then repeat
above check.
5. If NG, replace fuel rail. MBIB1803E

EC-171
 DTC P0201 - P0204 FUEL INJECTOR
[ZD30DDTi WITH COMMON RAIL]
DTC P0201 - P0204 FUEL INJECTOR PFP:16600

Component Description BBS00CHV

The fuel injector is a small, precise solenoid valve. When the ECM
supplies a ground to the fuel injector circuit, the coil in the fuel injector
is energized. The energized coil pulls the needle valve back and al-
lows fuel to flow through the fuel injector into the cylinder. The amount
of fuel injected depends upon the injection pulse duration. Pulse du-
ration is the length of time the fuel injector remains open. The ECM
controls the injection pulse duration based on engine fuel needs.

PBIB0465E

CONSULT-II Reference Value in Data Monitor Mode BBS00CHW

Specification data are reference values.

MONITOR ITEM CONDITION SPECIFICATION
● Engine: After warming up Idle 5 - 10 mg/st
● Air conditioner switch: OFF
TRG INJ QTY
● Shift lever: Neutral (M/T), P or N (A/T) 2,000 rpm 5 - 10 mg/st
● No load

On Board Diagnosis Logic BBS00CHX

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
No.1 cylinder
An improper voltage signal is sent to ECM
P0201 4 P0201 fuel injector cir-
through No. 1 cylinder fuel injector.
cuit open
No.2 cylinder
An improper voltage signal is sent to ECM
P0202 4 P0202 fuel injector cir-
through No. 2 cylinder fuel injector. ● Harness or connectors
cuit open
(The fuel injector circuit is open.)
No.3 cylinder Fuel injector
An improper voltage signal is sent to ECM ●
P0203 4 P0203 fuel injector cir-
through No. 3 cylinder fuel injector.
cuit open
No.4 cylinder
An improper voltage signal is sent to ECM
P0204 4 P0204 fuel injector cir-
through No. 4 cylinder fuel injector.
cuit open

EC-172
 DTC P0201 - P0204 FUEL INJECTOR
[ZD30DDTi WITH COMMON RAIL]
DTC Confirmation Procedure BBS00CHY

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
TESTING CONDITION
Before performing the following procedure, confirm the ambient temperature is more than -20°C (-4°F).
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Start engine and let it idle for at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-176, "Diagnostic Procedure".
EC

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-173
 DTC P0201 - P0204 FUEL INJECTOR
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CHZ

TEC663M

EC-174
 DTC P0201 - P0204 FUEL INJECTOR
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.

0 - 14V
[Engine is running]
● Warm-up condition
● Idle speed
NOTE:
The pulse cycle changes depending on rpm at EC
101 R Fuel injector No. 3 idle.
MBIB1632E
102 G Fuel injector No. 2
125 BR Fuel injector No. 1
0 - 14V
126 OR Fuel injector No. 4

[Engine is running]
● Warm-up condition
● Engine speed: 2,000 rpm

MBIB1633E

0 - 14V
[Engine is running]
● Warm-up condition
● Idle speed
NOTE:
The pulse cycle changes depending on rpm at
149 G/W Fuel injector No. 2 idle.
151 L Fuel injector No. 4 MBIB1637E

173 B/W Fuel injector No. 3

0 - 14V
174 BR/Y Fuel injector No. 1

[Engine is running]
● Warm-up condition
● Engine speed: 2,000 rpm

MBIB1638E

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-175
 DTC P0201 - P0204 FUEL INJECTOR
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure BBS00CI0

1. CHECK FUEL INJECTOR POWER SUPPLY CIRCUIT FOR OPEN

1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Disconnect fuel injector (1) harness connector.
– : Vehicle front
4. Check harness continuity between the following terminals corre-
sponding to the malfunctioning cylinder. Refer to Wiring Diagram.
Terminal
DTC Cylinder
ECM Fuel injector
P0201 125 2 No.1
P0202 102 2 No.2
MBIB1607E
P0203 101 2 No.3
P0204 126 2 No.4

Continuity should exist.

OK or NG
OK >> GO TO 2.
NG >> Repair open circuit in harness or connectors.

2. CHECK FUEL INJECOR OUTPUT SIGNAL CIRCUIT FOR OPEN

Check harness continuity between the following terminals corresponding to the malfunctioning cylinder. Refer
to Wiring Diagram.
Terminal
DTC Cylinder
ECM Fuel injector
P0201 174 1 No.1
P0202 149 1 No.2
P0203 173 1 No.3
P0204 151 1 No.4

Continuity should exist.

OK or NG
OK >> GO TO 3.
NG >> Repair open circuit in harness or connectors.

3. CHECK FUEL INJECTOR

Refer to EC-177, "Component Inspection" .
OK or NG
OK >> GO TO 5.
NG >> GO TO 4.

4. REPLACE FUEL INJECOR

1. Replace fuel injector of malfunctioning cylinder.
2. Perform Injector Adjustment Value Registration. Refer to EC-34, "Injector Adjustment Value Registration" .

>> INSPECTION END

EC-176
 DTC P0201 - P0204 FUEL INJECTOR
[ZD30DDTi WITH COMMON RAIL]
5. CHECK INTERMITTENT INCIDENT
Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection BBS00CI1

FUEL INJECTOR
1. Disconnect fuel injector harness connector.
2. Check resistance between terminals as shown in the figure.
Resistance: 0.2 - 0.3Ω [at 20 - 70°C (68 - 158°F)]
3. If NG, replace fuel injector and go to next step.
EC
4. Perform EC-34, "Injector Adjustment Value Registration" .

PBIB0417E

EC-177
 DTC P0217 ENGINE OVER TEMPERATURE
[ZD30DDTi WITH COMMON RAIL]
DTC P0217 ENGINE OVER TEMPERATURE PFP:21481

On Board Diagnosis Logic BBS001ZM

This self-diagnosis has the one trip detection logic.

If the cooling fan or another component in the cooling system malfunctions, engine coolant tempera-
ture will rise.
When the engine coolant temperature reaches an abnormally high temperature condition, a malfunc-
tion is indicated.
NOTE:
If DTC P0217 is displayed with DTC P0480, first perform the trouble diagnosis for DTC P0480. Refer to
EC-268, "DTC P0480 COOLING FAN RELAY" .
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
● Cooling fan
● Cooling fan does not operate properly
(Overheat). ● Radiator hose
● Cooling fan system does not operate ● Radiator
Engine over tem- properly (Overheat). ● Reservoir tank cap
P0217 1 P0217 perature (Over-
heat) ● Engine coolant was not added to the sys- ● Water pump
tem using the proper filling method.
● Thermostat
● Engine coolant is not within the specified
For more information, refer to EC-184,
range.
"Main 12 Causes of Overheating" .

CAUTION:
When a malfunction is indicated, be sure to replace the coolant. Refer to LC section.
Also, replace the engine oil. Refer to LC section.
1. Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure to
use coolant with the proper mixture ratio. Refer to MA section.
2. After refilling coolant, run engine to ensure that no water-flow noise is emitted.
Overall Function Check BBS001ZN

Use this procedure to check the overall function of the cooling fan. During this check, a DTC might not be con-
firmed.
WARNING:
● Never remove the radiator cap when the engine is hot. Serious burns could be caused by high pres-
sure fluid escaping from the radiator.
● Wrap a thick cloth around cap. Carefully remove the cap by turning it a quarter turn to allow built-
up pressure to escape. Then turn the cap all the way off.
WITH CONSULT-II
1. Check the coolant level in the reservoir tank and radiator.
NOTE:
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to EC-181, "Di-
agnostic Procedure" .
2. Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to EC-181, "Di-
agnostic Procedure" .
3. Turn ignition switch ON.
SEF621W

EC-178
 DTC P0217 ENGINE OVER TEMPERATURE
[ZD30DDTi WITH COMMON RAIL]
4. Perform “COOLING FAN” in “ACTIVE TEST” mode with CON-
SULT-II.
5. If the results are NG, go to EC-181, "Diagnostic Procedure" .

SEF111X

WITHOUT CONSULT-II
1. Check the coolant level in the reservoir tank and radiator.
EC
NOTE:
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to EC-181, "Di-
agnostic Procedure" .
2. Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to EC-181, "Di-
agnostic Procedure" .
3. Start engine.
SEF621W
CAUTION:
Be careful not to overheat engine.
4. Set temperature control dial to full cold position.
5. Turn air conditioner switch ON.
6. Turn blower fan switch ON.
7. Run engine at idle for a few minutes with air conditioner operating.
CAUTION:
Be careful not to overheat engine.
8. Make sure that cooling fan operates.
If NG, go to EC-181, "Diagnostic Procedure" .

SEF863W

EC-179
 DTC P0217 ENGINE OVER TEMPERATURE
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS001ZO

TEC664M

EC-180
 DTC P0217 ENGINE OVER TEMPERATURE
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.
[Engine is running] BATTERY VOLTAGE
● Cooling fan: Not operating (11 - 14V)
242 L Cooling fan relay-1
[Engine is running]
Approximately 0.1V
● Cooling fan: Operating
[Engine is running] BATTERY VOLTAGE
● Air conditioner switch: OFF (11 - 14V) EC
255 Y/L Air conditioner relay [Engine is running]
● Both air conditioner switch and blower fan Approximately 0.1V
switch: ON (Compressor is operating)

Diagnostic Procedure BBS001ZP

1. INSPECTION START
Do you have CONSULT-II?
Yes or No
Yes >> GO TO 2.
No >> GO TO 3.

2. CHECK COOLING FAN LOW SPEED OPERATION

With CONSULT-II
1. Turn ignition switch ON.
2. Perform “COOLING FAN” in “ACTIVE TEST” mode with CON-
SULT-II and touch “ON” on the CONSULT-II screen.
3. Make sure that cooling fan-1 operates.
OK or NG
OK >> GO TO 4.
NG >> Check cooling fan control circuit. (Go to EC-183, "PRO-
CEDURE A" .)

MBIB0037E

EC-181
 DTC P0217 ENGINE OVER TEMPERATURE
[ZD30DDTi WITH COMMON RAIL]
3. CHECK COOLING FAN OPERATION
Without CONSULT-II
1. Start engine and let it idle.
2. Set temperature dial at full cold position.
3. Turn air conditioner switch ON.
4. Turn blower fan switch ON.
5. Make sure that cooling fan-1 operates.
OK or NG
OK >> GO TO 4.
NG >> Check cooling fan control circuit. (Go to EC-183, "PRO-
CEDURE A" .)

SEF863W

4. CHECK COOLING SYSTEM FOR LEAK

Refer to LC section.
OK or NG
OK >> GO TO 5.
NG >> Check the following for leak.
● Hose

● Radiator

● Reservoir tak cap

● Water pump

5. CHECK RESERVOIR TANK CAP

Refer to LC section.
OK or NG
OK >> GO TO 6.
NG >> Replace reservoir tank cap.

6. CHECK COMPONENT PARTS

Check the following.
● Thermostat. Refer to LC section.
● Engine coolant temperature sensor. Refer to EC-185, "Component Inspection" .
OK or NG
OK >> GO TO 7.
NG >> Replace malfunctioning component.

7. CHECK MAIN 12 CAUSES

If the cause cannot be isolated, go to EC-184, "Main 12 Causes of Overheating" .

>> INSPECTION END

EC-182
 DTC P0217 ENGINE OVER TEMPERATURE
[ZD30DDTi WITH COMMON RAIL]
PROCEDURE A
1. CHECK COOLING FAN POWER SUPPLY CIRCUIT
1. Turn ignition switch OFF.
2. Disconnect cooling fan relay-1 (1).
– A/C relay (2)
– : Vehicle front
3. Turn ignition switch ON.

EC
SEC095E

4. Check voltage between cooling fan relay-1 terminal 5 and ground

with CONSULT-II or tester.
Voltage: Battery voltage
OK or NG
OK >> GO TO 3.
NG >> GO TO 2.

PBIB0645E

2. DETECT MALFUNCTIONING PART

Check the following.
● 40A fusible link
● Harness for open or short between cooling fan relay-1 and battery

>> Repair open circuit or short to ground or short to power in harness or connectors.

3. CHECK COOLING FAN GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF.
2. Disconnect cooling fan motor-1 harness connector (1).
: Vehicle front
3. Check harness continuity between the following.
– Cooling fan relay-1 terminal 3 and cooling fan motor-1 terminal 1
– Cooling fan relay-1 terminal 2 and ground
– Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power. SEC094E

OK or NG
OK >> GO TO 4.
NG >> Repair open circuit or short to ground or short to power in harness or connectors.

EC-183
 DTC P0217 ENGINE OVER TEMPERATURE
[ZD30DDTi WITH COMMON RAIL]
4. CHECK COOLING FAN RELAY-1
Refer to EC-185, "Component Inspection" .
OK or NG
OK >> GO TO 5.
NG >> Replace cooling fan relay-1.

5. CHECK COOLING FAN MOTOR-1

Refer to EC-185, "Component Inspection" .
OK or NG
OK >> GO TO 6.
NG >> Replace cooling fan motor-1.

6. CHECK INTERMITTENT INCIDENT

Perform EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Main 12 Causes of Overheating BBS001ZQ

Engine Step Inspection item Equipment Standard Reference page

OFF 1 ● Blocked radiator ● Visual No blocking —
● Blocked condenser
● Blocked radiator grille
● Blocked bumper
2 ● Coolant mixture ● Coolant tester 50 - 50% coolant mixture See MA section.
3 ● Coolant level ● Visual Coolant up to MAX level See LC section.
in reservoir tank and radi-
ator filler neck
4 ● Radiator cap ● Pressure tester 59 - 98 kPa See LC section.
(0.59 - 0.98 bar, 0.6 - 1.0
kg/cm2 , 9 - 14 psi) (Limit)

ON*2 5 ● Coolant leaks ● Visual No leaks See LC section.

ON*2 6 ● Thermostat ● Touch the upper and Both hoses should be hot See LC section.
lower radiator hoses

ON*1 7 ● Cooling fan ● CONSULT-II Operating See trouble diagnosis for

DTC P0217 (EC-178 ).
OFF 8 ● Combustion gas leak ● Color checker chemical Negative —
tester 4 Gas analyzer

ON*3 9 ● Coolant temperature ● Visual Gauge less than 3/4 —

gauge when driving
● Coolant overflow to ● Visual No overflow during driving See LC section.
reservoir tank and idling

OFF*4 10 ● Coolant return from ● Visual Should be initial level in See LC section.
reservoir tank to radia- reservoir tank
tor
OFF 11 ● Cylinder head ● Straight gauge feeler 0.1 mm (0.004 in) Maxi- See EM section.
gauge mum distortion (warping)
12 ● Cylinder block and pis- ● Visual No scuffing on cylinder See EM section.
tons walls or piston
*1: Turn the ignition switch ON.
*2: Engine running at 3,000 rpm for 10 minutes.
*3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes.
*4: After 60 minutes of cool down time.

EC-184
 DTC P0217 ENGINE OVER TEMPERATURE
[ZD30DDTi WITH COMMON RAIL]
For more information, refer to LC section.

Component Inspection BBS001ZR

COOLING FAN RELAY-1

Check continuity between terminals (3) and (5).
Conditions Continuity
12V direct current supply between terminals (1) and
Yes
(2)
No current supply No

If NG, replace relay.

EC
PBIB0098E

COOLING FAN MOTOR-1

1. Disconnect cooling fan motor-1 harness connector.
2. Supply cooling fan motor-1 terminal with battery voltage and
check operation.

Terminals
(+) (-)
Cooling fan motor-1 1 2

Cooling fan motor should operate.

If NG, replace cooling fan motor.
PBIB1834E

EC-185
 DTC P0220 APP SENSOR
[ZD30DDTi WITH COMMON RAIL]
DTC P0220 APP SENSOR PFP:18005

Description BBS00CIB

The accelerator pedal position sensor is installed on the upper end of

the accelerator pedal assembly. The sensors detect the accelerator
pedal position and sends a signal to the ECM. The ECM uses the sig-
nal to determine the amount of fuel to be injected.

PBIB1741E

CONSULT-II Reference Value in Data Monitor Mode BBS00CIC

Specification data are reference values.

MONITOR ITEM CONDITION SPECIFICATION
Accelerator pedal: Fully released 0.4 - 1.05V
● Ignition switch: ON
ACCEL POS SEN* 3.1 - 4.7V (RHD)
(Engine stopped) Accelerator pedal: Fully depressed
3.3 - 4.7V (LHD)
Accelerator pedal: Fully released 0.4 - 1.05V
● Ignition switch: ON
ACCEL SEN 2* 3.1 - 4.7V (RHD)
(Engine stopped) Accelerator pedal: Fully depressed
3.3 - 4.7V (LHD)
*: This signal is converted by ECM internally. Thus, it differs from ECM terminal voltage.

On Board Diagnosis Logic BBS00CID

NOTE:
If DTC P0220 is displayed with DTC P0697 (GST: P0698, P0699), first perform the trouble diagnosis for
DTC P0697 (GST: P0698, P0699). Refer to EC-336, "DTC P0697 SENSOR POWER SUPPLY" .
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Accelerator
pedal position An excessively high voltage from the APP
1 P0223 ● Harness or connectors
sensor 2 circuit sensor 2 is sent to ECM.
(APP sensor 2 circuit is open or
high input
P0220 shorted.)
Accelerator ● Accelerator pedal position sensor
pedal position An excessively low voltage from the APP (APP sensor 2)
2 P0222
sensor 2 circuit sensor 2 is sent to ECM.
low input

DTC Confirmation Procedure BBS00CIE

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.

EC-186
 DTC P0220 APP SENSOR
[ZD30DDTi WITH COMMON RAIL]
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-190, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.
EC

EC-187
 DTC P0220 APP SENSOR
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CIF

LHD MODELS

TEC665M

EC-188
 DTC P0220 APP SENSOR
[ZD30DDTi WITH COMMON RAIL]
RHD MODELS

EC

TEC666M

EC-189
 DTC P0220 APP SENSOR
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage)
NO.
Sensor power supply
111 G (Accelerator pedal posi- [Ignition switch ON] Approximately 5V
tion sensor 1)

Sensor ground [Engine is running]

115 OR/L (Accelerator pedal posi- ● Warm-up condition Approximately 0V
tion sensor 2) ● Idle speed
[Engine is running]
Sensor ground
131 B ● Warm-up condition Approximately 0V
(Sensors shield circuit)
● Idle speed
Sensor power supply
135 W/L (Accelerator pedal posi- [Ignition switch ON] Approximately 5V
tion sensor 2)

Sensor ground [Engine is running]

140 Y (Accelerator pedal posi- ● Warm-up condition Approximately 0V
tion sensor 1) ● Idle speed
[Ignition switch ON]
● Engine stopped 0.4 - 1.05V
Accelerator pedal position ● Accelerator pedal: Fully released
164 L
sensor 1 [Ignition switch ON]
3.1 - 4.7V (RHD)
● Engine stopped
3.3 - 4.7V (LHD)
● Accelerator pedal: Fully depressed
[Ignition switch ON]
● Engine stopped 0.2 - 0.53V
Accelerator pedal position ● Accelerator pedal: Fully released
189 L/G
sensor 2 [Ignition switch ON]
1.56 - 2.35V (RHD)
● Engine stopped
1.66 - 2.35V (LHD)
● Accelerator pedal: Fully depressed

Diagnostic Procedure BBS00CIG

1. CHECK GROUND CONNECTIONS

1. Turn ignition switch OFF.
2. Loosen and retighten ground screws.
Refer to EC-107, "Ground Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 2.
NG >> Repair or replace ground connections.
SEC119E

EC-190
 DTC P0220 APP SENSOR
[ZD30DDTi WITH COMMON RAIL]
2. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT
1. Disconnect accelerator pedal position (APP) sensor harness
connector (3).
– Stop lamp switch (1)
– ASCD brake switch (2)
– Accelerator pedal (4)
2. Turn ignition switch ON.

SEC098E

EC
3. Check voltage between APP sensor terminal 2 and ground with
CONSULT-II or tester.
Voltage: Approximately 5V
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.

PBIB1168E

3. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M52, F7 (RHD models)
● Harness for open or short between APP sensor and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK APP SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between APP sensor terminal 6 and ECM terminal 115.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 6.
NG >> GO TO 5.

5. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M52, F7 (RHD models)
● Harness for open or short between APP sensor and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-191
 DTC P0220 APP SENSOR
[ZD30DDTi WITH COMMON RAIL]
6. CHECK APP SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Check harness continuity between ECM terminal 189 and APP sensor terminal 1.
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 8.
NG >> GO TO 7.

7. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M52, F7 (RHD models)
● Harness for open or short between APP sensor and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK APP SENSOR

Refer to EC-192, "Component Inspection" .
OK or NG
OK >> GO TO 9.
NG >> Replace accelerator pedal assembly.

9. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection BBS00CIH

ACCELERATOR PEDAL POSITION SENSOR

1. Reconnect all harness connectors disconnected.
2. Turn ignition switch ON.
3. Check voltage between ECM terminals 164 (APP sensor 1 sig-
nal), 189 (APP sensor 2 signal) and ground under the following
conditions.
Terminal Accelerator pedal Voltage

164 Fully released 0.4 - 1.05V

(Accelerator pedal position 3.1 - 4.7V (RHD)
sensor 1) Fully depressed
3.3 - 4.7V (LHD)

189 Fully released 0.4 - 1.05V

(Accelerator pedal position 3.1 - 4.7V (RHD)
sensor 2) Fully depressed MBIB1656E
3.3 - 4.7V (LHD)
4. If NG, replace accelerator pedal assembly.

EC-192
 DTC P0234 TC SYSTEM
[ZD30DDTi WITH COMMON RAIL]
DTC P0234 TC SYSTEM PFP:14411

Description BBS00CIJ

The load from the turbocharger boost control solenoid valve controls
the actuator. By changing the variable nozzle vane opening through
the rods, the intake air volume is adjusted.

MBIB0626E EC

The turbocharger boost control solenoid valve (2) is moved by ON/

OFF pulse from the ECM. The longer the ON pulse, the charge air
pressure rises.
● Mass air flow sensor (1)
● Battery (3)
● : Vehicle front

SEC089E

On Board Diagnosis Logic BBS00CIK

This self-diagnosis has the one trip detection logic.

The MI will not light up for this self-diagnosis.
NOTE:
● If DTC P0234 is displayed with DTC P0651 (GST: P0652, P0653), first perform the trouble diagnosis
for DTC P0651 (GST: P0652, P0653). Refer to EC-319, "DTC P0651 SENSOR POWER SUPPLY" .
● If DTC P0234 is displayed with DTC P0235 (GST: P0237, P0238), first perform the trouble diagnosis
for DTC P0235 (GST: P0237, P0238). Refer to EC-200, "DTC P0235 TC BOOST SENSOR" .

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
● Turbocharger
Turbocharger ● Vacuum pump
Turbocharger boost pressure is higher than
P0234 2 P0234 overboost condi- ● Turbocharger boost sensor
the target value.
tion
● Turbocharger boost control solenoid
valve

EC-193
 DTC P0234 TC SYSTEM
[ZD30DDTi WITH COMMON RAIL]
Overall Function Check BBS00CIL

Use this procedure to check the overall function of the turbocharger. During this check, a DTC might not be
confirmed.
WITH CONSULT-II
1. Start engine and let it idle.
2. Perform “TC BOOST CONT/V” in “ACTIVE TEST” mode with
CONSULT-II.

MBIB1818E

3. Turn turbocharger boost control valve solenoid valve “ON” and

“OFF”, and make sure that turbocharger boost control actuator
rod moves slightly.
● Turbocharger boost control actuator (1)

4. If NG, go to EC-196, "Diagnostic Procedure" .

SEC105E

WITH GST
1. Start engine and let it idle.
2. Make sure that turbocharger boost control actuator rod moves
slightly when engine is started.
● Turbocharger boost control actuator (1)

3. If NG, go to EC-196, "Diagnostic Procedure" .

SEC105E

EC-194
 DTC P0234 TC SYSTEM
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CIM

EC

TEC656M

EC-195
 DTC P0234 TC SYSTEM
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference valves, and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.

0 - 14V

[Engine is running]
● Warm-up condition
● Idle speed

SEC113E
Turbocharger boost con-
123 R/B
trol solenoid valve
0 - 14V

[Engine is running]
● Warm-up condition
● Engine speed: 2,000 rpm

SEC114E

201 W
BATTERY VOLTAGE
203 W Power supply for ECM [Ignition switch ON]
(11 - 14V)
205 W
[Ignition switch ON]
[Ignition switch OFF]
Approximately 1.2V
● For a few seconds after turning ignition
245 B/Y ECM relay (self-shutoff) switch OFF
[Ignition switch OFF]
BATTERY VOLTAGE
● More than a few seconds after turning igni- (11 - 14V)
tion switch OFF

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure BBS00CIN

1. CHECK VACUUM SOURCE

1. Turn ignition switch OFF.
2. Disconnect vacuum hose connected to turbocharger boost con-
trol actuator (1).
3. Start engine and let it idle.
4. Check vacuum hose for vacuum existence.
Vacuum should exist.
OK or NG
OK >> GO TO 9.
NG >> GO TO 2.
SEC104E

EC-196
 DTC P0234 TC SYSTEM
[ZD30DDTi WITH COMMON RAIL]
2. CHECK VACUUM HOSES AND VACUUM GALLERY
1. Turn ignition switch OFF.
2. Check vacuum hoses and vacuum gallery for clogging, cracks or improper connection.
Refer to EC-28, "Vacuum Hose Drawing" .
OK or NG
OK >> GO TO 3.
NG >> Repair or replace vacuum hoses and vacuum gallery.

EC
SEF109L

3. CHECK TURBOCHARGER BOOST CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT

1. Disconnect turbocharger boost control solenoid valve (2) har-
ness connector.
– Mass air flow sensor (1)
– Battery (3)
– : Vehicle front
2. Turn ignition switch ON.

SEC089E

3. Check voltage between turbocharger boost control solenoid

valve terminal 2 and ground with CONSULT-II or tester.
Voltage: Battery voltage
OK or NG
OK >> GO TO 5.
NG >> GO TO 4.

PBIB2605E

4. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M50, F5
● Harness for open or short between ECM relay and turbocharger boost control solenoid valve
● Harness for open or short between ECM and turbocharger boost control solenoid valve

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-197
 DTC P0234 TC SYSTEM
[ZD30DDTi WITH COMMON RAIL]
5. CHECK TURBOCHARGER BOOST CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR
OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminals 123 and turbocharger boost control solenoid valve ter-
minal 1. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 6.
NG >> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK TURBOCHARGE BOOST CONTROL SOLENOID VALVE

Refer to EC-199, "Component Inspection" .
OK or NG
OK >> GO TO 7.
NG >> Replace turbocharger boost control solenoid valve.

7. CHECK VACUUM PUMP

Refer to EM section.
OK or NG
OK >> GO TO 8.
NG >> Replace vacuum pump assembly.

8. CHECK TURBOCHARGER BOOST CONTROL ACTUATOR

1. Turn ignition switch OFF.
2. Install a vacuum pump (A) to turbocharger boost control actuator
(1).
3. Make sure that the turbocharger boost control actuator rod
moves smoothly when applying vacuum of -53.3 kPa (-533 mbar,
-400 mmHg, -15.75 inHg) and releasing it.
OK or NG
OK >> GO TO 9.
NG >> Replace turbocharger assembly.

SEC106E

9. CHECK TURBOCHARGER BOOST SENSOR

Refer to EC-205, "Component Inspection" .
OK or NG
OK >> GO TO 10.
NG >> Replace turbocharger boost sensor.

10. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

EC-198
 DTC P0234 TC SYSTEM
[ZD30DDTi WITH COMMON RAIL]
Component Inspection BBS00CIO

TURBOCHARGER BOOST CONTROL SOLENOID VALVE

1. Disconnect turbocharger boost control solenoid valve harness connector.
2. Apply 12V direct current between turbocharger boost control solenoid valve terminals.
3. Check air passage continuity of turbocharger boost control sole-
noid valve under the following conditions.
Air passage continuity Air passage continuity
CONDITIONS
between (A) and (B) between (A) and (C)
12V direct current supply
between terminals (1) and Yes No
(2)
No supply No Yes
EC
Operation takes less than 1 second.
MBIB0996E
If NG, replace turbocharger boost control solenoid valve.

EC-199
 DTC P0235 TC BOOST SENSOR
[ZD30DDTi WITH COMMON RAIL]
DTC P0235 TC BOOST SENSOR PFP:22693

Component Description BBS00CIQ

The turbocharger boost sensor detects pressure in the exit side of the
charge air cooler. The sensor output voltage to the ECM increases as
pressure increases.

MBIB0614E

MBIB0899E

CONSULT-II Reference Value in Data Monitor Mode BBS00CIR

Specification data are reference values.

MONITOR ITEM CONDITION SPECIFICATION
● Engine: After warming up Idle speed Approx. Atmospheric pressure
TURBO BST SEN ● Shift lever: Neutral (M/T), P or
Engine speed: 2,000 rpm 100 - 110 kPa
N (A/T)

On Board Diagnosis Logic BBS00CIS

If DTC P0235 is displayed with DTC P0651 (GST: P0652, P0653), first perform trouble diagnosis for DTC
P0651 (GST: P0652, P0653). Refer to EC-319, "DTC P0651 SENSOR POWER SUPPLY" .
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Turbocharger
An excessively high voltage from the sensor
1 P0238 boost sensor cir- ● Harness or connectors
is sent to ECM.
cuit high input (The sensor circuit is open or
P0235 shorted.)
Turbocharger
An excessively low voltage from the sensor
2 P0237 boost sensor cir- ● Turbocharger boost sensor
is sent to ECM.
cuit low input

DTC Confirmation Procedure BBS00CIT

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.

EC-200
 DTC P0235 TC BOOST SENSOR
[ZD30DDTi WITH COMMON RAIL]
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-203, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.
EC

EC-201
 DTC P0235 TC BOOST SENSOR
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CIU

TEC667M

EC-202
 DTC P0235 TC BOOST SENSOR
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values, and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage)
NO.
Sensor power supply
113 R (Turbocharger boost sen- [Ignition switch ON] Approximately 5V
sor)
[Engine is running]
Sensor ground
131 B ● Warm-up condition Approximately 0V
(Sensors shield circuit)
● Idle speed
EC
Sensor ground [Engine is running]
132 B (Turbocharger boost sen- ● Warm-up condition Approximately 0V
sor) ● Idle speed
[Engine is running]
● Warm-up condition 1.7 - 2.3V
● Idle speed
158 W Turbocharger boost sensor
[Engine is running]
● Warm-up condition 1.7 - 2.6V
● Engine speed: 2,000 rpm

Diagnostic Procedure BBS00CIV

1. CHECK GROUND CONNECTIONS

1. Turn ignition switch OFF.
2. Loosen and retighten ground screws. Refer to EC-107, "Ground
Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 2.
NG >> Repair or replace ground connections.
SEC119E

EC-203
 DTC P0235 TC BOOST SENSOR
[ZD30DDTi WITH COMMON RAIL]
2. CHECK TURBOCHARGER BOOST SENSOR POWER SUPPLY CIRCUIT
1. Disconnect turbocharger boost sensor (1) harness connector.
– : Vehicle front
2. Turn ignition switch ON.

SEC088E

3. Check voltage between turbocharger boost sensor terminal 1

and ground with CONSULT-II or tester.
Voltage: Approximately 5V
OK or NG
OK >> GO TO 3.
NG >> Repair open circuit or short to ground or short to power
in harness or connectors.

MBIB0072E

3. CHECK TURBOCHAGER BOOST SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between turbocharger boost sensor terminal 3 and ECM terminal 132.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 4.
NG >> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK TURBOCHAGER BOOST SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Check harness continuity between ECM terminals 158 and turbocharger boost sensor terminal 2. Refer to
Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 5.
NG >> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK TURBOCHARGER BOOST SENSOR

Refer to EC-205, "Component Inspection" .
OK or NG
OK >> GO TO 6.
NG >> Replace turbocharger boost sensor.

EC-204
 DTC P0235 TC BOOST SENSOR
[ZD30DDTi WITH COMMON RAIL]
6. CHECK INTERMITTENT INCIDENT
Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection BBS00CIW

TURBOCHARGER BOOST SENSOR

1. Remove turbocharger boost sensor with its harness connected.
2. Turn ignition switch ON.
3. Use pump to apply pressure sensor as shown in the figure.
CAUTION:
● Always calibrate the pressure pump gauge when using it.
EC
● Inspection should be done at room temperature [10-30°C (50-86°F)].

4. Check the output voltage between turbocharger boost sensor terminal 2 and ground.
Pressure (Relative to atmospheric pressure) Voltage V
0 kPa (0 mbar, 0 mmHg, 0 inHg) Approximately 2.3V
+40 kPa (400 mbar, 300mmHg, 11.81 inHg) Approximately 2.9V

MBIB0925E

EC-205
 DTC P0262, P0265, P0268, P0271 FUEL INJECTOR
[ZD30DDTi WITH COMMON RAIL]
DTC P0262, P0265, P0268, P0271 FUEL INJECTOR PFP:16600

Component Description BBS00CIY

The fuel injector is a small, precise solenoid valve. When the ECM
supplies a ground to the fuel injector circuit, the coil in the fuel injector
is energized. The energized coil pulls the needle valve back and al-
lows fuel to flow through the fuel injector into the cylinder. The amount
of fuel injected depends upon the injection pulse duration. Pulse du-
ration is the length of time the fuel injector remains open. The ECM
controls the injection pulse duration based on engine fuel needs.

PBIB0465E

CONSULT-II Reference Value in Data Monitor Mode BBS00CIZ

Specification data are reference values.

MONITOR ITEM CONDITION SPECIFICATION
● Engine: After warming up Idle 5 - 10 mg/st
● Air conditioner switch: OFF
TRG INJ QTY ● Shift lever: Neutral (M/T), P or N
2,000 rpm 5 - 10 mg/st
(A/T)
● No load

On Board Diagnosis Logic BBS00CJ0

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
1 No. 1 cylinder
An improper voltage signal is sent to ECM
P0262 P0262 fuel injector cir-
4 through No. 1 cylinder fuel injector.
cuit high input
1 No. 2 cylinder
An improper voltage signal is sent to ECM
P0265 P0265 fuel injector cir-
4 through No. 2 cylinder fuel injector. ● Harness or connectors
cuit high input
(The fuel injector circuit is shorted.)
1 No. 3 cylinder Fuel injector
An improper voltage signal is sent to ECM ●
P0268 P0268 fuel injector cir-
4 through No. 3 cylinder fuel injector.
cuit high input
1 No. 4 cylinder
An improper voltage signal is sent to ECM
P0271 P0271 fuel injector cir-
4 through No. 4 cylinder fuel injector.
cuit high input

EC-206
 DTC P0262, P0265, P0268, P0271 FUEL INJECTOR
[ZD30DDTi WITH COMMON RAIL]
DTC Confirmation Procedure BBS00CJ1

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
TESTING CONDITION
Before performing the following procedure, confirm the ambient temperature is more than -20°C (-4°F).
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Start engine and let it idle for at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-210, "Diagnostic Procedure"
.
EC

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-207
 DTC P0262, P0265, P0268, P0271 FUEL INJECTOR
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CJ2

TEC727M

EC-208
 DTC P0262, P0265, P0268, P0271 FUEL INJECTOR
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.

0 - 14V
[Engine is running]
● Warm-up condition
● Idle speed
NOTE:
The pulse cycle changes depending on rpm at EC
101 R Fuel injector No. 3 idle.
MBIB1632E
102 G Fuel injector No. 2
125 BR Fuel injector No. 1
0 - 14V
126 OR Fuel injector No. 4

[Engine is running]
● Warm-up condition
● Engine speed: 2,000 rpm

MBIB1633E

0 - 14V
[Engine is running]
● Warm-up condition
● Idle speed
NOTE:
The pulse cycle changes depending on rpm at
149 G/W Fuel injector No. 2 idle.
151 L Fuel injector No. 4 MBIB1637E

173 B/W Fuel injector No. 3

0 - 14V
174 BR/Y Fuel injector No. 1

[Engine is running]
● Warm-up condition
● Engine speed: 2,000 rpm

MBIB1638E

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-209
 DTC P0262, P0265, P0268, P0271 FUEL INJECTOR
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure BBS00CJ3

1. CHECK FUEL INJECOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Disconnect fuel injector (1) harness connector.
– : Vehicle front
4. Check harness for short to power, between the following termi-
nals. Refer to Wiring Diagram.
Terminal
DTC Cylinder
ECM Fuel injector
P0262 174 1 No.1
P0265 149 1 No.2
MBIB1607E
P0268 173 1 No.3
P0271 151 1 No.4
OK or NG
OK >> GO TO 2.
NG >> Repair short to power in harness or connectors.

2. CHECK FUEL INJECTOR

Refer to EC-210, "Component Inspection" .
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.

3. REPLACE FUEL INJECOR

1. Replace fuel injector of malfunctioning cylinder.
2. Perform Injector Adjustment Value Registration. Refer to EC-34, "Injector Adjustment Value Registration" .

>> INSPECTION END

4. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection BBS00CJ4

FUEL INJECTOR
1. Disconnect fuel injector.
2. Check continuity between terminals as shown in the figure.
Continuity should exist.
3. If NG, replace fuel injector and go to next step.
4. Perform EC-34, "Injector Adjustment Value Registration" .

PBIB0417E

EC-210
 DTC P0299 TC SYSTEM
[ZD30DDTi WITH COMMON RAIL]
DTC P0299 TC SYSTEM PFP:22365

Description BBS00CJ6

The load from the turbocharger boost control solenoid valve controls
the actuator. By changing the variable nozzle vane opening through
the rods, the intake air volume is adjusted.

MBIB0626E EC

The turbocharger boost control solenoid valve (2) is moved by ON/

OFF pulse from the ECM. The longer the ON pulse, the charge air
pressure rises.
● Mass air flow sensor (1)
● Battery (3)
● : Vehicle front

SEC089E

On Board Diagnosis Logic BBS00CJ7

This self-diagnosis has the one trip detection logic.

The MI will not light up for this self-diagnosis.
NOTE:
● If DTC P0299 is displayed with DTC P0651 (GST: P0652, P0653), first perform the trouble diagnosis
for DTC P0651 (GST: P0652, P0653). Refer to EC-319, "DTC P0651 SENSOR POWER SUPPLY" .
● If DTC P0299 is displayed with DTC P0235 (GST: P0237, P0238), first perform the trouble diagnosis
for DTC P0235 (GST: P0237, P0238). Refer to EC-200, "DTC P0235 TC BOOST SENSOR" .

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
● Turbocharger
● Vacuum pump
Turbocharger
Turbocharger boost pressure is lower than ● Turbocharger boost sensor
P0299 2 P0299 underboost con-
the target value. ● Turbocharger boost control solenoid
dition
valve
● Loose or disconnected vacuum hose

EC-211
 DTC P0299 TC SYSTEM
[ZD30DDTi WITH COMMON RAIL]
Overall Function Check BBS00D3N

Use this procedure to check the overall function of the turbocharger. During this check, a DTC might not be
confirmed.
WITH CONSULT-II
1. Start engine and let it idle.
2. Perform “TC BOOST CONT/V” in “ACTIVE TEST” mode with
CONSULT-II.

MBIB1818E

3. Turn turbocharger boost control valve solenoid valve “ON” and

“OFF”, and make sure that turbocharger boost control actuator
rod moves slightly.
● Turbocharger boost control actuator (1)

4. If NG, go to EC-214, "Diagnostic Procedure" .

SEC105E

WITH GST
1. Start engine and let it idle.
2. Make sure that turbocharger boost control actuator rod moves
slightly when engine is started.
● Turbocharger boost control actuator (1)

3. If NG, go to EC-214, "Diagnostic Procedure" .

SEC105E

EC-212
 DTC P0299 TC SYSTEM
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CJ9

EC

TEC656M

EC-213
 DTC P0299 TC SYSTEM
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference valves, and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.

0 - 14V

[Engine is running]
● Warm-up condition
● Idle speed

SEC113E
Turbocharger boost con-
123 R/B
trol solenoid valve
0 - 14V

[Engine is running]
● Warm-up condition
● Engine speed: 2,000 rpm

SEC114E

201 W
BATTERY VOLTAGE
203 W Power supply for ECM [Ignition switch ON]
(11 - 14V)
205 W
[Ignition switch ON]
[Ignition switch OFF]
Approximately 1.2V
● For a few seconds after turning ignition
245 B/Y ECM relay (self-shutoff) switch OFF
[Ignition switch OFF]
BATTERY VOLTAGE
● More than a few seconds after turning igni- (11 - 14V)
tion switch OFF

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure BBS00CJA

1. CHECK VACUUM SOURCE

1. Turn ignition switch OFF.
2. Disconnect vacuum hose connected to turbocharger boost con-
trol actuator (1).
3. Start engine and let it idle.
4. Check vacuum hose for vacuum existence.
Vacuum should exist.
OK or NG
OK >> GO TO 9.
NG >> GO TO 2.
SEC104E

EC-214
 DTC P0299 TC SYSTEM
[ZD30DDTi WITH COMMON RAIL]
2. CHECK VACUUM HOSES AND VACUUM GALLERY
1. Turn ignition switch OFF.
2. Check vacuum hoses and vacuum gallery for clogging, cracks or improper connection.
Refer to EC-28, "Vacuum Hose Drawing" .
OK or NG
OK >> GO TO 3.
NG >> Repair or replace vacuum hoses and vacuum gallery.

EC
SEF109L

3. CHECK TURBOCHARGER BOOST CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT

1. Disconnect turbocharger boost control solenoid valve (2) har-
ness connector.
– Mass air flow sensor (1)
– Battery (3)
– : Vehicle front
2. Turn ignition switch ON.

SEC089E

3. Check voltage between turbocharger boost control solenoid

valve terminal 2 and ground with CONSULT-II or tester.
Voltage: Battery voltage
OK or NG
OK >> GO TO 5.
NG >> GO TO 4.

PBIB2605E

4. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M50, F5
● Harness for open or short between ECM relay and turbocharger boost control solenoid valve
● Harness for open or short between ECM and turbocharger boost control solenoid valve

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-215
 DTC P0299 TC SYSTEM
[ZD30DDTi WITH COMMON RAIL]
5. CHECK TURBOCHARGER BOOST CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR
OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminals 123 and turbocharger boost control solenoid valve ter-
minal 2. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 6.
NG >> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK TURBOCHARGE BOOST CONTROL SOLENOID VALVE

Refer to EC-217, "Component Inspection" .
OK or NG
OK >> GO TO 7.
NG >> Replace turbocharger boost control solenoid valve.

7. CHECK VACUUM PUMP

Refer to EM section.
OK or NG
OK >> GO TO 8.
NG >> Replace vacuum pump assembly.

8. CHECK TURBOCHARGER BOOST CONTROL ACTUATOR

1. Turn ignition switch OFF.
2. Install a vacuum pump A to turbocharger boost control actuator
(1).
3. Make sure that the turbocharger boost control actuator rod
moves smoothly when applying vacuum of -53.3kPa (-533mbar,
-400mmHg, -15.75inHg) and releasing it.
OK or NG
OK >> GO TO 9.
NG >> Replace turbocharger assembly.

SEC106E

9. CHECK TURBOCHARGER BOOST SENSOR

Refer to EC-205, "Component Inspection" .
OK or NG
OK >> GO TO 10.
NG >> Replace turbocharger boost sensor.

10. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

EC-216
 DTC P0299 TC SYSTEM
[ZD30DDTi WITH COMMON RAIL]
Component Inspection BBS00CJB

TURBOCHARGER BOOST CONTROL SOLENOID VALVE

1. Disconnect turbocharger boost control solenoid valve harness connector.
2. Apply 12V direct current between turbocharger boost control solenoid valve terminals.
3. Check air passage continuity of turbocharger boost control sole-
noid valve under the following conditions.
Air passage continuity Air passage continuity
CONDITIONS
between (A) and (B) between (A) and (C)
12V direct current supply
between terminals (1) and Yes No
(2)
No supply No Yes
EC
Operation takes less than 1 second.
MBIB0996E
If NG, replace turbocharger boost control solenoid valve.

EC-217
 DTC P0335 CKP SENSOR
[ZD30DDTi WITH COMMON RAIL]
DTC P0335 CKP SENSOR PFP:23731

Description BBS00CJD

The crankshaft position (CKP) sensor is located on the cylinder block

rear housing facing the gear teeth (cogs) of the signal plate.
The ECM receives the voltage signal and detects the fluctuation of
the engine revolution.

MBIB1530E

CONSULT-II Reference Value in Data Monitor Mode BBS00CJE

Specification data are reference values.

MONITOR ITEM CONDITION SPECIFICATION
● Run engine and compare CONSULT-II value with the tachometer Almost the same speed as the
CKPS-RPM (TDC)
indication. tachometer indication

On Board Diagnosis Logic BBS00CJF

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
● Harness or connectors
Crankshaft posi- (The sensor circuit is open or
Crankshaft position sensor signal is not
1 P0335 tion sensor cir- shorted.)
detect by the ECM when engine is running.
cuit
● Crankshaft position sensor
P0335 ● Harness or connectors
Crankshaft posi- (The sensor circuit is open or
tion sensor cir- Crankshaft position sensor signal is not in shorted.)
2 P0336
cuit range/ the normal pattern when engine is running.
● Crankshaft position sensor
performance
● Signal plate

DTC Confirmation Procedure BBS00CJG

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Start engine and let it idle for at least 5 seconds.
If engine can not start, keep ignition switch at START position for
5 seconds.
4. If 1st trip DTC is detected, go to EC-221, "Diagnostic Procedure"
.

SEF817Y

EC-218
 DTC P0335 CKP SENSOR
[ZD30DDTi WITH COMMON RAIL]
WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC

EC-219
 DTC P0335 CKP SENSOR
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CJH

TEC668M

EC-220
 DTC P0335 CKP SENSOR
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.

Sensor ground [Engine is running]

112 B/R (Crankshaft position sen- ● Warm-up condition Approximately 0V
sor) ● Idle speed
[Engine is running]
Sensor ground
131 B ● Warm-up condition Approximately 0V EC
(Sensors shield circuit)
● Idle speed

0 - 6V
[Engine is running]
● Warm-up condition
● Idle speed
NOTE:
The pulse cycle changes depending on rpm at
idle.
MBIB1635E
136 BR Crankshaft position sensor
0 - 14V

[Engine is running]
● Warm-up condition
● Engine speed: 2,000 rpm

MBIB1636E

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure BBS00CJI

1. CHECK GROUND CONNECTIONS

1. Turn ignition switch OFF.
2. Loosen and retighten ground screws.
Refer to EC-107, "Ground Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 2.
NG >> Repair or replace ground connections.
SEC119E

EC-221
 DTC P0335 CKP SENSOR
[ZD30DDTi WITH COMMON RAIL]
2. CHECK CKP SENSOR POWER SUPPLY CIRCUIT
1. Disconnect crankshaft position (CKP) sensor (1) harness con-
nector.
2. Turn ignition switch ON.

SEC085E

3. Check voltage between CKP sensor terminal 1 and ground with

CONSULT-II or tester.
Voltage: Approximately 5V
OK or NG
OK >> GO TO 3.
NG >> Repair open circuit or short to ground or short to power
in harness or connectors.

SEC121E

3. CHECK CKP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminal 112 and CKP sensor terminal 2.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for and short to ground and short to power.
OK or NG
OK >> GO TO 4.
NG >> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK CRANKSHAFT POSITION SENSOR

Refer to EC-222, "Component Inspection" .
OK or NG
OK >> GO TO 6.
NG >> Replace crankshaft position sensor.

5. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection BBS00CJJ

CRANKSHAFT POSITION SENSOR

1. Loosen the fixing bolt of the sensor.
2. Disconnect crankshaft position sensor harness connector.
3. Remove the sensor.

EC-222
 DTC P0335 CKP SENSOR
[ZD30DDTi WITH COMMON RAIL]
4. Visually check the sensor for chipping.

SEF981Y

5. Check resistance as shown in the figure.

Resistance : 500 - 600Ω [at 25°C (77°F)] EC
6. If NG, replace crankshaft position sensor.

SEC122E

EC-223
 DTC P0340 CMP SENSOR
[ZD30DDTi WITH COMMON RAIL]
DTC P0340 CMP SENSOR PFP:23731

Description BBS00CJL

The camshaft position (CMP) sensor senses the retraction with cam-
shaft (left side) to identify a particular cylinder. The camshaft position
(CMP) sensor senses the piston position.
When the crankshaft position (CKP) sensor system becomes inoper-
ative, the camshaft position (CMP) sensor provides various controls
of engine parts instead, utilizing timing of cylinder identification sig-
nals.
The sensor consists of a permanent magnet and Hall IC.
When engine is running, the high and low parts of the teeth cause the
gap with the sensor to change.
The changing gap causes the magnetic field near the sensor to
MBIB1532E
change.
Due to the changing magnetic field, the voltage from the sensor changes.
CONSULT-II Reference Value in Data Monitor Mode BBS00D1Q

Specification data are reference values.

MONITOR ITEM CONDITION SPECIFICATION
● Run engine and compare CONSULT-II value with the tachometer indi- Almost the same as half of the
CMPS-RPM
cation tachometer indication

On Board Diagnosis Logic BBS00CJM

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
● Harness or connectors
Camshaft posi- (The sensor circuit is open or
Camshaft position sensor signal is not
1 P0340 tion sensor cir- shorted.)
detect by the ECM when engine is running.
cuit
● Camshaft position sensor
P0340 ● Harness or connectors
Camshaft posi- (The sensor circuit is open or
tion sensor cir- Camshaft position sensor signal is not in the shorted.)
2 P0341
cuit range/ normal pattern when engine is running.
● Camshaft position sensor
performance
● Signal plate

DTC Confirmation Procedure BBS00CJN

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Start engine and let it idle for at least 5 seconds.
If engine can not start, keep ignition switch at START position for
5 seconds.
4. If 1st trip DTC is detected, go to EC-227, "Diagnostic Procedure"
.

SEF817Y

EC-224
 DTC P0340 CMP SENSOR
[ZD30DDTi WITH COMMON RAIL]
WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC

EC-225
 DTC P0340 CMP SENSOR
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CJO

TEC669M

EC-226
 DTC P0340 CMP SENSOR
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.
[Engine is running]
Sensor ground
129 L ● Warm-up condition Approximately 0V
(Camshaft position sensor)
● Idle speed

0 - 14V
[Engine is running]
EC
● Warm-up condition
● Idle speed
NOTE:
The pulse cycle changes depending on rpm at
idle.
MBIB1641E
177 W Camshaft position sensor
0 - 14V

[Engine is running]
● Warm-up condition
● Engine speed: 2,000 rpm

MBIB1642E

201 W
BATTERY VOLTAGE
203 W Power supply for ECM [Ignition switch ON]
(11 - 14V)
205 W
[Ignition switch ON]
[Ignition switch OFF]
Approximately 1.2V
● For a few seconds after turning ignition
245 B/Y ECM relay (self-shutoff) switch OFF
[Ignition switch OFF]
BATTERY VOLTAGE
● More than a few seconds after turning igni- (11 - 14V)
tion switch OFF

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure BBS00CJP

1. CHECK GROUND CONNECTIONS

1. Turn ignition switch OFF.
2. Loosen and retighten ground screws.
Refer to EC-107, "Ground Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 2.
NG >> Repair or replace ground connections.
SEC119E

EC-227
 DTC P0340 CMP SENSOR
[ZD30DDTi WITH COMMON RAIL]
2. CHECK CMP SENSOR POWER SUPPLY CIRCUIT
1. Disconnect camshaft position (CMP) sensor (1) harness connec-
tor.
– Engine coolant temperature sensor (2)
– : Vehicle front
2. Turn ignition switch ON.

SEC086E

3. Check voltage between CMP sensor terminal 3 and ground with

CONSULT-II or tester.
Voltage: Approximately 5V
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.

SEC123E

3. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M50, F5
● Harness connector F33, E271
● Harness for open or short between camshaft position sensor and ECM relay
● Harness for open or short between camshaft position sensor and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK CMP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminal 129 and CMP sensor terminal 1.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 6.
NG >> GO TO 5.

5. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors E271, F33
● Harness for open or short between camshaft position sensor and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-228
 DTC P0340 CMP SENSOR
[ZD30DDTi WITH COMMON RAIL]
6. CHECK CMP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Check harness continuity between ECM terminal 177 and CMP sensor terminal 2.
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 8.
NG >> GO TO 7.

7. DETECT MALFUNCTIONING PART

Check the following. EC
● Harness connectors E271, F33
● Harness for open or short between camshaft position sensor and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK CAMSHAFT POSITION SENSOR

Refer to EC-229, "Component Inspection" .
OK or NG
OK >> GO TO 9.
NG >> Replace camshaft position sensor.

9. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection BBS00CJQ

CAMSHAFT POSITION SENSOR

1. Loosen the fixing bolt of the sensor.
2. Disconnect camshaft position sensor harness connector.
3. Remove the sensor.
4. Visually check the sensor for chipping.

SEF583P

EC-229
 DTC P0340 CMP SENSOR
[ZD30DDTi WITH COMMON RAIL]
5. Check resistance as shown in the figure.
Terminal No. (Polarity) Resistance Ω [at 25°C (77°F)]
1 (+) - 2 (-)
3 (+) - 1 (-) Except 0 or ∞
3 (+) - 2 (-)
6. If NG, replace camshaft position sensor.

SEF935X

EC-230
 DTC P0380 GLOW RELAY
[ZD30DDTi WITH COMMON RAIL]
DTC P0380 GLOW RELAY PFP:25230

On Board Diagnosis Logic BBS00CJS

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
An excessively high voltage is sent to ECM
1
through glow relay.
● Harness or connectors
2 An excessively low voltage is sent to ECM (The glow relay circuit is open or
P0380 P0380 Glow relay circuit shorted.)
4 through glow relay.
● Glow relay
An improper voltage is sent to ECM through EC
8
glow relay.

DTC Confirmation Procedure BBS00CJT

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-233, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-231
 DTC P0380 GLOW RELAY
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CJU

TEC670M

EC-232
 DTC P0380 GLOW RELAY
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.
201 W
BATTERY VOLTAGE
203 W Power supply for ECM [Ignition switch ON]
(11 - 14V)
205 W
[Ignition switch ON]
[Ignition switch OFF]
Approximately 1.2V
● For a few seconds after turning ignition
245 B/Y ECM relay (self-shutoff) switch OFF EC
[Ignition switch OFF]
BATTERY VOLTAGE
● More than a few seconds after turning igni- (11 - 14V)
tion switch OFF
254 LG/B Glow relay Refer to EC-419, "GLOW CONTROL SYSTEM" .

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure BBS00CJV

1. CHECK GLOW RELAY POWER SUPPLY CIRCUIT

1. Turn ignition switch OFF.
2. Disconnect glow relay (1).
3. Turn ignition switch ON.

SEC093E

4. Check voltage between glow relay terminal 1 and ground with

CONSULT-II or tester.
Voltage: Battery voltage
OK or NG
OK >> GO TO 3.
NG >> GO TO 2.

MBIB1694E

EC-233
 DTC P0380 GLOW RELAY
[ZD30DDTi WITH COMMON RAIL]
2. DETECT MALFUNCTIONING PART
Check the following.
● Harness connectors M50, F5
● Harness connectors E127, M21
● Harness for open and short between glow relay and ECM
● Harness for open and short between glow relay and ECM relay

>> Repair open circuit or short to ground or short to power in harness or connectors.

3. CHECK GLOW RELAY OUTPUT SIGNAL CIRCUIT FOR SHORT TO GROUND

1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminal 254 and glow relay terminal 2.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 5.
NG >> GO TO 4.

4. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors E127, M21
● Harness connectors M51, F6
● Harness for open and short between glow relay and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK GLOW RELAY

Refer to EC-235, "Component Inspection" .
OK or NG
OK >> GO TO 6.
NG >> Replace glow relay.

6. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
OK or NG
OK >> INSPECTION END
NG >> Repair or replace harness or connectors.

EC-234
 DTC P0380 GLOW RELAY
[ZD30DDTi WITH COMMON RAIL]
Component Inspection BBS00CJW

GLOW RELAY
Check continuity between glow relay terminals (3) and (5) under the
following conditions.
Conditions Continuity
12V direct current supply between ter-
Yes
minals (1) and (2)
No current supply No
Operation takes less than 1 second.

PBIB0428E

EC

EC-235
 DTC P0400 EGR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
DTC P0400 EGR FUNCTION PFP:14710

Description BBS00CJX

SYSTEM DESCRIPTION
Sensor Input Signal to ECM ECM Function Actuator
Crankshaft position sensor Engine speed
Engine coolant temperature sensor Engine coolant temperature
Mass air flow sensor Amount of intake air
Accelerator pedal position sensor Accelerator pedal position
Vehicle speed sensor Vehicle speed*
EGR volume control
Ignition switch Start signal EGR volume control
valve
Air conditioner switch Air conditioner operation*
Intake air temperature sensor Intake air temperature
Barometric pressure sensor Barometric pressure
EGR volume control valve control position EGR volume control valve control
sensor position
*: This signal is sent to the ECM through CAN communication line.

This system controls the flow rate of EGR led from exhaust manifold to intake manifold. The opening of the EGR
passage in the EGR volume control valve changes to control the EGR flow rate. A built-in DC motor moves the
valve continuously corresponding to the ECM output signal. The EGR volume control valve control position sen-
sor detects the valve position and sends the voltage signals to the ECM. The ECM judges the current opening
angle of the valve from this signals and the ECM controls the DC motor to make the valve opening angle prop-
erly.
The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is deter-
mined by considering various engine conditions.
The EGR volume control valve remains close under the following conditions.
● Engine stopped
● Engine starting
● Low engine coolant temperature
● Excessively high engine coolant temperature
● High engine speed
● Accelerator pedal fully depressed

MBIB1824E

EC-236
 DTC P0400 EGR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
COMPONENT DESCRIPTION
EGR Volume Control Valve
The EGR volume control valve consists of valve, actuator and posi-
tion sensor, etc. The valve is installed in EGR passage, and operated
by the actuator according to the output signal of the ECM. The actu-
ator used DC motor and it opens or closes the valve to change the
EGR flow rate.
The EGR volume control valve control position sensor consists of a
permanent magnet and Hall IC. It senses the valve shaft movement
and feeds the voltage signals to the ECM.The ECM judges the cur-
rent opening angle of the valve from this signals, and controls the DC
motor to make the valve opening angle in response to driving condi-
tions.
MBIB1780E
EC
On Board Diagnosis Logic BBS00CJY

DTC No.
CONSULT-II
Trouble diagnosis name DTC detecting condition Possible cause
ID GST
FLAG
The EGR volume control valve ● Harness or connector
A) closed position is not in the speci- (EGR volume control motor circuit
fied range. is shorted.)
Exhaust gas recirculation ● Incorrect EGR volume control
P0400 1 P0400 valve installation
flow Excessively high duty voltage sig-
B) nal is sent to the valve for the ● EGR volume control valve stuck
specified time. closed
● EGR volume control valve

DTC Confirmation Procedure BBS00CJZ

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
PROCEDURE FOR MALFUNCTION A
With CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Turn ignition switch OFF and wait at least 30 seconds.
4. Turn ignition switch ON.
5. If 1st trip DTC is detected, go to EC-241, "Diagnostic Procedure"
.

PBIB2156E

With GST
Follow the procedure “With CONSULT-II” above.
PROCEDURE FOR MALFUNCTION B
With CONSULT-II
1. Start engine and warm it up to the normal operation temperature.

EC-237
 DTC P0400 EGR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Stop engine and wait at least 30 seconds.
4. Restart engine and let it idle for 5 seconds.
5. If 1st trip DTC is detected, go to EC-241, "Diagnostic Procedure"
.

PBIB2156E

With GST
Follow the procedure “With CONSULT-II” above.

EC-238
 DTC P0400 EGR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CK0

EC

TEC671M

EC-239
 DTC P0400 EGR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.
[Engine is running]
Sensor ground
131 B ● Warm-up condition Approximately 0V
(Sensors shield circuit)
● Idle speed
Sensor power supply
138 OR/L (EGR volume control [Ignition switch ON] Approximately 5V
valve)
[Ignition switch OFF]
● For a few seconds after the following condi- 1 - 14V
tions are met and ignition switch is turned
OFF.
EGR volume control valve
139 G/B – Warm-up condition
(DC motor)
– Start engine and let it idle for 3 minutes.
NOTE:
The duty cycle changes depending on EGR MBIB1822E
volume control valve operation.

Sensor ground [Engine is running]

178 W/L (EGR volume control ● Warm-up condition Approximately 0V
valve) ● Idle speed

EGR volume control valve [Ignition switch ON]

184 L/G (EGR volume control valve ● Warm-up condition 1 - 4.2V
control position sensor) ● Idle speed
[Ignition switch OFF]
● For a few seconds after the following condi-
EGR volume control valve tions are met and ignition switch is turned
196 G/W OFF. 0V or Battery voltage (11 - 14V)
(DC motor)
– Warm-up condition
– Start engine and let it idle for 3 minutes.

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-240
 DTC P0400 EGR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure BBS00CK1

PROCEDURE FOR MALFUNCTION A

1. CHECK EGR VOLUME CONTROL VALVE INSTALLATION
Check that EGR volume control valve is installed properly. Refer to EM section.
OK or NG
OK >> GO TO 2.
NG >> Install EGR volume control valve properly.

2. CHECK EGR VOLUME CONTROL VALVE VISUALLY

1. Remove the EGR cooler.
2. Check if foreign matter is caught between the EGR volume con-
EC
trol valve (1) and the housing.
– : Vehicle front
OK or NG
OK >> GO TO 3.
NG >> Remove the foreign matter and clean the EGR volume
control valve.

SEC092E

3. REPLACE EGR VOLUME CONTROL VALVE

1. Replace the EGR volume control valve.
2. Perform EC-37, "EGR Volume Control Valve Closed Position Learning Value Clear" .
3. Perform EC-37, "EGR Volume Control Valve Closed Position Learning" .

>> INSPECTION END

PROCEDURE FOR MALFUNCTION B
1. CHECK GROUND CONNECTIONS
1. Turn ignition switch OFF.
2. Loosen and retighten ground screws.
Refer to EC-107, "Ground Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 2.
NG >> Repair or replace ground connections.
SEC119E

EC-241
 DTC P0400 EGR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
2. CHECK EGR VOLUME CONTROL VALVE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN
AND SHORT
1. Disconnect EGR volume control valve (1) harness connector.
– : Vehicle front
2. Disconnect ECM harness connector.
3. Check harness continuity between the following terminals.
Refer to Wiring Diagram.
EGR volume control valve
ECM terminal Continuity
terminal
139 Should not exist
1
196 Should exist SEC092E

139 Should exist

2
196 Should not exist
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.

3. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors E271, F33
● Harness for short between EGR volume control valve and ECM

>> Repair short to ground or short to power in harness or connectors.

4. CHECK EGR VOLUME CONTROL VALVE (DC MOTOR)

Refer to EC-242, "Component Inspection" .
OK or NG
OK >> GO TO 6.
NG >> GO TO 5.

5. REPLACE EGR VOLUME CONTROL VALVE

1. Replace the EGR volume control valve.
2. Perform EC-37, "EGR Volume Control Valve Closed Position Learning Value Clear" .
3. Perform EC-37, "EGR Volume Control Valve Closed Position Learning" .

>> INSPECTION END

6. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection BBS00D2O

EGR VOLUME CONTROL VALVE (DC MOTOR)

1. Disconnect EGR volume control valve harness connector.

EC-242
 DTC P0400 EGR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
2. Check resistance between terminals 1 and 2.
Resistance: 0.3 - 100 Ω [at 25°C (77°F)]
3. If NG, replace EGR volume control valve and go to next step.
4. Perform EC-37, "EGR Volume Control Valve Closed Position
Learning Value Clear" .
5. Perform EC-37, "EGR Volume Control Valve Closed Position
Learning" .

SEC068E

EC

EC-243
 DTC P0401 EGR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
DTC P0401 EGR FUNCTION PFP:14710

Description BBS00CK4

SYSTEM DESCRIPTION
Sensor Input Signal to ECM ECM Function Actuator
Crankshaft position sensor Engine speed
Engine coolant temperature sensor Engine coolant temperature
Mass air flow sensor Amount of intake air
Accelerator pedal position sensor Accelerator pedal position
Vehicle speed sensor Vehicle speed*
EGR volume control
Ignition switch Start signal EGR volume control
valve
Air conditioner switch Air conditioner operation*
Intake air temperature sensor Intake air temperature
Barometric pressure sensor Barometric pressure
EGR volume control valve control position EGR volume control valve control
sensor position
*: This signal is sent to the ECM through CAN communication line.

This system controls the flow rate of EGR led from exhaust manifold to intake manifold. The opening of the EGR
passage in the EGR volume control valve changes to control the EGR flow rate. A built-in DC motor moves the
valve continuously corresponding to the ECM output signal. The EGR volume control valve control position sen-
sor detects the valve position and sends the voltage signals to the ECM. The ECM judges the current opening
angle of the valve from this signals and the ECM controls the DC motor to make the valve opening angle prop-
erly.
The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is deter-
mined by considering various engine conditions.
The EGR volume control valve remains close under the following conditions.
● Engine stopped
● Engine starting
● Low engine coolant temperature
● Excessively high engine coolant temperature
● High engine speed
● Accelerator pedal fully depressed

MBIB1824E

EC-244
 DTC P0401 EGR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
COMPONENT DESCRIPTION
EGR Volume Control Valve
The EGR volume control valve consists of valve, actuator and posi-
tion sensor, etc. The valve is installed in EGR passage, and operated
by the actuator according to the output signal of the ECM. The actu-
ator used DC motor and it opens or closes the valve to change the
EGR flow rate.
The EGR volume control valve control position sensor consists of a
permanent magnet and Hall IC. It senses the valve shaft movement
and feeds the voltage signals to the ECM.The ECM judges the cur-
rent opening angle of the valve from this signals, and controls the DC
motor to make the valve opening angle in response to driving condi-
tions.
MBIB1780E
EC
On Board Diagnosis Logic BBS00CK5

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
● Harness or connectors
(The EGR volume control valve cir-
cuit is open or shorted.)
Exhaust gas
The exhaust gas recirculation flow is insuffi- ● EGR volume control valve stuck
P0401 1 P0401 recirculation flow
cient. closed
insufficient
● EGR passage clogged
● EGR volume control valve

DTC Confirmation Procedure BBS00CK6

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON and select “DATA MONITOR” mode with
CONSULT-II.
2. Start engine and let it idle.
3. Maintain the following conditions for at least 40 consecutive sec-
onds.
COOLAN TEMP/S 50 - 89 °C (122 - 192 °F)
I/C INT/A T/S 0 - 37°C (32 - 99°F)
BARO SEN More than 90 hPa
P/N POSI SW ON MBIB1814E

4. If 1st trip DTC is detected, go to EC-248, "Diagnostic Procedure"

.
WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-245
 DTC P0401 EGR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CK7

TEC725M

EC-246
 DTC P0401 EGR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.
[Engine is running]
Sensor ground
131 B ● Warm-up condition Approximately 0V
(Sensors shield circuit)
● Idle speed
Sensor power supply
138 OR/L (EGR volume control [Ignition switch ON] Approximately 5V
EC
valve)
[Ignition switch OFF]
● For a few seconds after the following condi- 1 - 14V
tions are met and ignition switch is turned
OFF.
EGR volume control valve
139 G/B – Warm-up condition
(DC motor)
– Start engine and let it idle for 3 minutes.
NOTE:
The duty cycle changes depending on EGR MBIB1822E
volume control valve operation.

Sensor ground [Engine is running]

178 W/L (EGR volume control ● Warm-up condition Approximately 0V
valve) ● Idle speed

EGR volume control valve [Ignition switch ON]

184 L/G (EGR volume control valve ● Warm-up condition 1 - 4.2V
control position sensor) ● Idle speed
[Ignition switch OFF]
● For a few seconds after the following condi-
EGR volume control valve tions are met and ignition switch is turned
196 G/W OFF. 0V or Battery voltage (11 - 14V)
(DC motor)
– Warm-up condition
– Start engine and let it idle for 3 minutes.

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-247
 DTC P0401 EGR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure BBS00CK8

1. CHECK EGR PASSAGE

Check the following for clogging and cracks.
● EGR tube
● EGR hose
● EGR cooler
OK or NG
OK >> GO TO 2.
NG >> Repair or replace EGR passage.

2. CHECK GROUND CONNECTIONS

1. Turn ignition switch OFF.
2. Loosen and retighten ground screws.
Refer to EC-107, "Ground Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 3.
NG >> Repair or replace ground connections.
SEC119E

3. CHECK EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR POWER SUPPLY CIRCUIT
1. Disconnect EGR volume control valve (1) harness connector.
– : Vehicle front
2. Turn ignition switch ON.

SEC092E

3. Check voltage between EGR volume control valve terminal 4 and

ground with CONSULT-II or tester.
Voltage: Approximately 5V
OK or NG
OK >> GO TO 5.
NG >> GO TO 4.

SEC069E

4. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors E272, F34
● Harness for open or short between EGR volume control valve and ECM

>> Repair open circuit or short to ground or short to power in harness connectors.
EC-248
 DTC P0401 EGR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
5. CHECK EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR GROUND CIRCUIT FOR
OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between EGR volume control valve terminal 3 and ECM terminal 178. Refer to
Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 7.
NG >> GO TO 6. EC
6. DETECT MALFUNCTIONING PART
Check the following.
● Harness connectors E272, F34
● Harness for open or short between EGR volume control valve and ECM

>> Repair open circuit or short to ground or short to power in harness connectors.

7. CHECK EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR INPUT SIGNAL CIRCUIT
FOR OPEN AND SHORT
1. Check harness continuity between ECM terminal 184 and EGR volume control valve terminal 5. Refer to
Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 9.
NG >> GO TO 8.

8. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors E272, F34
● Harness for open or short between EGR volume control valve and ECM

>> Repair open circuit or short to ground or short to power in harness connectors.

EC-249
 DTC P0401 EGR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
9. CHECK EGR VOLUME CONTROL VALVE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN
AND SHORT
1. Disconnect EGR volume control valve (1) harness connector.
– : Vehicle front
2. Disconnect ECM harness connector.
3. Check harness continuity between the following terminals.
Refer to Wiring Diagram.
EGR volume control valve
ECM terminal Continuity
terminal
139 Should not exist
1
196 Should exist SEC092E

139 Should exist

2
196 Should not exist
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 11.
NG >> GO TO 10.

10. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors E271, F33
● Harness for open or short between EGR volume control valve and ECM

>> Repair open circuit or short to ground or short to power in harness connectors.

11. CHECK EGR VOLUME CONTROL VALVE (EGR VOLUME CONTROL VALVE CONTROL POSITION
SENSOR)
Refer to EC-252, "Component Inspection" .
OK or NG
OK >> GO TO 12.
NG >> GO TO 13.

12. CHECK EGR VOLUME CONTROL VALVE (DC MOTOR)

Refer to EC-252, "Component Inspection" .
OK or NG
OK >> GO TO 14.
NG >> GO TO 13.

13. REPLACE EGR VOLUME CONTROL VALVE

1. Replace the EGR volume control valve.
2. Perform EC-37, "EGR Volume Control Valve Closed Position Learning Value Clear" .
3. Perform EC-37, "EGR Volume Control Valve Closed Position Learning" .

>> INSPECTION END

EC-250
 DTC P0401 EGR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
14. CHECK INTERMITTENT INCIDENT
Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

EC

EC-251
 DTC P0401 EGR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
Component Inspection BBS00D2P

EGR VOLUME CONTROL VALVE (EGR VOLUME CONTROL VALVE CONTROL POSITION SEN-
SOR)
With CONSULT-II
1. Turn ignition switch ON, and select “EGR/V ANGLE” in “ACTIVE TEST” mode with CONSULT-II.
2. Change the valve opening percentage with touching “Qu” or “Qd”
on CONSULT-II screen.
3. Check “EGR V/POS SEN” voltage under the following conditions.
Condition Voltage
EGR/V ANGLE EGR V/POS SEN
100 % 3,800 - 4,200 mV
0% 1,000 - 1,400 mV
4. If NG, replace EGR volume control valve and go to next step.
5. Perform EC-37, "EGR Volume Control Valve Closed Position MBIB1817E

Learning Value Clear" .

6. Perform EC-37, "EGR Volume Control Valve Closed Position Learning" .
EGR VOLUME CONTROL VALVE (DC MOTOR)
1. Disconnect EGR volume control valve harness connector.
2. Check resistance between terminals 1 and 2.
Resistance: 0.3 - 100 Ω [at 25°C (77°F)]
3. If NG, replace EGR volume control valve and go to next step.
4. Perform EC-37, "EGR Volume Control Valve Closed Position
Learning Value Clear" .
5. Perform EC-37, "EGR Volume Control Valve Closed Position
Learning" .

SEC068E

EC-252
 DTC P0403 EGR VOLUME CONTROL VALVE
[ZD30DDTi WITH COMMON RAIL]
DTC P0403 EGR VOLUME CONTROL VALVE PFP:14710

Description BBS00CKB

The ECM consists of a microcomputer and connectors for signal input

and output and for power supply. The ECM controls the engine.

MBIB0625E EC
On Board Diagnosis Logic BBS00CKC

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Engine control
P0403 8 P0403 module ECM driver IC is malfunctioning. ● ECM
(Driver IC)

DTC Confirmation Procedure BBS00CKD

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Start engine and let it idle for 5 seconds.
4. If 1st trip DTC is detected, go to EC-254, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-253
 DTC P0403 EGR VOLUME CONTROL VALVE
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure BBS00CKE

1. INSPECTION START
With CONSULT-II
1. Turn ignition switch ON.
2. Select “SELF DIAG RESULTS” mode with CONSULT-II.
3. Touch “ERASE”.
4. Perform EC-253, "DTC Confirmation Procedure" , again.
5. Is DTC P0403 displayed again?
With GST
1. Turn ignition switch ON.
2. Select Service $04 with GST.
3. Perform EC-253, "DTC Confirmation Procedure" , again.
4. Is DTC P0403 displayed again?
Yes or No
Yes >> GO TO 2.
No >> INSPECTION END

2. REPLACE ECM
1. Replace ECM.
2. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to EL section.
3. Perform Injector Adjustment Value Registration. Refer to EC-34, "Injector Adjustment Value Registration" .
4. Perform EGR Volume Control Valve Closed Position Learning Value Clear. Refer to EC-37, "EGR Volume
Control Valve Closed Position Learning Value Clear" .
5. Perform EGR Volume Control Valve Closed Position Learning. Refer to EC-37, "EGR Volume Control
Valve Closed Position Learning" .
6. Perform Throttle Valve Closed Position Learning Value Clear.
Refer to EC-39, "Throttle Valve Closed Position Learning Value Clear" .
7. Perform Throttle Valve Closed Position Learning.
Refer to EC-39, "Throttle Valve Closed Position Learning" .

>> INSPECTION END

EC-254
 DTC P0404 EGR VOLUME CONTROL VALVE
[ZD30DDTi WITH COMMON RAIL]
DTC P0404 EGR VOLUME CONTROL VALVE PFP:14710

Description BBS00CKF

SYSTEM DESCRIPTION
Sensor Input Signal to ECM ECM Function Actuator
Crankshaft position sensor Engine speed
Engine coolant temperature sensor Engine coolant temperature
Mass air flow sensor Amount of intake air
Accelerator pedal position sensor Accelerator pedal position
Vehicle speed sensor Vehicle speed*
EGR volume control
Ignition switch Start signal EGR volume control
valve
Air conditioner switch Air conditioner operation* EC
Intake air temperature sensor Intake air temperature
Barometric pressure sensor Barometric pressure
EGR volume control valve control position EGR volume control valve control
sensor position
*: This signal is sent to the ECM through CAN communication line.

This system controls the flow rate of EGR led from exhaust manifold to intake manifold. The opening of the EGR
passage in the EGR volume control valve changes to control the EGR flow rate. A built-in DC motor moves the
valve continuously corresponding to the ECM output signal. The EGR volume control valve control position sen-
sor detects the valve position and sends the voltage signals to the ECM. The ECM judges the current opening
angle of the valve from this signals and the ECM controls the DC motor to make the valve opening angle prop-
erly.
The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is deter-
mined by considering various engine conditions.
The EGR volume control valve remains close under the following conditions.
● Engine stopped
● Engine starting
● Low engine coolant temperature
● Excessively high engine coolant temperature
● High engine speed
● Accelerator pedal fully depressed

MBIB1824E

EC-255
 DTC P0404 EGR VOLUME CONTROL VALVE
[ZD30DDTi WITH COMMON RAIL]
COMPONENT DESCRIPTION
EGR Volume Control Valve
The EGR volume control valve consists of valve, actuator and posi-
tion sensor, etc. The valve is installed in EGR passage, and operated
by the actuator according to the output signal of the ECM. The actu-
ator used DC motor and it opens or closes the valve to change the
EGR flow rate.
The EGR volume control valve control position sensor consists of a
permanent magnet and Hall IC. It senses the valve shaft movement
and feeds the voltage signals to the ECM.The ECM judges the cur-
rent opening angle of the valve from this signals, and controls the DC
motor to make the valve opening angle in response to driving condi-
tions.
MBIB1780E

On Board Diagnosis Logic BBS00CKG

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Exhaust gas
ECM detects DC motor circuit for EGR vol-
1 P0490 recirculation con-
ume control valve is short to power.
trol circuit high
Exhaust gas ● Harness or connector
ECM detects DC motor circuit for EGR vol- (EGR volume control motor circuit is
2 P0489 recirculation con-
P0404 ume control valve is short to ground. open or shorted.)
trol circuit low
Exhaust gas ● EGR volume control valve
recirculation con- ECM detects DC motor circuit for EGR vol-
4 P0404
trol circuit open/ ume control valve is open or shorted
shorted

DTC Confirmation Procedure BBS00CKH

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-258, "Diagnostic Procedure"
.

PBIB2156E

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-256
 DTC P0404 EGR VOLUME CONTROL VALVE
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CKI

EC

TEC671M

EC-257
 DTC P0404 EGR VOLUME CONTROL VALVE
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.
[Engine is running]
Sensor ground
131 B ● Warm-up condition Approximately 0V
(Sensors shield circuit)
● Idle speed
Sensor power supply
138 OR/L (EGR volume control [Ignition switch ON] Approximately 5V
valve)
[Ignition switch OFF]
● For a few seconds after the following condi- 1 - 14V
tions are met and ignition switch is turned
OFF.
EGR volume control valve
139 G/B – Warm-up condition
(DC motor)
– Start engine and let it idle for 3 minutes.
NOTE:
The duty cycle changes depending on EGR MBIB1822E
volume control valve operation.

Sensor ground [Engine is running]

178 W/L (EGR volume control ● Warm-up condition Approximately 0V
valve) ● Idle speed

EGR volume control valve [Ignition switch ON]

184 L/G (EGR volume control valve ● Warm-up condition 1 - 4.2V
control position sensor) ● Idle speed
[Ignition switch OFF]
● For a few seconds after the following condi-
EGR volume control valve tions are met and ignition switch is turned
196 G/W OFF. 0V or Battery voltage (11 - 14V)
(DC motor)
– Warm-up condition
– Start engine and let it idle for 3 minutes.

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure BBS00CKJ

1. CHECK GROUND CONNECTIONS

1. Turn ignition switch OFF.
2. Loosen and retighten ground screws.
Refer to EC-107, "Ground Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 2.
NG >> Repair or replace ground connections.
SEC119E

EC-258
 DTC P0404 EGR VOLUME CONTROL VALVE
[ZD30DDTi WITH COMMON RAIL]
2. CHECK EGR VOLUME CONTROL VALVE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN
AND SHORT
1. Disconnect EGR volume control valve (1) harness connector.
– : Vehicle front
2. Disconnect ECM harness connector.
3. Check harness continuity between the following terminals.
Refer to Wiring Diagram.
EGR volume control valve
ECM terminal Continuity
terminal
139 Should not exist
1
196 Should exist SEC092E EC
139 Should exist
2
196 Should not exist
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.

3. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors E271, F33
● Harness for open or short between EGR volume control valve and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK EGR VOLUME CONTROL VALVE (DC MOTOR)

Refer to EC-260, "Component Inspection" .
OK or NG
OK >> GO TO 6.
NG >> GO TO 5.

5. REPLACE EGR VOLUME CONTROL VALVE

1. Replace the EGR volume control valve.
2. Perform EC-37, "EGR Volume Control Valve Closed Position Learning Value Clear" .
3. Perform EC-37, "EGR Volume Control Valve Closed Position Learning" .

>> INSPECTION END

6. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

EC-259
 DTC P0404 EGR VOLUME CONTROL VALVE
[ZD30DDTi WITH COMMON RAIL]
Component Inspection BBS00D3L

EGR VOLUME CONTROL VALVE (DC MOTOR)

1. Disconnect EGR volume control valve harness connector.
2. Check resistance between terminals 1 and 2.
Resistance: 0.3 - 100 Ω [at 25°C (77°F)]
3. If NG, replace EGR volume control valve and go to next step.
4. Perform EC-37, "EGR Volume Control Valve Closed Position
Learning Value Clear" .
5. Perform EC-37, "EGR Volume Control Valve Closed Position
Learning" .

SEC068E

EC-260
 DTC P0409 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
[ZD30DDTi WITH COMMON RAIL]
DTC P0409 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
PFP:22693

Description BBS00CKM

SYSTEM DESCRIPTION
Sensor Input Signal to ECM ECM Function Actuator
Crankshaft position sensor Engine speed
Engine coolant temperature sensor Engine coolant temperature
Mass air flow sensor Amount of intake air
Accelerator pedal position sensor Accelerator pedal position
Vehicle speed sensor Vehicle speed*
EGR volume control
Ignition switch Start signal EGR volume control
valve
EC
Air conditioner switch Air conditioner operation*
Intake air temperature sensor Intake air temperature
Barometric pressure sensor Barometric pressure
EGR volume control valve control position EGR volume control valve control
sensor position
*: This signal is sent to the ECM through CAN communication line.

This system controls the flow rate of EGR led from exhaust manifold to intake manifold. The opening of the EGR
passage in the EGR volume control valve changes to control the EGR flow rate. A built-in DC motor moves the
valve continuously corresponding to the ECM output signal. The EGR volume control valve control position sen-
sor detects the valve position and sends the voltage signals to the ECM. The ECM judges the current opening
angle of the valve from this signals and the ECM controls the DC motor to make the valve opening angle prop-
erly.
The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is deter-
mined by considering various engine conditions.
The EGR volume control valve remains close under the following conditions.
● Engine stopped
● Engine starting
● Low engine coolant temperature
● Excessively high engine coolant temperature
● High engine speed
● Accelerator pedal fully depressed

MBIB1824E

EC-261
 DTC P0409 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
[ZD30DDTi WITH COMMON RAIL]
COMPONENT DESCRIPTION
EGR Volume Control Valve
The EGR volume control valve consists of valve, actuator and posi-
tion sensor, etc. The valve is installed in EGR passage, and operated
by the actuator according to the output signal of the ECM. The actu-
ator used DC motor and it opens or closes the valve to change the
EGR flow rate.
The EGR volume control valve control position sensor consists of a
permanent magnet and Hall IC. It senses the valve shaft movement
and feeds the voltage signals to the ECM.The ECM judges the cur-
rent opening angle of the valve from this signals, and controls the DC
motor to make the valve opening angle in response to driving condi-
tions.
MBIB1780E

On Board Diagnosis Logic BBS00CKO

NOTE:
If DTC P0409 is displayed with DTC P0651 (GST: P0652, P0653), first perform the trouble diagnosis for
DTC P0651 (GST: P0652, P0653). Refer to EC-319, "DTC P0651 SENSOR POWER SUPPLY" .
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
EGR volume
control valve
An excessively high voltage from the sensor
1 P0406 control position
is sent to ECM.
sensor circuit ● Harness or connectors
high input (The sensor circuit is open or
P0409 shorted.)
EGR volume
control valve ● EGR volume control valve
An excessively low voltage from the sensor
2 P0405 control position
is sent to ECM.
sensor circuit low
input

DTC Confirmation Procedure BBS00CKP

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-264, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-262
 DTC P0409 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CKQ

EC

TEC726M

EC-263
 DTC P0409 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.
[Engine is running]
Sensor ground
131 B ● Warm-up condition Approximately 0V
(Sensors shield circuit)
● Idle speed
Sensor power supply
138 OR/L (EGR volume control [Ignition switch ON] Approximately 5V
valve)
[Ignition switch OFF]
● For a few seconds after the following condi- 1 - 14V
tions are met and ignition switch is turned
OFF.
EGR volume control valve
139 G/B – Warm-up condition
(DC motor)
– Start engine and let it idle for 3 minutes.
NOTE:
The duty cycle changes depending on EGR MBIB1822E
volume control valve operation.

Sensor ground [Engine is running]

178 W/L (EGR volume control ● Warm-up condition Approximately 0V
valve) ● Idle speed

EGR volume control valve [Ignition switch ON]

184 L/G (EGR volume control valve ● Warm-up condition 1 - 4.2V
control position sensor) ● Idle speed
[Ignition switch OFF]
● For a few seconds after the following condi-
EGR volume control valve tions are met and ignition switch is turned
196 G/W OFF. 0V or Battery voltage (11 - 14V)
(DC motor)
– Warm-up condition
– Start engine and let it idle for 3 minutes.

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

Diagnostic Procedure BBS00CKR

1. CHECK GROUND CONNECTIONS

1. Turn ignition switch OFF.
2. Loosen and retighten ground screws.
Refer to EC-107, "Ground Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 2.
NG >> Repair or replace ground connections.
SEC119E

EC-264
 DTC P0409 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
[ZD30DDTi WITH COMMON RAIL]
2. CHECK EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR POWER SUPPLY CIRCUIT
1. Disconnect EGR volume control valve (1) harness connector.
– : Vehicle front
2. Turn ignition switch ON.

SEC092E

EC
3. Check voltage between EGR volume control valve terminal 4 and
ground with CONSULT-II or tester.
Voltage: Approximately 5V
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.

SEC069E

3. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors E272, F34
● Harness for open or short between EGR volume control valve and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR GROUND CIRCUIT FOR
OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between EGR volume control valve terminal 3 and ECM terminal 178. Refer to
Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 6.
NG >> GO TO 5.

5. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors E272, F34
● Harness for open or short between EGR volume control valve and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-265
 DTC P0409 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
[ZD30DDTi WITH COMMON RAIL]
6. CHECK EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR INPUT SIGNAL CIRCUIT
FOR OPEN AND SHORT
1. Check harness continuity between ECM terminal 184 and EGR volume control valve terminal 5. Refer to
Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 8.
NG >> GO TO 7.

7. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors E272, F34
● Harness for open or short between EGR volume control valve and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK EGR VOLUME CONTROL VALVE (EGR VOLUME CONTROL VALVE CONTROL POSITION
SENSOR)
Refer to EC-266, "Component Inspection" .
OK or NG
OK >> GO TO 10.
NG >> GO TO 9.

9. REPLACE EGR VOLUME CONTROL VALVE

1. Replace the EGR volume control valve.
2. Perform EC-37, "EGR Volume Control Valve Closed Position Learning Value Clear" .
3. Perform EC-37, "EGR Volume Control Valve Closed Position Learning" .

>> INSPECTION END

10. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection BBS00D3M

EGR VOLUME CONTROL VALVE (EGR VOLUME CONTROL VALVE CONTROL POSITION SEN-
SOR)
With CONSULT-II
1. Turn ignition switch ON, and select “EGR/V ANGLE” in “ACTIVE TEST” mode with CONSULT-II.

EC-266
 DTC P0409 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR
[ZD30DDTi WITH COMMON RAIL]
2. Change the valve opening percentage with touching “Qu” or “Qd”
on CONSULT-II screen.
3. Check “EGR V/POS SEN” voltage under the following conditions.
Condition Voltage
EGR/V ANGLE EGR V/POS SEN
100 % 3,800 - 4,200 mV
0% 1,000 - 1,400 mV
4. If NG, replace EGR volume control valve and go to next step.
5. Perform EC-37, "EGR Volume Control Valve Closed Position MBIB1817E

Learning Value Clear" .

6. Perform EC-37, "EGR Volume Control Valve Closed Position Learning" .
EC

EC-267
 DTC P0480 COOLING FAN RELAY
[ZD30DDTi WITH COMMON RAIL]
DTC P0480 COOLING FAN RELAY PFP:21481

System Description B99988

COOLING FAN CONTROL

Sensor Input signal to ECM ECM function Actuator
Vehicle speed sensor Vehicle speed *
Cooling fan
Engine coolant temperature sensor Engine coolant temperature Cooling fan relay
control
Air conditioner switch Air conditioner ON signal *
*: This signal is sent to the ECM through CAN communication line.

The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, and air con-
ditioner ON signal. The control system has 2-step control [ON/OFF].
OPERATION

SEF450Z

CONSULT-II Reference Value in Data Monitor Mode B99986

Specification data are reference values.

MONITOR ITEM CONDITION SPECIFICATION
Air conditioner switch: OFF OFF
● Engine: After warming up, idle
AIR COND RLY Air conditioner switch: ON
the engine ON
(Compressor operates.)
● Cooling fan: Stopped OFF
COOLING FAN
● Cooling fan: Operates ON

On Board Diagnosis Logic B99985

This self-diagnosis has the one trip detection logic.

The MI will not light up for this self-diagnosis.
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Cooling fan relay
ECM detects cooling fan relay circuit is short
1 P0692 control circuit
to power.
high
● Harness or connectors
Cooling fan relay ECM detects cooling fan relay circuit is short
2 P0691 (Cooling fan relay circuit is open or
P0480 control circuit low to ground.
shorted.)
ECM detects cooling fan relay circuit is Cooling fan relay
4 ●
Cooling fan relay open.
P0480
control circuit ECM detects cooling fan relay internal cir-
8
cuit is open or short.

EC-268
 DTC P0480 COOLING FAN RELAY
[ZD30DDTi WITH COMMON RAIL]
DTC Confirmation Procedure B99984

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If DTC is detected, go to EC-271, "Diagnostic Procedure" .

EC

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-269
 DTC P0480 COOLING FAN RELAY
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram B99983

TEC729M

EC-270
 DTC P0480 COOLING FAN RELAY
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.
[Engine is running] BATTERY VOLTAGE
● Cooling fan: Not operating (11 - 14V)
242 L Cooling fan relay-1
[Engine is running]
Approximately 0.1V
● Cooling fan: Operating
[Engine is running] BATTERY VOLTAGE
● Air conditioner switch: OFF (11 - 14V) EC
255 Y/L Air conditioner relay [Engine is running]
● Both air conditioner switch and blower fan Approximately 0.1V
switch: ON (Compressor is operating)

Diagnostic Procedure B99982

1. CHECK COOLING FAN POWER SUPPLY CIRCUIT

1. Turn ignition switch OFF.
2. Disconnect cooling fan relay-1 (1).
– A/C relay (2)
– Battery (3)
– : Vehicle front
3. Turn ignition switch ON.

SEC095E

4. Check voltage between cooling fan relay-1 terminal 1, 5 and

ground with CONSULT-II or tester.
Voltage: Battery voltage
OK or NG
OK >> GO TO 3.
NG >> GO TO 2.

PBIB0303E

2. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M21, E127
● Harness for open or short between cooling fan relay-1 and ECM relay
● Harness for open or short between cooling fan relay-1 and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-271
 DTC P0480 COOLING FAN RELAY
[ZD30DDTi WITH COMMON RAIL]
3. CHECK COOLING FAN OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Disconnect ECM harness connector.
2. Check harness continuity between cooling fan relay-1 terminal 2 and ECM terminal 242.
Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 5.
NG >> GO TO 4.

4. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors E127, M21
● Harness connectors M52, F7
● Harness for open or short between cooling fan relay-1 and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK COOLING FAN RELAY-1

Refer to EC-185, "Component Inspection" .
OK or NG
OK >> GO TO 7.
NG >> Replace cooling fan relay-1.

6. CHECK INTERMITTENT INCIDENT

Perform EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection B99980

COOLING FAN RELAY-1

Check continuity between terminals (3) and (5).
Conditions Continuity
12V direct current supply between terminals (1) and
Yes
(2)
No current supply No

If NG, replace relay.

PBIB0098E

EC-272
 DTC P0500 VSS
[ZD30DDTi WITH COMMON RAIL]
DTC P0500 VSS PFP:32702

Description BBS00CKU

NOTE:
● If DTC P0500 is displayed with DTC U1000 or U1001, first perform the trouble diagnosis for DTC
U1000, U1001. Refer to EC-108, "DTC U1000, U1001 CAN COMMUNICATION LINE" .
● If DTC P0500 is displayed with DTC U1010, first perform the trouble diagnosis for DTC U1010. Refer
to EC-111, "DTC U1010 CAN COMMUNICATION" .
The vehicle speed signal is sent to the combination meter from the “ABS actuator and electric unit (control unit)”
through CAN communication line. The combination meter then sends a signal to the ECM through CAN com-
munication line.
On Board Diagnosis Logic BBS00CKV

This self-diagnosis has the one trip detection logic. EC

The MI will not light up for this diagnosis.
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
● Harness or connectors
(The CAN communication line is
Vehicle speed The almost 0 km/h (0 MPH) signal is sent to open or shorted.)
P0500 8 P0500
sensor ECM even when vehicle is being driven.
● Wheel sensor
● Combination meter

DTC Confirmation Procedure BBS00D71

CAUTION:
Always drive vehicle at a safe speed.
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Lift up drive wheels.
2. Start engine.
3. Read “VHCL SPEED SE” in “DATA MONITOR” mode with CON-
SULT-II.
The vehicle speed on CONSULT-II should be almost the same
speed as speedometer indication with suitable gear position.
If NG, go to EC-274, "Diagnostic Procedure" .
If OK, go to the next step.
4. Select “DATA MONITOR” mode with CONSULT-II.
5. Warm engine up to normal operating temperature.
6. Maintain the following conditions for at least 15 consecutive sec-
onds.
SEF864Y

CKPS-RPM (TDC) More than 2,000 rpm

COOLAN TEMP/S More than 70°C (158°F)
TRG INJ QTY More than 20 mg/st
Shift lever Suitable position

7. If DTC is detected, go to EC-274, "Diagnostic Procedure" .

Overall Function Check BBS00CKX

Use this procedure to check the overall function of the vehicle speed signal circuit. During this check, a DTC
might not be confirmed.

EC-273
 DTC P0500 VSS
[ZD30DDTi WITH COMMON RAIL]
WITH GST
1. Lift up drive wheels.
2. Start engine.
3. Read vehicle speed signal in Service $01 with GST.
The vehicle speed on GST should be almost the same speed as speedometer indication with suitable gear
position.
4. If NG, go to EC-274, "Diagnostic Procedure" .
Diagnostic Procedure BBS00CKY

1. CHECK DTC WITH “ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)”
Refer to BR section.
OK or NG
OK >> GO TO 2.
NG >> Repair or replace.

2. CHECK COMBINATION METER

Check combination meter function.
Refer to EL section.

>> INSPECTION END

EC-274
 DTC P0504 ASCD BRAKE SWITCH
[ZD30DDTi WITH COMMON RAIL]
DTC P0504 ASCD BRAKE SWITCH PFP:25320

Component Description BBS00226

When the brake pedal is depressed, ASCD brake switch (2) and stop
lamp switch (1) are turned ON. ECM detects the state of the brake
pedal by this input of two kinds (ON/OFF signal).
Refer to EC-404, "AUTOMATIC SPEED CONTROL DEVICE
(ASCD)" for the ASCD function.
● Accelerator pedal position sensor (3)
● Accelerator pedal (4)

SEC098E EC
CONSULT-II Reference Value in Data Monitor Mode BBS00227

Specification data are reference values.

MONITOR ITEM CONDITION SPECIFICATION
Brake pedal: Fully released OFF
BRAKE SW
● Ignition switch: ON Brake pedal: Slightly
(Stop lamp switch) ON
depressed
Brake pedal: Fully released OFF
BRAKE SW2
● Ignition switch: ON Brake pedal: Slightly
(ASCD brake switch) ON
depressed (A/T)

On Board Diagnosis Logic BBS00228

This self-diagnosis has the one trip detection logic.

The MI will not light up for this self-diagnosis.
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
● Harness or connectors
(ASCD brake switch circuit is open
or shorted.)
(Stop lamp switch circuit is open or
shorted.)
The correlation between ASCD brake switch
ASCD brake ● ASCD brake switch
P0504 8 P0504 signal and stop lamp switch signal is out of
switch
the normal range. ● Stop lamp switch
● Incorrect ASCD brake switch instal-
lation
● Incorrect stop lamp switch installa-
tion

EC-275
 DTC P0504 ASCD BRAKE SWITCH
[ZD30DDTi WITH COMMON RAIL]
DTC Confirmation Procedure BBS00229

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Depress brake pedal for more than 5 seconds and release it for
more than 15 seconds.
4. Repeat step 3 for 3 times.
5. If DTC is detected, go to EC-278, "Diagnostic Procedure" .

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-276
 DTC P0504 ASCD BRAKE SWITCH
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS0022A

EC

TEC697M

EC-277
 DTC P0504 ASCD BRAKE SWITCH
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TER-
WIRE
MINAL ITEM CONDITION DATA (DC Voltage)
COLOR
NO.
[Igniton switch ON] BATTERY VOLTAGE
● Brake pedal: Fully released (11 - 14V)
208 R ASCD brake switch
[Igniton switch ON]
Approximately 0V
● Brake pedal: Slightly depressed
[Ignition switch OFF]
Approximately 0V
● Brake pedal: Fully released
221 G/Y Stop lamp switch
[Ignition switch OFF] BATTERY VOLTAGE
● Brake pedal: Slightly depressed (11 - 14V)

Diagnostic Procedure BBS0022B

1. CHECK OVERALL FUNCTION-I

With CONSULT-II
1. Turn ignition switch ON.
2. Select “BRAKE SW” in “DATA MONITOR” mode with CON-
SULT-II.
3. Check “BRAKE SW” indication under the following conditions.
CONDITION INDICATION
Brake pedal: Fully released OFF
Brake pedal: Slightly depressed ON

PBIB0472E

Without CONSULT-II
Check voltage between ECM terminal 221 and ground under the fol-
lowing conditions.
Condition Voltage
Brake pedal: Fully released Approximately 0V
Brake pedal: Slightly depressed battery voltage
OK or NG
OK >> GO TO 2.
NG >> GO TO 3.
SEC070E

EC-278
 DTC P0504 ASCD BRAKE SWITCH
[ZD30DDTi WITH COMMON RAIL]
2. CHECK OVERALL FUNCTION-II
With CONSULT-II
Check “BRAKE SW2” indication in “DATA MONITOR” mode.
CONDITION INDICATION
Brake pedal: Fully released OFF
Brake pedal: Slightly depressed ON

EC
SEC013D

Without CONSULT-II
1. Turn ignition switch ON.
2. Check voltage between ECM terminal 101 and ground under the
following conditions.
Condition Voltage
Brake pedal: Fully released Battery voltage
Brake pedal: Slightly depressed Approximately 0V

PBIB1677E

OK or NG
OK >> GO TO 12.
NG >> GO TO 8.

EC-279
 DTC P0504 ASCD BRAKE SWITCH
[ZD30DDTi WITH COMMON RAIL]
3. CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT
1. Turn ignition switch OFF.
2. Disconnect stop lamp switch (2) harness connector.
– ASCD brake switch (1) harness connector
– Accelerator pedal position sensor (3)
– Accelerator pedal (4)

SEC098E

3. Check voltage between stop lamp switch terminal 1 and ground

with CONSULT -II or tester.
Voltage: Battery voltage
OK or NG
OK >> GO TO 5.
NG >> GO TO 4.

PBIB0117E

4. DETECT MALFUNCTIONING PART

Check the following.
● Fuse block (J/B) connector M3
● 10A fuse
● Harness for open or short between stop lamp switch and battery

>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK STOP LAMP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminal 221 and stop lamp switch terminal 2.
Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 7.
NG >> GO TO 6.

6. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M52, F7
● Harness for open or short between stop lamp switch and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-280
 DTC P0504 ASCD BRAKE SWITCH
[ZD30DDTi WITH COMMON RAIL]
7. CHECK STOP LAMP SWITCH
Refer to EC-283, "Component Inspection"
OK or NG
OK >> GO TO 12.
NG >> Replace stop lamp switch.

8. CHECK ASCD BRAKE SWITCH POWER SUPPLY CIRCUIT

1. Turn ignition switch OFF.
2. Disconnect ASCD brake switch (2) harness connector.
– Stop lamp switch (1)
– Accelerator pedal position sensor (3) EC
– Accelerator pedal (4)
3. Turn ignition switch ON.

SEC098E

4. Check voltage between ASCD brake switch terminal 1 and

ground with CONSULT-II or tester.
Voltage: Approximately 5V
OK or NG
OK >> GO TO 10.
NG >> GO TO 9.

PBIB0799E

9. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors F7, M52
● Harness for open or short between ASCD brake switch and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

10. CHECK ASCD BRAKE SWITCH GROUND CIRCUIT OPEN AND SHORT
1. Check harness continuity between ASCD brake switch terminal 2 and ground.
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to power.
OK or NG
OK >> GO TO 11.
NG >> Repair open circuit or short to power in harness or connectors.

EC-281
 DTC P0504 ASCD BRAKE SWITCH
[ZD30DDTi WITH COMMON RAIL]
11. CHECK ASCD BRAKE SWITCH
Refer to EC-283, "Component Inspection"
OK or NG
OK >> GO TO 12.
NG >> Replace ASCD brake switch.

12. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

EC-282
 DTC P0504 ASCD BRAKE SWITCH
[ZD30DDTi WITH COMMON RAIL]
Component Inspection BBS0022C

ASCD BRAKE SWITCH

1. Turn ignition switch OFF.
2. Disconnect ASCD brake switch harness connector.
3. Check continuity between ASCD brake switch terminals 1 and 2
under the following conditions.
Condition Continuity
Brake pedal: Fully released Should exist
Brake pedal: Slightly depressed Should not exist

If NG, adjust ASCD brake switch installation, refer to BR section,

and perform step 3 again.
EC
SEC024D

STOP LAMP SWITCH

1. Turn ignition switch OFF.
2. Disconnect stop lamp switch harness connector.
3. Check continuity between stop lamp switch terminals 1 and 2 un-
der the following conditions.
Condition Continuity
Brake pedal: Fully released Should not exist
Brake pedal: Slightly depressed Should exist

If NG, adjust stop lamp switch installation, refer to BR section,

and perform step 3 again.

PBIB0118E

EC-283
 DTC P0520 ENGINE OIL PRESSURE SENSOR
[ZD30DDTi WITH COMMON RAIL]
DTC P0520 ENGINE OIL PRESSURE SENSOR PFP:22365

Component Description BBS00207

The engine oil pressure sensor is installed to the cylinder block and
detects a engine oil pressure. This sensor is a potentiometer which
transforms the engine oil pressure into output voltage, and emits the
voltage signal to the ECM.

SEC111E

SEC112E

CONSULT-II Reference Value in Data Monitor Mode BBS00208

Specification data are reference values.

MONITOR ITEM CONDITION SPECIFICATION
OIL PRESS SEN ● Engine: After warming up, idle the engine Approximatetely 1.2V

On Board Diagnosis Logic BBS00209

This self-diagnosis has the one trip detection logic.

The MI will not light up for this self-diagnosis.
NOTE:
If DTC P0520 is display with DTC P0697 (GST: P0698, P0699), first perform the trouble diagnosis for DTC
P0697 (GST: P0698, P0699). Refer to EC-336, "DTC P0697 SENSOR POWER SUPPLY" .
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Engine oil pres-
An excessively high voltage from the sensor
1 P0523 sure sensor high ● Harness or connectors
is sent to ECM.
voltage (Engine oil pressure sensor circuit is
P0520 open or shorted.)
Engine oil pres-
An excessively low voltage from the sensor Engine oil pressure sensor
2 P0522 sure sensor low ●
is sent to ECM.
voltage

EC-284
 DTC P0520 ENGINE OIL PRESSURE SENSOR
[ZD30DDTi WITH COMMON RAIL]
DTC Confirmation Procedure BBS0020A

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If DTC is detected, go to EC-287, "Diagnostic Procedure" .

EC

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-285
 DTC P0520 ENGINE OIL PRESSURE SENSOR
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS0020B

TEC695M

EC-286
 DTC P0520 ENGINE OIL PRESSURE SENSOR
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values, and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may damage the
ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage)
NO.
Sensor power supply
110 W (Engine oil pressure sen- [Igniton switch ON] Approximately 5V
sor)

Sensor ground [Engine is running]

122 B (Engine oil pressure sen- ● Warm-up condition Approximately 0V
sor) ● Idle speed
EC
[Engine is running]
180 R Engine oil pressure sensor ● Warm-up condition Approximately 1.2V
● Idle speed

Diagnostic Procedure BBS0020C

1. CHECK GROUND CONNECTIONS

1. Turn ignition switch OFF.
2. Loosen and retighten ground screws on the body. Refer to EC-
107, "Ground Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 2.
NG >> Repair or replace ground connections.
SEC119E

2. CHECK ENGINE OIL PRESSURE SENSOR POWER SUPPLY CIRCUIT

1. Disconnect engine oil pressure sensor (2) harness connector.
– Swirl control valve actuator (1)
– Starter motor (3)
– : Vehicle front
2. Turn ignition switch ON.

SEC090E

3. Check voltage between engine oil pressure sensor terminal 1

and ground with CONSULT-II or tester.
Voltage: Approximately 5V
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.

PBIB0188E

EC-287
 DTC P0520 ENGINE OIL PRESSURE SENSOR
[ZD30DDTi WITH COMMON RAIL]
3. DETECT MALFUNCTIONING PART
Check following.
● Harness connectors E272, F34
● Harness for open and short between ECM and engine oil pressure sensor

>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK ENGINE OIL PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between engine oil pressure sensor terminal 3 and ECM terminal 122.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 6.
NG >> GO TO 5.

5. DETECT MALFUNCTIONING PART

Check following.
● Harness connectors E272, F34
● Harness for open and short between ECM and engine oil pressure sensor

>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK ENGINE OIL PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Check harness continuity between ECM terminals 180 and engine oil pressure sensor terminal 2. Refer to
Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 8.
NG >> GO TO 7.

7. DETECT MALFUNCTIONING PART

Check following.
● Harness connectors E272, F34
● Harness for open and short between ECM and engine oil pressure sensor

>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK TURBOCHARGER BOOST SENSOR

Refer to EC-289, "Component Inspection" .
OK or NG
OK >> GO TO 9.
NG >> Replace engine oil pressure sensor.

EC-288
 DTC P0520 ENGINE OIL PRESSURE SENSOR
[ZD30DDTi WITH COMMON RAIL]
9. CHECK INTERMITTENT INCIDENT
Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection BBS0020D

CHECK ENGINE OIL PRESSURE SENSOR

1. Turn ignition switch ON.
2. Check voltage between ECM terminal 180 (engine oil pressure
sensor signal) and ground with CONSULT-II or tester.
Voltage: 0.3 - 0.8V
If NG, replace engine oil pressure sensor. EC
If OK, go to next steps.
3. Start engine and warm it up to normal operating temperature.
4. Stop engine and check engine oil level.
Refer to LC section.
If engine oil level is out of range, adjust it. Then go to next steps.
5. Start engine again and warm it up to normal operating tempera- SEC128E

ture.
6. Check voltage between ECM terminal 180 (engine oil pressure
sensor signal) and ground with CONSULT-II or tester.
Voltage: Approximately 1.2V (at idle)
If NG, replace engine oil pressure sensor.

SEC128E

EC-289
 DTC P0581 ASCD STEERING SWITCH
[ZD30DDTi WITH COMMON RAIL]
DTC P0581 ASCD STEERING SWITCH PFP:25551

Component Description BBS0022G

ASCD steering switch has variant values of electrical resistance for each button. ECM reads voltage variation
of switch, and determines which button is operated.

SEC110E

1. ASCD steering switch 2. RESUME/ACCELERATE switch 3. CANCEL switch

4. SET/COAST switch 5. MAIN switch

Refer to EC-404, "AUTOMATIC SPEED CONTROL DEVICE (ASCD)" for the ASCD function.
CONSULT-II Reference Value in Data Monitor Mode BBS0022H

Specification data are reference values.

MONITOR ITEM CONDITION SPECIFICATION
MAIN switch: Released OFF
MAIN SW ● Ignition switch: ON
MAIN switch: Pressed ON
CANCEL switch: Released OFF
CANCEL SW ● Ignition switch: ON
CANCEL switch: Pressed ON
RESUME/ACCELERATE switch:
OFF
Released
RESUME/ACC SW ● Ignition switch: ON
RESUME/ACCELERATE switch:
ON
Pressed
SET/COAST switch: Released OFF
SET SW ● Ignition switch: ON
SET/COAST switch: Pressed ON

EC-290
 DTC P0581 ASCD STEERING SWITCH
[ZD30DDTi WITH COMMON RAIL]
On Board Diagnosis Logic BBS0022I

These self-diagnoses have the one trip detection logic.

DTC No.
CONSULT-II
Trouble diagnosis name DTC detecting condition Possible cause
ID GST
FLAG
ASCD steering switch circuit ECM detects that the ASCD steer- ● Harness or connectors
1 P0578
stuck ing switch is stuck ON. (ASCD steering switch circuit is
P0581 open or shorted.)
ASCD steering switch circuit is ECM detects the out of range volt-
1 P0581
out of range age from ASCD steering switch. ● ASCD steering switch

DTC Confirmation Procedure BBS0022J

EC
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Press MAIN switch for at least 5 seconds, then release it, wait at
least 5 seconds and check that CRUISE indicator is displayed in
combination meter.
4. Wait at least 60 seconds.
5. Press RESUME/ACCELERATE switch for at least 5 seconds,
then release it and wait at least 5 seconds.
6. Press SET COAST switch for at least 5 seconds, then release it
and wait at least 5 seconds.
7. Press CANCEL switch for at least 5 seconds, then release it and SEF817Y
wait at least 5 seconds.
8. If DTC is detected, go to EC-293, "Diagnostic Procedure" .
WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-291
 DTC P0581 ASCD STEERING SWITCH
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS0022K

TEC672M

EC-292
 DTC P0581 ASCD STEERING SWITCH
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage)
NO.
[Engine is running]
Sensor ground
121 G/W ● Warm-up condition Approximately 0V
(ASCD steering switch)
● Idle speed
[Igniton switch ON]
Approximately 4.3V
● ASCD steering switch: OFF
[Igniton switch ON] EC
Approximately 0.3V
● MAIN switch: Pressed
[Igniton switch ON]
187 GY/R ASCD steering switch Approximately 1.3V
● CANCEL switch: Pressed
[Igniton switch ON]
Approximately 3.3V
● RESUME/ACCELERATE switch: Pressed
[Igniton switch ON]
Approximately 2.3V
● SET/COAST switch: Pressed

Diagnostic Procedure BBS0022L

1. CHECK GROUND CONNECTIONS

1. Turn ignition switch OFF.
2. Loosen and retighten ground screws on the body. Refer to EC-
107, "Ground Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 2.
NG >> Repair or replace ground connections.
SEC119E

EC-293
 DTC P0581 ASCD STEERING SWITCH
[ZD30DDTi WITH COMMON RAIL]
2. CHECK ASCD STEERING SWITCH CIRCUIT
With CONSULT-II
1. Turn ignition switch ON.
2. Select “MAIN SW”, “RESUME/ACC SW”, “SET SW” and “CANCEL SW” in “DATA MONITOR” mode with
CONSULT-II.
3. Check each item indication under the following conditions.
Switch Monitor item Condition Indication
Pressed ON
MAIN switch MAIN SW
Released OFF
Pressed ON
CANCEL switch CANCEL SW
Released OFF

RESUME/ACCEL- Pressed ON
RESUME/ACC SW
ERATE switch Released OFF
SEC006D
Pressed ON
SET/COAST switch SET SW
Released OFF

Without CONSULT-II
1. Turn ignition switch ON.
2. Check voltage between ECM terminal 187 and ground under the
following conditions.
Switch Condition Voltage (V)
Pressed Approx. 0.3
MAIN switch
Released Approx. 4.3
Pressed Approx. 1.3
CANCEL switch
Released Approx. 4.3

RESUME/ACCELERATE Pressed Approx. 3.3

switch Released Approx. 4.3 SEC071E

Pressed Approx. 2.3

SET/COAST switch
Released Approx. 4.3
OK or NG
OK >> GO TO 8.
NG >> GO TO 3.

3. CHECK ASCD STEERING SWITCH GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ASCD steering switch harness connector.
3. Disconnect ECM harness connector.
4. Check harness continuity between ASCD steering switch terminal 2 and ECM terminal 121 or ground. Re-
fer to Wiring Diagram.
Continuity should exist.
5. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 5.
NG >> GO TO 4.

EC-294
 DTC P0581 ASCD STEERING SWITCH
[ZD30DDTi WITH COMMON RAIL]
4. DETECT MALFUNCTIONING PART
Check the following.
● Harness connectors M51, F6
● Combination switch (spiral cable)
● Harness for open or short between ASCD steering switch and ground
● Harness for open or short between ECM and ASCD steering switch

>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK ASCD STEERING SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Check harness continuity between ECM terminal 187 and ASCD steering switch terminal 1. EC
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 7.
NG >> GO TO 6.

6. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M51, F6
● Combination switch (spiral cable)
● Harness for open or short between ECM and ASCD steering switch

>> Repair open circuit or short to ground or short to power in harness or connectors.

7. CHECK ASCD STEERING SWITCH

Refer to EC-296, "Component Inspection" .
OK or NG
OK >> GO TO 8.
NG >> Replace ASCD steering switch.

8. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

EC-295
 DTC P0581 ASCD STEERING SWITCH
[ZD30DDTi WITH COMMON RAIL]
Component Inspection BBS0022M

ASCD STEERING SWITCH

1. Disconnect ASCD steering switch.
2. Check continuity between ASCD steering switch terminals 1 and
2 with pushing each switch.
Switch Condition Resistance (Ω)
Pressed Approx. 0
MAIN switch
Released Approx. 4,000
Pressed Approx. 250
CANCEL switch
Released Approx. 4,000
SEC008D
RESUME/ACCELERATE Pressed Approx. 1,480
switch Released Approx. 4,000
Pressed Approx. 660
SET/COAST switch
Released Approx. 4,000

EC-296
 DTC P0606 ECM
[ZD30DDTi WITH COMMON RAIL]
DTC P0606 ECM PFP:23710

Description BBS00CKZ

The ECM consists of a microcomputer and connectors for signal input

and output and for power supply. The ECM controls the engine.

MBIB0625E EC
On Board Diagnosis Logic BBS00CL0

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Engine control
P0606 — P0606 module ECM calculation function is malfunctioning. ● ECM
(Processor)

DTC Confirmation Procedure BBS00CL1

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-298, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-297
 DTC P0606 ECM
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure BBS00CL2

1. INSPECTION START
With CONSULT-II
1. Turn ignition switch ON.
2. Select “SELF DIAG RESULTS” mode with CONSULT-II.
3. Touch “ERASE”.
4. Perform EC-297, "DTC Confirmation Procedure" , again.
5. Is 1st trip DTC P0606 displayed again?
With GST
1. Turn ignition switch ON.
2. Select Service $04 with GST.
3. Perform EC-297, "DTC Confirmation Procedure" , again.
4. Is 1st trip DTC P0606 displayed again?
Yes or No
Yes >> GO TO 2.
No >> INSPECTION END

2. REPLACE ECM
1. Replace ECM.
2. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to EL section.
3. Perform Injector Adjustment Value Registration. Refer to EC-34, "Injector Adjustment Value Registration" .
4. Perform EGR Volume Control Valve Closed Position Learning Value Clear. Refer to EC-37, "EGR Volume
Control Valve Closed Position Learning Value Clear" .
5. Perform EGR Volume Control Valve Closed Position Learning. Refer to EC-37, "EGR Volume Control
Valve Closed Position Learning" .
6. Perform Throttle Valve Closed Position Learning Value Clear.
Refer to EC-39, "Throttle Valve Closed Position Learning Value Clear" .
7. Perform Throttle Valve Closed Position Learning.
Refer to EC-39, "Throttle Valve Closed Position Learning" .

>> INSPECTION END

EC-298
 DTC P0607 ECM
[ZD30DDTi WITH COMMON RAIL]
DTC P0607 ECM PFP:23710

Description BBS00CL3

The ECM consists of a microcomputer and connectors for signal input

and output and for power supply. The ECM controls the engine.

MBIB0625E EC
On Board Diagnosis Logic BBS00CL4

This self-diagnosis has the one trip detection logic.

The MI will not light up for this diagnosis.
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Engine control
P0607 — P0607 module ECM calculation function is malfunctioning. ● ECM
(IC error)

DTC Confirmation Procedure BBS00CL5

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If DTC is detected, go to EC-300, "Diagnostic Procedure" .

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-299
 DTC P0607 ECM
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure BBS00CL6

1. INSPECTION START
With CONSULT-II
1. Turn ignition switch ON.
2. Select “SELF DIAG RESULTS” mode with CONSULT-II.
3. Touch “ERASE”.
4. Perform EC-299, "DTC Confirmation Procedure" , again.
5. Is DTC P0607 displayed again?
With GST
1. Turn ignition switch ON.
2. Select Service $04 with GST.
3. Perform EC-299, "DTC Confirmation Procedure" , again.
4. Is DTC P0607 displayed again?
Yes or No
Yes >> GO TO 2.
No >> INSPECTION END

2. REPLACE ECM
1. Replace ECM.
2. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to EL section.
3. Perform Injector Adjustment Value Registration. Refer to EC-34, "Injector Adjustment Value Registration" .
4. Perform EGR Volume Control Valve Closed Position Learning Value Clear. Refer to EC-37, "EGR Volume
Control Valve Closed Position Learning Value Clear" .
5. Perform EGR Volume Control Valve Closed Position Learning. Refer to EC-37, "EGR Volume Control
Valve Closed Position Learning" .
6. Perform Throttle Valve Closed Position Learning Value Clear.
Refer to EC-39, "Throttle Valve Closed Position Learning Value Clear" .
7. Perform Throttle Valve Closed Position Learning.
Refer to EC-39, "Throttle Valve Closed Position Learning" .

>> INSPECTION END

EC-300
 DTC P0611 ECM
[ZD30DDTi WITH COMMON RAIL]
DTC P0611 ECM PFP:23710

Description BBS00CL7

The ECM consists of a microcomputer and connectors for signal input

and output and for power supply. The ECM controls the engine.

MBIB0625E EC
On Board Diagnosis Logic BBS00CL8

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
1
2 Engine control
P0611 P0611 module ECM ROM is malfunctioning. ● ECM
4 (ROM)
8

DTC Confirmation Procedure BBS00CL9

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-302, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-301
 DTC P0611 ECM
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure BBS00CLA

1. INSPECTION START
With CONSULT-II
1. Turn ignition switch ON.
2. Select “SELF DIAG RESULTS” mode with CONSULT-II.
3. Touch “ERASE”.
4. Perform EC-301, "DTC Confirmation Procedure" , again.
5. Is 1st trip DTC P0611 displayed again?
With GST
1. Turn ignition switch ON.
2. Select Service $04 with GST.
3. Perform EC-301, "DTC Confirmation Procedure" , again.
4. Is 1st trip DTC P0611 displayed again?
Yes or No
Yes >> GO TO 2.
No >> INSPECTION END

2. REPLACE ECM
1. Replace ECM.
2. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to EL section.
3. Perform Injector Adjustment Value Registration. Refer to EC-34, "Injector Adjustment Value Registration" .
4. Perform EGR Volume Control Valve Closed Position Learning Value Clear. Refer to EC-37, "EGR Volume
Control Valve Closed Position Learning Value Clear" .
5. Perform EGR Volume Control Valve Closed Position Learning. Refer to EC-37, "EGR Volume Control
Valve Closed Position Learning" .
6. Perform Throttle Valve Closed Position Learning Value Clear.
Refer to EC-39, "Throttle Valve Closed Position Learning Value Clear" .
7. Perform Throttle Valve Closed Position Learning.
Refer to EC-39, "Throttle Valve Closed Position Learning" .

>> INSPECTION END

EC-302
 DTC P0638 ELECTRIC THROTTLE CONTROL ACTUATOR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
DTC P0638 ELECTRIC THROTTLE CONTROL ACTUATOR FUNCTION PFP:16119

Component Description BBS002KV

Electric throttle control actuator (1) consists of throttle control motor

which operates throttle valve, throttle position sensor which detects
the opening angle of throttle valve, etc.
Throttle valve is fully opened when the engine is running. The valve
is closed only to perform smooth engine stop when the ignition switch
is turned OFF.
Based on the signal from throttle position sensor, ECM judges wheth-
er or not throttle control actuator operates properly.
● : Vehicle front

SEC084E EC
On Board Diagnosis Logic BBS002KW

This self-diagnosis has the one trip detection logic.

The MI will not light up for this self-diagnosis.
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Electric throttle
control actuator The electric throttle control actuator closed ● Electric throttle control valve
P0638 8 P0638
range/perfor- position is not in the specified range. ● Electric throttle control valve stuck
mance

DTC Confirmation Procedure BBS002KX

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
WITH CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Stop engine and wait at least 30 seconds.
3. Turn ignition switch ON.
4. Select “DATA MONITOR” mode with CONSULT-II.
5. If DTC is detected, go to EC-305, "Diagnostic Procedure" .

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-303
 DTC P0638 ELECTRIC THROTTLE CONTROL ACTUATOR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram B88872

TEC728M

EC-304
 DTC P0638 ELECTRIC THROTTLE CONTROL ACTUATOR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.
Sensor power supply
109 B (Electric throttle control [Igniton switch ON] Approximately 5V
actuator position sensor)

Sensor ground [Engine is running]

117 R (Electric throttle control ● Warm-up condition Approximately 0V
actuator position sensor) ● Idle speed
EC
[Engine is running]
Sensor ground
131 B ● Warm-up condition Approximately 0V
(Sensor shield circuit)
● Idle speed
Approximately 4.2V
[Ignition switch OFF] ↓
Approximately 0.5V
Electric throttle control ● When the engine is stopped ↓
163 W
actuator position sensor Approximately 4.2V
[Ignition switch ON]
Approximately 4.2V
[Engine is running]

Throttle control motor [Ignition switch OFF]

246 W 0V or Battery voltage (11 - 14V)
(DC motor) ● When the engine is stopped

0 - 14V

Throttle control motor [Ignition switch OFF]

253 PU
(DC motor) ● When the engine is stopped

SEC115E

Diagnostic Procedure B88871

1. CHECK GROUND CONNECTIONS

1. Turn ignition switch OFF.
2. Loosen and retighten ground screws on the body. Refer to EC-
107, "Ground Inspection" .
OK or NG
OK >> GO TO 2.
NG >> Repair or replace ground connections.

SEC119E

EC-305
 DTC P0638 ELECTRIC THROTTLE CONTROL ACTUATOR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
2. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT
1. Disconnect electric throttle control actuator (1) harness connec-
tor.
– : Vehicle front
2. Turn ignition switch ON.

SEC084E

3. Check voltage between electric throttle control actuator terminal

5 and ground with CONSULT-II or tester.
Voltage: Approximately 5V
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.

PBIB1169E

3. DETECT MALFUNCTIONING PART

Check following.
● Harness connectors E272, F34
● Harness for open and short between electric throttle control actuator and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK THROTTLE POSITION SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between electric throttle control actuator terminal 4 and ECM terminal 117.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 6.
NG >> GO TO 5.

5. DETECT MALFUNCTIONING PART

Check following.
● Harness connectors E272, F34
● Harness for open and short between ECM and electric throttle control actuator

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-306
 DTC P0638 ELECTRIC THROTTLE CONTROL ACTUATOR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
6. CHECK THROTTLE POSITION SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Check harness continuity between electric throttle control actuator terminal 6 and ECM terminal 163.
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 8.
NG >> GO TO 7.

7. DETECTED MALFUNCTIONING PART

Check the following. EC
● Harness connectors E272, F34
● Harness for open or short between electric throttle control actuator and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT
1. Check harness continuity between the following terminals.
Refer to Wiring Diagram.
Electric throttle control
ECM terminal Continuity
actuator terminal
246 Should not exist
1
253 Should exist
246 Should exist
2
253 Should not exist

2. Also check harness for short to ground and short to power.

OK or NG
OK >> GO TO 10.
NG >> GO TO 9.

9. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors E271, F33
● Harness for open or short between electric throttle control actuator and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

10. CHECK THROTTLE CONTROL MOTOR

Refer to EC-308, "Component Inspection" .
OK or NG
OK >> GO TO 13.
NG >> GO TO 12.

11. CHECK THROTTLE POSITION SENSOR

Refer to EC-308, "Component Inspection" .
OK or NG
OK >> GO TO 11.
NG >> GO TO 12.
EC-307
 DTC P0638 ELECTRIC THROTTLE CONTROL ACTUATOR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
12. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
With CONSULT-II
1. Replace the electric throttle control actuator.
2. Turn ignition switch ON and OFF.
3. Turn ignition switch ON and select “THRTL POSITION” in “AC-
TIVE TEST” mode.
4. Make sure that throttle valve operates correctly.
Without CONSULT-II
1. Replace the electric throttle control actuator.
2. Turn ignition switch ON and OFF.
3. Turn ignition switch ON and OFF, and make sure that throttle
valve operates correctly.

SEC124E
>> INSPECTION END

13. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection B88870

THROTTLE POSITION SENSOR

With CONSULT-II
1. Turn ignition switch OFF.
2. Reconnect harness connectors disconnected.
3. Turn ignition switch ON.
4. Select “THRTL POSITION” in “ACTIVE TEST” mode, and select
“THRTL SEN” as the monitor item with CONSULT-II.
5. Check indication under the following conditions.
Condition [THRTL POSITION (%)] THRTL SEN (V)
0.0 Approximately 4.2V
100.0 Approximately 0.5V
6. If NG, replace electric throttle control actuator.

SEC124E

THROTTLE CONTROL MOTOR

1. Disconnect electric throttle control actuator harness connector.
2. Check resistance between terminals 1 and 2.
Resistance: Approximately 0.3 - 100 Ω [at 25°C (77°F)]
3. If NG, replace electric throttle control actuator.

SEC074E

EC-308
 DTC P0641 SENSOR POWER SUPPLY
[ZD30DDTi WITH COMMON RAIL]
DTC P0641 SENSOR POWER SUPPLY PFP:22693

On Board Diagnosis Logic BBS00CLB

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Sensor power
ECM detects a voltage of power source for ● Harness or connectors
1 P0643 supply circuit
sensor is excessively high. (APP sensor 1 circuit is shorted.)
high input
P0641 ● Accelerator pedal position sensor
Sensor power (APP sensor 1)
ECM detects a voltage of power source for
2 P0642 supply circuit low
sensor is excessively low ● ECM
input EC
DTC Confirmation Procedure BBS00CLC

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-312, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-309
 DTC P0641 SENSOR POWER SUPPLY
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CLD

LHD MODELS

TEC673M

EC-310
 DTC P0641 SENSOR POWER SUPPLY
[ZD30DDTi WITH COMMON RAIL]
RHD MODELS

EC

TEC674M

EC-311
 DTC P0641 SENSOR POWER SUPPLY
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.
Sensor power supply
111 G (Accelerator pedal position [Ignition switch ON] Approximately 5V
sensor 1)

Sensor ground [Engine is running]

115 OR/L (Accelerator pedal position ● Warm-up condition Approximately 0V
sensor 2) ● Idle speed
[Engine is running]
Sensor ground
131 B ● Warm-up condition Approximately 0V
(Sensors shield circuit)
● Idle speed
Sensor power supply
135 W/L (Accelerator pedal position [Ignition switch ON] Approximately 5V
sensor 2)

Sensor ground [Engine is running]

140 Y (Accelerator pedal position ● Warm-up condition Approximately 0V
sensor 1) ● Idle speed
[Ignition switch ON]
● Engine stopped 0.4 - 1.05V
Accelerator pedal position ● Accelerator pedal: Fully released
164 L
sensor 1 [Ignition switch ON]
3.1 - 4.7V (RHD)
● Engine stopped
3.3 - 4.7V (LHD)
● Accelerator pedal: Fully depressed
[Ignition switch ON]
● Engine stopped 0.2 - 0.53V
Accelerator pedal position ● Accelerator pedal: Fully released
189 L/G
sensor 2 [Ignition switch ON]
1.56 - 2.35V (RHD)
● Engine stopped
1.66 - 2.35V (LHD)
● Accelerator pedal: Fully depressed

Diagnostic Procedure BBS00CLE

1. CHECK GROUND CONNECTIONS

1. Turn ignition switch OFF.
2. Loosen and retighten ground screws. Refer to EC-107, "Ground
Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 2.
NG >> Repair or replace ground connections.
SEC119E

EC-312
 DTC P0641 SENSOR POWER SUPPLY
[ZD30DDTi WITH COMMON RAIL]
2. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT-I
1. Disconnect accelerator pedal position (APP) sensor harness
connector (3).
– Stop lamp switch (1)
– ASCD brake switch (2)
– Accelerator pedal (4)
2. Turn ignition switch ON.

SEC098E

EC
3. Check voltage between APP sensor terminal 3 and ground with
CONSULT-II or tester.
Voltage: Approximately 5V
OK or NG
OK >> GO TO 5.
NG >> GO TO 3.

SEC072E

3. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT-II

1. Turn ignition switch ON.
2. Disconnect ECM harness connector.
3. Check harness for short to power and short to ground between the APP sensor terminal 3 and ECM termi-
nal 111. Refer to Wiring Diagram.
OK or NG
OK >> GO TO 5.
NG >> GO TO 4.

4. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M51, F6 (RHD models)
● Harness for open and short between APP sensor and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK APP SENSOR

Refer to EC-192, "Component Inspection" .
OK or NG
OK >> GO TO 6.
NG >> Replace accelerator pedal assembly.

6. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
OK or NG
OK >> GO TO 7.
NG >> Repair or replace harness or connectors.

EC-313
 DTC P0641 SENSOR POWER SUPPLY
[ZD30DDTi WITH COMMON RAIL]
7. REPLACE ECM
1. Replace ECM.
2. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to EL section.
3. Perform Injector Adjustment Value Registration. Refer to EC-34, "Injector Adjustment Value Registration" .
4. Perform EGR Volume Control Valve Closed Position Learning Value Clear. Refer to EC-37, "EGR Volume
Control Valve Closed Position Learning Value Clear" .
5. Perform EGR Volume Control Valve Closed Position Learning. Refer to EC-37, "EGR Volume Control
Valve Closed Position Learning" .
6. Perform Throttle Valve Closed Position Learning Value Clear.
Refer to EC-39, "Throttle Valve Closed Position Learning Value Clear" .
7. Perform Throttle Valve Closed Position Learning.
Refer to EC-39, "Throttle Valve Closed Position Learning" .

>> INSPECTION END

EC-314
 DTC P0645 A/C CLUTCH RELAY
[ZD30DDTi WITH COMMON RAIL]
DTC P0645 A/C CLUTCH RELAY PFP:21481

CONSULT-II Reference Value in Data Monitor Mode B99977

Specification data are reference values.

MONITOR ITEM CONDITION SPECIFICATION
Air conditioner switch: OFF OFF
● Engine: After warming up, idle
AIR COND RLY Air conditioner switch: ON
the engine ON
(Compressor operates.)
● Cooling fan: Stopped OFF
COOLING FAN
● Cooling fan: Operates ON

On Board Diagnosis Logic B99976

EC
This self-diagnosis has the one trip detection logic.
The MI will not light up for this self-diagnosis.
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Air conditioner
ECM detects air conditioner relay circuit is
1 P0647 relay control cir-
short to power.
cuit high
Air conditioner ● Harness or connectors
ECM detects air conditioner relay circuit is
2 P0646 relay control cir- (Air conditioner relay circuit is open
P0645 short to ground.
cuit low or shorted.)
ECM detects air conditioner relay circuit is ● Air conditioner relay
4 Air conditioner open.
P0645 relay control cir-
cuit ECM detects air conditioner relay internal
8
circuit is open or short.

DTC Confirmation Procedure B88866

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If DTC is detected, go to EC-317, "Diagnostic Procedure" .

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-315
 DTC P0645 A/C CLUTCH RELAY
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram B99974

TEC730M

EC-316
 DTC P0645 A/C CLUTCH RELAY
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.
[Engine is running] BATTERY VOLTAGE
● Cooling fan: Not operating (11 - 14V)
242 L Cooling fan relay-1
[Engine is running]
Approximately 0.1V
● Cooling fan: Operating
[Engine is running] BATTERY VOLTAGE
● Air conditioner switch: OFF (11 - 14V) EC
255 Y/L Air conditioner relay [Engine is running]
● Both air conditioner switch and blower fan Approximately 0.1V
switch: ON (Compressor is operating)

Diagnostic Procedure B99973

1. CHECK A/C RELAY POWER SUPPLY CIRCUIT

1. Turn ignition switch OFF.
2. Disconnect A/C relay (2).
– Cooling fan relay-1 (1)
– Battery (3)
– : Vehicle front
3. Turn ignition switch ON.

SEC095E

4. Check voltage between A/C relay terminal 1 and ground with

CONSULT-II or tester.
Voltage: Battery voltage
OK or NG
OK >> GO TO 3.
NG >> GO TO 2.

SEC073E

2. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M50, F5
● Harness connectors M21, E127
● Harness for open or short between air conditioner relay and ECM relay
● Harness for open or short between air conditioner relay and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-317
 DTC P0645 A/C CLUTCH RELAY
[ZD30DDTi WITH COMMON RAIL]
3. CHECK A/C RELAY OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Disconnect ECM harness connector.
2. Check harness continuity between cooling fan relay terminal 2 and ECM terminal 255.
Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 5.
NG >> GO TO 4.

4. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors E127, M21
● Harness connectors M52, F7
● Harness for open or short between A/C relay and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK A/C RELAY

Refer to EC-185, "Component Inspection" .
OK or NG
OK >> GO TO 6.
NG >> Replace A/C relay.

6. CHECK INTERMITTENT INCIDENT

Perform EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection B99971

A/C RELAY
Check continuity between terminals (3) and (5).
Conditions Continuity
12V direct current supply between terminals (1) and
Yes
(2)
No current supply No

If NG, replace relay.

PBIB0098E

EC-318
 DTC P0651 SENSOR POWER SUPPLY
[ZD30DDTi WITH COMMON RAIL]
DTC P0651 SENSOR POWER SUPPLY PFP:18919

On Board Diagnosis Logic BBS00CLF

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Sensor power ● Harness or connectors
ECM detects a voltage of power source for
1 P0653 supply circuit (EGR volume control valve position
sensor is excessively high.
high input sensor circuit is shorted.)
(Turbocharger boost sensor circuit is
shorted.)
(Fuel rail pressure sensor circuit is
P0651
shorted.)
EC
Sensor power
ECM detects a voltage of power source for
2 P0652 supply circuit low ● EGR volume control valve
sensor is excessively low
input ● Turbocharger boost sensor
● Fuel rail pressure sensor
● ECM

DTC Confirmation Procedure BBS00CLG

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-321, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-319
 DTC P0651 SENSOR POWER SUPPLY
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CLH

TEC724M

EC-320
 DTC P0651 SENSOR POWER SUPPLY
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
DATA
NAL WIRE ITEM CONDITION
(DC Voltage and Pulse Signal)
NO. COLOR
Sensor power supply
113 R (Turbocharger boost sen- [Ignition switch ON] Approximately 5V
sor)
[Engine is running]
Sensor ground
131 B ● Warm-up condition Approximately 0V
(Sensors shield circuit)
● Idle speed
EC
Sensor ground [Engine is running]
132 B (Accelerator pedal position ● Warm-up condition Approximately 0V
sensor 2) ● Idle speed
Sensor power supply
137 L/G [Ignition switch ON] Approximately 5V
(Fuel rail pressure sensor)
Sensor power supply
138 OR/L [Ignition switch ON] Approximately 5V
(EGR volume control valve)
[Engine is running]
● Warm-up condition 1.7 - 2.3V
● Idle speed
158 W Turbocharger boost sensor
[Engine is running]
● Warm-up condition 1.7 - 2.6V
● Engine speed: 2,000 rpm

Diagnostic Procedure BBS00CLI

1. CHECK GROUND CONNECTIONS

1. Turn ignition switch OFF.
2. Loosen and retighten ground screws. Refer to EC-107, "Ground
Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 2.
NG >> Repair or replace ground connections.
SEC119E

EC-321
 DTC P0651 SENSOR POWER SUPPLY
[ZD30DDTi WITH COMMON RAIL]
2. CHECK TURBOCHARGER BOOST SENSOR POWER SUPPLY CIRCUIT-I
1. Disconnect turbocharger boost sensor (1) harness connector.
– : Vehicle front
2. Turn ignition switch ON.

SEC088E

3. Check voltage between turbocharger boost sensor terminal 1

and ground with CONSULT-II or tester.
Voltage: Approximately 5V
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.

MBIB0072E

3. CHECK TURBOCHARGER BOOST SENSOR POWER SUPPLY CIRCUIT-II

1. Check harness continuity between ECM terminal 113 and turbocharger boost sensor terminal 1.
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 4.
NG >> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK SENSOR POWER SUPPLY CIRCUITS

Check the following.
Harness for short to power and short to ground, between the following terminals.
ECM terminal Sensor terminal Reference Wiring Diagram
113 Turbocharger boost sensor terminal 1 EC-286
137 Fuel rail pressure sensor terminal 1 EC-168
138 EGR volume control valve terminal 4 EC-239

OK or NG
OK >> GO TO 5.
NG >> Repair short to ground or short to power in harness or connectors.

EC-322
 DTC P0651 SENSOR POWER SUPPLY
[ZD30DDTi WITH COMMON RAIL]
5. CHECK COMPONENTS
Check the following.
● Fuel rail pressure sensor (Refer to EC-171, "Component Inspection".)
● EGR volume control valve (Refer to EC-242, "Component Inspection" .)
OK or NG
OK >> GO TO 6.
NG >> Replace malfunctioning component.

6. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
OK or NG EC
OK >> GO TO 7.
NG >> Repair or replace harness or connectors.

7. REPLACE ECM
1. Replace ECM.
2. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to EL section.
3. Perform Injector Adjustment Value Registration. Refer to EC-34, "Injector Adjustment Value Registration" .
4. Perform EGR Volume Control Valve Closed Position Learning Value Clear. Refer to EC-37, "EGR Volume
Control Valve Closed Position Learning Value Clear" .
5. Perform EGR Volume Control Valve Closed Position Learning. Refer to EC-37, "EGR Volume Control
Valve Closed Position Learning" .
6. Perform Throttle Valve Closed Position Learning Value Clear.
Refer to EC-39, "Throttle Valve Closed Position Learning Value Clear" .
7. Perform Throttle Valve Closed Position Learning.
Refer to EC-39, "Throttle Valve Closed Position Learning" .

>> INSPECTION END

EC-323
 DTC P0660 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
DTC P0660 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE PFP:14955

Description BBS00CLJ

SYSTEM DESCRIPTION
Sensor Input Signal to ECM ECM Function Actuator
Crankshaft position sensor Engine speed
Engine coolant temperature sensor Engine coolant temperature
Intake air temperature sensor Intake air temperature Swirl control Swirl control valve control
Ignition switch Start signal valve control solenoid valve

Mass air flow sensor Amount of intake air

Barometric pressure sensor Barometric pressure

This system has a swirl control valve is the throttle body While idling and during low engine speed operation,
the swirl control valve closes. Thus the velocity of the air in the intake passage increases, promoting the vapor-
ization of the fuel and producing a swirl in the combustion chamber.
Because of this operation, this system tends to increase the burning speed of the gas mixture, improve fuel
consumption, and increase the stability in running conditions.
Also, except when idling and during low engine speed operation, this system opens the swirl control valve. In
this condition, this system tends to increase power by improving intake efficiency via reduction of intake flow
resistance, intake flow.
The solenoid valve controls swirl control valve is shut/open condition. This solenoid valve is operated by the
ECM.

SEF452Z

Swirl control valve control sole-

Engine speed Engine coolant temperature Swirl control valve
noid valve
Less than 21°C (70°F) OFF Open
Less than 2,600 rpm* 22 - 100°C (72 - 212°F) ON Closed
More than 101°C (214°F) OFF Open
More than 2,600 rpm — OFF Open
*: If the engine continues idle for more than 40 seconds, swirl control valve is OFF.

COMPONENT DESCRIPTION
Swirl Control Valve Control Solenoid Valve
The swirl control valve control solenoid valve (1) responds to signals
from the ECM. When the ECM sends an ON (ground) signal, the so-
lenoid valve is bypassed to apply vacuum pump vacuum to the swirl
control valve actuator. This operation closes the swirl control valve.
When the ECM sends an OFF signal, the vacuum signal is cut and
the swirl control valve opens.
● : Vehicle front

SEC091E

EC-324
 DTC P0660 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
On Board Diagnosis Logic BBS00CLK

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
4 ● Harness or connectors
Swirl control (The swirl control valve control sole-
valve control cir- ECM detects swirl control valve control cir- noid valve circuit is open or shorted.)
P0660 P0660
8 cuit is open/ cuit is open or shorted.
shorted ● Swirl control valve control solenoid
valve

DTC Confirmation Procedure BBS00CLL

EC
NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-327, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-325
 DTC P0660 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CLM

TEC694M

EC-326
 DTC P0660 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.
[Engine is running]
● Warm-up condition
● Engine speed: Below 2,600 rpm
NOTE: Approximately 0V
If the engine continues idle for more than
Swirl control valve solenoid
195 L/B 40 seconds, swirl control valve is OFF. So
valve EC
please depress the accelerator pedal
slightly before measurement.
[Engine is running]
BATTERY VOLTAGE
● Warm-up condition
(11 - 14V)
● Engine speed: Above 2,600 rpm
201 W
BATTERY VOLTAGE
203 W Power supply for ECM [Ignition switch ON]
(11 - 14V)
205 W
[Ignition switch ON]
[Ignition switch OFF]
Approximately 1.2V
● For a few seconds after turning ignition
245 B/Y ECM relay (self-shutoff) switch OFF
[Ignition switch OFF]
BATTERY VOLTAGE
● More than a few seconds after turning igni- (11 - 14V)
tion switch OFF

Diagnostic Procedure BBS00CLN

1. CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VALVE SUPPLY CIRCUIT

1. Turn ignition switch OFF.
2. Disconnect swirl control valve control solenoid valve (1) harness
connector.
– : Vehicle front
3. Turn ignition switch ON.

SEC091E

4. Check voltage between swirl control valve control solenoid valve

terminal 2 and ground with CONSULT-II or tester.
Voltage: Battery voltage
OK or NG
OK >> GO TO 3.
NG >> GO TO 2.

PBIB0192E

EC-327
 DTC P0660 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
2. DETECT MALFUNCTIONING PART
Check the following.
● Harness connectors M50, F5
● Harness for open between swirl control valve control solenoid valve and ECM
● Harness for open between swirl control valve control solenoid valve and ECM relay

>> Repair open circuit in harness or connectors.

3. CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VLAVE OUTPUT SIGNAL CIRCUIT FOR
OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between swirl control valve control solenoid valve terminal 1 and ECM terminal
195. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 4.
NG >> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VLAVE

Refer to EC-328, "Component Inspection" .
OK or NG
OK >> GO TO 5.
NG >> Replace swirl control valve control solenoid valve.

5. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection BBS00CLO

SWIRL CONTROL VALVE CONTROL SOLENOID VALVE

With CONSULT-I
1. Reconnect all disconnected harness connectors.
2. Turn ignition switch ON.
3. Select “SWIRL CONT S/V 1” in “ACTIVE TEST” mode with CON-
SULT-II.
4. Check air passage continuity of swirl control valve control sole-
noid valve the following conditions.
Air passage continuity
SWIRL CONT S/V 1
between A and B
ON Yes
OFF No

MBIB1805E

EC-328
 DTC P0660 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
Without CONSULT-II
1. Apply 12V direct current between swirl control valve control sole-
noid valve terminals.
2. Check air passage continuity of swirl control valve control sole-
noid valve the following conditions.
Air passage continuity
SWIRL CONT S/V 1
between A and B
12V direct current supply
Yes
between terminals 1 and 2
No supply No
PBIB0150E

EC

EC-329
 DTC P0661, P0662 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
DTC P0661, P0662 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE
PFP:14955

Description BBS00CLQ

SYSTEM DESCRIPTION
Sensor Input Signal to ECM ECM Function Actuator
Crankshaft position sensor Engine speed
Engine coolant temperature sensor Engine coolant temperature
Intake air temperature sensor Intake air temperature Swirl control Swirl control valve control
Ignition switch Start signal valve control solenoid valve

Mass air flow sensor Amount of intake air

Barometric pressure sensor Barometric pressure

This system has a swirl control valve is the throttle body While idling and during low engine speed operation,
the swirl control valve closes. Thus the velocity of the air in the intake passage increases, promoting the vapor-
ization of the fuel and producing a swirl in the combustion chamber.
Because of this operation, this system tends to increase the burning speed of the gas mixture, improve fuel
consumption, and increase the stability in running conditions.
Also, except when idling and during low engine speed operation, this system opens the swirl control valve. In
this condition, this system tends to increase power by improving intake efficiency via reduction of intake flow
resistance, intake flow.
The solenoid valve controls swirl control valve is shut/open condition. This solenoid valve is operated by the
ECM.

SEF452Z

Swirl control valve control sole-

Engine speed Engine coolant temperature Swirl control valve
noid valve
Less than 21°C (70°F) OFF Open
Less than 2,600 rpm* 22 - 100°C (72 - 212°F) ON Closed
More than 101°C (214°F) OFF Open
More than 2,600 rpm — OFF Open
*: If the engine continues idle for more than 40 seconds, swirl control valve is OFF.

COMPONENT DESCRIPTION
Swirl Control Valve Control Solenoid Valve
The swirl control valve control solenoid valve (1) responds to signals
from the ECM. When the ECM sends an ON (ground) signal, the so-
lenoid valve is bypassed to apply vacuum pump vacuum to the swirl
control valve actuator. This operation closes the swirl control valve.
When the ECM sends an OFF signal, the vacuum signal is cut and
the swirl control valve opens.
● : Vehicle front

SEC091E

EC-330
 DTC P0661, P0662 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
On Board Diagnosis Logic BBS00CLR

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Swirl control
An excessively low voltage from the sensor ● Harness or connectors
P0661 2 P0661 valve control cir-
is sent to ECM. (The swirl control valve control sole-
cuit low input
noid valve circuit is shorted.)
Swirl control
An excessively high voltage from the sensor ● Swirl control valve control solenoid
P0662 1 P0662 valve control cir-
is sent to ECM. valve
cuit high input

DTC Confirmation Procedure BBS00CLS EC

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-333, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-331
 DTC P0661, P0662 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CLT

TEC694M

EC-332
 DTC P0661, P0662 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.
[Engine is running]
● Warm-up condition
● Engine speed: Below 2,600 rpm
NOTE: Approximately 0V
If the engine continues idle for more than
Swirl control valve solenoid
195 L/B 40 seconds, swirl control valve is OFF. So
valve EC
please depress the accelerator pedal
slightly before measurement.
[Engine is running]
BATTERY VOLTAGE
● Warm-up condition
(11 - 14V)
● Engine speed: Above 2,600 rpm
201 W
BATTERY VOLTAGE
203 W Power supply for ECM [Ignition switch ON]
(11 - 14V)
205 W
[Ignition switch ON]
[Ignition switch OFF]
Approximately 1.2V
● For a few seconds after turning ignition
245 B/Y ECM relay (self-shutoff) switch OFF
[Ignition switch OFF]
BATTERY VOLTAGE
● More than a few seconds after turning igni- (11 - 14V)
tion switch OFF

Diagnostic Procedure BBS00CLU

1. CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VALVE SUPPLY CIRCUIT

1. Turn ignition switch OFF.
2. Disconnect swirl control valve control solenoid valve (1) harness
connector.
– : Vehicle front
3. Turn ignition switch ON.

SEC091E

4. Check voltage between swirl control valve control solenoid valve

terminal 2 and ground with CONSULT-II or tester.
Voltage: Battery voltage
OK or NG
OK >> GO TO 3.
NG >> GO TO 2.

PBIB0192E

EC-333
 DTC P0661, P0662 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
2. DETECT MALFUNCTIONING PART
Check the following.
● Harness connectors M50, F5
● Harness for short between swirl control valve control solenoid valve and ECM
● Harness for short between swirl control valve control solenoid valve and ECM relay

>> Repair short to ground or short to power in harness or connectors.

3. CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VLAVE OUTPUT SIGNAL CIRCUIT FOR
SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between swirl control valve control solenoid valve terminal 2 and ECM terminal
195. Refer to Wiring Diagram.
OK or NG
OK >> GO TO 4.
NG >> Repair short to ground or short to power in harness or connectors.

4. CHECK SWIRL CONTROL VALVE CONTROL SOLENOID VLAVE

Refer to EC-334, "Component Inspection" .
OK or NG
OK >> GO TO 5.
NG >> Replace swirl control valve control solenoid valve.

5. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection BBS00CLV

SWIRL CONTROL VALVE CONTROL SOLENOID VALVE

With CONSULT-I
1. Reconnect all disconnected harness connectors.
2. Turn ignition switch ON.
3. Select “SWIRL CONT S/V 1” in “ACTIVE TEST” mode with CON-
SULT-II.
4. Check air passage continuity of swirl control valve control sole-
noid valve the following conditions.
Air passage continuity
SWIRL CONT S/V 1
between A and B
ON Yes
OFF No

MBIB1805E

EC-334
 DTC P0661, P0662 SWIRL CONTROL VALVE CONTROL SOLENOID VALVE
[ZD30DDTi WITH COMMON RAIL]
Without CONSULT-II
1. Apply 12V direct current between swirl control valve control sole-
noid valve terminals.
2. Check air passage continuity of swirl control valve control sole-
noid valve the following conditions.
Air passage continuity
SWIRL CONT S/V 1
between A and B
12V direct current supply
Yes
between terminals 1 and 2
No supply No
PBIB0150E

EC

EC-335
 DTC P0697 SENSOR POWER SUPPLY
[ZD30DDTi WITH COMMON RAIL]
DTC P0697 SENSOR POWER SUPPLY PFP:18919

On Board Diagnosis Logic BBS00CLX

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Sensor power ● Harness or connectors
ECM detects a voltage of power source for
1 P0699 supply circuit (APP sensor 2 circuit is shorted.)
sensor is excessively high.
high input (TP sensor circuit is shorted.)
(Engine oil pressure sensor circuit is
shorted.)
P0697 ● Accelerator pedal position sensor
Sensor power (APP sensor 2)
ECM detects a voltage of power source for
2 P0698 supply circuit low ● Electric throttle control actuator
sensor is excessively low
input (TP sensor)
● Engine oil pressure sensor
● ECM

DTC Confirmation Procedure BBS00CLY

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-339, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-336
 DTC P0697 SENSOR POWER SUPPLY
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CLZ

LHD MODELS

EC

TEC675M

EC-337
 DTC P0697 SENSOR POWER SUPPLY
[ZD30DDTi WITH COMMON RAIL]
RHD MODELS

TEC676M

EC-338
 DTC P0697 SENSOR POWER SUPPLY
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.
Sensor power supply
109 B (Electric throttle control [Igniton switch ON] Approximately 5V
actuator position sensor)
Sensor power supply
110 R [Ignition switch ON] Approximately 5V
(Engine oil pressure sensor)
Sensor power supply
111 R/L (Accelerator pedal position [Ignition switch ON] Approximately 5V EC
sensor 1)

Sensor ground [Engine is running]

115 OR/L (Accelerator pedal position ● Warm-up condition Approximately 0V
sensor 2) ● Idle speed
[Engine is running]
Sensor ground
131 B ● Warm-up condition Approximately 0V
(Sensors shield circuit)
● Idle speed
Sensor power supply
135 W/L (Accelerator pedal position [Ignition switch ON] Approximately 5V
sensor 2)

Sensor ground [Engine is running]

140 W (Accelerator pedal position ● Warm-up condition Approximately 0V
sensor 1) ● Idle speed
[Ignition switch ON]
● Engine stopped 0.4 - 1.05V
Accelerator pedal position ● Accelerator pedal: Fully released
164 W/R
sensor 1 [Ignition switch ON]
3.1 - 4.7V (RHD)
● Engine stopped
3.3 - 4.7V (LHD)
● Accelerator pedal: Fully depressed
[Ignition switch ON]
● Engine stopped 0.2 - 0.53V
Accelerator pedal position ● Accelerator pedal: Fully released
189 L/G
sensor 2 [Ignition switch ON]
1.56 - 2.35V (RHD)
● Engine stopped
1.66 - 2.35V (LHD)
● Accelerator pedal: Fully depressed

Diagnostic Procedure BBS00CM0

1. CHECK GROUND CONNECTIONS

1. Turn ignition switch OFF.
2. Loosen and retighten ground screws. Refer to EC-107, "Ground
Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 2.
NG >> Repair or replace ground connections.
SEC119E

EC-339
 DTC P0697 SENSOR POWER SUPPLY
[ZD30DDTi WITH COMMON RAIL]
2. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-I
1. Disconnect accelerator pedal position (APP) sensor harness
connector (3).
– Stop lamp switch (3)
– ASCD brake switch (2)
– Accelerator pedal (4)
2. Turn ignition switch ON.

SEC098E

3. Check voltage between APP sensor terminal 2 and ground with

CONSULT-II or tester.
Voltage: Approximately 5V
OK or NG
OK >> GO TO 5.
NG >> GO TO 3.

PBIB1168E

3. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-II

1. Turn ignition switch ON.
2. Disconnect ECM harness connector.
3. Check harness for short to power and short to ground between the APP sensor terminal 2 and ECM termi-
nal 135. Refer to Wiring Diagram.
OK or NG
OK >> GO TO 5.
NG >> GO TO 4.

4. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M51, F6 (RHD models)
● Harness for open and short between APP sensor and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK SENSOR POWER SUPPLY CIRCUITS

Check the following.
Harness for short to power and short to ground, between the following terminals.
ECM terminal Sensor terminal Reference Wiring Diagram
109 Engine oil pressure sensor terminal 1 EC-286
110 Throttle position sensor terminal 5 EC-396
OK or NG
OK >> GO TO 6.
NG >> Repair short to ground or short to power in harness or connectors.

EC-340
 DTC P0697 SENSOR POWER SUPPLY
[ZD30DDTi WITH COMMON RAIL]
6. CHECK COMPONENTS
Check the following.
● Engine oil pressure sensor (Refer to EC-289, "Component Inspection" .)
● Throttle position sensor (Refer to EC-399, "Component Inspection" .)
OK or NG
OK >> GO TO 7.
NG >> Replace malfunctioning component.

7. CHECK APP SENSOR

Refer to EC-192, "Component Inspection" .
OK or NG EC
OK >> GO TO 8.
NG >> Replace accelerator pedal assembly.

8. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
OK or NG
OK >> GO TO 9.
NG >> Repair or replace harness or connectors.

9. REPLACE ECM
1. Replace ECM.
2. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to EL section.
3. Perform Injector Adjustment Value Registration. Refer to EC-34, "Injector Adjustment Value Registration" .
4. Perform EGR Volume Control Valve Closed Position Learning Value Clear. Refer to EC-37, "EGR Volume
Control Valve Closed Position Learning Value Clear" .
5. Perform EGR Volume Control Valve Closed Position Learning. Refer to EC-37, "EGR Volume Control
Valve Closed Position Learning" .
6. Perform Throttle Valve Closed Position Learning Value Clear.
Refer to EC-39, "Throttle Valve Closed Position Learning Value Clear" .
7. Perform Throttle Valve Closed Position Learning.
Refer to EC-39, "Throttle Valve Closed Position Learning" .

>> INSPECTION END

EC-341
 DTC P1089 FUEL PUMP
[ZD30DDTi WITH COMMON RAIL]
DTC P1089 FUEL PUMP PFP:16700

On Board Diagnosis Logic BBS00CM1

NOTE:
If DTC P1089 is displayed with DTC P0651 (GST: P0652, P0653), first perform trouble diagnosis for DTC
P0651 (GST: P0652, P0653). Refer to EC-319, "DTC P0651 SENSOR POWER SUPPLY" .
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
● Fuel pump
● Fuel injector
Fuel pump per- ● Air mixture with fuel
P1089 1 P0089 Fuel pressure is lower than the target value.
formance ● Lack of fuel
● Fuel rail pressure sensor
● Fuel rail pressure relief valve

DTC Confirmation Procedure BBS00CM2

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Let engine idle for at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-342, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.
Diagnostic Procedure BBS00CM3

1. CHECK FUEL RAIL PRESSURE SENSOR

Refer to EC-171, "Component Inspection" .
OK or NG
OK >> GO TO 2.
NG >> Replace fuel rail.

2. CHECK FUEL INJECTOR

Refer to EC-177, "Component Inspection" .
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.

EC-342
 DTC P1089 FUEL PUMP
[ZD30DDTi WITH COMMON RAIL]
3. REPLACE FUEL INJECTOR
1. Replace fuel injector of malfunctioning cylinder.
2. Perform Injector Adjustment Value Registration. Refer to EC-34, "Injector Adjustment Value Registration" .

>> INSPECTION END

4. CHECK FUEL PUMP

Perform EC-343, "Component Inspection" .
OK or NG
OK >> GO TO 5.
NG >> Replace fuel pump. EC
5. CHECK FUEL RAIL PRESSURE RELIEF VALVE
Refer to EC-343, "Component Inspection" .
OK or NG
OK >> GO TO 6.
NG >> Replace fuel rail.

6. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection BBS00CQT

FUEL PUMP
1. Disconnect fuel pump harness connector.
2. Check resistance between fuel pump terminals 1 and 2.
Resistance: 2.6 - 3.5 Ω [at 20 - 40°C (68 - 104°F)]
3. If NG, replace fuel pump.

SEC066E

FUEL RAIL PRESSURE RELIEF VALVE

WARNING:
● Confirm that the engine is cooled down and there are no fire hazards near the vehicle.
● Prepare pans or saucers under the disconnected fuel line because the fuel may spill out.
1. Turn ignition switch OFF.

EC-343
 DTC P1089 FUEL PUMP
[ZD30DDTi WITH COMMON RAIL]
2. Remove fuel hose from fuel rail pressure relief valve.
3. Attach a blind cap or plug to removed hose.
4. Start engine and keep engine speed more than 2,000 rpm for at
least 5 seconds.
5. Confirm that the fuel does not come out from the fuel rail pressure
relief valve.
WARNING:
● Be careful not to allow leaked fuel to contaminate engine
compartment. Especially, ensure to keep engine mount
insulator clear of fuel. SEC103E
● If the fuel comes out, stop the engine immediately.

EC-344
 DTC P1090 FUEL PUMP
[ZD30DDTi WITH COMMON RAIL]
DTC P1090 FUEL PUMP PFP:16700

On Board Diagnosis Logic BBS00CM5

NOTE:
If DTC P1090 is displayed with DTC P0651 (GST: P0652, P0653), first perform trouble diagnosis for DTC
P0651 (GST: P0652, P0653). Refer to EC-319, "DTC P0651 SENSOR POWER SUPPLY" .
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG

Fuel pump per- Fuel pressure is higher than the target ● Fuel pump
P1090 1 P0089
formance value. ● Fuel rail pressure sensor
EC
DTC Confirmation Procedure BBS00CM6

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Let engine idle for at least 10 seconds.
4. If 1st trip DTC is detected, go to EC-345, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.
Diagnostic Procedure BBS00CM7

1. CHECK FUEL RAIL PRESSURE SENSOR

Refer to EC-171, "Component Inspection" .
OK or NG
OK >> GO TO 2.
NG >> Replace fuel rail.

2. CHECK FUEL PUMP

Perform EC-346, "Component Inspection" .
OK or NG
OK >> GO TO 3.
NG >> Replace fuel pump.

3. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

EC-345
 DTC P1090 FUEL PUMP
[ZD30DDTi WITH COMMON RAIL]
Component Inspection BBS00D1W

FUEL PUMP
1. Disconnect fuel pump harness connector.
2. Check resistance between fuel pump terminals 1 and 2.
Resistance: 2.6 - 3.5 Ω [at 20 - 40°C (68 - 104°F)]
3. If NG, replace fuel pump.

SEC066E

EC-346
 DTC P1276, P1277 FUEL INJECTOR
[ZD30DDTi WITH COMMON RAIL]
DTC P1276, P1277 FUEL INJECTOR PFP:16600

Component Description BBS00CM9

The fuel injector is a small, precise solenoid valve. When the ECM
supplies a ground to the fuel injector circuit, the coil in the fuel injector
is energized. The energized coil pulls the needle valve back and al-
lows fuel to flow through the fuel injector into the cylinder. The amount
of fuel injected depends upon the injection pulse duration. Pulse du-
ration is the length of time the fuel injector remains open. The ECM
controls the injection pulse duration based on engine fuel needs.

PBIB0465E EC
CONSULT-II Reference Value in Data Monitor Mode BBS00CMA

Specification data are reference values.

MONITOR ITEM CONDITION SPECIFICATION
● Engine: After warming up Idle 5 - 10 mg/st
● Air conditioner switch: OFF
TRG INJ QTY ● Shift lever: Neutral (M/T), P or N
2,000 rpm 5 - 10 mg/st
(A/T)
● No load

On Board Diagnosis Logic BBS00CMB

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
No. 1 or 4 cylin-
ECM detects the No.1 or 4 cylinder fuel
P1276 1 P1276 der fuel injector
injector circuit is short to ground. ● Harness or connectors
circuit low input
(The fuel injector circuit is shorted.)
No. 2 or 3 cylin- Fuel injector
ECM detects the No. 2 or 3 cylinder fuel ●
P1277 1 P1277 der fuel injector
injector circuit is short to ground.
circuit low input

DTC Confirmation Procedure BBS00CMC

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
TESTING CONDITION
Before performing the following procedure, confirm the ambient temperature is more than -20°C (-4°F).
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Start engine and let it idle for at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-351, "Diagnostic Procedure"
.

SEF817Y

EC-347
 DTC P1276, P1277 FUEL INJECTOR
[ZD30DDTi WITH COMMON RAIL]
WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-348
 DTC P1276, P1277 FUEL INJECTOR
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CMD

EC

TEC727M

EC-349
 DTC P1276, P1277 FUEL INJECTOR
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.

0 - 14V
[Engine is running]
● Warm-up condition
● Idle speed
NOTE:
The pulse cycle changes depending on rpm at
101 R Fuel injector No. 3 idle.
MBIB1632E
102 G Fuel injector No. 2
125 BR Fuel injector No. 1
0 - 14V
126 OR Fuel injector No. 4

[Engine is running]
● Warm-up condition
● Engine speed: 2,000 rpm

MBIB1633E

0 - 14V
[Engine is running]
● Warm-up condition
● Idle speed
NOTE:
The pulse cycle changes depending on rpm at
149 G/W Fuel injector No. 2 idle.
151 L Fuel injector No. 4 MBIB1637E

173 B/W Fuel injector No. 3

0 - 14V
174 BR/Y Fuel injector No. 1

[Engine is running]
● Warm-up condition
● Engine speed: 2,000 rpm

MBIB1638E

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-350
 DTC P1276, P1277 FUEL INJECTOR
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure BBS00CME

1. CHECK FUEL INJECTOR OUTPUT SIGNALCIRCUIT FOR SHORT

1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Disconnect fuel injector harness connector (1).
– : Vehicle front
4. Check harness continuity between the following terminals and
ground. Refer to Wiring Diagram.
Terminal
Cylinder
ECM Fuel injector
174 1 No.1 EC
MBIB1607E
149 1 No. 2
173 1 No. 3
151 1 No.4

Continuity should not exist.

OK or NG
OK >> GO TO 2.
NG >> Repair short to ground in harness or connectors.

2. CHECK FUEL INJECTOR

Refer to EC-210, "Component Inspection" .
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.

3. REPLACE FUEL INJECTOR

1. Replace fuel injector of malfunctioning cylinder.
2. Perform Injector Adjustment Value Registration. Refer to EC-34, "Injector Adjustment Value Registration" .

>> INSPECTION END

4. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

EC-351
 DTC P1409 EGR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
DTC P1409 EGR FUNCTION PFP:14710

Description BBS00CML

SYSTEM DESCRIPTION
Sensor Input Signal to ECM ECM Function Actuator
Crankshaft position sensor Engine speed
Engine coolant temperature sensor Engine coolant temperature
Mass air flow sensor Amount of intake air
Accelerator pedal position sensor Accelerator pedal position
Vehicle speed sensor Vehicle speed*
EGR volume control
Ignition switch Start signal EGR volume control
valve
Air conditioner switch Air conditioner operation*
Intake air temperature sensor Intake air temperature
Barometric pressure sensor Barometric pressure
EGR volume control valve control position EGR volume control valve control
sensor position
*: This signal is sent to the ECM through CAN communication line.

This system controls the flow rate of EGR led from exhaust manifold to intake manifold. The opening of the EGR
passage in the EGR volume control valve changes to control the EGR flow rate. A built-in DC motor moves the
valve continuously corresponding to the ECM output signal. The EGR volume control valve control position sen-
sor detects the valve position and sends the voltage signals to the ECM. The ECM judges the current opening
angle of the valve from this signals and the ECM controls the DC motor to make the valve opening angle prop-
erly.
The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is deter-
mined by considering various engine conditions.
The EGR volume control valve remains close under the following conditions.
● Engine stopped
● Engine starting
● Low engine coolant temperature
● Excessively high engine coolant temperature
● High engine speed
● Accelerator pedal fully depressed

MBIB1824E

EC-352
 DTC P1409 EGR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
COMPONENT DESCRIPTION
EGR Volume Control Valve
The EGR volume control valve consists of valve, actuator and posi-
tion sensor, etc. The valve is installed in EGR passage, and operated
by the actuator according to the output signal of the ECM. The actu-
ator used DC motor and it opens or closes the valve to change the
EGR flow rate.
The EGR volume control valve control position sensor consists of a
permanent magnet and Hall IC. It senses the valve shaft movement
and feeds the voltage signals to the ECM.The ECM judges the cur-
rent opening angle of the valve from this signals, and controls the DC
motor to make the valve opening angle in response to driving condi-
tions.
MBIB1780E
EC
On Board Diagnosis Logic BBS00CMM

NOTE:
If DTC P1409 is displayed with DTC P0651 (GST: P0652, P0653), first perform the trouble diagnosis for
DTC P0651 (GST: P0652, P0653). Refer to EC-319, "DTC P0651 SENSOR POWER SUPPLY" .
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
EGR volume
control valve The EGR volume control valve closed posi- ● EGR volume control valve
P1409 1 P1409
does not oper- tion is not in the specified range. ● EGR volume control valve stuck
ate properly

DTC Confirmation Procedure BBS00CMN

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Start engine and warm it up to normal operating temperature
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Turn ignition switch OFF and wait at least 30 seconds.
4. Turn ignition switch ON.
5. If 1st trip DTC is detected, go to EC-354, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-353
 DTC P1409 EGR FUNCTION
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure BBS00CMO

1. CHECK EGR VOLUME CONTROL VALVE VISUALLY

1. Remove the EGR cooler.
2. Check if foreign matter is caught between the EGR volume con-
trol valve (1) and the housing.
– : Vehicle front
OK or NG
OK >> GO TO 2.
NG >> Remove the foreign matter and clean the EGR volume
control valve.

SEC092E

2. REPLACE EGR VOLUME CONTROL VALVE

1. Replace the EGR volume control valve.
2. Perform EC-37, "EGR Volume Control Valve Closed Position Learning Value Clear" .
3. Perform EC-37, "EGR Volume Control Valve Closed Position Learning" .

>> INSPECTION END

EC-354
 DTC P1603 ECM
[ZD30DDTi WITH COMMON RAIL]
DTC P1603 ECM PFP:23710

Description BBS00CMQ

The ECM consists of a microcomputer and connectors for signal input

and output and for power supply. The ECM controls the engine.

MBIB0625E EC
On Board Diagnosis Logic BBS00CMR

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
2 Engine control
P1603 P0603 module ECM ROM is malfunctioning. ● ECM
4 (ROM)

DTC Confirmation Procedure BBS00CMS

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Turn ignition switch OFF and wait at least 30 seconds.
4. Turn ignition switch ON.
5. If 1st trip DTC is detected, go to EC-356, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-355
 DTC P1603 ECM
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure BBS00CMT

1. INSPECTION START
With CONSULT-II
1. Turn ignition switch ON.
2. Select “SELF DIAG RESULTS” mode with CONSULT-II.
3. Touch “ERASE”.
4. Perform EC-355, "DTC Confirmation Procedure" , again.
5. Is 1st trip DTC P1603 displayed again?
With GST
1. Turn ignition switch ON.
2. Select Service $04 with GST.
3. Perform EC-355, "DTC Confirmation Procedure" , again.
4. Is 1st trip DTC P0603 displayed again?
Yes or No
Yes >> GO TO 2.
No >> INSPECTION END

2. REPLACE ECM
1. Replace ECM.
2. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to EL section.
3. Perform Injector Adjustment Value Registration. Refer to EC-34, "Injector Adjustment Value Registration" .
4. Perform EGR Volume Control Valve Closed Position Learning Value Clear. Refer to EC-37, "EGR Volume
Control Valve Closed Position Learning Value Clear" .
5. Perform EGR Volume Control Valve Closed Position Learning. Refer to EC-37, "EGR Volume Control
Valve Closed Position Learning" .
6. Perform Throttle Valve Closed Position Learning Value Clear.
Refer to EC-39, "Throttle Valve Closed Position Learning Value Clear" .
7. Perform Throttle Valve Closed Position Learning.
Refer to EC-39, "Throttle Valve Closed Position Learning" .

>> INSPECTION END

EC-356
 DTC P1625 INJECTOR ADJUSTMENT VALUE
[ZD30DDTi WITH COMMON RAIL]
DTC P1625 INJECTOR ADJUSTMENT VALUE PFP:23710

Description BBS00CMU

Injector adjustment value indicates manufacturing tolerance and the value is printed on the top of fuel injector.
The injector adjustment value which is correctly stored in ECM is needed for precise fuel injection control.
A performance of emission control and a drivability may effect when there is a mismatch between the following
two values.
● The injector adjustment value stored in ECM
● The injector adjustment value of the fuel injector which is installed on the vehicle

EC

MBIB1648E

1. Injector adjustment value

Example: Injector adjustment value = C1TGMA

On Board Diagnosis Logic BBS00CMV

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Injector adjust- ● Injector adjustment value
Injector adjustment value is not stored in
P1625 4 P1625 ment value data (Injector adjustment value has not
ECM.
uninput been written onto ECM memory yet.)

DTC Confirmation Procedure BBS00CMW

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-358, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-357
 DTC P1625 INJECTOR ADJUSTMENT VALUE
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure BBS00CMX

1. PERFORM INJECTOR ADJUSTMENT VALUE REGISTRATION

Perform Injector Adjustment Value Registration. Refer to EC-34, "Injector Adjustment Value Registration" .

>> INSPECTION END

EC-358
 DTC P2100 THROTTLE CONTROL MOTOR
[ZD30DDTi WITH COMMON RAIL]
DTC P2100 THROTTLE CONTROL MOTOR PFP:16119

Component Description BBS002LA

Throttle control motor is operated by ECM and it opens throttle valve.

Throttle valve is fully opened when the engine is running. The valve
is closed only to perform smooth engine stop when the ignition switch
is turned OFF.
Based on the signal from throttle position sensor, ECM judges wheth-
er throttle control actuator (1) operates throttle valve properly or not.
● : Vehicle front

SEC084E EC
CONSULT-II Reference Value in Data Monitor Mode BBS002MJ

Specification data are reference values.

MONITOR ITEM CONDITION SPECIFICATION
● Ignition switch: OFF
ETC OPEN ANGL 0%
● When the engine is stopped

On Board Diagnosis Logic BBS002LB

This self-diagnosis has the one trip detection logic.

The MI will not light up for this self-diagnosis.
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
ECM detects throttle control motor circuit for
Throttle control
1 P2103 electric throttle control actuator is short to
motor circuit high
power.
ECM detects throttle control motor circuit for
Throttle control
2 P2102 electric throttle control actuator is short to ● Harness or connectors
motor circuit low
ground. (Throttle control motor circuit is open
P2100 Throttle control or shorted.)
ECM detects throttle control motor circuit for Electric throttle control actuator
4 P2100 motor circuit ●
electric throttle control actuator is open. (Throttle control motor)
open
Throttle control
motor circuit ECM detects throttle control motor internal
4 P2101
range/perfor- circuit is open or short.
mance

DTC Confirmation Procedure BBS002LC

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.

EC-359
 DTC P2100 THROTTLE CONTROL MOTOR
[ZD30DDTi WITH COMMON RAIL]
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 second.
4. If DTC is detected, go to EC-362, "Diagnostic Procedure" .

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-360
 DTC P2100 THROTTLE CONTROL MOTOR
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS002LD

EC

TEC690M

EC-361
 DTC P2100 THROTTLE CONTROL MOTOR
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TER-
WIRE
MINAL ITEM CONDITION DATA (DC Voltage)
COLOR
NO.
Sensor power supply
109 B (Electric throttle control [Igniton switch ON] Approximately 5V
actuator position sensor)

Sensor ground [Engine is running]

117 R (Electric throttle control ● Warm-up condition Approximately 0V
actuator position sensor) ● Idle speed
[Engine is running]
Sensor ground
131 B ● Warm-up condition Approximately 0V
(Sensor shield circuit)
● Idle speed
Approximately 4.2V
[Ignition switch OFF] ↓
Approximately 0.5V
Electric throttle control actu- ● When the engine is stopped ↓
163 W
ator position sensor Approximately 4.2V
[Ignition switch ON]
Approximately 4.2V
[Engine is running]

Throttle control motor [Ignition switch OFF]

246 W 0V or Battery voltage (11 - 14V)
(DC motor) ● When the engine is stopped

0 - 14V

Throttle control motor [Ignition switch OFF]

253 PU
(DC motor) ● When the engine is stopped

SEC115E

Diagnostic Procedure BBS002LE

1. CHECK GROUND CONNECTIONS

1. Turn ignition switch OFF.
2. Loosen and retighten ground screws. Refer to EC-107, "Ground
Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 2.
NG >> Repair or replace ground connections.
SEC119E

EC-362
 DTC P2100 THROTTLE CONTROL MOTOR
[ZD30DDTi WITH COMMON RAIL]
2. CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT
1. Disconnect electric throttle control actuator (1) harness connec-
tor.
– : Vehicle front
2. Disconnect ECM harness connector.
3. Check harness continuity between the following terminals.
Refer to Wiring Diagram.
Electric throttle control
ECM terminal Continuity
actuator terminal
246 Should not exist
1 SEC084E
253 Should exist EC
246 Should exist
2
253 Should not exist
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.

3. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M271, F33
● Harness for open or short between electric throttle control actuator and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK THROTTLE CONTROL MOTOR

Refer to EC-364, "Component Inspection" .
OK or NG
OK >> GO TO 5.
NG >> GO TO 6.

5. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
OK or NG
OK >> GO TO 6.
NG >> Repair or replace harness or connectors.

EC-363
 DTC P2100 THROTTLE CONTROL MOTOR
[ZD30DDTi WITH COMMON RAIL]
6. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
With CONSULT-II
1. Replace the electric throttle control actuator.
2. Turn ignition switch ON and OFF.
3. Turn ignition switch ON and select “THRTL POSITION” in “AC-
TIVE TEST” mode.
4. Make sure that throttle valve operates correctly.
Without CONSULT-II
1. Replace the electric throttle control actuator.
2. Turn ignition switch ON and OFF.
3. Turn ignition switch ON and OFF, and make sure that throttle
valve operates correctly.

SEC124E
>> INSPECTION END
Component Inspection BBS002LF

THROTTLE CONTROL MOTOR

1. Disconnect electric throttle control actuator harness connector.
2. Check resistance between terminals 1 and 2.
Resistance: Approximately 0.3 - 100 Ω [at 25°C (77°F)]
3. If NG, replace electric throttle control actuator.

SEC074E

EC-364
 DTC P2101 THROTTLE CONTROL MOTOR
[ZD30DDTi WITH COMMON RAIL]
DTC P2101 THROTTLE CONTROL MOTOR PFP:16119

Component Description B99968

Throttle control motor is operated by ECM and it opens throttle valve.

Throttle valve is fully opened when the engine is running. The valve
is closed only to perform smooth engine stop when the ignition switch
is turned OFF.
Based on the signal from throttle position sensor, ECM judges wheth-
er throttle control actuator (1) operates throttle valve properly or not.
● : Vehicle front

SEC084E EC
CONSULT-II Reference Value in Data Monitor Mode B99967

Specification data are reference values.

MONITOR ITEM CONDITION SPECIFICATION
● Ignition switch: OFF
ETC OPEN ANGL 0%
● When the engine is stopped

On Board Diagnosis Logic B99966

This self-diagnosis has the one trip detection logic.

The MI will not light up for this self-diagnosis.
NOTE:
If DTC P2101 is displayed with DTC P2118, first perform the trouble diagnosis for DTC P2118. Refer to
EC-371, "DTC P2118 THROTTLE CONTROL MOTOR" .
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
● Harness or connectors
Throttle control The ECM internal circuit for driving the elec- (Throttle control motor circuit is open
motor circuit tric throttle control valve does not function or shorted.)
P2101 8 P2101
range/perfor- properly due to high temperature or exces- ● Electric throttle control actuator
mance sive current. (Throttle control motor)
● ECM

DTC Confirmation Procedure B99965

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
WITH CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Stop engine and wait at least 30 seconds.
3. Turn ignition switch ON.

EC-365
 DTC P2101 THROTTLE CONTROL MOTOR
[ZD30DDTi WITH COMMON RAIL]
4. Select “DATA MONITOR” mode with CONSULT-II.
5. Restart engine let it idle for 5 seconds.
6. If DTC is detected, go to EC-368, "Diagnostic Procedure" .

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-366
 DTC P2101 THROTTLE CONTROL MOTOR
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram B99964

EC

TEC690M

EC-367
 DTC P2101 THROTTLE CONTROL MOTOR
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TER-
WIRE
MINAL ITEM CONDITION DATA (DC Voltage)
COLOR
NO.
Sensor power supply
109 B (Electric throttle control [Igniton switch ON] Approximately 5V
actuator position sensor)

Sensor ground [Engine is running]

117 R (Electric throttle control ● Warm-up condition Approximately 0V
actuator position sensor) ● Idle speed
[Engine is running]
Sensor groud
131 B ● Warm-up condition Approximately 0V
(Sensor shield circuit)
● Idle speed
Approximately 4.2V
[Ignition switch OFF] ↓
Approximately 0.5V
Electric throttle control actu- ● When the engine is stopped ↓
163 W
ator position sensor Approximately 4.2V
[Ignition switch ON]
Approximately 4.2V
[Engine is running]

Throttle cotnrol motor [Ignition switch OFF]

246 W 0V or Battery voltage (11 - 14V)
(DC motor) ● When the engine is stopped

0 - 14V

Throttle cotnrol motor [Ignition switch OFF]

253 PU
(DC motor) ● When the engine is stopped

SEC115E

Diagnostic Procedure B99963

1. CHECK GROUND CONNECTIONS

1. Turn ignition switch OFF.
2. Loosen and retighten ground screws. Refer to EC-107, "Ground
Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 2.
NG >> Repair or replace ground connections.
SEC119E

EC-368
 DTC P2101 THROTTLE CONTROL MOTOR
[ZD30DDTi WITH COMMON RAIL]
2. CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT
1. Disconnect electric throttle control actuator (1) harness connec-
tor.
– : Vehicle front
2. Disconnect ECM harness connector.
3. Check harness continuity between the following terminals.
Refer to Wiring Diagram.
Electric throttle control
ECM terminal Continuity
actuator terminal
246 Should not exist
1 SEC084E
253 Should exist EC
246 Should exist
2
253 Should not exist
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.

3. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors E271, F33
● Harness for open or short between electric throttle control actuator and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK THROTTLE CONTROL MOTOR

Refer to EC-364, "Component Inspection" .
OK or NG
OK >> GO TO 5.
NG >> GO TO 6.

5. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
OK or NG
OK >> GO TO 6.
NG >> Repair or replace harness or connectors.

EC-369
 DTC P2101 THROTTLE CONTROL MOTOR
[ZD30DDTi WITH COMMON RAIL]
6. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
With CONSULT-II
1. Replace the electric throttle control actuator.
2. Turn ignition switch ON and OFF.
3. Turn ignition switch ON and select “THRTL POSITION” in “AC-
TIVE TEST” mode.
4. Make sure that throttle valve operates correctly.
Without CONSULT-II
1. Replace the electric throttle control actuator.
2. Turn ignition switch ON and OFF.
3. Turn ignition switch ON and OFF, and make sure that throttle
valve operates correctly.

SEC124E
>> INSPECTION END
Component Inspection B99962

THROTTLE CONTROL MOTOR

1. Disconnect electric throttle control actuator harness connector.
2. Check resistance between terminals 1 and 2.
Resistance: Approximately 0.3 - 100 Ω [at 25°C (77°F)]
3. If NG, replace electric throttle control actuator.

SEC074E

EC-370
 DTC P2118 THROTTLE CONTROL MOTOR
[ZD30DDTi WITH COMMON RAIL]
DTC P2118 THROTTLE CONTROL MOTOR PFP:16119

Component Description B99958

Throttle control motor is operated by ECM and it opens throttle valve.

Throttle valve is fully opened when the engine is running. The valve
is closed only to perform smooth engine stop when the ignition switch
is turned OFF.
Based on the signal from throttle position sensor, ECM judges wheth-
er throttle control actuator (1) operates throttle valve properly or not.
● : Vehicle front

SEC084E EC
CONSULT-II Reference Value in Data Monitor Mode B99957

Specification data are reference values.

MONITOR ITEM CONDITION SPECIFICATION
● Ignition switch: OFF
ETC OPEN ANGL 0%
● When the engine is stopped

On Board Diagnosis Logic B99956

This self-diagnosis has the one trip detection logic.

The MI will not light up for this self-diagnosis.
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
● Harness or connectors
(Throttle control motor circuit is
shorted.)
● Electric throttle control valve stuck
Throttle control Excessively high duty voltage signal is sent open or stuck close
P2118 1 P2118
motor to the valve for the specified time.
● Electric throttle control actuator
(Throttle control motor)
● Electric throttle control position sen-
sor

DTC Confirmation Procedure B99955

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
WITH CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Stop engine and wait at least 30 seconds.
3. Turn ignition switch ON.

EC-371
 DTC P2118 THROTTLE CONTROL MOTOR
[ZD30DDTi WITH COMMON RAIL]
4. Select “DATA MONITOR” mode with CONSULT-II.
5. If DTC is detected, go to EC-374, "Diagnostic Procedure" .

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-372
 DTC P2118 THROTTLE CONTROL MOTOR
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram B99954

EC

TEC728M

EC-373
 DTC P2118 THROTTLE CONTROL MOTOR
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TER-
WIRE
MINAL ITEM CONDITION DATA (DC Voltage)
COLOR
NO.
Sensor power supply
109 B (Electric throttle control [Igniton switch ON] Approximately 5V
actuator position sensor)

Sensor ground [Engine is running]

117 R (Electric throttle control ● Warm-up condition Approximately 0V
actuator position sensor) ● Idle speed
[Engine is running]
Sensor ground
131 B ● Warm-up condition Approximately 0V
(Sensor shield circuit)
● Idle speed
Approximately 4.2V
[Ignition switch OFF] ↓
Approximately 0.5V
Electric throttle control actu- ● When the engine is stopped ↓
163 W
ator position sensor Approximately 4.2V
[Ignition switch ON]
Approximately 4.2V
[Engine is running]

Throttle control motor [Ignition switch OFF]

246 W 0V or Battery voltage (11 - 14V)
(DC motor) ● When the engine is stopped

0 - 14V

Throttle control motor [Ignition switch OFF]

253 PU
(DC motor) ● When the engine is stopped

SEC115E

Diagnostic Procedure B99953

1. CHECK GROUND CONNECTIONS

1. Turn ignition switch OFF.
2. Loosen and retighten ground screws. Refer to EC-107, "Ground
Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 2.
NG >> Repair or replace ground connections.
SEC119E

EC-374
 DTC P2118 THROTTLE CONTROL MOTOR
[ZD30DDTi WITH COMMON RAIL]
2. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT
1. Disconnect electric throttle control actuator (1) harness connec-
tor.
– : Vehicle front
2. Turn ignition switch ON.

SEC084E

EC
3. Check voltage between electric throttle control actuator terminal
5 and ground with CONSULT-II or tester.
Voltage: Approximately 5V
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.

PBIB1169E

3. DETECT MALFUNCTIONING PART

Check following.
● Harness connectors E272, F34
● Harness for open and short between electric throttle control actuator and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK THROTTLE POSITION SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between electric throttle control actuator terminal 4 and ECM terminal 117.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 6.
NG >> GO TO 5.

5. DETECT MALFUNCTIONING PART

Check following.
● Harness connectors E272, F34
● Harness for open and short between ECM and electric throttle control actuator

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-375
 DTC P2118 THROTTLE CONTROL MOTOR
[ZD30DDTi WITH COMMON RAIL]
6. CHECK THROTTLE POSITION SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Check harness continuity between electric throttle control actuator terminal 6 and ECM terminal 163.
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 8.
NG >> GO TO 7.

7. DETECTED MALFUNCTIONING PART

Check the following.
● Harness connectors E272, F34
● Harness for open or short between electric throttle control actuator and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT
1. Check harness continuity between the following terminals.
Refer to Wiring Diagram.
Electric throttle control
ECM terminal Continuity
actuator terminal
246 Should not exist
1
253 Should exist
246 Should exist
2
253 Should not exist

2. Also check harness for short to ground and short to power.

OK or NG
OK >> GO TO 10.
NG >> GO TO 9.

9. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors E271, F33
● Harness for open or short between electric throttle control actuator and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

10. CHECK THROTTLE CONTROL MOTOR

Refer to EC-377, "Component Inspection" .
OK or NG
OK >> GO TO 13.
NG >> GO TO 12.

11. CHECK THROTTLE POSITION SENSOR

Refer to EC-377, "Component Inspection" .
OK or NG
OK >> GO TO 11.
NG >> GO TO 12.
EC-376
 DTC P2118 THROTTLE CONTROL MOTOR
[ZD30DDTi WITH COMMON RAIL]
12. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR
With CONSULT-II
1. Replace the electric throttle control actuator.
2. Turn ignition switch ON and OFF.
3. Turn ignition switch ON and select “THRTL POSITION” in “AC-
TIVE TEST” mode.
4. Make sure that throttle valve operates correctly.
Without CONSULT-II
1. Replace the electric throttle control actuator.
2. Turn ignition switch ON and OFF.
3. Turn ignition switch ON and OFF, and make sure that throttle EC
valve operates correctly.

SEC124E
>> INSPECTION END

13. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection B88864

THROTTLE POSITION SENSOR

With CONSULT-II
1. Turn ignition switch OFF.
2. Reconnect harness connectors disconnected.
3. Turn ignition switch ON.
4. Select “THRTL POSITION” in “ACTIVE TEST” mode, and select
“THRTL SEN” as the monitor item with CONSULT-II.
5. Check indication under the following conditions.
Condition [THRTL POSITION (%)] THRTL SEN (V)
0.0 Approximately 4.2V
100.0 Approximately 0.5V
6. If NG, replace electric throttle control actuator.

SEC124E

THROTTLE CONTROL MOTOR

1. Disconnect electric throttle control actuator harness connector.
2. Check resistance between terminals 1 and 2.
Resistance: Approximately 0.3 - 100 Ω [at 25°C (77°F)]
3. If NG, replace electric throttle control actuator.

SEC074E

EC-377
 DTC P2119 ELECTRIC THROTTLE CONTROL ACTUATOR
[ZD30DDTi WITH COMMON RAIL]
DTC P2119 ELECTRIC THROTTLE CONTROL ACTUATOR PFP:16119

Component Description BBS002LH

Electric throttle control actuator (1) consists of throttle control motor

which operates throttle valve, throttle position sensor which detects
the opening angle of throttle valve, etc.
Throttle valve is fully opened when the engine is running. The valve
is closed only to perform smooth engine stop when the ignition switch
is turned OFF.
Based on the signal from throttle position sensor, ECM judges wheth-
er or not throttle control actuator operates properly.
● : Vehicle front

SEC084E

On Board Diagnosis Logic BBS002LI

This self-diagnosis has the one trip detection logic.

The MI will not light up for this self-diagnosis.
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Electric throttle control actuator does not
Throttle control
P2119 1 P2119 function properly due to the return spring ● Electric throttle control actuator
actuator
malfunction.

DTC Confirmation Procedure BBS002LJ

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If DTC is detected, go to EC-379, "Diagnostic Procedure" .

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-378
 DTC P2119 ELECTRIC THROTTLE CONTROL ACTUATOR
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure BBS002LK

1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY

1. Remove the intake air duct.
2. Check if a foreign matter is caught between the throttle valve (1)
and the housing.
– : Vehicle front
– This illustration shows the view with intake air duct removed.
OK or NG
OK >> GO TO 2.
NG >> Remove the foreign matter and clean the electric throttle
control actuator inside.
EC
SEC099E

2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR

With CONSULT-II
1. Replace the electric throttle control actuator.
2. Turn ignition switch ON and OFF.
3. Turn ignition switch ON and select “THRTL POSITION” in “AC-
TIVE TEST” mode.
4. Make sure that throttle valve operates correctly.
Without CONSULT-II
1. Replace the electric throttle control actuator.
2. Turn ignition switch ON and OFF.
3. Turn ignition switch ON and OFF, and make sure that throttle
valve operates correctly.

SEC124E
>> INSPECTION END

EC-379
 DTC P2135 APP SENSOR
[ZD30DDTi WITH COMMON RAIL]
DTC P2135 APP SENSOR PFP:18002

Description BBS00CMY

The accelerator pedal position sensor is installed on the upper end of

the accelerator pedal assembly. The sensors detect the accelerator
pedal position and sends a signal to the ECM. The ECM uses the sig-
nal to determine the amount of fuel to be injected.

PBIB1741E

CONSULT-II Reference Value in Data Monitor Mode BBS00CMZ

Specification data are reference values.

MONITOR ITEM CONDITION SPECIFICATION
Accelerator pedal: Fully released 0.4 - 1.05V
● Ignition switch: ON
ACCEL POS SEN* 3.1 - 4.7V (RHD)
(Engine stopped) Accelerator pedal: Fully depressed
3.3 - 4.7V (LHD)
Accelerator pedal: Fully released 0.4 - 1.05V
● Ignition switch: ON
ACCEL SEN 2* 3.1 - 4.7V (RHD)
(Engine stopped) Accelerator pedal: Fully depressed
3.3 - 4.7V (LHD)
*: This signal is converted by ECM internally. Thus, it differs from ECM terminal voltage.

On Board Diagnosis Logic BBS00CN0

NOTE:
● If DTC P2135 is displayed with DTC P0641 (GST: P0642, P0643), first perform the trouble diagnosis
for DTC P0641 (GST: P0642, P0643). Refer to EC-309, "DTC P0641 SENSOR POWER SUPPLY" .
● If DTC P2135 is displayed with DTC P0697 (GST: P0698, P0699), first perform the trouble diagnosis
for DTC P0697 (GST: P0698, P0699). Refer to EC-336, "DTC P0697 SENSOR POWER SUPPLY" .

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
● Harness or connectors
Accelerator (The APP sensor 1 or 2 circuit is
The correlation between APP sensor 1 sig-
pedal position open or shorted.)
P2135 8 P2135 nal and APP sensor 2 signal is out of the
sensor 1, 2 sig-
normal range. ● Accelerator pedal position sensor
nal correlation
(APP sensor 1 or 2)

EC-380
 DTC P2135 APP SENSOR
[ZD30DDTi WITH COMMON RAIL]
DTC Confirmation Procedure BBS00CN1

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. Depress accelerator pedal slowly spending 5 seconds, and then
release it slowly spending 5 seconds.
5. If 1st trip DTC is detected, go to EC-384, "Diagnostic Procedure"
. EC

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-381
 DTC P2135 APP SENSOR
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CN2

LHD MODELS

TEC678M

EC-382
 DTC P2135 APP SENSOR
[ZD30DDTi WITH COMMON RAIL]
RHD MODELS

EC

TEC679M

EC-383
 DTC P2135 APP SENSOR
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage)
NO.
Sensor power supply
111 G (Accelerator pedal posi- [Ignition switch ON] Approximately 5V
tion sensor 1)

Sensor ground [Engine is running]

115 OR/L (Accelerator pedal posi- ● Warm-up condition Approximately 0V
tion sensor 2) ● Idle speed
[Engine is running]
Sensor ground
131 B ● Warm-up condition Approximately 0V
(Sensors shield circuit)
● Idle speed
Sensor power supply
135 W/L (Accelerator pedal posi- [Ignition switch ON] Approximately 5V
tion sensor 2)

Sensor ground [Engine is running]

140 Y (Accelerator pedal posi- ● Warm-up condition Approximately 0V
tion sensor 1) ● Idle speed
[Ignition switch ON]
● Engine stopped 0.4 - 1.05V
Accelerator pedal position ● Accelerator pedal: Fully released
164 L
sensor 1 [Ignition switch ON]
3.1 - 4.7V (RHD)
● Engine stopped
3.3 - 4.7V (LHD)
● Accelerator pedal: Fully depressed
[Ignition switch ON]
● Engine stopped 0.2 - 0.53V
Accelerator pedal position ● Accelerator pedal: Fully released
189 L/G
sensor 2 [Ignition switch ON]
1.56 - 2.35V (RHD)
● Engine stopped
1.66 - 2.35V (LHD)
● Accelerator pedal: Fully depressed

Diagnostic Procedure BBS00CN3

1. CHECK GROUND CONNECTIONS

1. Turn ignition switch OFF.
2. Loosen and retighten ground screws.
Refer to EC-107, "Ground Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 2.
NG >> Repair or replace ground connections.
SEC119E

EC-384
 DTC P2135 APP SENSOR
[ZD30DDTi WITH COMMON RAIL]
2. CHECK APP SENSOR POWER SUPPLY CIRCUIT
1. Disconnect accelerator pedal position (APP) sensor harness
connector (3).
– Stop lamp switch (1)
– ASCD brake switch (2)
– Accelerator pedal (4)
2. Turn ignition switch ON.

SEC098E

EC
3. Check voltage between APP sensor terminals 2, 3 and ground
with CONSULT-II or tester.
Voltage: Approximately 5V
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.

SEC075E

3. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M51, F6 (RHD models)
● Harness connectors M52, F7 (RHD models)
● Harness for open or short between APP sensor and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK APP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between APP sensor terminal 5 and ECM terminal 140, APP sensor terminal 6
and ECM terminal 115. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 6.
NG >> GO TO 5.

5. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M52, F7 (RHD models)
● Harness for open or short between APP sensor and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-385
 DTC P2135 APP SENSOR
[ZD30DDTi WITH COMMON RAIL]
6. CHECK APP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Check harness continuity between APP sensor terminal 4 and ECM terminal 164, APP sensor terminal 1
and ECM terminal 189. Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 8.
NG >> GO TO 7.

7. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M52, F7 (RHD models)
● Harness for open or short between APP sensor and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK APP SENSOR

Refer to EC-386, "Component Inspection" .
OK or NG
OK >> GO TO 9.
NG >> Replace accelerator pedal assembly.

9. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection BBS00CN4

ACCELERATOR PEDAL POSITION SENSOR

1. Reconnect all harness connectors disconnected.
2. Turn ignition switch ON.
3. Check voltage between ECM terminals 164 (APP sensor 1 sig-
nal), 189 (APP sensor 2 signal) and ground under the following
conditions.
Terminal Accelerator pedal Voltage

164 Fully released 0.4 - 1.05V

(Accelerator pedal position 3.1 - 4.7V (RHD)
sensor 1) Fully depressed
3.3 - 4.7V (LHD)

189 Fully released 0.4 - 1.05V

(Accelerator pedal position 3.1 - 4.7V (RHD)
sensor 2) Fully depressed MBIB1656E
3.3 - 4.7V (LHD)
4. If NG, replace accelerator pedal assembly.

EC-386
 DTC P2146, P2149 FUEL INJECTOR POWER SUPPLY
[ZD30DDTi WITH COMMON RAIL]
DTC P2146, P2149 FUEL INJECTOR POWER SUPPLY PFP:16600

Component Description BBS00CN6

The fuel injector is a small, precise solenoid valve. When the ECM
supplies a ground to the fuel injector circuit, the coil in the fuel injector
is energized. The energized coil pulls the needle valve back and al-
lows fuel to flow through the fuel injector into the cylinder. The amount
of fuel injected depends upon the injection pulse duration. Pulse du-
ration is the length of time the fuel injector remains open. The ECM
controls the injection pulse duration based on engine fuel needs.

PBIB0465E EC
CONSULT-II Reference Value in Data Monitor Mode BBS00CN7

Specification data are reference values.

MONITOR ITEM CONDITION SPECIFICATION
● Engine: After warming up Idle 5 - 10 mg/st
● Air conditioner switch: OFF
TRG INJ QTY
● Shift lever: Neutral (M/T), P or N (A/T) 2,000 rpm 5 - 10 mg/st
● No load

On Board Diagnosis Logic BBS00CN8

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
No.1 and 4 cylin-
der fuel injector
ECM detects the No.1 or 4 cylinder fuel
1 P2146 power supply cir-
injector power supply circuit is shorted.
cuit high or low
P2146 input
Fuel injector
ECM detects the fuel injector power supply
8 P0200 power supply cir- ● Harness or connectors
circuit is open or shorted.
cuit open/shorted (The fuel injector circuit is open or
No. 2 and 3 cyl- shorted.)
inder fuel injector ● Fuel injector
ECM detects the No.2 or 3 cylinder fuel
1 P2149 power supply cir-
injector power supply circuit is shorted.
cuit high or low
P2149 input
Fuel injector
ECM detects the fuel injector power supply
8 P0200 power supply cir-
circuit is open or shorted.
cuit open/shorted

EC-387
 DTC P2146, P2149 FUEL INJECTOR POWER SUPPLY
[ZD30DDTi WITH COMMON RAIL]
DTC Confirmation Procedure BBS00CN9

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
TESTING CONDITION
Before performing the following procedure, confirm the ambient temperature is more than -20°C (-4°F).
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Start engine and let it idle for at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-391, "Diagnostic Procedure"
.

SEF817Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-388
 DTC P2146, P2149 FUEL INJECTOR POWER SUPPLY
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CNA

EC

TEC680M

EC-389
 DTC P2146, P2149 FUEL INJECTOR POWER SUPPLY
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
Pulse signal is measured by CONSULT-II.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.

0 - 14V
[Engine is running]
● Warm-up condition
● Idle speed
NOTE:
The pulse cycle changes depending on rpm at
101 R Fuel injector No. 3 idle.
MBIB1632E
102 G Fuel injector No. 2
125 BR Fuel injector No. 1
0 - 14V
126 OR Fuel injector No. 4

[Engine is running]
● Warm-up condition
● Engine speed: 2,000 rpm

MBIB1633E

0 - 14V
[Engine is running]
● Warm-up condition
● Idle speed
NOTE:
The pulse cycle changes depending on rpm at
149 G/W Fuel injector No. 2 idle.
151 L Fuel injector No. 4 MBIB1637E

173 B/W Fuel injector No. 3

0 - 14V
174 BR/Y Fuel injector No. 1

[Engine is running]
● Warm-up condition
● Engine speed: 2,000 rpm

MBIB1638E

: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)

EC-390
 DTC P2146, P2149 FUEL INJECTOR POWER SUPPLY
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure BBS00CNB

1. CHECK FUEL INJECTOR POWER SUPPLY CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Disconnect fuel injector (1) harness connector.
– : Vehicle front
4. Check harness continuity between the following terminals corre-
sponding to the malfunctioning cylinder.
Refer to Wiring Diagram.
Terminal
Cylinder
ECM Fuel injector EC
125 2 No.1
102 2 No.2 MBIB1607E

101 2 No.3
126 2 No.4

Continuity should exist.

5. Also check harness for short to ground.
OK or NG
OK >> GO TO 2.
NG >> Repair open circuit or short to ground in harness or connectors.

2. CHECK FUEL INJECTOR

Refer to EC-210, "Component Inspection" .
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.

3. REPLACE FUEL INJECTOR

1. Replace fuel injector of malfunctioning cylinder.
2. Perform Injector Adjustment Value Registration. Refer to EC-34, "Injector Adjustment Value Registration" .

>> INSPECTION END

4. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

EC-391
 DTC P2226 BARO SENSOR
[ZD30DDTi WITH COMMON RAIL]
DTC P2226 BARO SENSOR PFP:22693

Description BBS00CNC

The barometric pressure sensor is built into ECM. The sensor detects
ambient barometric pressure and sends the voltage signal to the mi-
crocomputer.

MBIB0625E

On Board Diagnosis Logic BBS00CND

DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Barometric pres- An excessively high voltage from the baro-
1 P2229 sure sensor cir- metric pressure sensor (built-into ECM) is
cuit high input sent to ECM.
P2226 ● ECM
Barometric pres- An excessively low voltage from the baro-
2 P2228 sure sensor cir- metric pressure sensor (built-into ECM) is
cuit low input sent to ECM.

DTC Confirmation Procedure BBS00CNE

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 30 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-393, "Diagnostic Procedure"
.

SEF058Y

WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC-392
 DTC P2226 BARO SENSOR
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure BBS00CNF

1. INSPECTION START
With CONSULT-II
1. Turn ignition switch ON.
2. Select “SELF DIAG RESULTS” mode with CONSULT-II.
3. Touch “ERASE”.
4. Perform EC-392, "DTC Confirmation Procedure" , again.
5. Is 1st trip DTC P2226 displayed again?
With GST
1. Turn ignition switch ON.
2. Select Service $04 with GST. EC
3. Perform EC-392, "DTC Confirmation Procedure" , again.
4. Is 1st trip DTC P2228 or P2229 displayed again?
Yes or No
Yes >> GO TO 2.
No >> INSPECTION END

2. REPLACE ECM
1. Replace ECM.
2. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to EL section.
3. Perform Fuel Pump Learning Valve Clearing. Refer to EC-34, "Injector Adjustment Value Registration" .
4. Perform EGR Volume Control Valve Closed Position Learning Value Clear. Refer to EC-37, "EGR Volume
Control Valve Closed Position Learning Value Clear" .
5. Perform EGR Volume Control Valve Closed Position Learning. Refer to EC-37, "EGR Volume Control
Valve Closed Position Learning" .
6. Perform Throttle Valve Closed Position Learning Value Clear.
Refer to EC-39, "Throttle Valve Closed Position Learning Value Clear" .
7. Perform Throttle Valve Closed Position Learning.
Refer to EC-39, "Throttle Valve Closed Position Learning" .

>> INSPECTION END

EC-393
 DTC P2620 TP SENSOR
[ZD30DDTi WITH COMMON RAIL]
DTC P2620 TP SENSOR PFP:16119

Description BBS002LR

Electric throttle control actuator consists of the following two compo-

nents, throttle control motor with gear which operates throttle valve,
throttle position sensor which detects throttle position sensor.
Throttle valve is fully opened when the engine is running. The valve
is closed only to perform smooth engine stop when the ignition switch
is turned OFF.
Throttle position sensor detects the opening angle of throttle valve
and converts the angle into a voltage signal. Based on the signal,
ECM judges whether throttle control actuator operates throttle valve
properly or not.
PBIB3184E

CONSULT-II Reference Value in Data Monitor Mode BBS002MK

Specification data are reference values.

MONITOR ITEM CONDITION SPECIFICATION
Approximately 4.2V
● Ignition switch: OFF ↓
THRTL SEN Approximately 0.5V
● When the engine is stopped ↓
Approximately 4.2V

On Board Diagnosis Logic BBS002LS

NOTE:
If DTC P2620 is display with DTC P0697 (GST: P0698, P0699), first perform the trouble diagnosis for DTC
P0697 (GST: P0698, P0699). Refer to EC-336, "DTC P0697 SENSOR POWER SUPPLY" .
DTC No.
CONSULT-II Trouble diagno-
DTC detecting condition Possible cause
GST sis name
ID
FLAG
Throttle position ● Harness or connector
An excessively high voltage from the sensor
1 P2622 sensor circuit (Throttle position sensor circuit is
is sent to ECM.
P2620 high open or shorted.)
Throttle position An excessively low voltage from the sensor ● Electric throttle control actuator
2 P2621 (Throttle position sensor)
sensor circuit low is sent to ECM.

DTC Confirmation Procedure BBS002LT

NOTE:
If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at
least 10 seconds before conducting the next test.
WITH CONSULT-II
1. Turn ignition switch ON.
2. Select “DATA MONITOR” mode with CONSULT-II.
3. Wait at least 5 seconds.
4. If 1st trip DTC is detected, go to EC-397, "Diagnostic Procedure"
.

SEF817Y

EC-394
 DTC P2620 TP SENSOR
[ZD30DDTi WITH COMMON RAIL]
WITH GST
Follow the procedure “WITH CONSULT-II” above.

EC

EC-395
 DTC P2620 TP SENSOR
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS002LU

TEC689M

EC-396
 DTC P2620 TP SENSOR
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.
Sensor power supply
109 B (Electric throttle control [Igniton switch ON] Approximately 5V
actuator position sensor)

Sensor ground [Engine is running]

117 R (Electric throttle control ● Warm-up condition Approximately 0V
actuator position sensor) ● Idle speed
EC
[Engine is running]
Sensor ground
131 B ● Warm-up condition Approximately 0V
(Sensor shield circuit)
● Idle speed
Approximately 4.2V
[Ignition switch OFF] ↓
Approximately 0.5V
Electric throttle control ● When the engine is stopped ↓
163 W
actuator position sensor Approximately 4.2V
[Ignition switch ON]
Approximately 4.2V
[Engine is running]

Throttle control motor [Ignition switch OFF]

246 W 0V or Battery voltage (11 - 14V)
(DC motor) ● When the engine is stopped

0 - 14V

Throttle control motor [Ignition switch OFF]

253 PU
(DC motor) ● When the engine is stopped

SEC115E

Diagnostic Procedure BBS002LV

1. CHECK GROUND CONNECTIONS

1. Turn ignition switch OFF.
2. Loosen and retighten ground screws. Refer to EC-107, "Ground
Inspection" .
– Body ground (1)
– ECM (2)
– Accelerator pedal (3)
OK or NG
OK >> GO TO 2.
NG >> Repair or replace ground connections.
SEC119E

EC-397
 DTC P2620 TP SENSOR
[ZD30DDTi WITH COMMON RAIL]
2. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT
1. Disconnect electric throttle control actuator (1) harness connec-
tor.
– : Vehicle front
2. Turn ignition switch ON.

SEC084E

3. Check voltage between electric throttle control actuator terminal

5 and ground with CONSULT-II or tester.
Voltage: Approximately 5V
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.

PBIB1169E

3. DETECTED MALFUNCTIONING PART

Check the following.
● Harness connectors E272, F34
● Harness for open or short between electric throttle control actuator and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

4. CHECK THROTTLE POSITION SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between electric throttle control actuator terminal 4 and ECM terminal 117.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 6.
NG >> GO TO 5.

5. DETECTED MALFUNCTIONING PART

Check the following.
● Harness connectors E272, F34
● Harness for open or short between electric throttle control actuator and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-398
 DTC P2620 TP SENSOR
[ZD30DDTi WITH COMMON RAIL]
6. CHECK THROTTLE POSITION SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Check harness continuity between electric throttle control actuator terminal 6 and ECM terminal 163.
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 8.
NG >> GO TO 7.

7. DETECTED MALFUNCTIONING PART

Check the following. EC
● Harness connectors E272, F34
● Harness for open or short between electric throttle control actuator and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

8. CHECK THROTTLE POSITION SENSOR

Refer to EC-399, "Component Inspection" .
OK or NG
OK >> GO TO 10.
NG >> GO TO 9.

9. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR

With CONSULT-II
1. Replace the electric throttle control actuator.
2. Turn ignition switch ON and OFF.
3. Turn ignition switch ON and select “THRTL POSITION” in “AC-
TIVE TEST” mode.
4. Make sure that throttle valve operates correctly.
Without CONSULT-II
1. Replace the electric throttle control actuator.
2. Turn ignition switch ON and OFF.
3. Turn ignition switch ON and OFF, and make sure that throttle
valve operates correctly.

SEC124E
>> INSPECTION END

10. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection BBS002LW

THROTTLE POSITION SENSOR

With CONSULT-II
1. Turn ignition switch OFF.
2. Reconnect harness connectors disconnected.
3. Turn ignition switch ON.

EC-399
 DTC P2620 TP SENSOR
[ZD30DDTi WITH COMMON RAIL]
4. Select “THRTL POSITION” in “ACTIVE TEST” mode, and select
“THRTL SEN” as the monitor item with CONSULT-II.
5. Check indication under the following conditions.
Condition [THRTL POSITION (%)] THRTL SEN (V)
0.0 Approximately 4.2V
100.0 Approximately 0.5V
6. If NG, replace electric throttle control actuator.

SEC124E

EC-400
 ASCD INDICATOR
[ZD30DDTi WITH COMMON RAIL]
ASCD INDICATOR PFP:24814

Component Description BBS0026G

ASCD indicator lamp illuminates to indicate ASCD operation status. The Lamp has two indicators, CRUISE and
SET, and is integrated in combination meter.
CRUISE indicator illuminates when MAIN switch on ASCD steering switch is turned ON to indicated that ASCD
system is ready for operation.
SET indicator illuminates when the following conditions are met.
● CRUISE indicator is illuminated.
● SET/COAST switch on ASCD steering switch is turned ON while vehicle speed is within the range of ASCD
setting.
SET indicator remains lit during ASCD control.
Refer to EC-404, "AUTOMATIC SPEED CONTROL DEVICE (ASCD)" for the ASCD function.
EC

EC-401
 ASCD INDICATOR
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS0026H

TEC685M

EC-402
 ASCD INDICATOR
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure BBS0026J

1. CHECK OVERALL FUNCTION

Check ASCD indicator under the following conditions.
ASCD INDICATOR CONDITION SPECIFICATION
● MAIN switch: Pressed at the
CRUISE LAMP ● Ignition switch: ON ON → OFF
1st time → at the 2nd time
● MAIN switch: ON ● ASCD: Operating ON
● When vehicle speed is
between 48 km/h (30 MPH)
SET LAMP and 130km/h (81 MPH) (For
● ASCD: Not operating OFF
Australia models), 150 km/h
(93 MPH) (Except for Austra-
lia models) EC

OK or NG
OK >> INSPECTION END
NG >> GO TO 2.

2. CHECK DTC
Check that DTC U1000 is not displayed.
OK or NG
OK >> Perform trouble diagnoses for DTC U1000. Refer to EC-108, "DTC U1000, U1001 CAN COMMU-
NICATION LINE" .
NG >> GO TO 3.

3. CHECK COMBINATION METER OPERATION

Does combination meter operate normally?
Yes or No
Yes >> GO TO 4.
No >> Check combination meter circuit. Refer to EL section.

4. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

EC-403
 AUTOMATIC SPEED CONTROL DEVICE (ASCD)
[ZD30DDTi WITH COMMON RAIL]
AUTOMATIC SPEED CONTROL DEVICE (ASCD) PFP:18930

System Description BBS0026E

INPUT/OUTPUT SIGNAL CHART

Sensor Input signal to ECM ECM function Actuator
ASCD brake switch Brake pedal operation
Stop lamp switch Brake pedal operation
ASCD vehicle speed control Fuel injector and Fuel pump
ASCD steering switch ASCD steering switch operation
Combination meter Vehicle speed*
*: This signal is sent to the ECM through CAN communication line.

BASIC ASCD SYSTEM

Refer to Owner's Manual for ASCD operating instructions.
Automatic Speed Control Device (ASCD) allows a driver to keep vehicle at predetermined constant speed with-
out depressing accelerator pedal. Driver can set vehicle speed in advance between approximately 40 km/h (25
MPH) and 130 km/h (81 MPH) (For Australia models), 150 km/h (93 MPH) (Except for Australia models).
ECM controls fuel injection value to regulate engine speed.
Operation status of ASCD is indicated by CRUISE indicator and SET indicator in combination meter. If any mal-
function occurs in ASCD system, it automatically deactivates control.
SET OPERATION
Press ASCD MAIN switch. (The CRUISE indicator in combination meter illuminates.)
When vehicle speed reaches a desired speed between approximately 48 km/h (30 MPH) and 130 km/h (81
MPH) (For Australia models), 150 km/h (93 MPH) (Except for Australia models), press SET switch. (Then SET
indicator in combination meter illuminates.)
ACCELERATE OPERATION
If the RESUME/ACCELERATE switch is depressed during cruise control driving, increase the vehicle speed
until the switch is released or vehicle speed reaches maximum speed controlled by the system.
And then ASCD will keep the new set speed.
CANCEL OPERATION
When any of following conditions exist, cruise operation will be canceled.
● CANCEL switch is depressed
● More than 2 switches at ASCD steering switch are depressed at the same time (Set speed will be cleared.).
● Brake pedal is depressed
● Vehicle speed increased to 13 km/h higher than the set speed
● Vehicle speed decreased to 13 km/h lower than the set speed
● ESP system is operated
When the ECM detects any of the following conditions, the ECM will cancel the cruise operation and inform the
driver by blinking indicator lamp.
● Malfunction for some self-diagnoses regarding ASCD control: SET lamp will blink quickly.
If MAIN switch is turned to OFF during ASCD is activated, all of ASCD operations will be canceled and vehicle
speed memory will be erased.
COAST OPERATION
When the SET/COAST switch is depressed during cruise control driving, decrease vehicle set speed until the
switch is released. And then ASCD will keep the new set speed.
RESUME OPERATION
When the RESUME/ACCELERATE switch is depressed after cancel operation other than depressing MAIN
switch is performed, vehicle speed will return to last set speed. To resume vehicle set speed, vehicle condition
must meet following conditions.
● Brake pedal is released
● Vehicle speed is greater than 48 km/h (30 MPH) and less than 130 km/h (81 MPH) (For Australia models),
150 km/h (93 MPH) (Except for Australia models).

EC-404
 AUTOMATIC SPEED CONTROL DEVICE (ASCD)
[ZD30DDTi WITH COMMON RAIL]
Component Description BBS0026F

ASCD STEERING SWITCH

Refer to EC-290 .
ASCD BRAKE SWITCH
Refer to EC-275 and EC-406 .
STOP LAMP SWITCH
Refer to EC-275 and EC-406 .
ASCD INDICATOR
Refer to EC-401 .

EC

EC-405
 ASCD BRAKE SWITCH
[ZD30DDTi WITH COMMON RAIL]
ASCD BRAKE SWITCH PFP:25320

Component Description B99948

When the brake pedal is depressed, ASCD brake switch (2) and stop
lamp switch (1) are turned ON. ECM detects the state of the brake
pedal by this input of two kinds (ON/OFF signal).
Refer to EC-404, "AUTOMATIC SPEED CONTROL DEVICE
(ASCD)" for the ASCD function.
● Accelerator pedal position sensor (3)
● Accelerator pedal (4)

SEC098E

CONSULT-II Reference Value in Data Monitor Mode B99947

Specification data are reference values.

MONITOR ITEM CONDITION SPECIFICATION
Brake pedal: Fully released OFF
BRAKE SW
● Ignition switch: ON Brake pedal: Slightly
(Stop lamp switch) ON
depressed
● Brake pedal: Fully released OFF
BRAKE SW2
● Ignition switch: ON ● Brake pedal: Slightly
(ASCD brake switch) ON
depressed

EC-406
 ASCD BRAKE SWITCH
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram B99946

EC

TEC696M

EC-407
 ASCD BRAKE SWITCH
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TER-
WIRE
MINAL ITEM CONDITION DATA (DC Voltage)
COLOR
NO.
[Igniton switch ON] BATTERY VOLTAGE
● Brake pedal: Fully released (11 - 14V)
208 R ASCD brake switch
[Igniton switch ON]
Approximately 0V
● Brake pedal: Slightly depressed
[Ignition switch OFF]
Approximately 0V
● Brake pedal: Fully released
221 G/Y Stop lamp switch
[Ignition switch OFF] BATTERY VOLTAGE
● Brake pedal: Slightly depressed (11 - 14V)

Diagnostic Procedure B99945

1. CHECK OVERALL FUNCTION-I

With CONSULT-II
1. Turn ignition switch ON.
2. Select “BRAKE SW” in “DATA MONITOR” mode with CON-
SULT-II.
3. Check “BRAKE SW” indication under the following conditions.
CONDITION INDICATION
Brake pedal: Fully released OFF
Brake pedal: Slightly depressed ON

PBIB0472E

Without CONSULT-II
Check voltage between ECM terminal 221 and ground under the fol-
lowing conditions.
Condition Voltage
Brake pedal: Fully released Approximately 0V
Brake pedal: Slightly depressed battery voltage
OK or NG
OK >> GO TO 2.
NG >> GO TO 3.
SEC070E

EC-408
 ASCD BRAKE SWITCH
[ZD30DDTi WITH COMMON RAIL]
2. CHECK OVERALL FUNCTION-II
With CONSULT-II
Check “BRAKE SW2” indication in “DATA MONITOR” mode.
CONDITION INDICATION
Brake pedal: Fully released OFF
Brake pedal: Slightly depressed ON

EC
SEC013D

Without CONSULT-II
1. Turn ignition switch ON.
2. Check voltage between ECM terminal 101 and ground under the
following conditions.
Condition Voltage
Brake pedal: Fully released Battery voltage
Brake pedal: Slightly depressed Approximately 0V

PBIB1677E

OK or NG
OK >> INSPECTION END
NG >> GO TO 8.

EC-409
 ASCD BRAKE SWITCH
[ZD30DDTi WITH COMMON RAIL]
3. CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT
1. Turn ignition switch OFF.
2. Disconnect stop lamp switch (2) harness connector.
– ASCD brake switch (1)
– Accelerator pedal position sensor (3)
– Accelerator pedal (4)

SEC098E

3. Check voltage between stop lamp switch terminal 1 and ground

with CONSULT -II or tester.
Voltage: Battery voltage
OK or NG
OK >> GO TO 5.
NG >> GO TO 4.

PBIB0117E

4. DETECT MALFUNCTIONING PART

Check the following.
● Fuse block (J/B) connector M3
● 10A fuse
● Harness for open or short between stop lamp switch and battery

>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK STOP LAMP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminal 221 and stop lamp switch terminal 2.
Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 7.
NG >> GO TO 6.

6. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M52, F7
● Harness for open or short between stop lamp switch and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-410
 ASCD BRAKE SWITCH
[ZD30DDTi WITH COMMON RAIL]
7. CHECK STOP LAMP SWITCH
Refer to EC-283, "Component Inspection"
OK or NG
OK >> GO TO 12.
NG >> Replace stop lamp switch.

8. CHECK ASCD BRAKE SWITCH POWER SUPPLY CIRCUIT

1. Turn ignition switch OFF.
2. Disconnect ASCD brake switch (2) harness connector.
– Stop lamp switch (1)
– Accelerator pedal position sensor (3) EC
– Accelerator pedal (4)
3. Turn ignition switch ON.

SEC098E

4. Check voltage between ASCD brake switch terminal 1 and

ground with CONSULT-II or tester.
Voltage: Approximately 5V
OK or NG
OK >> GO TO 10.
NG >> GO TO 9.

PBIB0799E

9. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors F7, M52
● Harness for open or short between ASCD brake switch and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

10. CHECK ASCD BRAKE SWITCH GROUND CIRCUIT OPEN AND SHORT
1. Check harness continuity between ASCD brake switch terminal 208 and ground.
Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to power.
OK or NG
OK >> GO TO 11.
NG >> Repair open circuit or short to power in harness or connectors.

EC-411
 ASCD BRAKE SWITCH
[ZD30DDTi WITH COMMON RAIL]
11. CHECK ASCD BRAKE SWITCH
Refer to EC-283, "Component Inspection"
OK or NG
OK >> GO TO 12.
NG >> Replace ASCD brake switch.

12. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

EC-412
 ASCD BRAKE SWITCH
[ZD30DDTi WITH COMMON RAIL]
Component Inspection B99944

ASCD BRAKE SWITCH

1. Turn ignition switch OFF.
2. Disconnect ASCD brake switch harness connector.
3. Check continuity between ASCD brake switch terminals 1 and 2
under the following conditions.
Condition Continuity
Brake pedal: Fully released Should exist
Brake pedal: Slightly depressed Should not exist

If NG, adjust ASCD brake switch installation, refer to BR section,

and perform step 3 again.
EC
SEC024D

STOP LAMP SWITCH

1. Turn ignition switch OFF.
2. Disconnect stop lamp switch harness connector.
3. Check continuity between stop lamp switch terminals 1 and 2 un-
der the following conditions.
Condition Continuity
Brake pedal: Fully released Should not exist
Brake pedal: Slightly depressed Should exist

If NG, adjust stop lamp switch installation, refer to BR section,

and perform step 3 again.

PBIB0118E

EC-413
 HEAT UP SWITCH
[ZD30DDTi WITH COMMON RAIL]
HEAT UP SWITCH PFP:25230

Component Description B99938

The heat up switch (1) is located on the lower side of the instrument
panel. This switch is used to speed up the heater's operation when
the engine is cold.
When the ECM received the heat up switch ON signal, the ECM in-
creases the engine idle speed to 1,100 to 1,200 rpm to warm up en-
gine quickly.
This system works when all conditions listed below are met.
Heat up switch ON
Engine coolant temperature Below 105°C (221°F)
P or N (A/T) SEC101E
Shift lever
Neutral (M/T)
Accelerator pedal Fully released

CONSULT-II Reference Value in Data Monitor Mode B99937

Specification data are reference values.

MONITOR ITEM CONDITION SPECIFICATION
Heat up switch: ON ON
WARM UP SW ● Ignition switch: ON
Heat up switch: OFF OFF

ECM Terminals And Reference Value B99936

Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may damage the
ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.
[Ignition switch ON]
0V
● Heat up switch is OFF.
194 BR/W Heat up switch
[Ignition switch ON] BATTERY VOLTAGE
● Heat up switch is ON. (11 - 14V)

EC-414
 HEAT UP SWITCH
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram B99935

EC

TEC691M

EC-415
 HEAT UP SWITCH
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure B99934

1. INSPECTION START
Do you have CONSULT-II?
Yes or No
Yes >> GO TO 2.
No >> GO TO 3.

2. CHECK OVERALL FUNCTION

With CONSULT-II
1. Turn ignition switch ON.
2. Check “WARM UP SW” in “DATA MONITOR” mode with CONSULT-II under the following conditions.

SEF302Z

OK or NG
OK >> INSPECTION END
NG >> GO TO 4.

3. CHECK OVERALL FUNCTION

Without CONSULT-II
1. Turn ignition switch ON.
2. Check voltage between ECM terminal 194 and ground under the following conditions.

SEC076E

OK or NG
OK >> INSPECTION END
NG >> GO TO 4.

EC-416
 HEAT UP SWITCH
[ZD30DDTi WITH COMMON RAIL]
4. CHECK HEAT UP SWITCH POWER SUPPLY CIRCUIT
1. Turn heat up switch OFF.
2. Turn ignition switch OFF.
3. Disconnect heat up switch harness connector.
4. Turn ignition switch ON.
5. Check voltage between heat up switch terminal 1 and ground with CONSULT-II or tester.

EC

SEC125E

OK or NG
OK >> GO TO 6.
NG >> GO TO 5.

5. DETECT MALFUNCTIONING PART

Check the following.
● Fuse block (J/B) connector M3
● 10A fuse
● Harness for open or short between heat up switch and fuse

>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK HEAT UP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN OR SHORT

1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminal 194 and heat up switch terminal 3. Refer to Wiring Dia-
gram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 8.
NG >> GO TO 7.

7. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M51, F6
● Harness for open or short between heat up switch and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-417
 HEAT UP SWITCH
[ZD30DDTi WITH COMMON RAIL]
8. CHECK HEAT UP SWITCH
Check continuity between heat up switch terminals 1 and 3 under the following conditions.

SEC126E

OK or NG
OK >> GO TO 9.
NG >> Replace heat up switch.

9. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

EC-418
 GLOW CONTROL SYSTEM
[ZD30DDTi WITH COMMON RAIL]
GLOW CONTROL SYSTEM PFP:25230

Description BBS00CNJ

SYSTEM DESCRIPTION
Sensor Input Signal to ECM ECM Function Actuator
Crankshaft position sensor Engine speed Glow lamp*
Glow control Glow relay
Engine coolant temperature sensor Engine coolant temperature Glow plugs
*: The output signal is sent from the ECM through CAN communication line.

EC

MBIB1820E

● Ignition switch ON
After ignition switch has turned to ON, the glow relay turns ON for a certain period of time in relation to
engine coolant temperature, allowing current to flow through glow plug.
● Cranking
The glow relay turns ON, allowing current to flow through glow plug.
● Starting
After engine has started, current continues to flow through glow plug (after-glow mode) for a certain period
in relation to engine coolant temperature.
The glow indicator lamp turns ON for a certain period of time in relation to engine coolant temperature at the
time glow relay is turned ON.
COMPONENT DESCRIPTION
Glow Plug
The glow plug is provided with a metallic heating element to obtain a
high-temperature resistance. It glows in response to a signal sent
from the ECM, allowing current to flow through the glow plug via the
glow relay.

MBIB1819E

EC-419
 GLOW CONTROL SYSTEM
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CNK

TEC681M

EC-420
GLOW CONTROL SYSTEM
[ZD30DDTi WITH COMMON RAIL]

EC

TEC682M

EC-421
 GLOW CONTROL SYSTEM
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure BBS00CNL

1. INSPECTION START
Check fuel level, fuel supplying system, starter motor, etc.
OK or NG
OK >> GO TO 2.
NG >> Correct.

2. CHECK INSTALLATION
Check that glow plug nut and all glow plug connecting plate nuts are
installed properly.
● Connecting plate (1)
OK or NG
OK >> GO TO 3.
NG >> Install properly.

MBIB1618E

3. CHECK GLOW INDICATOR LAMP OPERATION

1. Turn ignition switch ON.
2. Make sure that glow indicator lamp is turned ON for after turning ignition switch ON, and then glow indicator
lamp turned OFF.

OK or NG
OK >> GO TO 4.
NG >> GO TO 5.

EC-422
 GLOW CONTROL SYSTEM
[ZD30DDTi WITH COMMON RAIL]
4. CHECK GLOW CONTROL SYSTEM OVERALL FUNCTION
With CONSULT-II
1. Select “COOLAN TEMP/S” in “DATA MONITOR” mode with
CONSULT-II.
2. Confirm that “COOLAN TEMP/S” indicates approximately 25°C
(77°F). If NG, cool down engine.
3. Turn ignition switch OFF.
4. Set voltmeter probe between glow plug and engine body.
5. Turn ignition switch ON.

SEF013Y
EC

6. Check the voltage between glow plug and engine body under the
following conditions.
Conditions Voltage
For few seconds after turning ignition switch ON Battery voltage
More than few seconds after turning ignition
Approx. 0V
switch ON

MBIB1619E

Without CONSULT-II
1. Set the tester probe between ECM terminal 185 (engine coolant
temperature sensor signal) and ground.
2. Confirm that the voltage indicates approximately 3.62V. If NG,
cool down engine.
3. Turn ignition switch OFF.
4. Set voltmeter probe between glow plug and engine body.
5. Turn ignition switch ON.

MBIB1696E

6. Check the voltage between glow plug and engine body under the
following conditions.
Conditions Voltage
For few seconds after turning ignition switch ON Battery voltage
More than few seconds after turning ignition
Approx. 0V
switch ON

MBIB1619E

OK or NG
OK >> INSPECTION END
NG >> GO TO 7.

EC-423
 GLOW CONTROL SYSTEM
[ZD30DDTi WITH COMMON RAIL]
5. CHECK DTC
Check that DTC U1000 or U1001 is not displayed.
Yes or No
Yes >> Perform trouble diagnoses for DTC U1000 or U1001, refer to EC-108, "DTC U1000, U1001 CAN
COMMUNICATION LINE" .
No >> GO TO 6.

6. CHECK COMBINATON METER OPERATION

Does combination meter operate normally?
Yes or No
Yes >> GO TO 15.
No >> Check combination meter circuit. Refer to EL section.

7. CHECK GLOW RELAY POWER SUPPLY CIRCUIT

1. Turn ignition switch OFF.
2. Disconnect glow relay (1).
3. Turn ignition switch ON.

SEC093E

4. Check voltage between glow relay terminals 1, 3 and ground with

CONSULT-II or tester.
Voltage: Battery voltage
OK or NG
OK >> GO TO 9.
NG >> GO TO 8.

MBIB1697E

8. DETECT MALFUNCTIONING PART

Check the following.
● 100A fusible link
● Harness connectors E127, M21
● Harness connectors M50, F5
● Harness for open or short between glow relay and battery
● Harness for open or short between glow relay and ECM
● Harness for open or short between glow relay and ECM relay

>> Repair harness or connectors.

EC-424
 GLOW CONTROL SYSTEM
[ZD30DDTi WITH COMMON RAIL]
9. CHECK GLOW RELAY OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminal 254 and glow relay terminal 2.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 11.
NG >> GO TO 10.
EC
10. DETECT MALFUNCTIONING PART
Check the following.
● Harness connectors E127, M21
● Harness connectors M51, F6
● Harness for open and short between glow relay and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

11. CHECK HARNESS CONTINUITY BETWEEN GLOW RELAY AND GLOW PLUG FOR OPEN AND
SHORT
1. Disconnect glow plug harness connector.
2. Check harness continuity between glow relay terminal 5 and glow plug harness connector.
Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 13.
NG >> GO TO 12.

12. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors E67, E223
● Harness for open or short between glow relay and glow plug harness connector

>> Repair open circuit or short to ground or short to power in harness or connectors.

13. CHECK GLOW RELAY

Refer to EC-426, "Component Inspection" .
OK or NG
OK >> GO TO 14.
NG >> Replace glow relay.

14. CHECK GLOW PLUG

Refer to EC-426, "Component Inspection" .
OK or NG
OK >> GO TO 15.
NG >> Replace glow plug.

EC-425
 GLOW CONTROL SYSTEM
[ZD30DDTi WITH COMMON RAIL]
15. CHECK INTERMITTENT INCIDENT
Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection BBS00CNM

GLOW RELAY
Check continuity between glow relay terminals (3) and (5) under the
following conditions.
Conditions Continuity
12V direct current supply between ter-
Yes
minals (1) and (2)
No current supply No
Operation takes less than 1 second.

PBIB0428E

GLOW PLUG
1. Remove glow plug connecting plate.
2. Check glow plug resistance.
Resistance: Approximately 0.8 Ω [at 25°C (77°F)]
NOTE:
● Do not bump glow plug heating element. If it is bumped,
replace glow plug with a new one.
● If glow plug is dropped from a height of 10 cm (3.94 in) or
higher, replace with a new one.
● If glow plug installation hole is contaminated with carbon,
remove it with a reamer or suitable tool.
● Hand-tighten glow plug by turning it two or three times, MBIB1620E

then tighten using a tool to specified torque.

: 20.1 N-m (2.1 kg-m, 15 ft-lb)

EC-426
 CLUTCH SWITCH
[ZD30DDTi WITH COMMON RAIL]
CLUTCH SWITCH PFP:25230

Wiring Diagram BBS00CNV

EC

TEC731M

EC-427
 CLUTCH SWITCH
[ZD30DDTi WITH COMMON RAIL]

Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.
[Ignition switch ON]
Approximately 0V
● Clutch pedal: Fully released
207 BR Clutch switch
[Ignition switch ON] BATTERY VOLTAGE
● Clutch pedal: Slightly depressed (11 - 14V)

Diagnostic Procedure BBS00CNW

1. CHECK OVERALL FUNCTION-I

With CONSULT-II
1. Turn ignition switch ON.
2. Select “CLUTCH SW” in “DATA MONITOR” mode with CONSULT-II.
3. Check “CLUTCH SW” indication under the following conditions.
CONDITION INDICATION
Clutch pedal: Slightly depressed ON
Clutch pedal: Fully released OFF

SEC077E

Without CONSULT-II
1. Turn ignition switch ON.
2. Check voltage between ECM terminal 207 and ground under the
following conditions.
CONDITION VOLTAGE
Clutch pedal: Slightly depressed Battery voltage (11 - 14V)
Clutch pedal: Fully released Approximately 0V

OK or NG
OK >> INSPECTION END
NG >> GO TO 2.
SEC078E

EC-428
 CLUTCH SWITCH
[ZD30DDTi WITH COMMON RAIL]
2. CHECK CLUTCH SWITCH GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition OFF.
2. Disconnect clutch switch (1) harness connector.
– Clutch pedal (2)
3. Check harness continuity between clutch switch terminal 2 and
ground.
Continuity should exist.
OK or NG
OK >> GO TO 3.
NG >> Repair open circuit or short to power in harness or con-
nectors. EC
SEC118E

3. CHECK STOP LAMP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminal 207 and clutch switch terminal 1.
Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 5.
NG >> GO TO 4.

4. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M52, F7
● Harness for open or short between clutch switch and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

5. CHECK CLUTCH SWITCH

Refer to EC-430, "Component Inspection" .
OK or NG
OK >> GO TO 6.
NG >> Replace clutch switch.

6. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

EC-429
 CLUTCH SWITCH
[ZD30DDTi WITH COMMON RAIL]
Component Inspection BBS00CNX

CLUTCH SWITCH
1. Turn ignition switch OFF.
2. Disconnect clutch switch harness connector.
3. Check continuity between clutch switch terminals 1 and 2 under
the following conditions.
Condition Continuity
Clutch pedal: Fully released Should not exist
Clutch pedal: Slightly depressed Should exist

If NG, adjust clutch switch installation, refer to CL section, and

perform step 3 again.

SEC024D

EC-430
 PNP SWITCH
[ZD30DDTi WITH COMMON RAIL]
PNP SWITCH PFP:32006

Description BBS00CNY

When the gear position is in Neutral (M/T), P or N (A/T), park/neutral position is ON. ECM detects the position
because the continuity of the line (the ON signal) exists.
CONSULT-II Reference Value in Data Monitor Mode BBS00CNZ

Specification data are reference values.

MONITOR ITEM CONDITION SPECIFICATION
Shift lever: Neutral (M/T), P or N (A/T) ON
P/N POSI SW ● Ignition switch: ON
Shift lever: Except above OFF

EC

EC-431
 PNP SWITCH
[ZD30DDTi WITH COMMON RAIL]
Wiring Diagram BBS00CO0

TEC684M

EC-432
 PNP SWITCH
[ZD30DDTi WITH COMMON RAIL]
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
WIRE DATA
NAL ITEM CONDITION
COLOR (DC Voltage and Pulse Signal)
NO.
[Ignition switch ON]
Approximately 0V
● Shift lever: Neutral (M/T), P or N (A/T)
209 P/B Park/Neutral position switch
[Ignition switch ON] BATTERY VOLTAGE
● Shift lever: Except above (11 - 14V)

Diagnostic Procedure BBS00CO1

EC
1. CHECK OVERALL FUNCTION
With CONSULT-II
1. Turn ignition switch ON.
2. Select “P/N POSI SW” in “DATA MONITOR” mode with CON-
SULT-II.
3. Check “P/N POSI SW” signal under the following conditions.
Shift lever position P/N POSI SW
Neutral (M/T), P or N (A/T) ON
Except above OFF

SEF212Y

Without CONSULT-II
1. Turn ignition switch ON.
2. Check voltage between ECM terminal 209 and ground under the
following conditions.
Shift lever position Voltage
Neutral (M/T), P or N (A/T) Approximately 0V
Except above Battery voltage

OK or NG
OK >> INSPECTION END
NG >> GO TO 2.
MBIB1665E

2. CHECK PNP SWITCH GROUND CIRCUIT FOR OPEN AND SHORT

1. Turn ignition switch OFF.
2. Disconnect park/neutral position (PNP) switch harness connector.
3. Check harness continuity between PNP switch terminal 2 and ground.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to power.
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.

EC-433
 PNP SWITCH
[ZD30DDTi WITH COMMON RAIL]
3. DETECT MALFUNCTIONING PART
Check the following.
● Harness connectors E202, M69
● Harness for open or short between PNP switch and ground

>> Repair open circuit or short to power in harness or connectors.

4. CHECK PNP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminal 209 and PNP switch terminal 1.
Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 6.
NG >> GO TO 5.

5. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M52, F7
● Harness connectors M21, E127
● Harness connectors E70, E201
● Harness for open or short between PNP switch and ECM

>> Repair open circuit or short to ground or short to power in harness or connectors.

6. CHECK PARK/NEUTRAL POSITION SWITCH

Refer to EC-434, "Component Inspection" .
OK or NG
OK >> GO TO 7.
NG >> Replace park/neutral position switch.

7. CHECK INTERMITTENT INCIDENT

Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

Component Inspection BBS00DGQ

PARK/NEUTRAL POSITION (PNP) SWITCH

1. Turn ignition switch OFF.
2. Disconnect PNP switch harness connector.

EC-434
 PNP SWITCH
[ZD30DDTi WITH COMMON RAIL]
3. Check continuity between PNP switch terminals 1 and 2 under
the following conditions.
CONDITION CONTINUITY
Shift lever: Neutral position (M/T), P or
Should exist
N (A/T)
Shift lever: Except above Should not exist

4. If NG, replace PNP switch.

MBIB1741E

EC

EC-435
 START SIGNAL
[ZD30DDTi WITH COMMON RAIL]
START SIGNAL PFP:48750

Wiring Diagram BBS00CO2

TEC686M

EC-436
 START SIGNAL
[ZD30DDTi WITH COMMON RAIL]
Diagnostic Procedure BBS00CO3

1. CHECK START SIGNAL OVERALL FUNCTION

With CONSULT-II
1. Turn ignition switch ON.
2. Check “START SIGNAL” in “DATA MONITOR” mode with CON-
SULT-II under the following conditions.
Condition START SIGNAL
Ignition switch ON OFF
Ignition switch START ON

EC

PBIB0433E

Without CONSULT-II
Check voltage between ECM terminal 192 and ground under the fol-
lowing conditions.
Condition Voltage
Ignition switch ON Approximately 0V
Ignition switch START Battery voltage
OK or NG
OK >> INSPECTION END
NG >> GO TO 2.
MBIB1666E

2. CHECK START SIGNAL INPUT SIGNAL CIRCUIT

1. Turn ignition switch OFF.
2. Disconnect ECM harness connector and ignition switch harness connector.
3. Check harness continuity between ECM terminal 192 and ignition switch terminal 6.
Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 4.
NG >> GO TO 3.

3. DETECT MALFUNCTIONING PART

Check the following.
● Harness connectors M52, F7
● 7.5A fuse
● Fuse block (J/B) connector M3, E112
● Harness for open or short between ECM and ignition switch

>> Repair open circuit or short to ground or short to power in harness or connectors.

EC-437
 START SIGNAL
[ZD30DDTi WITH COMMON RAIL]
4. CHECK INTERMITTENT INCIDENT
Refer to EC-100, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .

>> INSPECTION END

EC-438
 MI & DATA LINK CONNECTORS
[ZD30DDTi WITH COMMON RAIL]
MI & DATA LINK CONNECTORS PFP:24814

Wiring Diagram BBS00CO5

EC

TEC687M

EC-439
MI & DATA LINK CONNECTORS
[ZD30DDTi WITH COMMON RAIL]

TEC688M

EC-440
 SERVICE DATA AND SPECIFICATIONS (SDS)
[ZD30DDTi WITH COMMON RAIL]
SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00100

General Specifications BBS00CO6

M/T No load* (in Neutral position)

Target Idle speed 750±25 rpm
A/T No load* (in P or N position)
M/T In Neutral position
Air conditioner: ON 750±25 rpm
A/T In P or N position
M/T No load* (in Neutral position)
Maximum engine speed 4,300±100 rpm
A/T No load* (in P or N position)
*: Under the following conditions:
● Heat up switch: OFF
● Air conditioner switch: OFF EC
● Electric load: OFF (Lights, heater fan & rear window defogger)
● Steering wheel: Kept in straight-ahead position

Mass Air Flow Sensor BBS00CO7

Supply voltage Battery voltage (11 - 14V)

Ignition switch ON (Engine stopped.) 0.3 - 1.0V
Idle (Engine is warmed up to normal operating temperature.) 1.6 - 2.3V *
*: Engine is warmed up to normal operating temperature and running under no load.

Intake Air Temperature Sensor BBS00CO8

Temperature °C (°F) Resistance kΩ

25 (77) 1.800 - 2.200
80 (176) 0.283 - 0.359

Engine Coolant Temperature Sensor BBS00CO9

Temperature °C (°F) Resistance kΩ

20 (68) 2.1 - 2.9
50 (122) 0.68 - 1.00
90 (194) 0.236 - 0.260

Fuel Rail Pressure Sensor BBS00COA

Supply voltage Approximately 5V

Idle (Engine is warmed up to normal operating temperature.) 1.0 - 1.6V
2,000 rpm (Engine is warmed up to normal operating tempera-
2.0 - 2.7V
ture.)

Fuel Injector BBS00COB

Resistance [at 20 - 70°C (68 - 158°F)] 0.2 - 0.3Ω

Glow Plug BBS00COC

Resistance [at 25°C (77°F)] Approximately 0.8Ω

EGR Volume Control Valve Motor BBS00COD

Resistance [at 25°C (77°F)] 0.3 - 100Ω

Crankshaft Position Sensor BBS00COE

Resistance [at 25°C (77°F)] 500 - 600Ω

EC-441
 SERVICE DATA AND SPECIFICATIONS (SDS)
[ZD30DDTi WITH COMMON RAIL]
Camshaft Position Sensor BBS00COF

Refer to EC-229, "Component Inspection" .

Fuel Pump BBS00COG

Resistance [at 20 - 40°C (68 - 104°F)] 2.6 - 3.5Ω

Throttle Control Motor BBS003ZC

Resistance [at 25°C (77°F)] Approximately 0.3 - 100Ω

EC-442