Page 627 of 1839
DIESEL FUEL <4D5-stepIII>-Troubleshooting13E-17
Code No. 25 Timer piston position sensor systemProbable cause
Range of Check
DIgnition switch: OK
DNot during the engine cranking
Set Conditions
DThe sensor output voltage for 1 second is 4.9 V* or more
or
DThe sensor output voltage for 1 second is 0.25 V* or lessDTimer piston position sensor inoperative
DTimer piston position sensor open circuit, short
circuit, or connector contact inoperative
DEngine-ECU inoperative
NOTE:
*: This voltage is derived from the input pulse signal converted in the engine-ECU and cannot be measured.
Replace injection pump assembly (timer
piston fully closed/opened position
inoperative, etc.)
NG
NG
OK
OK
NG
Check the following connector:D-113NG
Repair
OK
Repair
NGTimer piston position sensor check
(Refer to P.13E-62.)
NG
NG OK
NG
Check the trouble symptoms.
Replace injection pump assembly.
Check the following connector:B-39
OK
Replace the engine-ECU.NGMUT-IIData list
19 Injection timing (command value)
(Refer to P.13E-41.)
OK
Check the trouble symptoms.
Check the trouble symptoms.
Check the harness between the
engine-ECU and the timer piston sensor
connector.
MUT-IIData list
18 Actual injection timing (Refer to
P.13E-41.)Replace the engine-ECU.
www.WorkshopManuals.co.uk
Purchased from www.WorkshopManuals.co.uk
Page 628 of 1839
DIESEL FUEL <4D5-stepIII>-Troubleshooting13E-18
Code No. 26 Control sleeve position sensor systemProbable cause
Range of Check
DIgnition switch: ON
Set Conditions
DThe sensor output voltage for 0.3 second is 4.5 V* or more
or
DThe sensor output voltage for 0.3 second is 0.25 V* or lessDControl sleeve position sensor inoperative
DControl sleeve position sensor open circuit, short
circuit, or connector contact inoperative
DEngine-ECU inoperative
NOTE:
*: This voltage is derived from the input pulse signal converted in the engine-ECU and cannot be measured.
OK
NG
Check the following connector:D-113NG
Repair
OK
Repair
NGControl sleeve position sensor check (Refer
to P.13E-62.)
NG
NG OK
NG
Check the trouble symptoms.
Replace injection pump assembly.
Check the following connector:B-38
OK
Replace the engine-ECU.NGMUT-IIData list
17 Control sleeve position sensor (target
value) (Refer to P.13E-41.)
OK
Check the trouble symptoms.
Replace injection pump assembly.
Check the trouble symptoms.
NG
NG
Check the harness between the
engine-ECU and the injection pump
assembly connector.
MUT-IIData list
23 Control sleeve position sensor (actual
value) (Refer to P.13E-41.)Replace the engine-ECU. OK
www.WorkshopManuals.co.uk
Purchased from www.WorkshopManuals.co.uk
Page 629 of 1839
DIESEL FUEL <4D5-stepIII>-Troubleshooting13E-19
Code No. 27 Accelerator pedal position sensor (sub)
systemProbable cause
Range of Check
DIgnition switch: ON, accelerator pedal position sensor (main) operative, except
for during engine cranking
Set Conditions
DAccelerator pedal position sensor output voltage for 1 second
Sub side: 0.2 V or higher, lower than 2.5 V
Main side: 4.5 V or higher
or
Sub or main: Lower than 0.2 V
Range of Check
DIgnition switch: ON, except for during engine cranking
Set Conditions
DThe difference in the output sensor voltage between the main and the sub
sensor is 1 V or higher, or the idle switch ON, and sensor main output
voltage is 1.875 V or higher.DAccelerator pedal position sensor inoperative
DAccelerator pedal position sensor open circuit,
short circuit, or connector contact inoperative
DEngine-ECU inoperative
OK
Measure at D-135 accelerator pedal position
sensor connector
DDisconnect the connector and measure at
the harness side.
DVoltage between 8 and the earth
(Ignition switch: ON)
OK:4.5 - 5.5 V
DContinuity between 7 and the earth
OK:ContinuityNGNG
Repair
OK
OKRepair
NGAccelerator pedal position sensor check
(Refer to P.13E-57.)
NG
Replace the engine-ECU.OKNG
OK
Replace
NG
Check the trouble symptoms.
NG
RepairCheck the following connector:D-135
Check the harness between the
engine-ECU and the accelerator pedal
position sensor connector.
Check the trouble symptoms.
Replace the engine-ECU.
Check the following connector:
D-112
www.WorkshopManuals.co.uk
Purchased from www.WorkshopManuals.co.uk
Page 630 of 1839
DIESEL FUEL <4D5-stepIII>-Troubleshooting13E-20
Code No. 41 Throttle solenoid valve systemProbable cause
Range of Check
DIgnition switch: OFF
DBarometric pressure is 95.4 kPa or over (equivalent to an altitude of 500 m).
Set Conditions
DBoost pressure sensor output does not change.DThrottle solenoid valve inoperative
DThrottle solenoid valve open circuit, short circuit, or
connector contact inoperative
DEngine-ECU inoperative
DMalfunction of throttle actuator
Check and repair the harness between the
engine-ECU and the solenoid valve
connector.
NG
OK
Check the trouble symptoms.
OK
Check and repair the harness between the
control relay and the solenoid valve
connector. NG
OKMeasure at B-62 throttle solenoid valve
connector
DDisconnect the connector and measure at
the harness side.
DVoltage between 2 and the earth
(Ignition switch: ON)
OK:System voltage
OK
Replace
Throttle actuator check
(Refer to P.13E-63.)NG
OK
Throttle solenoid valve check
(Refer to P.13E-62.)
Replace the engine-ECU. OK
RepairCheck the following connector:D-110
Check the trouble symptoms.NGReplace NG
Check the following connector:
B-62NG
RepairNGMeasure at D-110 engine-ECU connector
DDisconnect the connector and measure at
the harness side.
DVoltage between 14 and the earth
(Ignition switch: ON)
OK:System voltage
NG
www.WorkshopManuals.co.uk
Purchased from www.WorkshopManuals.co.uk
Page 631 of 1839
DIESEL FUEL <4D5-stepIII>-Troubleshooting13E-21
Code No. 43 Timing control valve systemProbable cause
Range of Check
DEngine coolant temperature 80_C or higher and the engine running
Set Conditions
DTarget value minus actual value is 0.64 V or more for 5 secondsDTiming control valve inoperative
DTiming control valve open circuit, short circuit, or
connector contact inoperative
DEngine-ECU inoperative
DBlockage in fuel system
OK
OK
Check and repair the harness between the
control relay and the injection pump
assembly connector.
Timing control valve check
(Refer to P.13E-61.)
Replace the engine-ECU. OK
RepairCheck the following connector:D-110
Check the trouble symptoms.NG NG NG
Check the following connector:B-38NG
Repair
OK
Check the trouble symptoms.
NG
NGMeasure at D-110 engine-ECU connector.
DDisconnect the connector and measure at
the harness side.
DVoltage between 3 and the earth
(Ignition switch: ON)
OK:11 V or higherOK
Measure at B-38 injection pump assembly
connector.
DDisconnect the connector and measure at
the harness side.
DVoltage between 5 and the earth
(Ignition switch: ON)
OK:System voltage
Replace injection pump assembly.
Check and repair the harness between the
engine-ECU and the injection pump
assembly connector.
Fuel system blockage check
DFuel filter blocked
DFuel hose blocked or bent
DFuel tank filter blockedOK
Replace NG
NG
www.WorkshopManuals.co.uk
Purchased from www.WorkshopManuals.co.uk
Page 632 of 1839
DIESEL FUEL <4D5-stepIII>-Troubleshooting13E-22
Code No. 46 Injection volume adjusting ROM systemProbable cause
Range of Check
DIgnition switch: ON
Set Conditions
DWhen communication failsDInjection volume adjusting ROM inoperative
DEngine-ECU inoperative
Repair
OK
Replace the engine-ECU. OK
RepairCheck the following connector:B-37
Check the trouble symptoms.NG NG
Check the following connector:D-112
NG
Repair OK
Check the trouble symptoms.
NG
Measure at B-37 injection volume adjusting
ROM connector.
DDisconnect the connector and measure at
the harness side.
DVoltage between 3 and the earth
(Ignition switch: ON)
OK:4.5 - 5.5 V
DContinuity between 4 and the earth
OK:Continuity
Check the harness between the
engine-ECU and the injection volume
adjusting ROM connector.
OK
Replace the engine-ECU.NG
NG
RepairCheck the harness between the
engine-ECU and the injection volume
adjusting ROM connector.
OK
Check the trouble symptoms.
NG
Replace injection pump assembly.
www.WorkshopManuals.co.uk
Purchased from www.WorkshopManuals.co.uk
Page 633 of 1839
DIESEL FUEL <4D5-stepIII>-Troubleshooting13E-23
Code No. 48 GE actuator (in the middle of control sleeve
position sensor inoperative) systemProbable cause
Range of Check
DIgnition switch: ON
Set Conditions
DTarget value minus actual value is 1 V or more for 1 secondDControl sleeve position sensor inoperative
DGE actuator inoperative
DControl sleeve position sensor open circuit, short
circuit, or connector contact inoperative
DEngine-ECU inoperative
OK
OK
Check and repair the harness between the
control relay and the injection pump
assembly connector.
GE actuator check (Refer to P.13E-61.)
Replace the engine-ECU. OK
RepairCheck the following connector:D-110
Check the trouble symptoms.NGNG NG
Check the following connector:B-38NG
Repair
OK
Check the trouble symptoms.
NG
NGMeasure at D-110 engine-ECU connector
DDisconnect the connector and measure at
the harness side.
DVoltage between 1 and the earth
(Ignition switch: ON)
OK:9 V or higherOK
Measure at B-38 injection pump assembly
connector.
DDisconnect the connector and measure at
the harness side.
DVoltage between 6 and the earth
(Ignition switch: ON)
OK:System voltage
Replace injection pump assembly.
Check and repair the harness between the
control relay and the injection pump
assembly connector.
NG
www.WorkshopManuals.co.uk
Purchased from www.WorkshopManuals.co.uk
Page 634 of 1839
DIESEL FUEL <4D5-stepIII>-Troubleshooting13E-24
Code No. 49 Over boostProbable cause
Range of Check
DIgnition switch: ON
Set Conditions
DBoost pressure is higher than the barometric pressure + 133 kPaDMalfunction of the variable geometry actuator
DMalfunction of variable geometry solenoid valve
DVariable geometry solenoid valve open circuit, short
circuit, or connector contact inoperative
DEngine-ECU inoperative
OKOK
Check and repair the harness between the
control relay and the solenoid valve
connector.
Replace the engine-ECU.OK
ReplaceVariable geometry solenoid valve check
(Refer to GROUP 15 - On-vehicle Service.)
Check the trouble symptoms.NG
NG
Check the following connector:B-61NG
Repair
OK
Check the trouble symptoms.
NG
NGMeasure at D-110 engine-ECU connector
DDisconnect the connector and measure at
the harness side.
DVoltage between 17 and earth
(Ignition switch: ON)
OK:System voltageOK
Measure at B-61 variable geometry solenoid
valve connector
DDisconnect the connector and measure at
the harness side.
DVoltage between 2 and earth
(Ignition switch: ON)
OK:System voltage
Check and repair the harness between the
engine-ECU and the solenoid valve
connector.
ReplaceVariable geometry actuator check (Refer to
GROUP 15 - On-vehicle Service.)NG
OK
Repair
Check the following connector:D-110NG
NG
Replace the turbocharger assembly. YESConnect a boost gauge to the boost
pressure sensor hose. When the vehicle is
driven at 1st gear with full throttle, does
boost pressure exceed 133 kPa
momentarily?
NO
www.WorkshopManuals.co.uk
Purchased from www.WorkshopManuals.co.uk