Page 435 of 1033

Component Description
The charge air pressure sensor detects pressure in the exit side
of the charge air cooler. The sensor output voltage to the ECM
increases as pressure increases. The charge air pressure sen-
sor is not used to control the engine system under normal con-
ditions.
ECM Terminals and Reference Value
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.
TER-
MINAL
NO.WIRE
COLORITEM CONDITION DATA (DC Voltage)
46 LCharge air pressure sen-
sorEngine is running.
Warm-up condition
Idle speedApproximately 2.0V
On Board Diagnosis Logic
Malfunction is detected when ... Check Items (Possible Cause)
+An excessively high or low voltage from the sensor is sent to
ECM.+Harness or connectors
(The sensor circuit is open or shorted.)
+Charge air pressure sensor
SEF340VA
SEF627RA
DTC 0905 TURBO PRESSUREZD30DDTi
EC-1202
Page 438 of 1033

Diagnostic Procedure
1 CHECK CHARGE AIR PRESSURE SENSOR POWER SUPPLY CIRCUIT
1. Stop engine.
2. Disconnect charge air pressure sensor harness connector.
SEF283Z
3. Turn ignition switch ªONº.
4. Check voltage between charge air pressure sensor terminal 1 and ground with CONSULT-II or tester.
SEF306Z
OK or NG
OKcGO TO 2.
NGcRepair harness or connectors.
2 CHECK CHARGE AIR PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch ªOFFº.
2. Check harness continuity between charge air pressure sensor terminal 3 and engine ground. Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OKcGO TO 4.
NGcGO TO 3.
3 DETECT MALFUNCTIONING PART
Check the following.
+Harness connectors F6, M51 (A/T models)
+Harness connectors M88, E106 (A/T models)
+Harness for open or short between ECM and charge air pressure sensor
+Harness for open or short between TCM (Transmission control module) and charge air pressure sensor
cRepair open circuit or short to ground or short to power in harness or connectors.
DTC 0905 TURBO PRESSUREZD30DDTi
EC-1205
Page 439 of 1033

4 CHECK CHARGE AIR PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminal 46 and charge air pressure sensor terminal 2. Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OKcGO TO 5.
NGcRepair open circuit or short to ground or short to power in harness or connectors.
5 CHECK CHARGE AIR PRESSURE SENSOR
1. Remove charge air pressure sensor with its harness connector connected.
2. Turn ignition switch ªONº.
3. Use pump to apply pressure to charge air pressure sensor as shown in the figure.
CAUTION:
+Always calibrate the pressure pump gauge when using it.
+Inspection should be done at room temperature [10 - 30ÉC (50 - 86ÉF)].
4. Check the output voltage between charge air pressure sensor terminal 2 and engine ground.
SEF449Z
OK or NG
OKcGO TO 6.
NGcReplace charge air pressure sensor.
6 CHECK INTERMITTENT INCIDENT
Refer to ªTROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENTº, EC-1076.
cINSPECTION END
DTC 0905 TURBO PRESSUREZD30DDTi
Diagnostic Procedure (Cont'd)
EC-1206
Page 440 of 1033

Description
SYSTEM DESCRIPTION
Sensor Input Signal to ECM ECM Function Actuator
Electronic controlled fuel injection pump Fuel injection signal
EGR volume control EGR volume control valve Crankshaft position sensor (TDC) Engine speed
Vehicle speed sensor Vehicle speed
Engine coolant temperature sensor Engine coolant temperature
Ignition switch Start signal
Throttle position sensor Throttle position
Battery Battery voltage
Mass air flow sensor Amount of intake air
Air conditioner switch Air conditioner operation
Electrical load Electrical load signal
PNP switch Park/Neutral position signal
This system controls flow rate of EGR led from exhaust manifold
to intake manifold. The opening of the EGR by-pass passage in
the EGR volume control valve changes to control the flow rate.
A built-in step motor moves the valve in steps corresponding to
the ECM output pulses. The opening of the valve varies for opti-
mum engine control. The optimum value stored in the ECM is
determined by considering various engine conditions.
The EGR volume control valve remains close under the follow-
ing conditions.
+Engine stopped
+Engine starting
+Low engine coolant temperature
+Excessively high engine coolant temperature
+High engine speed
+Wide open throttle
+Low battery voltage
SEF908Y
DTC 1003 EGR VOLUME CONT/VZD30DDTi
EC-1207
Page 448 of 1033

Description
SYSTEM DESCRIPTION
The ECM and the electronic control fuel injection pump control
unit (abbreviated as the injection pump control unit) perform the
real time communication (signal exchange).
The ECM transmits the signals of the target fuel injection
amount, target fuel injection timing, and engine speed, etc., and
receives the signals of the pump speed and fuel temperature,
etc. from the injection pump control unit.
By those signals, the injection pump controls the optimum fuel
injection amount and injection timing of the spill valve and tim-
ing control valve.
Injection pump control unit has an on board diagnostic system,
which detects malfunctions related to sensors or actuators built-
into electronic control fuel injection pump. These malfunction
information are transferred through the line (circuit) from injection
pump control unit to ECM.
FUEL INJECTION AMOUNT CONTROL
In accordance with the target fuel injection amount signal from
the ECM, the injection amount is controlled by controlling the spill
valve in the injection pump and by changing the needle opening
time.
FUEL INJECTION TIMING CONTROL
Based on the target fuel injection timing signal from the ECM, the
injection timing is controlled in accordance with the timer spring
by performing the duty control of the timing control valve in the
injection pump and by adjusting the pressure of the timer piston
high pressure chamber.
FUEL TEMPERATURE SENSOR
The sensor detects the fuel temperature in the injection pump
and calibrates the injection amount change by the fuel tempera-
ture.
CAM RING POSITION SENSOR
The sensor detects the passing of the protrusion on the sensor
wheel in the injection pump by the semiconductor magnetic
resistance element sensor. The cam ring position sensor syn-
chronizes with the cam ring, and detects the actual advance
amount. The injection pump control unit measures the injection
pump revolution by the signal of the cam ring position sensor.
SEF437Y
DTC 1004 FUEL CUT SYSTEM1ZD30DDTi
EC-1215
Page 454 of 1033

Description
SYSTEM DESCRIPTION
Sensor Input Signal to ECMECM
FunctionActuator
Crankshaft position
sensor (TDC)Engine speed
Glow
controlGlow lamp,
Glow relay
¯
Glow plugs Engine coolant tem-
perature sensorEngine coolant tem-
perature
When engine coolant temperature is more than approximately
75ÉC (167ÉF), the glow relay turns off, inactivating the quick-glow
control until coolant temperature drops below approximately
55ÉC (131ÉF).
When coolant temperature is lower than approximately 75ÉC
(167ÉF):
+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.
When engine speed exceeds approximately 4,800 rpm, cur-
rent flow through glow plug is interrupted.
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 ceramic 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.
+This engine uses two types of glow plugs.
Type A has a blue or yellow paint mark.
Type B has no paint mark.
The location of the paint mark is shown in the figure.
WARNING:
Do not use two types of glow plugs at the same time.
SEF376Y
SEF280Z
GLOW CONTROL SYSTEMZD30DDTi
EC-1221
Page 479 of 1033

Description
SYSTEM DESCRIPTION
Sensor Input Signal to ECMECM
FunctionActuator
Ignition switch Start signal
Swirl
control
valve
controlSwirl control valve control solenoid valve
¯Vacuum signal
Swirl control valve actuator
¯Swirl control valve Crankshaft position sensor (TDC) Engine speed
PNP switch Park/Neutral position signal
Engine coolant temperature sensor Engine coolant temperature
This system has a swirl control valve in 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 vaporization 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's shut/open con-
dition. This solenoid valve is operated by the ECM.
PNP switch Engine speedEngine cool-
ant tempera-
tureSwirl control
valve control
solenoid valveSwirl control
valve
OFFLess than
1,250 rpmLess than
50ÉC (122ÉF)OFF Open
More than
50ÉC (122ÉF)ON Closed
More than
1,250 rpmLess than
50ÉC (122ÉF)OFF Open
More than
50ÉC (122ÉF)OFF Open
ON Ð Ð OFF Open
SEF452Z
SWIRL CONTROL VALVE CONTROL
SOLENOID VALVEZD30DDTi
EC-1246
Page 510 of 1033
General Specifications
Unit: rpm
EngineZD30DDTi
Idle speed750 25
Maximum engine speed4,300
Injection Pump Numbers
Engine Part number Pump assembly number
ZD30DDTi 16700 VG100 109342-4023
Injection Nozzle
Unit: kPa (bar, kg/cm2, psi)
Initial injection pressureUsed 19,026 (190.3, 194, 2,759)
New 19,516 - 20,497 (195.2 - 205.0, 199 - 209, 2,830 - 2,972)
Limit 16,182 (161.8, 165, 2,346)
Engine Coolant Temperature Sensor
Temperature ÉC (ÉF) Resistance kW
20 (68) 2.1 - 2.9
50 (122) 0.68 - 1.00
90 (194) 0.236 - 0.260
Crankshaft Position Sensor (TDC)
Resistance [at 20ÉC (68ÉF)]W1,287 - 1,573
Glow Plug
Resistance [at 20ÉC (68ÉF)]WApproximately 0.5
Accelerator Position Sensor
Throttle valve conditions Resistance between terminals 2 and 3 kW[at 25ÉC (77ÉF)]
Completely closedApproximately 0.5
Partially open0.5-4
Completely openApproximately 4
EGR Volume Control Valve
Resistance [at 25ÉC (77ÉF)]W13-17
SERVICE DATA AND SPECIFICATIONS (SDS)ZD30DDTi
EC-1277