Page 534 of 1306

CONSULT-II Reference Value in Data Monitor
Mode
Remarks: Specification data are reference values.
MONITOR ITEM CONDITION SPECIFICATION
FUEL TEMP SEN+Engine: After warming up More than 40ÉC (104ÉF)
SPILL/V+Engine: After warm-
ing upIdle Approx. 13ÉCA
INJ TIMG C/V+Engine: After warming up,
idle the engine.Approx. 50 - 70%
DECELER F/CUT+Engine: After warm-
ing upIdle OFF
BARO SEN+Ignition switch: ONAltitude
Approx.0m(0ft): Approx. 100.62 kPa (1.0062 bar, 1.026 kg/cm
2, 14.59
psi)
Approx. 1,000 m (3,281 ft): Approx. 88.95 kPa (0.8895 bar, 0.907 kg/cm
2,
12.90 psi)
Approx. 1,500 m (4,992 ft): Approx. 83.16 kPa (0.8316 bar, 0.848 kg/cm
2,
12.06 psi)
Approx. 2,000 m (6,562 ft): Approx. 78.36 kPa (0.7836 bar, 0.799 kg/cm
2,
11.36 psi)
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)
33 G/YElectronic control fuel
injection pumpEngine is running.
Warm-up condition
Idle speedApproximately 2.4V
40 PUElectronic control fuel
injection pumpEngine is running.
Warm-up condition
Idle speedApproximately 2.4V
52 L/WElectronic control fuel
injection pumpEngine is running.
Idle speedApproximately 0.1V
53 L/RElectronic control fuel
injection pumpEngine is running.
Idle speedApproximately 0.45V
Engine is running.
Engine speed is 2,000 rpmApproximately 0.7V
DTC 0402 P9zFUEL TEMP SENYD25DDTi
EC-3509
Page 535 of 1306

On Board Diagnosis Logic
Malfunction is detected when .... Check Items (Possible cause)
+An improper voltage signal from fuel temperature sensor
(Built-into electronic control fuel injection pump) is sent to
injection pump control unit.+Harness or connectors
(Electronic control fuel injection pump circuit is open or
shorted.)
+Electronic control fuel injection pump
DTC Confirmation Procedure
WITH CONSULT-II
1) Turn ignition switch ªONº and wait at least 2 seconds.
2) Select ªDATA MONITORº mode with CONSULT-II.
3) Start engine and run it for at least 2 seconds at idle speed.
(If engine does not run, turn ignition switch to ªSTARTº for at
least 2 seconds.)
4) If DTC is detected, go to ªDiagnostic Procedureº, EC-3514.
WITHOUT CONSULT-II
1) Turn ignition switch ªONº and wait at least 2 seconds.
2) Start engine and run it for at least 2 seconds at idle speed.
(If engine does not run, turn ignition switch to ªSTARTº for at
least 2 seconds.)
3) Turn ignition switch ªOFFº, wait at least 5 seconds and then
turn ªONº.
4) Perform ªDiagnostic Test Mode II (Self-diagnostic results)º
with ECM.
5) If DTC is detected, go to ªDiagnostic Procedureº, EC-3514.
SEF817Y
DTC 0402 P9zFUEL TEMP SENYD25DDTi
EC-3510
Page 539 of 1306

4 DETECT MALFUNCTIONING PART
Check the following.
+Harness connectors E236, M278 (LHD models)
+Harness connectors E236, F35 (RHD models)
+Harness for open or short between electronic control fuel injection pump and engine ground
cRepair open circuit or short to ground or short to power in harness or connectors.
5 CHECK COMMUNICATION LINE FOR OPEN AND SHORT
1. Check continuity between the following terminals. Refer to Wiring Diagram.
MTBL0444
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OKcGO TO 7.
NGcGO TO 6.
6 DETECT MALFUNCTIONING PART
Check the following.
+Harness connectors E237, M279 (LHD models)
+Harness connectors E237, F36 (RHD models)
+Harness for open or short between electronic control fuel injection pump and ECM
cRepair open circuit or short to ground or short to power in harness or connectors.
7 CHECK INTERMITTENT INCIDENT
Refer to ªTROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENTº, EC-3469.
OK or NG
OKcReplace electronic control fuel injection pump.
NGcRepair open circuit or short to ground or short to power in harness or connectors.
DTC 0402 P9zFUEL TEMP SENYD25DDTi
Diagnostic Procedure (Cont'd)
EC-3514
Page 540 of 1306

Description
The accelerator work unit is installed on the upper end of the accelerator pedal assembly. The sensor detects
the accelerator position and sends a signal to the ECM. The ECM uses the signal to determine the amount
of fuel to be injected.
The accelerator position switch detects Off-accelerator switch signal and Full-accelerator switch signal and
send these signals to the ECM. The ECM will then determine engine idle conditions. These signals are also
used for diagnosing the accelerator position sensor.
CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM CONDITION SPECIFICATION
ACCEL POS SEN+Ignition switch: ON
(Engine stopped)Accelerator pedal: released 0.29 - 0.79V
Accelerator pedal: depressed 3.48 - 4.64V
FULL ACCEL SW+Ignition switch: ON
(Engine stopped)Accelerator pedal: fully depressed ON
Except above OFF
OFF ACCEL SW+Ignition switch: ON
(Engine stopped)Accelerator pedal: fully released ON
Accelerator pedal: slightly open OFF
SEC262D
DTC 0403 ACCEL POS SENSORYD25DDTi
EC-3515
Page 541 of 1306

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)
23 WAccelerator position sen-
sorIgnition switch ªONº
Accelerator pedal fully released0.29 - 0.79V
Ignition switch ªONº
Accelerator pedal fully depressed3.48 - 4.64V
31 YAccelerator position switch
(Idle)Ignition switch ªONº
Accelerator pedal fully releasedBATTERY VOLTAGE
(11 - 14V)
Ignition switch ªONº
Accelerator pedal depressedApproximately 0V
32 GAccelerator position switch
(Full)Ignition switch ªONº
Accelerator pedal releasedApproximately 0V
Ignition switch ªONº
Accelerator pedal fully depressedBATTERY VOLTAGE
(11 - 14V)
48 OR/LAccelerator position sen-
sor power supplyIgnition switch ªONº
Approximately 5V
51 B/WAccelerator position sen-
sor groundEngine is running.
Warm-up condition
Idle speedApproximately 0V
On Board Diagnosis Logic
Malfunction is detected when ... Check Items (Possible Cause)
+The relation between sensor and switch signal is not in the
normal range during the specified accelerator position.+Harness or connectors
(The sensor circuit is open or shorted.)
+Accelerator position sensor
+Accelerator position switch
DTC 0403 ACCEL POS SENSORYD25DDTi
EC-3516
Page 550 of 1306

5 CHECK ACCELERATOR POSITION SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch ªOFFº.
2. Loosen and retighten engine ground screw.
SEC245D
3. Check harness continuity between accelerator work unit terminal 3 and engine ground. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OKcGO TO 7.
NGcGO TO 6.
6 DETECT MALFUNCTIONING PART
Check the following.
+Harness connectors F54, M48 (RHD models)
+Harness for open or short between ECM and accelerator work unit
cRepair open circuit or short to ground or short to power in harness or connectors.
7 CHECK ACCELERATOR POSITION SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminal 23 and accelerator work unit 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 (With CONSULT-II)cGO TO 9.
OK (Without CONSULT-II)cGO TO 10.
NGcGO TO 8.
8 DETECT MALFUNCTIONING PART
Check the following.
+Harness connectors F55, M47 (RHD models)
+Harness for open or short between ECM and accelerator work unit
cRepair open circuit or short to ground or short to power in harness or connectors.
DTC 0403 ACCEL POS SENSORYD25DDTi
Diagnostic Procedure (Cont'd)
EC-3525
Page 552 of 1306

11 CHECK ACCELERATOR POSITION SENSOR SHIELD CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch ªOFFº.
2. Check harness continuity between harness connector F55 terminal 13 and engine ground. Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to power.
OK or NG
OK (With CONSULT-II)cGO TO 13.
OK (Without CONSULT-II)cGO TO 14.
NGcGO TO 12.
12 DETECT MALFUNCTIONING PART
Check the following.
+Harness connectors M47, F55
+Harness for open or short between harness connector F55 and engine ground
cRepair harness or connectors.
13 RESET ACCELERATOR POSITION SENSOR IDLE POSITION MEMORY
With CONSULT-II
1. Turn ignition switch ªONº.
2. Select ªOFF ACCEL PO SIGº in ªACTIVE TESTº mode with CONSULT-II.
3. Touch ªCLEARº.
cGO TO 24.
14 RESET ACCELERATOR POSITION SENSOR IDLE POSITION MEMORY
Without CONSULT-II
1. Start engine and warm it up to normal operating temperature.
2. Let engine idle for 10 minutes.
cGO TO 24.
DTC 0403 ACCEL POS SENSORYD25DDTi
Diagnostic Procedure (Cont'd)
EC-3527
Page 555 of 1306
22 RESET ACCELERATOR POSITION SENSOR IDLE POSITION MEMORY
With CONSULT-II
1. Reconnect all connectors disconnected.
2. Turn ignition switch ªONº.
3. Select ªOFF ACCEL PO SIGº in ªACTIVE TESTº mode with CONSULT-II.
4. Touch ªCLEARº.
cGO TO 24.
23 RESET ACCELERATOR POSITION SENSOR IDLE POSITION MEMORY
Without CONSULT-II
1. Reconnect all connectors disconnected.
2. Start engine and warm it up to normal operating temperature.
3. Let engine idle for 10 minutes.
cGO TO 24.
24 CHECK INTERMITTENT INCIDENT
Refer to ªTROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENTº, EC-3469.
cINSPECTION END
DTC 0403 ACCEL POS SENSORYD25DDTi
Diagnostic Procedure (Cont'd)
EC-3530