Fuel Injection Control System
DESCRIPTION
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 compensated to improve engine performance.
Pulse signals are exchanged between ECM and electronic control fuel injection pump (control unit is built-in).
The fuel injection pump control unit performs duty control on the spill valve (built into the fuel injection pump)
according to the input signals to compensate the amount of fuel injected to the preset value.
Start control
Input/output signal chart
Sensor Input Signal to ECM ECM Function Actuator
Engine coolant temperature sensor Engine coolant temperature
Fuel injection con-
trol (start control)Electronic control fuel injec-
tion pump Crankshaft position sensor (TDC) Engine speed
Ignition switch Start signal
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 and
engine coolant temperature.
For better startability under cool engine conditions, the lower the
coolant 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.
Idle control
Input/output signal chart
Sensor Input Signal to ECM ECM Function Actuator
Engine coolant temperature sensor Engine coolant temperature
Fuel injection con-
trol (Idle control)Electronic control fuel injec-
tion pump Crankshaft position sensor (TDC) Engine speed
Park/Neutral position (PNP) switch Gear position
Battery Battery voltage
Accelerator position switch Idle position
Vehicle speed sensor Vehicle speed
Air conditioner switch Air conditioner signal
Heat up switch Heat up switch signal
When the ECM determines that the engine speed is at idle, the fuel injection system is adapted for the idle
control. 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
engine coolant temperature and heat up switch signal.
SEF648S
ENGINE AND EMISSION BASIC CONTROL SYSTEM
DESCRIPTIONZD30DDTi
EC-20
REAL TIME DIAGNOSIS IN DATA MONITOR MODE
CONSULT-II has two kinds of triggers and they can be selected by
touching ªSETTINGº in ªDATA MONITORº mode.
1) ªAUTO TRIGº (Automatic trigger):
IThe malfunction will be identified on the CONSULT-II screen in
real time.
In other words, DTC will be displayed if the malfunction is
detected by ECM.
At the moment a malfunction is detected by ECM, ªMONITORº
in ªDATA MONITORº screen is changed to ªRecording Data ...
xx%º as shown at left, and the data after the malfunction detec-
tion is recorded. Then when the percentage reached 100%,
ªREAL-TIME DIAGº screen is displayed. If ªSTOPº is touched
on the screen during ªRecording Data ... xx%º, ªREAL-TIME
DIAGº screen is also displayed.
The recording time after the malfunction detection and the
recording speed can be changed by ªTRIGGER POINTº and
ªRecording Speedº. Refer to CONSULT-II OPERATION
MANUAL.
2) ªMANU TRIGº (Manual trigger):
IDTC 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) ªAUTO TRIGº
IWhile trying to detect the DTC by performing the ªDTC Confir-
mation Procedureº, be sure to select to ªDATA MONITOR
(AUTO TRIG)º mode. You can confirm the malfunction at the
moment it is detected.
IWhile narrowing down the possible causes, CONSULT-II
should be set in ªDATA MONITOR (AUTO TRIG)º mode, espe-
cially in case the incident is intermittent.
When you are inspecting the circuit by gently shaking (or twist-
ing) the suspicious connectors, components and harness in the
ªDTC Confirmation Procedureº, the moment a malfunction is
found the DTC will be displayed. (Refer to GI section, ªIncident
Simulation Testsº in ªHOW TO PERFORM EFFICIENT DIAG-
NOSIS FOR AN ELECTRICAL INCIDENTº.)
2) ªMANU TRIGº
IIf the malfunction is displayed as soon as ªDATA MONITORº is
selected, reset CONSULT-II to ªMANU TRIGº. By selecting
ªMANU TRIGº 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.
SEF373Y
SEF707X
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONZD30DDTi
CONSULT-II (Cont'd)
EC-44
6 CHECK ACCELERATOR POSITION SENSOR
With CONSULT-II
1. Reconnect all disconnected harness connectors.
2. Turn ignition switch ªONº.
3. Select ªDATA MONITORº mode with CONSULT-II.
4. Check the indication of ªACCEL POS SENº under the following conditions.
SEF818Y
OK or NG
OKEGO TO 7.
NGEReplace accelerator pedal assembly.
7 CHECK ACCELERATOR POSITION SENSOR
Without CONSULT-II
1. Reconnect all disconnected harness connectors.
2. Turn ignition switch ªONº.
3. Check voltage between ECM terminal 23 and ground under the following conditions.
SEF407Y
OK or NG
OKEGO TO 8.
NGEReplace accelerator pedal assembly.
8 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.
EGO TO 9.
DTC 0403 ACCEL POS SENSORZD30DDTi
Diagnostic Procedure (Cont'd)
EC-139
9 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.
EGO TO 10.
10 CHECK INTERMITTENT INCIDENT
Refer to ªTROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENTº, EC-78.
EINSPECTION END
11 CHECK ACCELERATOR POSITION SWITCH POWER SUPPLY CIRCUIT
1. Turn ignition switch ªOFFº.
2. Disconnect accelerator position switch harness connector.
MEC995D
3. Turn ignition switch ªONº.
4. Check voltage between accelerator position switch terminal 5 and ground with CONSULT-II or tester.
SEF346X
OK or NG
OKEGO TO 13.
NGEGO TO 12.
12 DETECT MALFUNCTIONING PART
Check the following.
IHarness connectors M787, F6 (LHD models)
IHarness for open or short between accelerator position switch and ECM relay
IHarness for open or short between accelerator position switch and ECM
ERepair harness or connectors.
DTC 0403 ACCEL POS SENSORZD30DDTi
Diagnostic Procedure (Cont'd)
EC-140
13 CHECK ACCELERATOR POSITION SWITCH INPUT SIGNAL CIRCUIT-I FOR OPEN AND SHORT
1. Turn ignition switch ªOFFº.
2. Disconnect ECM harness connector.
3. Check harness continuity between accelerator position switch terminal 6 and ECM terminal 31. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OKEGO TO 14.
NGERepair open circuit or short to ground or short to power in harness or connectors.
14 CHECK ACCELERATOR POSITION SWITCH INPUT SIGNAL CIRCUIT-II FOR OPEN AND SHORT
1. Check harness continuity between accelerator position switch terminal 4 and ECM terminal 32. Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OKEGO TO 15.
NGERepair open circuit or short to ground or short to power in harness or connectors.
15 CHECK ACCELERATOR POSITION SWITCH
Check continuity between accelerator position switch terminals 4 and 5, 5 and 6 under the following conditions.
SEF418Y
OK or NG
OK (With CONSULT-II)EGO TO 16.
OK (Without CONSULT-II)EGO TO 17.
NGEReplace accelerator pedal assembly.
16 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.
EGO TO 18.
17 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.
EGO TO 18.
DTC 0403 ACCEL POS SENSORZD30DDTi
Diagnostic Procedure (Cont'd)
EC-141
Fuel Injection System
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 compensated to improve engine performance. The ECM performs duty cycle
control on the electric governor (built into the fuel injection pump) according to sensor signals to compensate
the amount of fuel injected to the preset value.
START CONTROL
Input/output signal line
Engine coolant temperature sensorEEngine coolant temperature
ECM
EElectric
governorCrankshaft position sensor (TDC)EEngine speed
Control sleeve position sensor
EControl sleeve position
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 and
engine coolant temperature.
For better startability under cool engine conditions, the lower the
coolant temperature becomes, the greater the amount of fuel
injected. The ECM ends the start control when the engine speed
reaches a value between 800 rpm and 1,200 rpm, which is deter-
mined by the engine coolant temperature and shifts the control to
the normal or idle control.
SEF648S
ENGINE AND EMISSION BASIC CONTROL
SYSTEM DESCRIPTIONTD27Ti
EC-306
REAL TIME DIAGNOSIS IN DATA MONITOR MODE
CONSULT-II has two kinds of triggers and they can be selected by
touching ªSETTINGº in ªDATA MONITORº mode.
1) ªAUTO TRIGº (Automatic trigger):
IThe malfunction will be identified on the CONSULT-II screen in
real time.
In other words, DTC will be displayed if the malfunction is
detected by ECM.
At the moment a malfunction is detected by ECM, ªMONITORº
in ªDATA MONITORº screen is changed to ªRecording Data ...
xx%º as shown at left, and the data after the malfunction detec-
tion is recorded. Then when the percentage reached 100%,
ªREAL-TIME DIAGº screen is displayed. If ªSTOPº is touched
on the screen during ª Recording Data ... xx%º, ªREAL-TIME
DIAGº screen is also displayed.
The recording time after the malfunction detection and the
recording speed can be changed by ªTRIGGER POINTº and
ªRecording Speedº. Refer to CONSULT-II OPERATION
MANUAL.
2) ªMANU TRIGº (Manual trigger):
IDTC 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) ªAUTO TRIGº
IWhile trying to detect the DTC by performing the ªDTC Confir-
mation Procedureº, be sure to select to ªDATA MONITOR
(AUTO TRIG)º mode. You can confirm the malfunction at the
moment it is detected.
IWhile narrowing down the possible causes, CONSULT-II
should be set in ªDATA MONITOR (AUTO TRIG)º mode, espe-
cially in case the incident is intermittent.
When you are inspecting the circuit by gently shaking (or twist-
ing) the suspicious connectors, components and harness in the
ªDTC Confirmation Procedureº, the moment a malfunction is
found the DTC will be displayed. Refer to GI-22, ªIncident Simu-
lation Testsº.
2) ªMANU TRIGº
IIf the malfunction is displayed as soon as ªDATA MONITORº is
selected, reset CONSULT-II to ªMANU TRIGº. By selecting
ªMANU TRIGº 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.
SEF373Y
SEF707X
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONTD27Ti
CONSULT-II (Cont'd)
EC-332
Combination Meter Self-Diagnosis
PERFORMING SELF-DIAGNOSIS MODE
1. Turn the ignition switch to the ªLOCKº position.
2. Press both reset buttons on the combination meter and keep
them depressed.
3. Turn the ignition switch to the ªONº position, while keeping the
reset buttons pressed.
4. Release both reset buttons then self-diagnosis will start. The
sequence (A to I) is activated by press the either reset buttons.
NOTE:
If either reset button is not pressed for 20 seconds at each step or
if the ignition switch is turned OFF, the self-diagnosis mode is
exited.
Check items Display Remarks
A) Odometer segment test All odo trip meter segments are ON.
B) Software code
NEL735
This information is not used for service. Please skip this
step.
C) EEPROM code
NEL736
This information is not used for service. Please skip this
step.
D) Hardware code
NEL737
This information is not used for service. Please skip this
step.
E) PCB code
NEL738
This information is not used for service. Please skip this
step.
F)Meter/gauge test
(Sweeping movement)
SEL440X
Tachometer, speedometer, fuel level gauge and water tem-
perature gauge have sweeping movement test.
(The meter/gauges operate MIN.,MAX., MAX.,MIN. for
2 times)
The odo trip meter segment flashes during the sweep move-
ment.
G)Error 1
(Bit 0 - Bit 3)
SEL441X
The segment of each bit displays ª0º, meaning no failure. If
the bit(s) displays figures other than ª0º, the item of the bit
has failed.
For details, refer to ªFailure chart for Error 1 and Error Eº
below.
H)Error E
(Bit 4 - Bit 7)
SEL442X
METER AND GAUGES
EL-76