Page 506 of 1767

Diagnostic Procedure
1 CHECK INTAKE AIR LEAK
Listen for an intake air leak after the mass air flow sensor.
OK or NG
OKEGO TO 2.
NGERepair or replace.
2 CHECK VARIABLE NOZZLE TURBOCHARGER OVERALL FUNCTION
1. Start engine and let it idle.
2. Make sure that variable nozzle turbocharger control actuator rod moves when revving engine up to 3,000 rpm and returning to
idle.
MEC015E
OK or NG
OKEGO TO 3.
NGEGo to ªDiagnostic Procedureº in ªVARIABLE NOZZLE TURBOCHARGER CONTROL SOLE-
NOID VALVEº, EC-284.
3 CHECK MASS AIR FLOW SENSOR
1. Start engine and warm it up to normal operating temperature.
2. Check voltage between ECM terminal 35 (Mass air flow sensor signal) and ground.
SEF400Y
3. If the voltage is out of specification, disconnect MAFS harness connector and connect it again.
Then repeat above check.
OK or NG
OKEGO TO 4.
NGEReplace mass air flow sensor.
4 CHECK INTERMIT INCIDENT
Refer to ªTROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENTº, EC-78.
EINSPECTION END
DTC 0406 INT AIR VOLZD30DDTi
EC-144
Page 507 of 1767

Description
The crankshaft position sensor (TDC) monitors engine speed by
means of signals from the sensing plate (with three protrusions)
installed to the crankshaft pulley. The data signal output is detected
at ATDC 70É and sent to the ECM. The sensor signal is used for
fuel injection control and fuel injection timing control.
CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEM CONDITION SPECIFICATION
CKPS×RPM (TDC)ITachometer: Connect
IRun engine and compare tachometer indication with the CONSULT-II
value.Almost the same speed as the
CONSULT-II value.
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 CONDITIONDATA (DC Voltage and
Pulse Signal)
44 L/GCrankshaft position sensor
(TDC)Engine is running.
Warm-up condition
Idle speedApproximately 0V
SEF333Y
Engine is running.
Warm-up condition
Engine speed is 2,000 rpmApproximately 0V
SEF334Y
47 L/RCrankshaft position sensor
(TDC) groundEngine is running.Warm-up condition
Idle speedApproximately 0V
SEF231Z
DTC 0407 CRANK POS SEN (TDC)ZD30DDTi
EC-145
Page 508 of 1767

On Board Diagnosis Logic
Malfunction is detected when ... Check Items (Possible Cause)
IAn improper signal from the sensor is sent to ECM during
engine running and cranking.IHarness or connectors
(The sensor circuit is open.)
ICrankshaft position sensor (TDC)
DTC Confirmation Procedure
Before performing the following procedure, confirm that bat-
tery voltage is more than 10V.
WITH CONSULT-II
1) Turn ignition switch ªONº and select ªDATA MONITORº mode
with CONSULT-II.
2) Crank engine for at least 1 second.
3) Start engine and run it for at least 2 seconds at idle speed.
4) If DTC is detected, go to ªDiagnostic Procedureº, EC-149.
WITHOUT CONSULT-II
1) Crank engine for at least 1 second.
2) Start engine and run it for at least 2 seconds at idle speed.
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-149.
SEF817Y
DTC 0407 CRANK POS SEN (TDC)ZD30DDTi
EC-146
Page 511 of 1767
Diagnostic Procedure
1 CHECK CRANKSHAFT POSITION SENSOR (TDC) GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch ªOFFº.
2. Loosen and retighten engine ground screws.
MEC994D
3. Disconnect crankshaft position sensor (TDC) harness connector and ECM harness connector.
MEC998D
MEC018E
4. Check harness continuity between ECM terminal 47 and terminal 2. Refer to Wiring Diagram.
Continuity should exist.
5. Also check harness for short to ground and short to power.
OK or NG
OKEGO TO 3.
NGEGO TO 2.
DTC 0407 CRANK POS SEN (TDC)ZD30DDTi
EC-149
Page 512 of 1767

2 DETECT MALFUNCTIONING PART
Check the following.
IHarness connectors F106, E227
IHarness connectors M842, F135 (RHD models)
IHarness for open or short between crankshaft position sensor (TDC) and ECM
ERepair open circuit or short to ground or short to power in harness or connectors.
3 CHECK CRANKSHAFT POSITION SENSOR (TDC) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Check harness continuity between terminal 1 and ECM terminal 44. Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OKEGO TO 5.
NGEGO TO 4.
4 DETECT MALFUNCTIONING PART
Check the following.
IHarness connectors F106, E227
IHarness connectors M842, F135 (RHD models)
IHarness for open or short between crankshaft position sensor (TDC) and ECM
ERepair open circuit or short to ground or short to power in harness or connectors.
5 CHECK CRANKSHAFT POSITION SENSOR SHIELD CIRCUIT
1. Check harness continuity between crankshaft position sensor (TDC) terminal 3 and engine ground. Refer to Wiring Diagram.
Continuity should exist.
2. Also check harness for short to ground and short to power.
OK or NG
OKEGO TO 7.
NGEGO TO 6.
6 DETECT MALFUNCTIONING PART
Check the following.
IHarness connectors F106, E227
IHarness connectors F108, E225
IHarness connectors M842, F135 (RHD models)
IHarness for open or short between crankshaft position sensor (TDC) and engine ground
ERepair open circuit or short to ground or short to power in harness or connectors.
DTC 0407 CRANK POS SEN (TDC)ZD30DDTi
Diagnostic Procedure (Cont'd)
EC-150
Page 513 of 1767
7 CHECK CRANKSHAFT POSITION SENSOR (TDC) INSTALLATION
Check the clearance between crankshaft position sensor (TDC) and protrusion on the crankshaft pulley.
JEF293Z
OK or NG
OKEGO TO 8.
NGEGO TO 9.
8 REINSTALL CRANKSHAFT POSITION SENSOR (TDC)
1. Remove crankshaft position sensor (TDC).
2. Install crankshaft position sensor (TDC) properly.
JEF294Z
EINSPECTION END
DTC 0407 CRANK POS SEN (TDC)ZD30DDTi
Diagnostic Procedure (Cont'd)
EC-151
Page 514 of 1767
9 CHECK CRANKSHAFT POSITION SENSOR (TDC)-I
1. Loosen the fixing bolt and remove the crankshaft position sensor (TDC).
2. Visually check the sensor for chipping.
SEF232Z
OK or NG
OKEGO TO 10.
NGEReplace crankshaft position sensor (TDC).
10 CHECK CRANKSHAFT POSITION SENSOR (TDC)-II
1. Disconnect crankshaft position sensor (TDC) harness connector.
2. Check resistance between crankshaft position sensor (TDC) terminals 1 and 2.
SEF295Z
OK or NG
OKEGO TO 11.
NGEReplace crankshaft position sensor (TDC).
11 CHECK INTERMITTENT INCIDENT
Refer to ªTROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENTº, EC-78.
EINSPECTION END
DTC 0407 CRANK POS SEN (TDC)ZD30DDTi
Diagnostic Procedure (Cont'd)
EC-152
Page 523 of 1767

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 timing
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 informa-
tion 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 injec-
tion 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 temperature.
CAM RING POSITION SENSOR
The sensor detects the passing of the protrusion on the sensor
wheel in the injection pump by the semiconductor magnetic resis-
tance element sensor. The cam ring position sensor synchronizes
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 0701 P1×CAM POS SENZD30DDTi
EC-161