Page 577 of 1767

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 sensor
is not used to control the engine system under normal conditions.
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 GCharge 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)
IAn excessively high or low voltage from the sensor is sent to
ECM.IHarness or connectors
(The sensor circuit is open or shorted.)
ICharge air pressure sensor
SEF340VA
SEF627RA
DTC 0905 TURBO PRESSUREZD30DDTi
EC-215
Page 581 of 1767

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
OKEGO TO 3.
NGEGO TO 2.
2 DETECT MALFUNCTIONING PART
Check the following.
IHarness connectors E225, F108
IHarness connectors F135, M842 (RHD models)
IHarness for open or short between charge air pressure sensor and ECM
ERepair open circuit or short to ground or short to power in harness or connectors.
3 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
OKEGO TO 5.
NGEGO TO 4.
DTC 0905 TURBO PRESSUREZD30DDTi
EC-219
Page 582 of 1767

4 DETECT MALFUNCTIONING PART
Check the following.
IHarness connectors E225, F108
IHarness connectors F135, M852 (RHD models)
IHarness for open or short between ECM and charge air pressure sensor
ERepair open circuit or short to ground or short to power in harness or connectors.
5 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
OKEGO TO 7.
NGEGO TO 6.
6 DETECT MALFUNCTIONING PART
Check the following.
IHarness connectors E225, F108
IHarness connectors F135, M842 (RHD models)
IHarness for open or short between charge air pressure sensor and ECM
ERepair open circuit or short to ground or short to power in harness or connectors.
7 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:
IAlways calibrate the pressure pump gauge when using it.
IInspection 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
OKEGO TO 8.
NGEReplace charge air pressure sensor.
DTC 0905 TURBO PRESSUREZD30DDTi
Diagnostic Procedure (Cont'd)
EC-220
Page 583 of 1767
8 CHECK SHIELD CIRCUIT
1. Disconnect charge air pressure sensor sub-harness connectors E225, F108 and ECM harness connector.
2. Check continuity between boost sensor sub-harness connector terminal 15 and ground.
Continuity should exist.
3. Check continuity between ECM terminal 43 and ground.
Continuity should exist.
4. Also check harness for short to power.
OK or NG
OKEGO TO 10.
NGEGO TO 9.
9 DETECT MALFUNCTIONING PART
Check the following.
IHarness connectors E225, F108
IHarness connectors F135, M842 (RHD models)
IHarness for open or short between charge air pressure sensor and ground
IHarness for open or short between ECM and ground
E
10 CHECK INTERMITTENT INCIDENT
Refer to ªTROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENTº, EC-78.
EINSPECTION END
DTC 0905 TURBO PRESSUREZD30DDTi
Diagnostic Procedure (Cont'd)
EC-221
Page 584 of 1767

Description
SYSTEM DESCRIPTION
Sensor Input Signal to ECM ECM Function Actuator
Electronic controlled fuel injection pump Fuel injection signal
EGR volume
controlEGR 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 optimum
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 following
conditions.
IEngine stopped
IEngine starting
ILow engine coolant temperature
IExcessively high engine coolant temperature
IHigh engine speed
IWide open throttle
ILow battery voltage
COMPONENT DESCRIPTION
EGR volume control valve
The EGR volume control valve uses a step motor to control the flow
rate of EGR from exhaust manifold. This motor has four winding
phases. It operates according to the output pulse signal of the
ECM. Two windings are turned ON and OFF in sequence. Each
time an ON pulse is issued, the valve opens or closes, changing
the flow rate. When no change in the flow rate is needed, the ECM
does not issue the pulse signal. A certain voltage signal is issued
so that the valve remains at that particular opening.
SEF908Y
SEF411Y
DTC 1003 EGR VOLUME CONT/VZD30DDTi
EC-222
Page 594 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 1004 FUEL CUT SYSTEM1ZD30DDTi
EC-232
Page 601 of 1767

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):
IIgnition 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.
ICranking
The glow relay turns ON, allowing current to flow through glow
plug.
IStarting
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, current
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
IThe 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.
IThis 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-239
Page 625 of 1767

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 con-
trol 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 burn-
ing 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 condi-
tion. 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-263