SYSTEM Ð ENGINE CONTROL system
Malfunction
SYMPTOM
Reference page
Feature of symptom, Check pointROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION
ABNORMAL SMOKE COLOR
DEAD BATTERY (UNDER CHARGE)
Malfunction indicator lamp illuminates.
Can be detected by CONSULT-II?
Fuel cutBLACK SMOKE
WHITE SMOKEWarranty symptom code AG AH AJ AK AL AM AP HA
ENGINE CONTROL
Accelerator switch (FC) circuit*a, *b
1 1 EC-104
*c
Fuel cut system line*a, *c 1 1
EC-232
*b 1 *2
Accelerator position sensor circuit *a, *b 1 1 EC-130
Crankshaft position sensor (TDC) cir-
cuit*a, *b 1 1
1 1 EC-145
*d
Charge air pressure sensor circuit *a, *b, *c 1 1 EC-215
Swirl control valve control solenoid
valve circuit*a, *b 1
EC-263
*c 1 1 1
Variable nozzle turbocharger control
solenoid valve circuit*a, *b 1 1
EC-281
*c 1 1
Intake air control valve control sole-
noid valve circuit*c EC-273
1 - 5: The numbers refer to the order of inspection.
(continued on next page)
*a: Open
*b: Short
*c: Ground short
*d: Noise
*2: Engine runs on after turning ignition switch OFF.
TROUBLE DIAGNOSIS Ð GENERAL DESCRIPTIONZD30DDTi
Symptom Matrix Chart (Cont'd)
EC-61
SYSTEM Ð ENGINE CONTROL system
Malfunction
SYMPTOM
Reference page
Feature of symptom, Check pointROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION
ABNORMAL SMOKE COLOR
DEAD BATTERY (UNDER CHARGE)
Malfunction indicator lamp illuminates.
Can be detected by CONSULT-II?
Fuel cutBLACK SMOKE
WHITE SMOKEWarranty symptom code AG AH AJ AK AL AM AP HA
ENGINE CONTROL
Start signal circuit *a, *b EC-248 *3
PNP switch circuit*a, *b
1 1 EC-251
*c
Accelerator position switch (Idle) cir-
cuit*a, *c
EC-130
*b 1 1 *4
Accelerator position switch (Full) cir-
cuit*a, *b 1 1 EC-130
Ignition switch circuit*a
EC-79
*b*5
Power supply for ECM circuit*a
111
EC-79
*b
1 - 5: The numbers refer to the order of inspection.
(continued on next page)
*a: Open
*b: Short
*c: Ground short
*d: Noise
*3: Start control does not function.
*4: Accelerator position sensor NG signal is output.
*5: Engine does not stop.
TROUBLE DIAGNOSIS Ð GENERAL DESCRIPTIONZD30DDTi
Symptom Matrix Chart (Cont'd)
EC-63
SYSTEM Ð ENGINE CONTROL system
Malfunction
SYMPTOM
Reference page
Feature of symptom, Check pointROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION
ABNORMAL SMOKE COLOR
DEAD BATTERY (UNDER CHARGE)
Malfunction indicator lamp illuminates.
Can be detected by CONSULT-II?
Fuel cutBLACK SMOKE
WHITE SMOKEWarranty symptom code AG AH AJ AK AL AM AP HA
ENGINE CONTROL
EGR volume control valve circuit*a, *b
EC-222
*c 1 *8
Glow relay circuit*a 1
EC-239*9
*b*10
ECM relay (Self-shutoff) circuit*a 1
EC-79
*b 1 1 *11
ECM, Connector circuit *a, *b222222222222EC-121,
200, 213
Air conditioner relay circuit*a
EC-289*12
*b*13
Air conditioner switch circuit*a, *c
EC-289*13
*b*14
1 - 5: The numbers refer to the order of inspection.
*a: Open
*b: Short
*c: Ground short
*d: Noise
*8: Does not stop operating.
*9: Glow lamp does not turn on.
*10: Glow lamp does not turn off.
*11: Ground short makes engine unable to stop.
*12: Air conditioner does not operate.
*13: Air conditioner does not stop operating.
*14: Air conditioner does not work.
TROUBLE DIAGNOSIS Ð GENERAL DESCRIPTIONZD30DDTi
Symptom Matrix Chart (Cont'd)
EC-65
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)
14 LG/R Cooling fan relayEngine is running.
Cooling fan is not operatingBATTERY VOLTAGE
(11 - 14V)
Engine is running.
Cooling fan is operatingApproximately 0.1V
On Board Diagnosis Logic
This diagnosis continuously monitors the engine coolant temperature.
If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will
rise.
When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is
indicated.
Malfunction is detected when ... Check Items (Possible Cause)
ICooling fan does not operate properly (Overheat).
ICooling fan system does not operate properly (Overheat).
IEngine coolant was not added to the system using the proper
filling method.IHarness or connectors
(The cooling fan circuit is open or shorted.)
ICooling fan
IRadiator hose
IRadiator
IRadiator cap
IWater pump
IThermostat
IFan belt
IEngine coolant temperature sensor
For more information, refer to ªMAIN 12 CAUSES OF
OVERHEATINGº, EC-120.
CAUTION:
When a malfunction is indicated, be sure to replace the coolant following the procedure in the MA
section (ªChanging Engine Coolantº, ªENGINE MAINTENANCEº). Also, replace the engine oil.
1) Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure to
use coolant with the proper mixture ratio. Refer to MA section (ªAnti-freeze Coolant Mixture Ratioº,
ªRECOMMENDED LUBRICANTS AND FLUIDSº).
2) After refilling coolant, run engine to ensure that no water-flow noise is emitted.
DTC 0208 OVER HEATZD30DDTi
EC-110
Symptom Matrix Chart
SYSTEM
Ð Basic engine
control systemSYMPTOM
Reference page
Feature of symptom, Check pointHARD/NO START/RESTART (EXCP. HA)
ENGINE STALL
HESITATION/SURGING/FLAT SPOT
SPARK KNOCK/DETONATION
LACK OF POWER
POOR ACCELERATION
HI IDLE
LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION
ABNORMAL SMOKE COLOR
DEAD BATTERY (UNDER CHARGE)
Malfunction indicator lamp illuminates.
Can be detected by CONSULT-II?
Fuel cutNO START (with first firing)
NO START (without first firing)
HARD TO START WHEN ENGINE IS COLD
HARD TO START WHEN ENGINE IS HOT
AT IDLE
DURING DRIVING
WHEN DECELERATING
BLACK SMOKE
WHITE SMOKENew CT/CS AA AB AC AD AE AF AG AH AJ AK AL AM AP HA
Injec-
tion
timingAdvancedqq
IIqIqqIqEC-338
Retardedqq
IIqIqqIqEC-338
Electric injection
pump mainframe
IIIIqqqqqIqqqIIqqIq qqqÐ*1
Injection nozzleqqqqqqq
Iqq qII IEC-313 *2
Glow systemqq
II I IEC-389
Engine body
qq
IIqqqIqq qIIqqqIEM-
section*3
EGR system
II IEC-431
Air cleaner and
ducts
II IqMA-
section*4
I; High Possibility Item
q; Low Possibility Item
*1: Insufficient or excess amount. Governor malfunction may be the cause.
*2: Depends on open-valve pressure and spray pattern.
*3: Caused mainly by insufficient compression pressure.
*4: Symptom varies depending on off-position of air duct, etc.
TROUBLE DIAGNOSESTD27Ti
EC-340
SYSTEM Ð Engine control system Malfunction
SYMPTOM
Reference page Feature of symptom
Check point
HARD/NO START/
RESTART (EXCP. HA) ENGINE STALL HESITATION/SURGING/FLAT SPOT SPARK KNOCK/DETONATION
LACK OF POWER
POOR ACCELERATION
HI IDLE
LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION ABNORMAL SMOKE COLOR
DEAD BATTERY (UNDER CHARGE) Malfunction indicator lamp illuminates.
Can be detected by CONSULT-II?
Fuel cut
NO START (with first firing) NO START (without first firing)
HARD TO START WHEN ENGINE IS COLD
HARD TO START WHEN ENGINE IS HOT
AT IDLE
DURING DRIVING
WHEN DECELERATINGBLACK SMOKE WHITE SMOKE
New CT/CS AA AB AC AD AE AF AG AH AJ AK AL AM AP HA
Mass air flow sensor circuit open, ground shortqqq q
EC-356
shortqqq
Engine coolant temperature sensor
circuit open, shortqqq qqq qqEC-361Compensation according to
engine coolant temperature does
not function.
Vehicle speed sensor circuit open, shortqqEC-397
Control sleeve position sensor circuit open, shortqqqqqqEC-414
Injection timing control valve circuit
open, shortqqq
EC-380Injection timing cannot be con-
trolled.
ground shortqq
Accelerator switch (F/C) circuit open, shortqqq
EC-365
ground shortqq
Needle lift sensor circuit open, shortqqqEC-427
Fuel cut solenoid valve circuit open, ground shortq qqqq
EC-376
shortqqqEngine runs on after turning igni-
tion switch OFF.
Fuel temperature sensor circuit
open, shortqq qq qq qq q qEC-372Compensation for amount of fuel
injected according to fuel tem-
perature does not function.
Accelerator position sensor circuit open, shortqqq qqEC-365
Crankshaft position sensor (TDC) cir-
cuitopen, shortqq qq
EC-385
noiseqqqqq
TROUBLE DIAGNOSESTD27Ti
Symptom Matrix Chart (Cont'd)
EC-341
SYSTEM Ð Engine control systemMalfunction
SYMPTOM
Reference page
Feature of symptom
Check point
HARD/NO START/
RESTART (EXCP. HA) ENGINE STALL HESITATION/SURGING/FLAT SPOT SPARK KNOCK/DETONATION
LACK OF POWER
POOR ACCELERATION
HI IDLE
LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION ABNORMAL SMOKE COLOR
DEAD BATTERY (UNDER CHARGE) Malfunction indicator lamp illuminates.
Can be detected by CONSULT-II?
Fuel cut
NO START (with first firing) NO START (without first firing)
HARD TO START WHEN ENGINE IS COLD
HARD TO START WHEN ENGINE IS HOT
AT IDLE
DURING DRIVING
WHEN DECELERATINGBLACK SMOKE WHITE SMOKE
New CT/CS AA AB AC AD AE AF AG AH AJ AK AL AM AP HA
Start signal circuit open, shortqqEC-449 Start control does not function.
Air conditioner switch circuit
open, ground short
EC-440Air Conditioner does not stop
operating.
shortAir Conditioner does not work.
Ignition switch circuit openq qqq
EC-449
shortEngine does not stop.
Power supply for ECM circuit openqqq
EC-352
shortqq
Throttle control solenoid valve circuit open, short
EC-435Does not operate.
ground shortqq qDoes not stop operating.
EGRC-solenoid valve A, B circuit open, short
EC-431
ground shortqDoes not stop operating.
Glow relay circuit openqqqqq
EC-389Glow lamp does not turn on.
shortGlow lamp does not turn off.
ECM relay (Self-shut off) circuit openqqqq
EC-446
shortqqGround short makes engine
unable to stop.
Air conditioner relay circuit open
EC-440Air conditioner does not operate.
shortAir conditioner does not stop
operating.
ECM, Connector circuit open, shortqqqqqqqqqqqqqq qqqqqqqqqqqEC-346, 452
TROUBLE DIAGNOSESTD27Ti
Symptom Matrix Chart (Cont'd)
EC-342
ECM INSPECTION TABLE
Remarks: 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 result in dam-
age to the ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TERMI-
NAL
NO.WIRE
COLORITEM CONDITIONDATA (DC Voltage and
Pulse Signal)
101
102
103G/R
G/R
G/RFuel cut solenoid valve[Ignition switch ªOFFº]Approximately 0V
[Ignition switch ªONº]BATTERY VOLTAGE
(11 - 14V)
104
105
106B
B
BECM ground[Engine is running]
IIdle speedApproximately 0V
107
108
109Y
Y
YPower supply for ECM[Ignition switch ªONº]BATTERY VOLTAGE
(11 - 14V)
202 Y/RInjection timing control
valve[Engine is running]
IWarm-up condition
IIdle speedApproximately 10 - 12V
NEF480
[Engine is running]
IWarm-up condition
IEngine speed is 2,000 rpmApproximately9-14V
NEF481
204 G/PU Air conditioner relay[Engine is running]
IAir conditioner switch is ªOFFºBATTERY VOLTAGE
(11 - 14V)
[Engine is running]
IBoth air conditioner switch and blower fan switch
are ªONº
(Compressor is operating)Approximately 0.1V
205 Y/PU Oil pressure switch[Ignition switch ªONº]Approximately 0V
[Engine is running]
IIdle speedVoltages
208 R/Y EGRC-solenoid valve A[Engine is running]
IWarm-up condition
IIdle speedApproximately 0.7V
[Engine is running]
IWarm-up condition
IEngine speed is 2,800 rpmBATTERY VOLTAGE
(11 - 14V)
TROUBLE DIAGNOSESTD27Ti
ECM Terminals and Reference Value (Cont'd)
EC-347