Page 422 of 1833

5 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 4. 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) EGO TO 6.
OK (without CONSULT-II) EGO TO 7.
NG ERepair open circuit or short to ground or short to power in harness or connectors.
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
OK EGO TO 8.
NG EReplace 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
OK EGO TO 9.
NG EReplace accelerator pedal assembly.
DTC 0403 ACCEL POS SENSORZD30DDTi
Diagnostic Procedure (Cont'd)
EC-147
http://vnx.su/
Page 424 of 1833

13 CHECK ACCELERATOR POSITION SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch ªOFFº.
2. Disconnect ECM harness connector.
3. Check harness continuity between accelerator work unit terminal 5 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
OK EGO TO 14.
NG ERepair open circuit or short to ground or short to power in harness or connectors.
14 CHECK ACCELERATOR POSITION SWITCH
Check continuity between accelerator work unit terminals 5 and 6 under the following conditions.
YEC708A
OK or NG
OK (With CONSULT-II) EGO TO 15.
OK (Without CONSULT-II) EGO TO 16.
NG EReplace accelerator pedal assembly.
15 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.
16 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.
17 CHECK INTERMITTENT INCIDENT
Refer to ªTROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENTº, EC-78.
EINSPECTION END
DTC 0403 ACCEL POS SENSORZD30DDTi
Diagnostic Procedure (Cont'd)
EC-149
http://vnx.su/
Page 495 of 1833

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
COLOR ITEM CONDITION DATA (DC Voltage)
46 G Charge air pressure sen-
sor Engine is running.
Warm-up condition
Idle speed
Approximately 2.0V
On Board Diagnosis Logic
Malfunction is detected when ...
Check Items (Possible Cause)
I An excessively high or low voltage from the sensor is sent to
ECM. I
Harness or connectors
(The sensor circuit is open or shorted.)
I Charge air pressure sensor
SEF340VA
SEF627RA
DTC 0905 TURBO PRESSUREZD30DDTi
EC-220
http://vnx.su/
Page 502 of 1833

Description
SYSTEM DESCRIPTION
SensorInput Signal to ECMECM FunctionActuator
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
I Engine starting
I Low engine coolant temperature
I Excessively high engine coolant temperature
I High engine speed
I Wide open throttle
I Low 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-227
http://vnx.su/
Page 503 of 1833

CONSULT-II Reference Value in Data Monitor
Mode
Specification data are reference values.
MONITOR ITEMCONDITION SPECIFICATION
EGR VOL CON/V I
Engine: After warming up
I Air conditioner switch: ªOFFº
I Shift lever: Neutral position
I No-load After 1 minute at idle More than 10 steps
Revving engine up to 3,200 rpm
quickly
0 step
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
COLOR ITEM CONDITION DATA (DC Voltage)
103 R/Y (LHD
mod-
els)
L/R
(RHD
mod-
els) EGR volume control valve
Engine is running.
Warm-up condition
Idle speed 0.1 - 14V
105
109 11 5 G/Y
Y/B
R/L
On Board Diagnosis Logic
DTC No.
Malfunction is detected when ... Check Items (Possible Cause)
1003 IAn excessively low voltage signal is sent to ECM. IHarness or connectors
(The EGR volume control valve circuit is open or
shorted.)
I EGR volume control valve
DTC 1003 EGR VOLUME CONT/VZD30DDTi
EC-228
http://vnx.su/
Page 526 of 1833

13 DETECT MALFUNCTIONING PART
Check the following.
IHarness connectors M787, F66 (LHD models)
I Harness for open or short between glow relay and ECM
ERepair open circuit or short to ground or short to power in harness or connectors.
14 CHECK HARNESS CONTINUITY BETWEEN GLOW RELAY AND GLOW PLUG FOR OPEN AND SHORT
1. Disconnect glow plug harness connector.
2. Check harness continuity between glow relay terminal 3 and glow plug harness connector. Refer to Wiring Diagram.
Continuity should exist.
3. Also check harness for short to ground and short to power.
OK or NG
OK EGO TO 16.
NG EGO TO 15.
15 DETECT MALFUNCTIONING PART
Check the following.
IHarness connectors M45, E202
I Harness connectors E230, E241
I Harness for open or short between glow relay and glow plug
ERepair open circuit or short to ground or short to power in harness or connectors.
16 CHECK GLOW RELAY
Check continuity between glow relay terminals 3 and 5 under the following conditions.
SEF433Y
OK or NG
OK EGO TO 17.
NG EReplace glow relay.
GLOW CONTROL SYSTEMZD30DDTi
Diagnostic Procedure (Cont'd)
EC-251
http://vnx.su/
Page 529 of 1833

Diagnostic Procedure
1 CHECK START SIGNAL OVERALL FUNCTION
With CONSULT-II
1. Turn ignition switch ªONº.
2. Check ªSTART SIGNALº in ªDATA MONITORº mode with CONSULT-II under the following conditions.
SEF604X
Without CONSULT-II
Check voltage between ECM terminal 20 and ground under the following conditions.
SEF415Y
OK or NG
OK EINSPECTION END
NG EGO TO 2.
2 CHECK START SIGNAL INPUT SIGNAL CIRCUIT
1. Turn ignition switch ªOFFº.
2. Disconnect ECM harness connector and ignition switch harness connector.
3. Check harness continuity between ECM terminal 20 and ignition switch terminal 5. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK EGO TO 4.
NG EGO TO 3.
3 DETECT MALFUNCTIONING PART
Check the following.
IHarness connectors M787, F66 (LHD models)
I Harness for open or short between ECM and ignition switch
ERepair open circuit or short to ground or short to power in harness or connectors.
START SIGNALZD30DDTi
EC-254
http://vnx.su/
Page 543 of 1833

4 CHECK OVERALL FUNCTION-II
Check heat up switch indicator in the heat up switch under the following conditions.
MTBL1846
OK or NG
OK EINSPECTION END
NG EGO TO 9.
5 CHECK HEAT UP SWITCH POWER SUPPLY CIRCUIT
1. Turn heat up switch ªOFFº.
2. Turn ignition switch ªOFFº.
3. Disconnect heat up switch harness connector.
4. Turn ignition switch ªONº.
5. Check voltage between heat up switch terminal 2 and ground with CONSULT-II or tester.
MEC983DVoltage: Battery voltage
OK or NG
OK EGO TO 7.
NG EGO TO 6.
6 DETECT MALFUNCTIONING PART
Check the following.
IFuse block (J/B) connector F48
I 10A fuse
I Harness for open or short between heat up switch and fuse
ERepair open circuit or short to ground or short to power in harness or connectors.
7 CHECK HEAT UP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch ªOFFº.
2. Disconnect ECM harness connector.
3. Check harness continuity between ECM terminal 59 and heat up switch terminal 1. Refer to Wiring Diagram.
Continuity should exist.
4. Also check harness for short to ground and short to power.
OK or NG
OK EGO TO 7.
NG ERepair open circuit or short to ground or short to power in harness or connectors.
HEAT UP SWITCHZD30DDTi
Diagnostic Procedure (Cont'd)
EC-268
http://vnx.su/