1/13/2018 Hilux Surf: Error 5 - Correction resistance (Pump) · The ramblings of galooph

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Hilux Surf: Error 5 - Correction

resistance (Pump)
JANUARY 11, 2014

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Error code 5 relates to a pair of resistors on the side of

the injection pump, at least on the 2.4TD engine.

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These resistors are installed when the pump is

calibrated and ne tune the timing and fuelling.

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I measured both resistors. The grey one was 0.622kΩ

while the beige one was open circuit. The insides are
potted in epoxy, so I dug out the trusty Dremel and
went in.

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The original epoxy.

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After a bit of Dremel action.

You can see a pair of solder tabs sticking up - the

original resistor, which I ground away, was soldered on
here. Judging from the resistor body, it was no more
than a standard 0.25W resistor.

The problem now was knowing what value the resistor

was originally.

I managed to nd a scan of the manual for the Denso

injector pump. I’ve also converted it into a pdf.

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1/13/2018 Hilux Surf: Error 5 - Correction resistance (Pump) · The ramblings of galooph

From that, I was able to work out the resistance value

from the part numbers. Here’s a list linking to the
resistors which are available from Farnell. First, the
grey one.

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1/13/2018 Hilux Surf: Error 5 - Correction resistance (Pump) · The ramblings of galooph

Code Resistance

001 0.243kΩ

002 0.267kΩ

003 0.294kΩ

004 0.316kΩ

005 0.348kΩ

006 0.384kΩ

007 0.412kΩ

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1/13/2018 Hilux Surf: Error 5 - Correction resistance (Pump) · The ramblings of galooph

Code Resistance

008 0.453kΩ

009 0.487kΩ

010 0.523kΩ

011 0.576kΩ

012 0.619kΩ

013 0.681kΩ

014 0.732kΩ

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1/13/2018 Hilux Surf: Error 5 - Correction resistance (Pump) · The ramblings of galooph

Code Resistance

015 0.787kΩ

016 0.866kΩ

017 0.931kΩ

018 1.020kΩ

019 1.100kΩ

020 1.210kΩ

021 1.330kΩ

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Code Resistance

022 1.430kΩ

023 0.068kΩ

025 0.100kΩ

026 0.121kΩ

027 0.133kΩ

028 0.154kΩ

029 0.174kΩ

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Code Resistance

030 0.196kΩ

031 0.221kΩ

Now the beige one.

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1/13/2018 Hilux Surf: Error 5 - Correction resistance (Pump) · The ramblings of galooph

Code Resistance

001 0.154kΩ

002 0.174kΩ

003 0.196kΩ

004 0.221kΩ

005 0.243kΩ

006 0.267kΩ

007 0.294kΩ

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Code Resistance

008 0.316kΩ

009 0.348kΩ

010 0.383kΩ

011 0.412kΩ

012 0.453kΩ

013 0.487kΩ

014 0.523kΩ

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Code Resistance

015 0.576kΩ

016 0.619kΩ

017 0.681kΩ

018 0.732kΩ

019 0.782kΩ

020 0.866kΩ

021 0.931kΩ

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Code Resistance

022 1.020kΩ

023 1.100kΩ

024 1.210kΩ

025 1.330kΩ

026 1.430kΩ

027 1.580kΩ

028 1.780kΩ

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Code Resistance

029 1.960kΩ

030 2.210kΩ

031 2.490kΩ

Solder the appropriate resistors in.

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Now they need sealing from the elements. Check they

read ok on a multimeter rst though! After a good clean
in some isopropyl alcohol, I used some Sugru to seal
them up.

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Instead of Sugru, you could use some proper potting

compound or even some mastic, but ONLY neutral cure
mastic. If the mastic smells of vinegar, don’t use it! The
acetic acid released as it cures will eat into the resistor
wires.

After all that, I reset the ECU and the code 5 had been
eliminated.

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© Copyright 2017 galooph

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