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ENGINE CONTROL SYSTEM SECTION EC CONTENTS

Contents

1. 114 Crankshaft Position Sensor TDO 114 TROUBLE DIAGNOSES 14 118 Glow Control 118 When you read wiring diagrams e Read GI section HOW TO READ WIRING D e See EL section POWER SUPPLY ROUTING TROUBLE DIAGNOSES 15 126 Air Conditioner Cut Control 126 TROUBLE DIAGNOSES 16 129 EGRC Solenoid Valve 129 TROUBLE DIAGNOSES 17 136 Brake SWITCH evt s UR r 136 TROUBLE DIAGNOSES 18 140 140 TROUBLE DIAGNOSES 19 141 MI amp Data Link Connectors 141 TROUBLE DIAGNOSES 20 145 NON 145 SERVICE DATA AND SPECIFICATIONS SDS 147 General 147 Injection Nozzle MM 147 Inspection and Adjustment 147 IAGRAMS for power distribution circuit e See EL section for NATS information and wiring diagram When you perform trouble diagnoses read GIs IN TROUBLE DIAGNOSES and HOW TO PE ELECTRICAL INCIDENT
2. EGRC solenoid valve c harness connector 134 EGR valve TROUBLE DIAGNOSES 16 BATTERY MEC488B EGRC Solenoid Valve Cont d COMPONENT INSPECTION EGR valve Apply vacuum to EGR vacuum port with a hand vacuum pump EGR valve spring should lift If NG replace EGR valve EGRC solenoid valve Check air passage continuity Air passage Air passage Condition continuity continuity between a and between 12V direct current sup ply between terminals Yes No 1 and 2 If NG replace solenoid valve EC 135 TROUBLE DIAGNOSES 17 Malfunction is detected when e Brake switch circuits are open or shorted Brake Switch The ECM receives signals from two brake switches One is a conventional brake lamp switch the other is referred to as a redundant RDNT brake switch In case the accelerator pedal does not return to the idle position pedal sticks the driver will react by depressing the brake In this emergency situation the ECM will disregard the accelera tor pedal signal and bring back the engine speed to 1200 rpm Check Items Possible Cause e Harness or connectors Brake switch circuits are open or shorted e Stop lamp switch e RDNT brake switch DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1 Turn ignition switch to position and select DATA MONITOR mode with CONSULT II 2 Depress brake pedal for at least 1 minute EC 136 TROUBLE DI
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6. 51449913 5 0009 Josues o1nsseuJd eJeudsouny 9A EA 5 0 Buijoo2 Josues peeds 104409 pue 5 sgy qd U91IMS 25 U91IMS Josues 5 YOUMS 9 V 20 V 9A EA 5 9 034 0 5993 125 12 ENGINE AND EMISSION CONTROL OVERALL SYSTEM Vacuum Hose Drawing e EGRC solenoid valve EGRC solenoid valve B IN V OY XQ 7 EGR valve YEC131A EGRC solenoid valves A and B to EGR valve EGRC solenoid valves A and B to air duct EGRC solenoid valve A to vacuum pump Refer to System Diagram on previous page for vacuum control system EC 13 ENGINE AND EMISSION CONTROL OVERALL SYSTEM System Chart position sensor Fuel injection control Electric governor Control sleeve position sensor Fuel injection timing control Injection timing control valve Fuel temperature sensor Mass air flow sensor Fuel cut control Fuel cut solenoid valve Engine coolant temperature sensor Glow control system Glow relay amp glow lamp Needle lift sensor Accelerator position sensor On board diagnostic system Malfunction indicator ECM On the instrument panel Accelerator position switch
7. 2 3 4 5 ON 1 7 Cooling fan e CONSULT Operating See TROUBLE DIAG NOSIS 8 10 11 12 ON 2 OFF e Combustion gas leak e Color checker Negative chemical tester 4 Gas analyzer e Coolant temperature e Visual Gauge less than 3 4 gauge when driving e Coolant overflow to e Visual No overflow during driv See Changing Engine reservoir tank ing and idling Coolant ENGINE MAINTENANCE in MA section e Coolant return from e Visual Should be initial level in See ENGINE MAINTE reservoir tank to reservoir tank NANCE MA section radiator e Cylinder head Straight gauge feeler 0 1 mm 0 004 in See Inspection CYL gauge mum distortion warping INDER HEAD in EM section e Cylinder block and e Visual No scuffing on cylinder See Inspection CYL pistons walls or piston INDER BLOCK in EM section 1 Turn the ignition switch ON 2 Engine running at 3 000 rpm for 10 minutes 3 Drive at 90 km h 55 mph for 30 minutes and then let idle for 10 minutes 4 After 60 minutes of cool down time For more information refer to OVERHEATING CAUSE ANALYSIS in LC section ON 3 OFF 4 OFF EC 95 TROUBLE DIAGNOSIS 8 Cooling fan relay 1 Cooling fan relay 3 3 j Cooling fan relay 2 YEC391 R DISCONNECT LE Cooling fan motor 1 amp 2 AEC781 Cooling Fan Overheat Cont d COMPONENT INSPECTION Cool
8. ECM F119 Detectable line for mm Non getectable line for DTC Refer to EL POWER REFER TO THE FOLLOWING FUSE BLOCK Junction Box J B E104 FUSE BLOCK Junction Box J B YEC817 TROUBLE DIAGNOSES 20 Start Signal Cont d DIAGNOSTIC PROCEDURE INSPECTION START DATA MONITOR MONITOR NO DTC C2DMM04 amp ECM 22 4 INSPECTION END CHECK OVERALL FUNCTION 1 Turn ignition switch to ON position 2 Check START SIGNAL in DATA MONITOR mode with CONSULT II IGN START OR Turn ignition switch to the LOCK position Disconnect ECM harness con nector Turn ignition switch to START position Check voltage between ECM connector terminal and ground Voltage Ignition switch START Battery voltage Except above Approximately Check if 10A fuse is OK Replace 10A fuse CHECK INPUT SIGNAL CIRCUIT Check the following 1 Turn ignition switch to LOCK posi e Harness or connec tion tors 260 2 Disconnect 10 fuse e Harness for open or 3 Check harness continuity between short circuit between ECM connector terminal and ECM and fuse block fuse block If NG repair harness Continuity should exist or connectors If OK check harness for short circuit NEF223A E 44 m 422 NEF224A Disconnect and reconnect harness con nectors in the circuit Then retest Tr
9. Tr Cont d ee M PROCEDURE Control sleeve position sensor connector 320 INSPECTION START CHECK POWER SUPPLY CIRCUIT Repair harness or connec 1 Turn ignition switch to LOCK position tors 2 Disconnect ECM harness connector and electronic injection pump harness connec NEF196A tor 3 Check harness continuity between control 2 Yn DISCONNECT 5 sleeve position sensor connector terminal p 3 and ECM connector terminal 320 T S LS Continuity should exist Control sleeve position If OK check harness for short circuit sensor connector F50 OL 321 CHECK INPUT SIGNAL CIRCUIT Check harness continuity between control sleeve position sensor connector terminal 2 and ECM terminal 321 Continuity should exist If OK check harness for short circuit Repair harness or connec tors NEF197A EANA Control sleeve position CHECK REFERENCE SIGNAL CIRCUIT sensor connector F50 Check harness continuity between control 9 sleeve position sensor connector terminal O CONNECTOR 7 2 and ECM connector terminal 322 322 6 9 9 Repair harness or connec Continuity should exist If OK check harness for short circuit CHECK COMPONENT Have the injection pump Control sleeve position sensor assembly serviced by an Refer to COMPONENT INSPECTION on authorised service represen next page tative NEF198A Disconnect and reconnect harne
10. Engine ground NEF399 EC 61 TROUBLE DIAGNOSIS 1 Mass Air Flow Sensor MAFS The mass air flow sensor measures the amount of intake air by analysing a part of the entire flow When intake air flows into the intake manifold heat is withdrawn from the hot film By regulat ing the electrical current that flows through the hot film the ECM maintains the hot film temperature on a constant level The amount of electric current that is needed to keep the hot film on a constant temperature level is proportional to the mass of air that flows into the engine NEF663 Check Items Malfunction is detected when Possible Cause e An excessively high or low voltage from the sensor is e Harness or connectors entered to ECM The sensor circuit is open or shorted e Mass air flow sensor DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1 Turn ignition switch to ON position 2 Select DATA MONITOR mode with CONSULT II 3 Start engine and wait for at least 20 seconds EC 62 TROUBLE DIAGNOSIS 1 Mass Air Flow Sensor MAFS BATTERY EC MAFS 01 ENEN Detectable line for DTC Refer to EL POWER Non detectable line for W R W R MASS AIR CONTROL FLOW SEN MODULE S RELAY E91 SE YEC799 EC 63 TROUBLE DIAGNOSIS 1 Mass air flow sensor harness connector 69 1 Mass air flow sensor connector NEF789 DISCONNECT 0 4
11. Symptoms No symptoms except MI collected lights up or Malfunction Code exists at STEP Il Verify the symptom by driving in the condition the customer described STEP Normal Code Malfunction Code at STEP Il at STEP Il Verify the malfunction item by performing the DIAGNOSTIC TROUBLE CON FIRMATION PROCEDURE 2 m U lt Choose the appropriate action STEP V Malfunction Code at STEP Il or IV Normal Code at both STEP II and IV BASIC INSPECTION SYMPTOM BASIS at STEP I or III Perform inspections according to Symptom Matrix Chart TROUBLE DIAGNOSIS FOR SPECIFIC MAL STEP VI FUNCTION ITEM REPAIR REPLACE NG FINAL CHECK Confirm that the incident is completely fixed by performing BASIC INSPECTION and DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE or OVERALL mmm STEP VII FUNCTION CHECK Then erase the unnecessary already fixed Malfunction Item in ECM OK CHECK OUT 1 If the incident cannot be duplicated refer to section Incident Simulation Tests HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT 2 If the on board diagnostic system cannot be performed check main power supply and ground circuit Refer to TROUBLE DIAGNOSIS FOR MAIN POWER SUPPLY AND GROUND CIRCUIT EC 35 TROUBLE DIAGNOSIS Work Flow Description for Work Flow STEP DESCRIPTION Get detaile
12. 2 gt X a tc 2 Lu Oo z LLI EC 28 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT II Cont d SELF DIAGNOSTIC MODE Regarding items detected in SELF DIAG RESULTS mode refer to Diagnostic Trouble chart DATA MONITOR MODE Monitored item ECM Unit input signals Main signals Description Remarks CKPS RPM TDC rpm The engine speed computed from the crankshaft position sensor TDC sig nal is displayed CMPS RPM PUMP rpm COOLAN TEMP S C or F The engine speed computed from the camshaft position sensor PUMP sig nal is displayed The engine coolant temperature deter e When the engine coolant temperature mined by the signal voltage of the sensor is open or short circuited ECM engine coolant temperature sensor is enters fail safe mode The engine cool displayed ant temperature determined by the ECM is displayed VHCL SPEED SE km h or mph The vehicle speed computed from the vehicle speed sensor signal or ABS actuator and electric unit control unit signal is displayed FUEL TEMP SEN C or F The fuel temperature determined by the signal voltage of the fuel tempera ture sensor is displayed ACCEL POS SEN e The accelerator position sensor signal voltage is displayed OFF ACCEL POS Indicates ON OFF condition from the ON OFF accelerator position switch signal C SLEEV POS S V e T
13. 3 Remove fuel hoses supply return and spill and injection tubes 4 Remove air duct and injection pump timing belt cover 5 Remove injection pump timing belt Refer to EM section Injection Pump Timing Belt 6 Remove injection pump sprocket with Tool e Remove key from injection pump shaft and store safely EC 24 Removal Cont d 7 Remove injection pump assembly SEF657S Installation 1 Install key on injection pump shaft then install injection pump sprocket 2 nstall injection pump timing belt Refer to EM section Injection Pump Timing Belt 3 Adjust injection timing Refer to Basic Inspection EC CD 37 4 Install all parts removed NEF866 Fuel cut solenoid valve 20 25 2 0 2 5 14 18 lt D di 53 lt gt C 20 25 2 0 2 5 14 18 7 Nem kg m in Ib 9 kg m ft lb EC 25 ELECTRONIC FUEL INJECTION PUMP Disassembly and Assembly CAUTION Do not disassemble the parts not shown in the illustra tion above e Before installing injection timing control valve apply coat of diesel fuel to O ring and its mating area Insert injection timing control valve straight into bore in fuel pump body After properly positioning injection timing control valve visually check for fuel leaks e After assembling the parts erase Diagnostic Trouble Code DTC and perform DTC CONFIRMATION PROCE DURE or OVERALL FUNC
14. Air conditioner switch EGR valve control EGRC solenoid valve amp Ignition switch ON amp ST POS ling fan Battery voltage Cooling fan control Cooling fan relays Vehicle speed sensor or ABS actuator and electric unit con mum trol unit Air conditioning cut control Air conditioner relay Brake switch Cooling fan motor control Cooling fan relay Atmospheric pressure sensor EC 14 Glow Control System SYSTEM DESCRIPTION Crankshaft position sensor TDC Glow relay Glow plugs Engine coolant temperature Engine coolant temperature sensor Glow lamp When coolant temperature is lower than 75 C 167 F Ignition switch ON After the ignition switch has been turned to ON the glow relay turns ON for a period of time depending on the engine coolant temperature allowing current to flow through the glow plugs Starting After starting the engine current will flow through the glow plugs for 300 seconds or until the coolant temperature exceeds 50 C 122 F Fuel Injection System SYSTEM DESCRIPTION Three types of fuel injection control are provided to accommodate the engine operating conditions normal control idle control and start control The ECM determines the appropriate fuel injection control Under each control the amount of fuel injected is compensated to improve engine performance The ECM performs duty cycle control on the electric governor built into the fuel injecti
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16. O 2 Brake pedal depressed Brake pedal released OFF BRAKE SW 2 e Ignition switch ON O zZ Brake pedal depressed FUEL CUT S V Ignition switch ON OFF ON OFF AIR COND RLY e Air conditioner switch OFF ON OFF ON GLOW RLY e Refer to EC CD 124 e When cooling fan is stopped OFF COOLING FAN e When cooling fan operates at low speed LOW e When cooling fan operates at high speed I Engine After warming up Air conditioner switch OFF EGRC SOL V A Shift lever N OFF No load At sea level 2 800 rpm ON EC 50 TROUBLE DIAGNOSIS General Description Major Sensor Reference Graph in Data Monitor Mode The following are the major sensor reference graphs in DATA MONITOR mode Select SPEED in DATA MONITOR with CONSULT II ACCEL POS SEN C SLEEV POS S ACT INJ TIMG Below is the data for ACCEL POS SEN C SLEEV POS S and ACT INJ TIMG when revving engine quickly up to 3 000 rpm under no load after warming up engine sufficiently Each value is for reference the exact value may vary 9 gt st 9 gt ACCEL POS SEN should increase ME while depressing the accelerator Q pedal and should decrease while releasing it co 29 e st C SLEEV 5 5 should increase gt when depressing the accelerator pedal and should decrease when the pedal is released co 29 eo st cie ACT INJ TIMG
17. Contd Remarks e When the fuel cut solenoid valve is not operating fuel supply is shut off e The control condition of the fuel cut solenoid valve determined by ECM according to the input signal is indi cated OFF Fuel cut solenoid valve is not operating ON Fuel cut solenoid valve is oper ating The air conditioner relay control condi tion determined by ECM according to the input signal is indicated The glow relay control condition deter mined by ECM according to the input signal is displayed Indicates the control condition of the cooling fans determined by ECM according to the input signal LOW Operates at low speed HI Operates at high speed OFF Stopped The control condition of the EGRC solenoid valve determined by ECM according to the input signal is indi cated OFF EGRC solenoid valve is not operating EGRC solenoid valve is oper ating EC 30 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT II Cont d ACTIVE TEST MODE TEST ITEM TARGET F INJ COOLING FAN FUEL CUT SOL V EGRC SOL V A GLOW RLY INJ TIMING CONDITION JUDGEMENT Engine Return to the original trouble condition Fix the target injection quantity using CONSULIT II Ignition switch ON Operate the cooling fan at LOW HI speed and turn OFF using CONSULT II Ignition switch ON Turn solenoid valve ON and OFF with the CONSULT II and
18. TROUBLE DIAGNOSIS 2 66 Engine Coolant Temperature ECT Sensor 66 TROUBLE DIAGNOSIS 3 70 Vehicle Speed Sensor VSS 70 TROUBLE DIAGNOSIS 4 74 Control Sleeve Position Sensor CSPS 74 TROUBLE DIAGNOSIS 5 78 ambe bd 78 TROUBLE DIAGNOSIS 6 82 Injection Timing Control Valve 82 TROUBLE DIAGNOSIS 7 86 Engine Control Module ECM 86 TROUBLE DIAGNOSIS 8 87 Cooling Fan 87 TROUBLE DIAGNOSIS 9 97 Needle Lift Sensor NLS 97 TROUBLE DIAGNOSIS 10 100 Fuel Cut Solenoid Valve 100 TROUBLE DIAGNOSIS 11 104 Fuel Temperature Sensor FTS 104 TROUBLE DIAGNOSIS 12 108 Accelerator Position Sensor amp Switch 108 TROUBLE DIAGNOSIS 13
19. and ground with CONSULT II or tester Voltage Battery voltage Check the following 15A fuse Harness for open or short circuit between ECM relay and battery If NG replace fuse or repair harness or connectors YEC352 DISCONNECT DISCONNECT T S 52 T S CHECK OUTPUT SIGNAL CIRCUIT ECM relay Check harness continuity between ECM connector E91 connector terminal 325 and ECM relay connector terminal 1 IXA Continuity should exist If OK check harness for short circuit Check harness connec tors Repair harness connec tors 325 CHECK ECM RELAY NEF189A 1 Apply 12V direct current between ECM relay connector terminals 1 2 2 Check continuity between engine control module relay connector terminals 3 and Replace ECM relay 5 12V applied Continuity exists No voltage applied ECM relay No continuity connector CHECK GROUND CIRCUIT NG 1 Turn ignition switch to LOCK position 2 Check harness continuity between ECM connector terminals C104 105 and engine ground Continuity should exist If resistance is too high loosen clean and retighten engine ground ECM CONNECTOR If OK check harness for short circuit 104 105 106 Repair harness or connec tors YEC354 DISCONNECT Check ECM pin terminals for damage and check the connection of ECM harness con nector INSPECTION END
20. below initial injection pressure 2 Check that there is no dripping from the nozzle tip or around the body 3 If there is leakage replace nozzle SPRAY PATTERN TEST 1 Check spray pattern by pumping tester handle one full stroke per second a main spray angle is within 30 degrees as shown injec tion nozzle is good b It is still normal even if a thin stream of spray deviates from the main spray pattern B 2 lest again and if spray pattern is not corrected replace nozzle EC 23 9 el ELECTRONIC FUEL INJECTION PUMP 6 3 8 2 0 64 0 84 55 6 72 9 16 21 1 6 2 1 12 15 2 7 31 37 3 2 3 8 23 27 6 59 69 6 0 7 0 43 51 kg m in Ib kg m ft lb Rear back cover Injection pump sprocket Injection pump bracket Injection timing mark Yellow painted HS pe lly Without V O mark SEF656S 6 3 8 3 0 64 0 85 55 6 73 ET 1 3 1 8 9 13 Front of engine 16 1 6 2 1 12 a a 2 4 2 8 17 20 49 59 7 6 U 5 0 6 0 36 43 ma 27 2 4 2 8 17 20 NEF777 Water connector 7 Electronic fuel injection pump Bracket Key Bracket Removal 1 Remove battery Disconnect electronic injection pump harness connectors 2 Set No 1 piston at TDC on its compression stroke TDC Crankshaft pulley notch without painted mark
21. should increase when depressing the accelerator pedal and should decrease when 0 the pedal is released 2 LS 780 51 TROUBLE DIAGNOSIS General Description ECM Terminals and Reference Value PREPARATION The ECM is located beneath the heater unit To access the ECM remove the center console under cover at the passenger side Perform all voltage measurements with all connectors con nected Since the ECM harness connector cannot be accessed from the backside voltages should be measured by connecting a break out box SST between ECM and ECM harness connec tor SEF883Y When measuring e Use extreme care not to touch 2 pins at the same time e Note that the data is for comparison and may not be exact e Be sure ECM unit is properly grounded before checking 2 To ECM har ness connec tor Y adapter NEF162A EC 52 TROUBLE DIAGNOSIS General Description ECM Terminals and Reference Value Cont d ECM INSPECTION TABLE 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 damage to the ECM s transistor Use a ground other than ECM terminals such as the ground TER WIRE DATA MINAL ITEM CONDITION DC Voltage and COLOR NO Pulse Signal gApproximately 10 5V Warm up condition Idle speed SEF562S 102 B L
22. 0 1V BATTERY VOLTAGE 11 14V Approximately OV Approximately Approximately OV TROUBLE DIAGNOSIS General Description ECM Terminals and Reference Value Cont d TER WIRE MINAL looi on ITEM CONDITION Warm up condition D Idle speed Crankshaft position sen sor TDC Signal Engine is running Engine speed is 2 000 rom Warm up condition Idle speed Needle lift sensor Warm up condition Engine speed is 2 000 rom oe is runnina ture sensor g 9 Fuel temperature sensor Engine is running Ignition switch LOCK Ignition switch ON 349 Fuel cut solenoid valve EC 56 DATA DC Voltage and Pulse Signal Approximately NEF867 Approximately NEF868 Approximately 3 8 4 0V NEF869 Approximately 3 8 4 0V NEF870 0 6 4 8V Output voltage varies with engine coolant tem perature 0 6 4 8V Output voltage varies with fuel temperature Approximately BATTERY VOLTAGE 11 14V TROUBLE DIAGNOSIS General Description ECM Terminals and Reference Value Cont d TER WIRE DATA MINAL ITEM CONDITION DC Voltage and COLOR NO Pulse Signal Engine is running Both air conditioner switch and blower Approximately Air conditioner switch switch are ON Compressor operates 403 BATTERY VOLTAGE Air conditioner switch is OFF 11 14V Igniti
23. 2 connector terminal 3 Continuity should exist If OK check harness for short circuit Check harness continuity between cooling fan motor 2 connector terminal 1 and cooling fan relay 1 connector terminal 3 cooling fan motor 2 connector terminal 2 and ground Continuity should exist If OK check harness for short circuit Repair harness or con nectors EC 91 TROUBLE DIAGNOSIS 8 Cooling Fan Overheat Cont d Cooling fan relay 1 connector E4 CHECK OUTPUT SIGNAL CIRCUIT 219 1 Disconnect ECM harness connector 2 Check harness continuity between ECM terminal and cooling fan relay 1 con nector terminal 2 Continuity should exist If OK check harness for short circuit NEF207A CHECK COMPONENT Cooling fan relay 1 2 Refer to COMPONENT INSPECTION EC CD 96 CHECK COMPONENT Cooling fan motors Refer to COMPONENT INSPECTION IEC CD 96 OK Disconnect and reconnect harness connec tors in the circuit Then retest Trouble is not fixed Check ECM pin terminals for damage and check the connection of ECM harness con nector Reconnect ECM harness connector and retest INSPECTION END PROCEDURE B INSPECTION START CHECK POWER SUPPLY 1 Turn ignition switch to LOCK position 2 Disconnect cooling fan relay 2 3 and cooling fan motor 1 3 Turn ignition switch to ON position 4 Check voltage between cooling fan motor
24. CHECK the malfunction item might not be confirmed e This is Quick Reference of OVERALL FUNCTION CHECK Details are described in each specific TROUBLE DIAGNOSIS CONSULT II may not detect but self diagnostic results are available with MI EC 46 95 wojdwAs _ II LINSNOO ue O SOJEUILUN JOJEOIPU uonounj e A J ll 39uvHO X 0709 3MONS 1VINHON8V serra lt _ CD20T SYMPTOM 9 i 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 POT Y Symptom Matrix Chart _ SI 3NION3 NAHM LYVLS OL GYVH TROUBLE DIAGNOSIS General Description VH dOX3 LHVLS3H LHVLS ON QHVH 184 1 LHWLS ON 194 UM LHYLS ON O 2 c 9 8 sE 9 E 55 gt olg lt gt u 95 _ 6 o als coe gt 89 515 4 98 oO 8 2 2 5 2 e High Possibility Item Low Possibility Item 4 Symptom varies depending on off position of air duct etc EC 47 9Q L 40sues uonisod
25. Cause Procedure tion Check Illumination Page Quick Ref e ECM IGN ON EC CD 86 Harness or connectors The glow relay circuit is open or shorted IGN ON EC CD 118 Glow relay Harness or connectors The air conditioner relay circuit is open or shorted IGN ON EC CD 128 Air conditioner relay Harness or connectors The EGRC solenoid valve A circuit is open or shorted RUNNING Lighting up EC CD 12d EGRC solenoid valve Harness or connectors Brake switch circuits are open or shorted RUNNING Lighting tip EC CD 138 Brake lamp switch RDNT brake switch Harness or connectors The ECCS D relay circuit is shorted EGGS Dicey IGN ON Lighting up 86 ECM ECM Lighting up 86 Harness or connectors The injection timing control valve circuit is open or IGN ON Lighting up EC CD 82l shorted Injection timing control valve IGN ON ECM Needle lift sensor RUNNING Lighting up 97 Low battery voltage e This is Quick Reference of DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE Details are described in each specific TROUBLE DIAGNOSIS e The OVERALL FUNCTION CHECK is a simplified and effective way to inspect a component or circuit In some cases the OVERALL FUNCTION CHECK is used rather than a DIAGNOSTIC TROUBLE CONFIRMATION PRO CEDURE When no DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE is available the NG result of the OVERALL FUNCTION CHECK can be con
26. Cooling f 2 1 4 Cooling fan motor 1 connector 3 connector 3 122 fan 2 1 irt Pi NEF416 Under the T Radiator TEES Cooling fan motor 2 harness connector ay 2 WR NEF417 DISCONNECT DISCONNECT TED motor 1 Mr m Cooling fan 2 relay 1 CS GIO nector 13 IPSI Cooling fan relay 2 connector Tun YEC386 46 gt D Een connector E45 connector E usn W L YEC387 CHECK POWER SUPPLY Turn ignition switch to LOCK posi Check the following e 10A fuse tion 40A 100A fusible Disconnect cooling fan relay 1 and links fan motor 1 connector Turn ignition switch to ON position Harness for open or short circuit between cooling fan motor 1 and battery Harness for open or short circuit between cooling fan relay 1 and fuse If NG replace fuse or fusible links or repair har ness or connectors Check voltage between cooling fan motor 1 connector terminal 1 fan relay 1 connector terminal 1 and ground Voltage Battery voltage CHECK GROUND CIRCUIT 1 Turn ignition switch to LOCK posi tion 2 Disconnect cooling fan relay 2 and fan motor 2 harness connector 3 Check harness continuity between cooling fan relay 1 con nector terminal 5 and cooling fan relay 2 connector terminal 4 cooling fan motor 1 con nector terminal 2 and cooling fan relay
27. FTS Cont d COMPONENT INSPECTION Fuel temperature sensor Wait until fuel temperature sensor reaches room temperature Check resistance between terminals 5 and 6 Fuel temperature C F Resistance kQ 25 77 Approximately 1 9 If NG have the injection pump assembly serviced by an rised service representative EC 107 TROUBLE DIAGNOSIS 12 Malfunction is detected when Accelerator Position Sensor amp Switch The accelerator position sensor is installed on the upper end of the accelerator pedal assembly The sensor detects the accel erator position and sends a signal to the ECM The ECM uses the signal to determine the amount of fuel to be injected LO E mE gt 5 2 O 45 90 Throttle valve opening angle deg NEF822 Check Items Possible Cause e An excessively low or high voltage from the sensor is e Harness or connectors detected by the ECM The sensor or switch circuit is open or shorted e Accelerator position sensor e Accelerator position switch DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1 Turn ignition switch to ON position 2 Select DATA MONITOR mode with CONSULT II 3 Depress accelerator pedal fully and keep it for at least 1 second Then release it and wait at least 5 seconds DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE For accelerator sti
28. OFF duty cycle ratio makes it possible to achieve an optimal advance angle and accurately control fuel injection timing Check Items Possible cause e Injection timing feedback system does not operate prop e Harness or connectors erly This system consists essentially of ECM injection Injection timing control valve needle lift sensor crankshaft timing control valve and needle lift sensor position sensor TDC circuits Injection timing control valve Needle lift sensor Crankshaft position sensor TDC Air in fuel line Injection timing control valve circuit it open or shorted e Harness or connectors The Injection timing control valve is open or shorted Injection timing control valve DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE FOR INJECTION TIMING CONTROL SYSTEM 1 Turn ignition switch to position and select DATA MONITOR mode with CONSULT I 2 Start engine Run engine for 10 seconds at idle NOTE If malfunction occurs intermittently conduct suitable driv ing pattern for 10 minutes This makes it possible to deter mine the diagnostic trouble DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE FOR INJECTION TIMING CONTROL VALVE CIRCUIT 1 Turn ignition switch to ON position 2 Select DATA MONITOR mode with CONSULT II 3 Wait at least 2 seconds EC 82 TROUBLE DIAGNOSIS 6 Injection Timing Control Valve Cont d EC TCV 01 BATTERY 15 Refer to EL POWER W R Detectable line fo
29. __ ECM O CONNECTOR 3 Mass air flow sensor connector NEF191A ass air flow sensor connector DISCONNECT Mass Air Flow Sensor MAFS Cont d DIAGNOSTIC PROCEDURE INSPECTION START CHECK POWER SUPPLY NG Turn ignition switch to LOCK position Disconnect mass air flow sensor harness connector Turn ignition switch to ON position Check voltage between mass air flow sensor connector terminal 2 and ground Voltage Battery positive voltage CHECK GROUND CIRCUIT NG 1 Turn ignition switch to LOCK position 2 Disconnect ECM harness connector 3 Check harness continuity between mass air flow sensor connector terminal 3 and ECM connector terminal 218 Continuity should exist If OK check harness for short circuit NG CHECK INPUT SIGNAL CIRCUIT Check harness continuity between mass air flow sensor connector terminal 4 ECM connector terminal 223 mass air flow sensor connector terminal G and ECM connector terminal 224 Continuity should exist If OK check harness for short OK CHECK COMPONENT NG Mass air flow sensor Refer to COMPONENT INSPECTION on next page Trouble is not fixed INSPECTION END Check ECM pin terminals for damage or the connection of ECM harness connector EC 64 Repair harness or connec tors Repair harness or connec tors Repair harness or connec tors Replace mass
30. as it may adversely affect electronic control sys tems depending on its installation location 1 Keep the antenna as far as possible away from the ECM 2 Keep the antenna feeder line more than 20 cm 7 9 in away from the harness of elec tronic controls Do not let them run parallel for a long dis tance 3 Adjust the antenna and feeder line so that the standing wave ratio can be kept small 4 Be sure to ground the radio to vehicle body ECM HARNESS HANDLING Connect ECM harness connectors securely A poor connection can cause an extremely high surge voltage to develop in coil and condenser thus resulting in damage to 105 Keep ECM harness at least 10 cm 3 9 in away from adjacent harnesses to prevent an ECM system malfunction due to receiving external noise degraded operation of 105 etc Keep ECM parts and harnesses dry Before removing parts turn off ignition switch and then disconnect battery ground cable NEF390 PRECAUTIONS AND PREPARATION Supplemental Restraint System SRS AIR BAG and SEAT BELT PRE TENSIONER 0002 The Supplemental Restraint System AIR BAG and SEAT BELT PRE TENSIONER used along with seat belt help to reduce the risk or severity of injury to the driver and front passenger in a frontal collision The Supplemental Restraint System consists of air bag modules located in the center of the steering wheel and on the instrument panel on the p
31. ection HOW TO FOLLOW FLOW CHART RFORM EFFICIENT DIAGNOSIS FOR AN For clarification of system component abbreviations and terminology read Gl section SAE J1930 TERMINOLOGY LIST EC 2 PRECAUTIONS AND PREPARATION Tool number Tool name KV11289004 Nozzle cleaning kit 1 KV11290012 Box 2 KV11290110 Brush 3 11290122 Nozzle oil sump scraper 4 11290140 Nozzle needle tip cleaner G KV11290150 Nozzle seat scraper KV11290210 Nozzle holder 7 11290220 Nozzle hole clean ing needle NT296 KV109E0010 Break out box NT825 KV109E0050 Y cable adapter NT826 KV11292010 Nozzle centering device NT293 KV11100300 No 2 4 injection nozzle holder socket NT563 Special Service Tools Description Break Out Box oooooooooooooocooonoon ooocooooooooooooooooo EC 3 PRECAUTIONS AND PREPARATION Special Service Tools Cont d Tool number Tool name KV119E0030 No 1 injection nozzle holder socket Description NT648 EC 4 PRECAUTIONS AND PREPARATION Engine Fuel amp Emission Control System ECM ECCS D control module Do not disassemble ECM e battery terminal is disconnected the memory will return to the ECM value The ECM will now start t
32. it up suffi ciently Air conditioner is OFF 2 Perform diagnostic test mode II Self diagnostic results Make sure that diagnostic trouble code No 55 is displayed Make sure that EGR diaphragm moves up and down Use your finger or a suitable tool under the following conditions At idle Spring does not move Racing engine from idle to 2800 rpm Spring moves up and down EGR e eg C DEA NEF434 CHECK VACUUM SOURCES TO EGR OK CHECK COMPONENTS VALVE EGR valve 1 Disconnect vacuum hoses to EGR See page EC CD 135 valve 2 Make sure that vacuum exists under the following conditions At idle Vacuum should not exist Racing engine from idle to 2800 rpm Vacuum should exist Replace malfunctioning component s EC 133 TROUBLE DIAGNOSES 16 EGRC Solenoid Valve Cont d ACTIVE TEST Orp CHECK CONTROL FUNCTION CHECK VACUUM 1 Turn ignition switch to ON HOSE position Check vacuum hose 2 2 Turn EGRC solenoid valve A for clogging cracks or ON and OFF in ACTIVE improper connection TEST mode with CONSULT II C2ESAO01 and check operating sound OR Check voltage between EGRC solenoid valve A connector ter minal 1 and ground with tester under the following condi tions Voltage At idle Battery voltage Engine speed is 2 800 rpm Approximately 0 4V Clogging Improper connection NEF846
33. listen to operating sound Ignition switch ON Turn solenoid valve ON and OFF with the CONSULT II and listen to operating sound Ignition switch ON Engine stopped Turn the glow relay ON and OFF using CONSULT II and listen to operating sound Engine Return to the original trouble condition Retard the injection timing using CONSULT II If trouble symptom disappears see CHECK ITEM Cooling fan moves at LOW speed and stops Solenoid valve makes an operating sound Solenoid valve makes an operating sound Glow relay makes the operating sound If trouble symptom disappears see CHECK ITEM EC 31 CHECK ITEM REMEDY Control sleeve position sensor Harness and connector Cooling fan motor Harness and connector Solenoid valve Harness and connector Solenoid valve Harness and connector Fuel pump relay Adjust initial injection timing ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT II Contd REAL TIME DIAGNOSIS IN DATA MONITOR MODE CONSULIT II has two kinds of triggers and they can be selected by touching SETTING in DATA MONI TOR mode 1 AUTO TRIG Automatic trigger e The malfunction will be identified the CONSULT II screen in real time In other words DTC and malfunction item will be displayed at the moment the malfunction is detected by ECM DATA MONITOR can be performed continuously until a malfunction is detected However DAT
34. of the ECM and tension of return spring installed to rotor The larger the current flow through the coil the greater the rotor s rotating angle This means that the control sleeve moves to the right increasing the amount of fuel injected The ECM regulates the current flow through the coil by chang ing the duty cycle ratio which controls the ON OFF operation of the electric governor grounding circuit Check Items Possible cause e Fuel injection feedback system does not operate properly e Main power supply circuit ECM connector terminals 107 This system consists essentially of ECM electric governor 108 C109 and fuse and control sleeve position sensor e Harness or connectors Electric governor and control sleeve position sensor cir cuit e Electric governor e ECM DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1 Turn ignition switch to ON position and select DATA MONITOR mode with CONSULT I 2 Start engine above 1 200 rpm 3 Runit for 2 seconds above 1 200 rpm Return engine speed to idle NOTE If malfunction occurs intermittently conduct suitable driv ing pattern for 10 minutes This makes it possible to deter mine the diagnostic trouble EC 78 TROUBLE DIAGNOSIS 5 Electric Governor Cont d BATTERY EC GOVN 0 1 Detectable line for DTC Non detectable line for Refer to EL POWER INJECTION PUMP ELECTRIC GOVER NOR F50 WIR 27 ENGINE CO
35. plug connector connector BI E CHECK POWER SUPPLY II Check the following 1 Disconnect glow plug harness con e Harness connectors nector CE 2 Check harness continuity between e Harness for open or E glow plug harness connector and short circuit between glow relay harness connector termi glow plug and glow nal 3 relay Continuity should exist If NG repair harness or If OK check harness for short cir connector cuit YEC374 CHECK GLOW PLUG AND GLOW RELAY Refer to COMPONENT INSPECTION Replace glow plug or glow relay Disconnect and reconnect harness connectors in the circuit Then retest INSPECTION END EC 123 Pre glow time After glow time sec lt gt 20 0 20 40 TROUBLE DIAGNOSES 14 Glow Control System Cont d SYSTEM OPERATION CHECK Set voltmeter between glow plug and engine body 1 Pre glow control system a Turn ignition switch to ON position b Read voltage Voltage Battery voltage for an engine coolant temperature dependent time Repeatedly turning the ignition switch to ON position and to LOCK position may change the pre glow time 4 32 68 104 Engine coolant temperature 40 20 0 20 40 4 32 68 104 Engine coolant temperature Glow relay Ohmmeter NEF838 2 After glow system Start engine and read voltage Voltage Battery voltage for 5 minutes Engine coolant temperature is lower than 50 C
36. 0 60 40 4 82 68 104 140 Engine coolant temperature gt F Post glow Time gt 40 20 0 20 40 60 40 4 32 68 104 140 Engine coolant temperature F NEF834 COMPONENT DESCRIPTION Glow plug Ceramic heater TR The 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 SEF857S Check Items Malfunction is detected when Possible cause e Glow relay signal circuit is open or shorted e Harness or connectors The glow relay signal circuit is open or shorted e Glow relay e Glow indicator lamp circuit is open or shorted e Harness or connectors The glow indicator lamp circuit is open or shorted e Glow lamp EC 118 TROUBLE DIAGNOSES 14 Glow Control System Cont d DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1 Turn ignition switch to ON position 2 Select DATA MONITOR mode with CONSULT II 3 Wait at least 5 seconds EC 119 TROUBLE DIAGNOSES 14 Glow Control System Cont d EC GLOW 01 FUSE o BLOCK IGNITION SWITCH ON or START Refer to EL POWER 15A 80A i B R E Detectable line for DTC Non detectable line for DTC Models before VIN P11U0548750 Models after VIN P11U0548750 COMBINATION METER GLOW INDICATOR LAMP W R E89 F
37. 1 Turn ignition switch to LOCK posi tion 2 Disconnect ECM harness connector and needle lift sensor harness con nector Check harness continuity between needle lift sensor connector terminal 1 and ECM connector terminal 345 Continuity should exist If OK check harness for short cir cuit Repair harness or con nectors CHECK GROUND CIRCUIT Check resistance between needle lift sensor connector terminal and ECM connector terminal 333 Continuity should exist If OK check harness for short circuit Repair harness or con nectors CHECK NO 1 INJECTION NOZZLE FOR CLOGGING Refer to spray pattern test of INJEC TION NOZZLE If NG replace No 1 injection nozzle Disconnect and reconnect harness connectors in the circuit Then retest Trouble is not fixed Check ECM pin terminals for damage and check the connection of ECM har ness connector Reconnect ECM har ness connector and retest INSPECTION END EC 99 TROUBLE DIAGNOSIS 10 Fuel Cut Solenoid Valve Fuel cut solenoid valve When the ignition switch is OFF the ECM turns the fuel cut solenoid valve OFF under this condition no current flows through the fuel cut solenoid valve shutting off fuel supply ignition When the engine is not operating due to trouble the fuel cut switch solenoid valve may be OFF even when the ignition switch is ON SEF667S Check Items Malfunction i hen alfunctio
38. 1 connector terminal 1 cooling fan relay 2 connector terminal 1 cool ing fan relay 3 connector terminals 1 amp 3 and ground Voltage Battery voltage Cooling fan Cooling fan Cooling fan motor 1 relay 2 relay 3 connector 1 connector connector 3 2 51 NEF203A EC 92 Check the following e Harness connectors Harness for open or short circuit between cooling fan relay 1 and ECM If NG repair harness or con nectors Replace cooling fan relay Replace cooling fan motors Check the following 10A fuse 40A 50A 100A fusible links Harness for open or short circuit between fan motor 1 fan relay 3 and fusible link or fan relay 2 3 and fuse If NG replace fuse or fus ible link or repair harness or connectors TROUBLE DIAGNOSIS 8 Cooling Fan Overheat Cont d 5 Cooling fan motor 1 connector Cooling fan relay 2 connector Cooling fan relay 3 Cooling fan connector motor 2 AAE connector 5 LQ W L W L NEF876 AE emm fan motor 2 connector 2 YEC389 Cooling fan relay 3 connector _ fofconnector 220 x t zl 5 Cooling fan relay 2 connector NEF204A CHECK GROUND CIRCUIT 1 Turn ignition switch to LOCK position 2 Disconnect cooling fan motor 2 harness connector 3 Check harness continuity between cooling fan motor 1 co
39. 12232 60 C CF NEF839 COMPONENT INSPECTION Glow relay 1 Check relay for coil continuity between glow relay terminals 1 2 Continuity should exist 2 Check relay for proper operation by applying 12V dc voltage between glow relay terminals 1 2 and checking con tinuity between terminals 3 5 Coil voltage Continuity and Contact point ov OFF 12V Yes ON SEC564B EC 124 TROUBLE DIAGNOSES 14 Glow Control System Cont d Glow plug J Glow nut Connecting plate Glow harness Washer Spring washer Glow plug SEC565B 1 2 Remove glow plug connecting plate Check each glow plug for continuity Continuity should exist Approximately 0 50 at 25 C 77 F If NG replace glow plug Install glow plug connecting plate securely Do not bump glow plug heating element If it is bumped replace glow plug with new one If glow plug is dropped from a height of 0 1 m 3 94 in or greater replace with new one If glow plug installation hole is contaminated with carbon remove using a reamer or suitable tool Hand tighten glow plug by turning it 2 to 3 times then tighten using a tool to specified torque 15 20 N m 1 5 2 0 kg m 11 14 ft lb EC 125 TROUBLE DIAGNOSES 15 Malfunction is detected when e Air conditioner relay signal circuit is shorted Air Conditioner Cut Control The Air Conditioner relay is controlled by the EC
40. 1U0583350 IGNITION SWITCH BATTERY ON or START EC VSS 01 FUSE BLOCK Refer to EL POWER J B Wa Dectable line for DTC Non detectable line for DTC L Y Y M50 M52 ORM m s M COMBINATION LY y F103 8 METER ESI SPEEDOMETER H M38 L Y Y gt VEHICLE SPEED E SENSOR F25 5 69 F104 3 ORAW do R 3 F104 M50 B B B B B EM ECM e M28 M26 REFER TO THE FOLLOWING FUSE BLOCK Junction Box J B e LL SEE E es 12 34 516 71819 10 314 56 ese W 1 0485 fase e 89 440 m DES YEC801 EC 71 TROUBLE DIAGNOSIS 3 Vehicle Speed Sensor VSS Cont d MODELS AFTER VIN P11U0583350 IGNITION SWITCH BATTERY ON or START EC VSS 02 EE Detectable line for DTC FUSE ed BLOCK Refer to EL POWER Non detectable line for DTC a B With ABS Without ABS LIY Y 89 52 lcu LIY Y LIY Y 27 3 VEHICLE SPEED SENSOR o Hp oa ef ABS 5 p CNN m L ACTUATOR AND ELECTRIC UNIT CONTROL UNIT REFER TO THE FOLLOWING FUSE BLOCK JUNCTION BOX J B 2 3 42 412 4 01202 403 404 405 4 6 407 408 409 HUS YEC101A EC 72 TROUBLE DIAGNOSIS 3 Vehicle Speed Sensor VSS Cont d DIAGNOSTIC PROCEDURE INSPECT
41. 25 2 2 2 5 kg m 16 18 ft lb Spill tube 39 49 4 0 5 0 kg m 29 36 ft lb Always clean the nozzle holes Always use new injection nozzle gasket Note that small washer should be installed in specified direction d Bleed air from fuel system Nozzle side No 1 injection nozzle AL u 119 0030 PPR NEF774 Test and Adjustment WARNING When using nozzle tester be careful not to allow diesel fuel sprayed from nozzle to contact your hands or body and make sure your eyes are properly protected with goggles INJECTION PRESSURE TEST 1 Install nozzle to injection nozzle tester and bleed air from flare nut EF791A EC 22 A B 2 j Faulty Jn P Ps SEF672A SEF674A TU wooo y Wrong SEF079S INJECTION NOZZLE and Adjustment Pump the tester handle slowly one time per second and watch the pressure gauge 3 Read the pressure gauge when the injection pressure just starts dropping Initial injection pressure Used 14 423 15 651 kPa 144 2 156 5 bar 148 159 kg cm 2 091 2 269 psi New 15 000 16 000 kPa 150 0 160 0 bar 153 163 kg cm 2 175 2 320 psi Always check initial injection pressure using a new nozzle If the pressure is not correct replace nozzle assembly LEAKAGE TEST 1 Maintain the pressure at about 981 to 1 961 kPa 9 8 to 19 6 bar 10 to 20 kg cm 142 to 284 psi
42. 485 GLOW PLUG Resistance at 25 C 77 0 5 ACCELERATOR POSITION SENSOR Resistance Throttle valve conditions at 25 C 77 F Approximately 1 2 1 2 1 9 Completely closed Partially open Completely open Approximately 1 9 FUEL TEMPERATURE SENSOR Temperature C F Resistance kQ 25 77 Approximately 1 9 EC 147 SERVICE DATA AND SPECIFICATIONS SDS NOTE EC 148
43. 48750 Models after 1100548750 5 185 2 13 PH 8 I gt 16 0 DATA LINK MALFUNCTION CONNECTOR INDICATOR M59 7 1 5 4 BR W G R B B W FUSE BLOCK J B 1 OR L BR W G R B 690 Ca DS 2104 OR L BR W G R B B B B B B B e em LL L 1 n 77 F15 F18 M28 M26 M is E15 NH REFER TO THE FOLLOWING FUSE BLOCK 755 Junction Box J B 8 7 6 5 4 3 211 i1 2 3 4 5 96 7 8 E 11 12 13 14 15 16 17 18 19 20 21 22 A91 480 439 494 436 4361437 438 430 440 421 422 423 404 425 426 427 428 429 430 207 208 212 44 1 412 413 414 415 416 417 418 419 420 401 402 409 404 405 406 407 408 409 410 YEC104A EC 142 TROUBLE DIAGNOSES 19 Combination meter harness connector YEC380 Combination meter harness connector YEC381 ru 44 DISCONNECT E uL 89 at 5 Combination meter harness connector eH NEF222A MI Data Link Connectors Cont d DIAGNOSTIC PROCEDURE MODELS BEFORE VIN P11U0548750 INSPECTION START MI circuit CHECK MI BULB Turn ignition switch to LOCK posi tion Disconnect combination meter har ness connector Apply battery voltage between com bination meter terminal 5 and 3 Check that MI lits on Repla
44. 7 Air conditioner relay harness connector E56 3 YEC375 1460 Air conditioner relay ECM O CONNECTOR harness connector 204 3 1 2 NEF218A CHECK POWER SUPPLY Turn ignition switch to LOCK posi tion Disconnect air conditioner relay har ness connector Turn ignition switch to ON position Check voltage between air condi tioner relay connector terminals 2 5 and engine ground Voltage Battery voltage CHECK GROUND CIRCUIT 1 Turn ignition switch to LOCK posi tion 2 Disconnect ECM harness connector 3 Check harness continuity between ECM harness connector terminal and air conditioner relay har ness connector terminal 1 Continuity should exist If OK check harness for short cir cuit CHECK AIR CONDITIONER RELAY Refer to HA section for inspection Disconnect and reconnect harness connectors in the circuit Then retest Trouble is not fixed Check ECM pin terminals for damage and check the connection of ECM har ness connector Reconnect ECM har ness connector and retest INSPECTION END EC 128 Check the following e Harness and connec tors for open or short circuit between ignition switch and air condi tioner relay e 10A fuse If NG replace or repair the parts affected Check the following e Harness connectors e Harness for open or short circuit between ECM and air condi tioner relay If NG repair
45. 96 m P L WG R R R W R ES ECM GLOW GRL O PLUG E117 REFER TO THE FOLLOWING FUSE BLOCK 1 2 3 4 5 6 7 8 9 10 11 JUNCTION BOX J B LHE W BBE LAED Slee ay Gs i ES 102 120 Glow relay ee LUT LPS CE 0 ETE Glow relay harness connector AEA Glow relay con nector Jee Glow relay connector jO CONNECTOR 214 NEF215A TROUBLE DIAGNOSES 14 Glow Control System Cont d DIAGNOSTIC PROCEDURE INSPECTION START Glow relay signal circuit CHECK MAIN POWER SUPPLY Check power supply to ECCS D relay Refer to TROUBLE DIAGNOSIS FOR POWER SUPPLY CHECK POWER SUPPLY 1 Turn ignition switch to the LOCK position 2 Disconnect glow relay 3 Turn ignition switch to the ON posi tion 4 Check voltage between glow relay connector terminals 1 5 and ground with tester Voltage Battery voltage CHECK OUTPUT SIGNAL CIRCUIT 1 Turn ignition switch to the LOCK position 2 Disconnect ECM harness connector 3 Check harness continuity between ECM connector terminal and glow relay connector terminal 2 Continuity should exist If OK check harness for short cir cuit CHECK GLOW PLUG AND GLOW RELAY Refer to COMPONENT INSPECTION Disconnect and reconnect harness connecto
46. A MONITOR cannot continue any longer after the malfunction detection 2 MANU TRIG Manual trigger e Malfunction item will not be displayed automatically CONSULIT II screen even though a malfunc tion is detected by ECM DATA MONITOR can be performed continuously even though a malfunction is detected Use these triggers as follows 1 AUTO TRIG While trying to detect the malfunction item by performing the DIAGNOSTIC TROUBLE CONFIR MATION PROCEDURE be sure to select to DATA MONITOR AUTO TRIG mode You can con firm the malfunction at the moment it is detected e While narrowing down the possible causes CONSULT II should be set in DATA MONITOR AUTO TRIG mode especially in case the incident is intermittent Inspect the circuit by gently shaking or twisting Suspicious connectors components and harness in the DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE The moment a malfunction is found the malfunction item will be displayed Refer to GI section Incident Simulation Tests in HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT 2 MANU TRIG e Ifthe malfunction is displayed as soon as DATA MONITOR is selected reset CONSULT II to MANU TRIG By selecting MANU TRIG you can monitor and store the data The data can be utilized for further diagnosis such as a comparison with the value for the normal operating condition DATA MONITOR SET RECORDING COND SET RECORD
47. AGNOSES 17 Brake Switch Cont d BATTERY EC BRK SW 01 Detectable line for DTC J B Refer to EL POWER Non detectable line for DTC LU LHD models E104 RHD models Previous models lt NH gt New models STOP LAMP STOP LAMP DEPRESSED SWITCH SWITCH ren R B R B 22 F104 STOP LAMP ES E43 M50 FUSE R G gt SWITCH R B R B BLOCK EL section R B R B 77 77 RDNT RDNT BRAKE BRAKE SWITCH SWITCH E122 M64 5 gt 1 mmm J J L p B B JL Ves REFER TO THE FOLLOWING 2 usa 64 E122 ia 107 213415 67 81910 F104 1 E ee T FUSE BLOCK JUNCTION BOX J B 34 lela ey BEBES YEC103A EC 137 TROUBLE DIAGNOSES 17 Brake Switch Cont d TA um INSPECTION START p 5 RDNT brake switch RDNT brake switch harness connector CHECK POWER SUPPLY Check the following Turn ignition switch to LOCK posi e Harness connectors tion F104 Disconnect RDNT brake switch har RHD models ness connector Harness connectors Turn ignition switch to position YEC377 Check voltage between RDNT brake LHD models Vnd zm switch harness connector terminal Harness for open or p 6 CA 1 body ground short circuit between RDNT brake switch Voltage Battery voltage RDNT brake switch harness con
48. Control sleeve position Control sleeve position sensor The amount of fuel leaking at or around high pressure parts inside the fuel injection pump varies with fuel temperature and engine speed This will result in a difference between the target amount of fuel injected and the actual amount The ECM compensates for the actual amount depending on the signal from the fuel temperature sensor the control sleeve position sensor and the crankshaft position sensor DECELERATION CONTROL Input output signal line Accelerator position Accelerator sensor Electri Engine speed pM Camshaft position sensor PUMP SOS Sp The ECM cuts power supply delivery to the electric governor during deceleration for better fuel efficiency The ECM determines the time of deceleration according to signals from the accelerator sensor and cam shaft position sensor PUMP EC 17 Fuel Injection Timing System SYSTEM DESCRIPTION The fuel injection timing system determines the optimal fuel injection timing based on engine speed injec tion quantity engine coolant temperature and atmospheric pressure The timing is formed by a basic value Basic Control and two correction values By performing a duty cycle signal on the timing control valve the ECM allows the valve to provide optimal injection timing The ECM also performs feedback control on the timing control valve using the signal from the needle lift sensor which detects the actual fuel injection tim ing BAS
49. ECM connector terminal 221 and combination meter connector termi nal or 5 Continuity should exist If OK check harness for short cir cuit CHECK GLOW INDICATOR LAMP Make sure that glow indicator lamp is not burnt out Disconnect and reconnect harness connectors in the circuit Then retest Trouble is not fixed Check the following e Harness for open or short circuit between combination meter and battery e 10A fuse If NG replace fuse or repair harness or con nectors Check the following e Harness connectors uso e Harness for open or short circuit between ECM and combination meter If NG repair harness or connectors Replace glow indicator lamp Check ECM pin terminals for damage and check the connection of ECM har ness connector Reconnect ECM har ness connector and retest YEC120A INSPECTION END EC 122 TROUBLE DIAGNOSES 14 Glow Control System Cont d Glow relay connector ee 5 CHECK POWER SUPPLY I Check the following 1 Turn ignition switch to LOCK posi e Harness for open or tion short circuit between 2 Disconnect glow relay harness con glow relay and battery nector e 80A fusible link NEF873 3 Check voltage between glow relay If NG replace fusible link harness connector terminal G and and repair harness con T DISCONNECT engine ground nectors DISCONNECT TS 15 Voltage Battery voltage Glow relay Glow
50. EIS 3v Jav gt gt N TROUBLE DIAGNOSIS General Description gt gt gt 42 Engine control module WH av wv ivpiv rv Hv ov av av laviov av SO LO MON e OJO I O oco lt lt xX x O zz E 6 22 gt LI x lt Ww wm n EIO is 0 E 5 EE 2 2 clelels 5 E gt gt amp E s m 2 2 5 oS 5 E gt 5 5 lt lt o9 5 2 2 5 56 2 16 5 w Ole 2 lt lt 2 215 2 9 5 lt lt 2 8 Tp Z Z O AAE 6 2 lt gt 9 2 5 9 5 rp gt lt gt gt 2 ed gt lt m lt x 5 25 5 s 9 x gt 5 5 u 9 z a lt a 8 GE 0 7 2 Z lt 0 2 S o e gt 0 0 0 lt Z lt LLI gt 2 lt d 63 9 26 SE S LLI TROUBLE DIAGNOSIS General Description CONSULT II Reference Value in Data Monitor Mod
51. ENGINE CONTROL SYSTEM SECTION CONTENTS 1 CD20T _________ PRECAUTIONS AND Special Service Tools iren Engine Fuel amp Emission Control System Supplemental Restraint System SRS AIR BAG and SEAT BELT PRE TENSIONER Precautions for On Board Diagnostic OBD System of Engine FAS CAO NS ENGINE AND EMISSION CONTROL OVERALL STEN Engine Control Module Component Parts Bees a TNI NT Circ it Diagram System Diagram Vacuum Hose Drawing System ENGINE AND EMISSION BASIC CONTROL SYSTEM Glow Fuel Injection System Fuel Injection Timing System Air Conditioning Cut Control Fan CRANKCASE VENTILATION 5 PERRO TET Blow by Control Valve INJECTION 771 Removal and Installation Test and 2221 ELECTRONIC FUEL
52. Electric governor ground Approximately 10 5 Warm up condition Engine speed is 2 000 rom SEF563S 104 m Engine ground 105 ECM ground Probe this terminal with 106 Idle speed tester probe when measuring BATTERY VOLTAGE Power supply for ECM Ignition switch ON 11 14V Approximately 9V Warm up condition Idle speed iection timi SEF564S 202 B W Injection timing control valve Approximately 8V Warm up condition Engine speed is 2 000 rom SEF565S EC 53 TROUBLE DIAGNOSIS General Description ECM Terminals and Reference Value Cont d TER WIRE DATA MINAL ITEM CONDITION DC Voltage and COLOR NO Pulse Signal Both A C switch and blower switch are Approximately 0 4V ON BATTERY VOLTAGE switch is OFF 11 14V Warm up condition BATTERY VOLTAGE 1 Idle speed 14V Warm up condition Engine speed is 2 800 rom 214 W R Glow relay Refer to Glow control System Ignition switch ON Malfunction indicator BATTERY VOLTAGE 11 14V 204 L W Air conditioner relay 208 EGRC solenoid valve A Approximately 0 3V Approximately 1 0V 215 OR L Idle speed Mass air flow sensor Engine is running 218 Approximately ground Idle speed i BATTERY VOLTAGE Cooling fan relay Cooling fan is not operating 11 14V 219 LG R Approximately 0 4V Cooling fan is operating Engine 1 running BA
53. Engine coolant Engine coolant temperature C F 20 80 20 80 12 50 12 50 Vehicle speed km h mph Vehicle speed km h mph N 2 Cooling fans do not operate Xs Cooling fans operate at low speed Cooling fans operate at high speed 772 20 CRANKCASE VENTILATION SYSTEM Description y control valve e n this system blow by gas is sucked into the air inlet pipe through the control valve after oil separation by the oil sepa rator in the rocker cover Baffle plate gt FRESH AIR BLOW GAS SEF851S Blow by Control Valve Check control valve for clogging and abnormalities Blow by control valve Intake manifold Rocker cover SEC586B Ventilation Hose 1 Check hoses and hose connections for leaks 2 Disconnect all hoses and clean with compressed lf any hose cannot be freed of obstructions replace SEC692 EC 21 INJECTION NOZZLE CAUTION Do not disassemble injection nozzle assembly Entrust disassembly or adjustment to BOSCH service shop Plug flare nut with a cap or rag so that no dust enters the nozzle Removal and Installation 1 Remove fuel injection tube and spill tube 2 Remove injection nozzle assembly Also remove gasket from nozzle end 3 Install injection nozzle in the reverse order of removal Injection nozzle to engine e 59 69 N m 6 0 7 0 kg m 43 51 ft lb Injection nozzle to tube 22
54. IC CONTROL Input output signal line Crankshaft position sensor TDC WO Injection Needle lift sensor eere mna ECM timing con trol valve Control sleeve position Control sleeve position sensor The optimal fuel injection timing data predetermined in propor tion to engine speeds and amount of fuel injected are stored in volum the ECM memory The ECM uses the data to control the fuel injection timing Small Fuel injection timing Engine 5 6505 HIGH ALTITUDE COMPENSATION Crankshaft position sensor Engine speed Control sleeve position sensor Control sleeve position Injection timing control Atmospheric pressure sensor valve Needle lift sensor Injection timing Fuel temperature Fuel temperature sensor For better drivability in high altitude areas the fuel injection tim ing is advanced and the fuel quantity is reduced according to the atmospheric pressure Normal High altitude o c Q O E 2 lt O 5 LL Engine rom gt NEF771 EC 18 Fuel Injection Timing System Cont d ENGINE COOLANT TEMPERATURE COMPENSATION During driving Input output signal line Crankshaft position sensor TDC Engine coolant temperature Engine coolant temperature sensor Injection ECM timing con Injection timin rol valv Needle lift sensor 9 trol valve Control sleev
55. IC TROUBLE CONFIRMATION PROCEDURE 1 Turn ignition switch to ON position 2 Select DATA MONITOR mode with CONSULT II 3 Wait at least 5 seconds EC 66 TROUBLE DIAGNOSIS 2 Engine Coolant Temperature ECT Sensor Cont d EC ECTS 01 ENGINE COOLANT TEMPERATURE SENSOR Detectable line for Non detectable line for DTC 2154316 fais 222812432528 901 302 904 05 306 507 506 30913101811 3121813 ott so 44 550 351 852 H S YEC800 EC 67 TROUBLE DIAGNOSIS 2 Engine Coolant Temperature ECT Sensor RH strut tower E connector 00078 N NEF401 DISCONNECT gt Engine coolant temperature F12 sensor connector NEF193A DISCONNECT AE aE Engine coolant temperature sensor connector F12 SEF542P Cont d DIAGNOSTIC PROCEDURE INSPECTION START CHECK POWER SUPPLY Turn ignition switch to LOCK tion Disconnect engine coolant tempera ture sensor harness connector Turn ignition switch to ON position Check voltage between engine cool ant temperature sensor connector terminal 2 and ground with CON SULT II or tester Voltage Approximately 4 9V CHECK GROUND CIRCUIT 1 Turn ignition switch to LOCK posi tion 2 Check harness continuity between engine coolant temperature sensor connector terminal 1 and engine ground Continuity should exist If OK check harness fo
56. ING Overall Function Check LIFTING e This is Quick Reference of DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE Not applicable MI Heference Illumination Page ems BL Lighting up IEC CD 78 Lighting up 0 82 e OVERALL FUNCTION CHECK is a simplified and effective way to inspect a component or circuit In some cases the OVERALL FUNCTION CHECK is used rather than a DIAGNOSTIC TROUBLE CONFIRMATION PRO CEDURE When no DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE is available the NG result of the OVERALL FUNCTION CHECK can be considered to mean the same as a malfunction item detection During an OVERALL FUNCTION CHECK the malfunction item might not be confirmed e This is Quick Reference of OVERALL FUNCTION CHECK Details are described in each TROUBLE DIAGNOSIS EC 40 TROUBLE DIAGNOSIS General Description Diagnostic Trouble Chart Cont d ENGINE RELATED ITEMS Detected items Screen terms for Malfunction is detected when CONSULT II SELF DIAG RESULTS mode Cooling fan e An excessive high engine coolant temperature sensor signal is detected by the ECM Over OVER HEAT heat ECM2 e ECM calculation function is malfunctioning ECM2 Needle lift sensor circuit e An incorrect signal from the sensor is detected by the ECM during engine running NEEDLE LIFT SEN Fuel cut solenoid valve 1 e Fuel cut solenoid valve circuit is mal
57. ING COND SELECTION FROM MENU AUTO TRIG AUTO TRIG ECM INPUT SIGNALS MANUTRIG MANUTRIG MAIN SIGNALS BE SELECTION FROM MENU 0 20 40 60 mil MIN MAX 164 32 16 78 f2 FULL 164 32 h6 78 12 FULL SETTING AUTO TRIG MANU TRIG A malfunction can be A malfunction can not be displayed on DATA displayed on DATA MONITOR screen MONITOR screen automatically if detected automatically even if detected EC 32 TROUBLE DIAGNOSIS Introduction SEF858S SEF234G Introduction The engine has an ECM to control major systems such as fuel injection control fuel injection timing control glow control system etc The ECM accepts input signals from sensors and instantly drive the electronic fuel injection pump use the data to based on current ambient conditions It is essential that both input and output signals are correct and stable At the same time it is important that there are no problems such as vacuum leaks or other problems with the engine It is much more difficult to diagnose a problem that occurs inter mittently rather than catastrophically Most intermittent problems are caused by poor electric connections or faulty wiring In this case careful checking of suspected circuits may help prevent the replacement of good parts A visual check only may not be sufficient to determine the cause of the problems A road test with CONSULT II or a circuit tester connected
58. ING SYSTEM FOR LEAK Check the following Apply pressure to the cooling system with a for leaks tester and check if the pressure drops e Hose Testing pressure e Radiator 157 1 57 bar 1 6 kg cm 23 psi e Water pump Pressure should not drop Refer to LC section CAUTION Water Pump Higher than the specified pressure may cause radiator damage CHECK RADIATOR CAP Apply pressure to cap with a tester Radiator cap relief pressure Standard 78 98 kPa 0 78 0 98 bar 0 8 1 0 kg cm 11 14 psi Limit 59 88 kPa 0 59 0 88 bar 0 6 0 9 kg cm 9 13 psi Replace radiator cap CHECK THERMOSTAT 1 Check valve seating condition at normal room temperatures It should seat tightly Check valve opening temperature and maximum valve lift Valve opening temperature 76 5 C 170 F standard Maximum valve lift More than 8 mm 90 C 0 31 in 194 F 3 Check if valve is closed at 5 C 9 F below valve opening temperature For details refer to LC section SLC343 Thermostat Replace thermostat Check engine coolant temperature sensor Replace engine cool Refer to COMPONENT INSPECTION ant temperature sen 69 Sor If the cause can not be isolated go to 12 MAIN CAUSES OF OVERHEATING on next page INSPECTION END Perform FINAL CHECK by the following procedure after repair is completed 1 Warm up engine Run the vehicle for at least 20 minutes Pay a
59. INJECTION POI ON 62 Installation Disassembly and 26 ON BOARD DIAGNOSTIC SYSTEM 27 044 000000 27 TROUBLE DIAGNOSIS INTRODUCTION 99 Introduction 33 Diagnostic 5 1 34 TROUBLE DIAGNOSIS WORK FLOW a5 MNO 95 Description for Work Flow 36 TROUBLE DIAGNOSIS BASIC INSPECTION 37 Basic 37 TROUBLE DIAGNOSIS GENERAL 39 Diagnostic Trouble 39 Symptom Matrix 47 CONSULT II Reference Value in Data Monitor CET 50 Major Sensor Reference Graph in Data Monitor 1 919 PRETEND 51 ECM Terminals and Reference Value 52 TROUBLE DIAGNOSIS FOR POWER SUPPLY 59 Main Power Supply and Ground Circuit 59 TROUBLE DIAGNOSIS 1 62 Mass Air Flow Sensor MAFS 62
60. ION This system improves acceleration when the air conditioner is used When the accelerator pedal is fully depressed the air conditioner is turned off for a few seconds When engine coolant temperature becomes excessively high the air conditioner is turned off This contin ues until the coolant temperature returns to normal Cooling Fan Control INPUT OUTPUT SIGNAL LINE Vehicle speed sensor or ABS actuator Vehicle speed and electric unit control unit Engine coolant temperature sensor Engine coolant temperature ECM Cooling fan relay s Air conditioner switch Air conditioner ON signal The ECM controls the cooling fan corresponding to the vehicle speed engine coolant temperature and air conditioner ON signal The control system has 3 step control OFF LOW HIGH Operation Air conditioner is OFF Air conditioner is ON 5 5556 XX 5 5 55 KO 5 KS 55 SxS 5 5 e 55 2 eee lt 5 55 5 52 lt gt UN lt gt temperature C F 2 5 2 55509 000000 5552 lt gt SS X lt lt 3 SA RRS don 000 55955 SO 5 9 SR exo ae 5 OOS L 55 soe KL 505 25506 99 000900900 555 22 56 RRI 22255 KOS 25 LS 5 225 LS 552 5 SS 55 59 5 gt 55 lt gt lt gt o 52 5 5 55 52 22 55 5 5 55 5 5 25 5 Q
61. ION START 09 Models before VIN P11U0548750 Y DISCONNECT ECM O CONNECTOR 4 su Combination meter connector lt MB gt CHECK INPUT SIGNAL CIRCUIT 1 Turn ignition switch to LOCK posi Check the following e Harness connectors Models after VIN P11U0548750 tion Disconnect ECM harness connector and combination meter harness con nector Check harness continuity between M50 e Harness for open or short circuit between ECM and combination meter DISCONNECT ECM connector terminal and combination meter connector termi nal 9 or 4 Continuity should exist If OK check harness for short cir cuit If NG repair harness or connectors Yn ECM O CONNECTOR p 417 Combination meter connector 124 CHECK SPEEDOMETER FUNCTION Make sure that speedometer functions Check the following e Harness connectors Harness for open or short circuit between combination meter and vehicle speed sensor or ABS actuator and electric unit control unit If NG repair harness or connectors Check vehicle speed sensor or ABS actuator and electric unit control unit and its circuit Refer to EL section correctly Disconnect and reconnect harness connectors in the circuit Then retest Trouble is not fixed Check ECM pin terminals for damage and check the connection of ECM har ness connector Reconnect ECM har ness c
62. M During the following conditions the ECM will cut the power supply towards the air conditioner relay Starting engine Quick acceleration from low speed Undershooting of idle speed High engine coolant temperature above 107 C 225 F Malfunctioning of engine speed sensor accelerator position sensor or vehicle soeed sensor when engine speed is below 2 100 rpm Check Items Possible cause e Harness or connectors The air conditioner relay signal circuit is shorted e Air conditioner relay DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1 Turn ignition switch and air conditioner switch to the ON position 2 Select DATA MONITOR mode with CONSULT II 3 Wait at least 2 seconds EC 126 TROUBLE DIAGNOSES 15 Air Conditioner Cut Control Cont d 01 IGNITION SWITCH ON or START J B Refer to EL POWER Detectable line for DTC Non detectable line for AIR CONDITIONER RELAY E56 L To compressor Refer to HA A C AIC LIOR AIC CONTROL SENS 25 M44 LG R LG EA TRIPLE PRESSURE SWITCH E20 THERMISTOR REFER TO THE FOLLOWING 6111213 FUSE BLOCK Junction Box J B 2104 FUSE BLOCK Junction Box J B 213p4 pto 207208 209 S YEC813 EC 127 TROUBLE DIAGNOSES 15 Air Conditioner Cut Control Cont d INSPECTION START Air conditioner relay signal circuit 5 2
63. NOSTIC PROCEDURE INSPECTION START CHECK COOLING FAN LOW SPEED OPERATION 1 Disconnect cooling fan relay 3 2 Turn ignition switch to ON position Perform COOLING FAN in ACTIVE TEST mode with CONSULT II OR Start engine Set temperature switch at full cold position Turn Air Conditioner switch to position Turn blower fan switch to ON position Run engine at idle speed for a few minutes with Air Conditioner operating Make sure that both cool ing fans operate at low speed Check cooling fan low speed control circuit Go to PROCEDURE CHECK COOLING FAN HIGH SPEED OPERATION 1 Turn ignition switch to LOCK position 2 Reconnect cooling fan relay 3 3 Disconnect cooling fan relay 1 4 Turn ignition switch to ON position 5 Perform COOLING FAN in ACTIVE TEST mode with CONSULT II OR 4 Turn Air Conditioner switch and blower fan switch to OFF position 5 Disconnect engine coolant temperature sensor har ness connector 6 Connect 150Q resistor to engine coolant temperature sensor harness connector 7 Restart engine and make sure that both cooling fans operate at higher speed than low speed B Go to Check cooling fan high speed control circuit Go to PROCEDURE EC 90 TROUBLE DIAGNOSIS 8 Cooling Fan Overheat Cont PROCEDURE A INSPECTION START JF DISCONNECT
64. NTROL MODULE RELAY 291 W G R n 1 000P 5 YEC803 EC 79 TROUBLE DIAGNOSIS 5 Electric Governor Cont d ae Sy 2 AS 0 4 ectronic injection pump harness nnector Electric governor NEF800 DISCONNECT Yn DISCONNECT EA OE Injection pump connector 0 cw 5 0 2 5 4 107 108 109 7 DISCONNECT q ls TS NEF199A Injection pump connector 2 OO 101 102 103 NEF200A DIAGNOSTIC PROCEDURE INSPECTION START CHECK MAIN POWER SUPPLY Refer to EC CD 59 CHECK POWER SUPPLY CIRCUIT 1 Turn ignition switch to LOCK posi tion Disconnect ECM harness connector and electronic injection pump har ness connector Check harness continuity between injection pump connector terminal 7 and ECM connector terminals Continuity should exist If OK check harness for short circuit CHECK GROUND CIRCUIT Check harness continuity between injection pump connector terminal 4 ECM connector terminals C101 19 163 Continuity should exist If OK check harness for short circuit CHECK COMPONENT Electric governor Refer to COMPONENT INSPECTION on next page Disconnect and reconnect harness con nectors in the circuit Then retest Trouble is not fixed Check ECM pin terminals for damage and check the connection of ECM har ness connector Reconnect ECM har ness connector an
65. SOR TDC F53 Detectable line for m Non detectable line for DTC Spe pepepepe pape gt ES DEEST EEG YEC811 EC 115 TROUBLE DIAGNOSIS 13 7 or position gt gt sensor TDC harness connector X S F617S e 55 34 G e 55 54 Crankshaft position harness connector O CONNECTOR ECM NEF213A r 53 AA Crankshaft position sensor connector CONNECTOR NEF214A Crankshaft Position Sensor TDC Cont d DIAGNOSTIC PROCEDURE CHECK INPUT SIGNAL CIRCUIT 1 Turn ignition switch to LOCK posi tion Disconnect crankshaft position sen sor TDC and ECM harness con nectors Check continuity between ECM ter minal and crankshaft position sensor TDC connector terminal 3 Continuity should exist If OK check harness for short cir cuit Loosen and retighten engine ground SCrews CHECK GROUND CIRCUIT Check harness continuity between crankshaft position sensor TDC con nector terminal 2 and ECM connec tor terminal C331 Continuity should exist If OK check harness for short circuit Repair harness or con nectors Repair harness or con nectors CHECK COMPONENT Crankshaft position sensor Refer to COMPONENT INSPECTION on next page Replace crankshaft posi tion sensor TDC Disconnect and reconnect harness co
66. TION CHECK EC 26 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT II se mex CONSULT II INSPECTION PROCEDURE 1 Turn off ignition switch 2 Connect CONSULT II to data link connector for CONSULT Data link connector for CONSULT II is located behind the fuse box cover Data link connector for CONSULT II NEF225A Turn on ignition switch Touch START Touch ENGINE Perform each diagnostic test mode according to each service procedure For further information see the CONSULT II Operation Manual DIAGNOSIS SYSTEM SELECTION poc PEF895K ACTIVE TEST DTC CONFIRMATION EC 27 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT II Contd ENGINE CONTROL MODULE COMPONENT PARTS CONTROL SYSTEMS APPLICATION DIAGNOSTIC TEST MODE No iid DATA ACTIVE BESIDES MONITOR TEST xe Control sleeve position sensor mem meet _ control unit E S X o X X X gt X X __________ _ X X swich ON X X Applicable 1 Imaginary sensor which produces secondary engine revolution signal using needle lift sensor pulse 2 CONSULT II may not display but self diagnostic results are available with MI 0 lt Q 2
67. TTERY VOLTAGE Cooling fan is not operating 11 14V 220 Cooling fan relay Cooling fan is operating at low speed High speed Approximately 0 5V Cooling fan is operating at high speed Approximately 1 0V Glow lamp is ON 221 P L Glow lamp Ignition switch ON BATTERY VOLTAGE L Glow lamp is OFF 11 14V Warm up condition 1 9 2 3V Idle speed 224 L W Mass air flow sensor Warm up condition 2 5 2 9 Engine speed is 2 000 rom EC 54 TROUBLE DIAGNOSIS General Description ECM Terminals and Reference Value Cont d ITEM Control sleeve position sensor power supply Control sleeve position sensor ground Control sleeve position sensor Reference sig nal Engine control module relay Self shutoff Crankshaft position sen sor TDC ground Needle lift sensor ground Sensors ground CONDITION Engine is running Idle speed Engine 1 running Idle speed Warm up condition Idle speed Ignition switch LOCK For a few seconds after turning ignition switch to the LOCK position Ignition switch LOCK E Following a few seconds delay after turning ignition switch to the LOCK position Engine is running Idle speed Ignition switch ON Idle speed EC 55 DATA DC Voltage and Pulse Signal Approximately 2 6V SEF559S Approximately 2 6V SEF560S Approximately 2 6V SEF561S
68. air flow sen sor TROUBLE DIAGNOSIS 1 GL E al Mass air flow sensor connector NEF669 Mass Air Flow Sensor MAFS Cont d COMPONENT INSPECTION Mass air flow sensor 1 Turn ignition switch to ON position 2 Start engine and warm it up sufficiently 3 Check voltage between mass air flow sensor connector ter minal 5 and ground Conditions Voltage V Ignition switch ON position Engine stopped Approximately 1 0 Idle Engine is warmed up sufficiently 1 9 2 3 4 NG remove mass air flow sensor from air duct Check hot film for damage or dust EC 65 TROUBLE DIAGNOSIS 2 Engine Coolant Temperature ECT Sensor Sensor The engine coolant temperature sensor is used to detect the engine coolant temperature The sensor modifies a voltage sig nal from the ECM The modified signal returns to the ECM as the engine coolant temperature input The sensor uses a thermistor which is sensitive to the change in temperature The electrical resistance of the thermistor decreases as temperature increases SEF594K lt Reference data gt n2 e 5 Voltage Resistance 5 Acceptable F V 5 19 10 14 70 114 8 20 68 21 29 50 122 0 68 1 00 ML eee Malfunction is detected when 114 An excessively high or low voltage from the sensor 1 e Harness or connectors entered to ECM The sensor circuit is open or shorted e Engine coolant temperature sensor DIAGNOST
69. assenger side seat belt pre tensioners a diagnosis sensor unit warning lamp wiring harness and spiral cable In addition to the supplemental air bag modules for a frontal collision the supplemental side air bag used along with the seat belt helps to reduce the risk or severity of injury to the driver and front passenger in a side collision The supplemental side air bag consists of air bag modules located in the outer side of front seats satellite sensor diagnosis sensor unit one of components of supplemental air bags for a frontal collision wiring harness warning lamp one of components of supplemental air bags for a frontal collision Information necessary to service the system safely is included in the RS section of this Service Manual WARNING To avoid rendering the SRS inoperative which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation all maintenance must be per formed by an authorized NISSAN dealer Improper maintenance including incorrect removal and installation of the SRS can lead to per sonal injury caused by unintentional activation of the system Donot use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual SRS wiring harnesses except SEAT BELT PRE TENSIONER connector can be identified with yellow harness connector and with yellow harness protector or yellow insulation tape before
70. atmospheric e pressure sensor is detected by the ECM e ECM calculation function is malfunctioning e ECM reference voltage 2 5V is excessively high or low e ECM e ECM version number or switching function is not plausible e ECM Ignition switch ON signal evaluation circuit in ECM is e malfunctioning Actually inspecting the ECM inside circuit is impossible Then ECM may be replaced DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1 Turn ignition switch to ON position 2 Select DATA MONITOR mode with CONSULT II 3 Wait at least 2 seconds EC 86 TROUBLE DIAGNOSIS 8 Cooling Fan Overheat SYSTEM DESCRIPTION Vehicle speed sensor Vehicle speed Engine coolant temperature sensor Engine coolant temperature ECM 2 relay s Air conditioner switch Air conditioner ON signal The ECM controls the cooling fan corresponding to the vehicle speed engine coolant temperature air con ditioner system pressure and air conditioner ON signal The control system has 3 step control HIGH LOW OFF This system indirectly relates to diagnostic trouble code 28 Overheat Operation Air conditioner is OFF Air conditioner is ON A 550 25004609600 550555 SS 5 5955652 655659 SS 55 595 569560 555555995009 NI Engine coolant temperature C F Engine coolant temperature C F 20 80 12 50 Vehicle speed km h mph Vehicle speed km h m
71. ce MI bulb CHECK POWER SUPPLY 1 Turn ignition switch to ON position 2 Check voltage between combination Check the following e Harness for open or short circuit between meter terminal 5 and body ground Voltage Battery voltage CHECK GROUND CIRCUIT Turn ignition switch to LOCK posi tion Disconnect ECM harness connector Check continuity between combina combination meter and ignition switch e 10A fuse If NG repair or replace harness or fuse Check the following e Harness connectors If NG repair harness or connectors e Harness and connec tors for open or short circuit between ECM and combination meter tion meter connector terminal 3 and ECM connector terminal 215 Continuity should exist If OK check harness for short cir cuit Disconnect and reconnect harness connectors in the circuit Then retest Trouble is not fixed Check ECM pin terminals for damage and check the connection of ECM har ness connector Reconnect ECM har ness connector and retest INSPECTION END EC 143 TROUBLE DIAGNOSES 19 MI Data Link Connectors Cont d DIAGNOSTIC PROCEDURE MODELS AFTER VIN Ec P11U0548750 Combination meter INSPECTION START harness connector MI circuit CHECK MI DIODE Turn ignition switch to LOCK posi tion Disconnect combination meter har ness connector Apply battery voltage between com bination met
72. ch Refer to COMPONENT INSPECTION on next page Disconnect and reconnect harness connec tors in the circuit Then retest Trouble is not fixed Check ECM pin terminals for damage and check the connection of ECM harness con nector Reconnect ECM harness connector and retest INSPECTION END EC 112 INSPECTION END Check the following e Harness connectors 12 Harness for open circuit between accelerator switch and ECM connector termi nal If NG repair harness or nectors Check the following Harness connectors 103 M52 Harness for open or short circuit between accelerator switch and ECM Replace accelerator switch Accelerator position sensor connector Accelerator position sensor connector DISCONNECT TROUBLE DIAGNOSIS 12 DISCONNECT Accelerator Position Sensor amp Switch Cont d COMPONENT INSPECTION Accelerator position sensor 1 Disconnect accelerator position sensor harness connector 2 Make sure that resistance between accelerator position sen sor terminals 2 and changes when opening throttle valve manually Throttle valve conditions Resistance at 25 C 77 Completely closed Approximately 1 2 kQ Partially open 1 2 1 9 Completely open Approximately 1 9 kQ If NG replace accelerator pedal assembly CAUTION e Do not disassemble accelerator pedal assembly COMPONENT INSPECTION Accelerator switch 1 Disconne
73. ch ON signal evaluation circuit in ECM is malfunctioning circuit 3 Injection timing control e Injection timing control valve circuit is open or shorted valve circuit INJ TIMING CONT V Camshaft position sensor e An improper signal is calculated by the ECM PUMP 4 3 Abbreviations for Quick Reference of DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE IGN ON _ Turning the ignition switch ON is required for checking the function of the sensor switch solenoid and circuit RUNNING Running engine is required for checking the function of the sensor switch solenoid and circuit LIFTING Lifting up the vehicle running engine and spinning wheels are required DRIVING Driving the vehicle the specified pattern is required Abbreviations for Quick Reference of OVERALL FUNCTION CHECK IGN ON Turning the ignition switch ON is required for the ECM to detect a malfunction if one exists RUNNING Running engine is required for the ECM to detect a malfunction if one exists LIFTING i the vehicle running engine and spinning wheels are required for the ECM to detect a malfunction if one exists DRIVING Driving the vehicle in the specified pattern is required for the ECM to detect a malfunction if one exists EC 43 TROUBLE DIAGNOSIS General Description Diagnostic Trouble Chart Cont d Not applicable 2 Confirmation Overall Func Reference Check Items Possible
74. ch ldi ewan ignition switch 442 Accelerator pedal depressed Ignition switch ON Approximately B Y Start signal _ BATTERY VOLTAGE Ignition switch START 11 14V Approximately 1 1 1 5V Engine running Warm up condition Snes sas speed SEF550S 439 Tachometer Approximately 1 1 1 5V Engine speed is 2 000 rpm EE SEF551S Approximately 2 7V Ignition switch LOCK OV 507 BR Y Ignition switch _ BATTERY VOLTAGE Ignition switch ON 11 14V EC 58 TROUBLE DIAGNOSIS FOR POWER SUPPLY Main Power Supply and Ground Circuit EC MAIN 01 15A Refer to EL POWER IGNITION SWITCH IGNITION SWITCH START ON or START Detectable line for DTC Non detectable line for DTC Models before VIN P11U0548750 Models after VIN P11U0548750 104 105 106 i Omm CHR C F18 F15 REFER TO THE FOLLOWING FUSE BLOCK JUNCTION BOX J B 507 508 509 5041505 506 901502 503 YEC100A TROUBLE DIAGNOSIS FOR POWER SUPPLY ECM relay ECM CONNECTOR YEC327 Main Power Supply and Ground Circuit INSPECTION START Start engine Is engine running Yes 1 Stop engine 2 Disconnect ECM harness connector 3 Turn ignition switch to ON position CHECK POWER SUPPLY II 1 Short between ECM connector terminal 325 and engine gr
75. ching 1 Turn ignition switch to ON position 2 Select DATA MONITOR mode with CONSULT II Start engine and rev it up above 1 300 rpm Depress brake pedal immediately after releasing accelerator pedal and keep it at least 5 seconds 3 4 EC 108 TROUBLE DIAGNOSIS 12 Accelerator Position Sensor amp Switch Cont d EC APS 01 ACCELERATOR POSITION SEN SOR M68 Detectable line for DTC NOn detectable line for LG W W PU BR M5O EJ 12 23 25 F104 AN W PU BR PWG12 PWG11 52 87 pT YEC809 EC 109 TROUBLE DIAGNOSIS 12 Accelerator Position Sensor amp Switch Cont d EC APP SW 01 ECM B GY R Detectable line for Non detectable line for GY R 52 GY R ACCELERATOR DEPRESSED WORK UNIT RELEASED 3141515 219 mD 810 110 TROUBLE DIAGNOSIS 12 Accelerator Position Sensor amp Switch Cont d DIAGNOSTIC PROCEDURE Accelerator position sensor harness con nector INSPECTION START Accelerator position sensor CHECK POWER SUPPLY Check the following Turn ignition switch to LOCK position e Harness connectors Disconnect accelerator position sensor M50 harness connector e Harness for open or Turn ignition switch to ON position short circuit between Check voltage between accelerator
76. circuit between injection timing control valve harness connec tor and ECM relay If NG repair harness or connectors Check the following e Electronic injection pump harness connec tor Harness for open or short circuit between injection timing control valve and ECM If NG repair harness or connectors TROUBLE DIAGNOSIS 6 Injection Timing Control Valve Cont d 9 CHECK COMPONENT Injection timing control valve Refer to COMPONENT INSPECTION below Replace injection timing control valve Disconnect and reconnect harness con nectors in the circuit Then retest Trouble is not fixed Check ECM pin terminals for damage and check the connection of ECM har ness connector Reconnect ECM har ness connector and retest INSPECTION END COMPONENT INSPECTION Injection timing control valve Injection timing 1 Disconnect injection timing control valve harness connector 2 Check resistance between terminals 2 3 Resistance Approximately 15Q at 25 C 77 F NG replace injection timing control valve YEC364 EC 85 TROUBLE DIAGNOSIS 7 Engine Control Module ECM The ECM consists of a microcomputer and connectors for signal input and output and for power supply The module monitors and controls the engine operation SEC220B Check Item Malfunction is detected when Possible Cause ECM e An excessively high or low voltage from the
77. ct accelerator switch harness connector 2 Check continuity between accelerator switch connector ter minals and 3 Conditions Continuity Accelerator pedal released NO Accelerator pedal depressed Yes If NG replace accelerator pedal assembly CAUTION e Do not disassemble accelerator pedal assembly EC 113 TROUBLE DIAGNOSIS 13 Crankshaft Position Sensor TDC The crankshaft position sensor TDC monitors engine speed by means of signals from the sensing plate with two protrusions installed to the crankshaft pulley The datum signal output is detected at ATDC 70 and sent to the ECM The sensor signal is used for fuel injection control and fuel injection timing control SEF615S a ip Crank pulley Crankshaft position sensor TDC 5 6165 Check Items Malfunction is detected when Possible Cause e An incorrect signal from the sensor is detected by ECM e Harness or connectors during engine running and cranking The sensor circuit is open e Crankshaft position sensor TDC DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE Before performing the following procedure confirm that battery voltage is more than 9V 1 Turn ignition switch to ON position and select DATA MONITOR mode with CONSULT I 2 Start engine and run it for at least 3 seconds above 1 200 rpm EC 114 TROUBLE DIAGNOSIS 13 Crankshaft Position Sensor TDC Cont d EC CKPS 01 CRANKSHAFT POSI TION SEN
78. d information about the conditions and the environment when the incident symptom occurred TEP using the DIAGNOSTIC WORKSHEET as shown on the previous page Before confirming the concern check and write down print out using CONSULT II the malfunction item STEP then erase the code The malfunction item can be used when duplicating the incident at STEP III amp IV Study the relationship between the cause specified by malfunction item and the symptom described by the customer The Symptom Matrix Chart will be useful Refer to Try to confirm the symptom and under what conditions the incident occurs The DIAGNOSTIC WORK SHEET is useful to verify the incident Connect CONSULT II to the vehicle in STEP Ill DATA MONITOR AUTO TRIG mode and check real time diagnosis results If the incident cannot be verified perform INCIDENT SIMULATION TESTS Refer to section If the malfunction code is detected skip STEP IV and perform STEP V Try to detect the malfunction item by driving in or performing the DIAGNOSTIC TROUBLE CONFIRMA TION PROCEDURE Check and read the malfunction item by using CONSULT I During the malfunction item verification be sure to connect CONSULT II to the vehicle in DATA MONITOR AUTO TRIG mode and check real time diagnosis results STEP IV If the incident cannot be verified perform INCIDENT SIMULATION TESTS Refer to GI section In case the DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE is not a
79. d retest INSPECTION END EC 80 NG Repair harness or con nectors Repair harness or con nectors Have the injection pump assembly serviced by an authorised service repre sentative TROUBLE DIAGNOSIS 5 O E 44 Electronic injection pump harness connector Electric Governor Cont d COMPONENT INSPECTION Electric governor 1 Disconnect electronic injection pump harness connector 2 Check continuity between injection pump connector termi nals 7 Resistance Approximately 1 00 at 25 C 77 If NG replace EC 81 TROUBLE DIAGNOSIS 6 Timer piston Fuel injection timing SEF638S Malfunction is detected when Injection Timing Control Valve The injection timing control valve is built into the fuel injection pump It controls the timer piston to change the fuel injection timing The timing control valve is a solenoid valve located in the line between high pressure chamber and low pressure chamber It changes fuel pressure in the high pressure chamber When current flows through the solenoid the solenoid turns ON the timing control valve opens advancing fuel injection timing When current does not flow through it the timing control valve closes retarding injection timing The ECM emits an ON OFF duty cycle signal The longer the OFF duration the greater the advance angle The longer the ON duration the greater the retard angle This means that changing the ON
80. e Remarks Specification data are reference values Specification data are output input values which are detected or supplied by the ECM at the connector Specification data may not be directly related to their components signals values operations CKPS RPM TDC e Tachometer Connect Almost the same speed as the CON CKPS RPM PUMP Run engine and compare tachometer indication with the CONSULT II value SULT II value VHCL SPEED SE 1 and compare speedometer indication with the CON 2 5 Ignition switch ON Accelerator pedal release Approx 0 40V Engine stopped Accelerator pedal depress Approx 3 3V e Ignition switch ON Accelerator pedal release ACCEL POS SEN O 2 OFF ACCEL POS Engine stopped Accelerator pedal slightly open OFF AIR COND SIG e Engine After warming up idle the Compressor operates s IGN SW e Ignition switch ON OFF OFF Engine After warming up Air conditioner switch OFF Shift lever N No load Engine After warming up Air conditioner switch OFF Shift lever N No load At sea level 0 8 2 7V MAS AIR FL SE 2 000 rpm 2 2 2 8V 0 5 to 1 5 ACT INJ TIMG 2 000 rpm 2 5 to 3 5 Engine After warming up Air conditioner switch OFF Shift lever N No load At sea level 8 0 8 8 mm stroke TARGET F INJ 2 000 rom Approx 7 6 mm stroke x Brake pedal released OFF BRAKE SW e Ignition switch ON
81. e position Control sleeve position sensor For better exhaust efficiency under cool engine conditions the fuel injection timing is controlled within a compensation range depending on the engine speed engine coolant temperature and amount of fuel injected Engine coolant temperature Low timing compensation Fuel injection Engine rpm SEF652S ENGINE COOLANT TEMPERATURE COMPENSATION When starting Input output signal line Crankshaft position sensor TDC Engine speed Injection timing con Engine coolant temperature sensor lbs usc dH add ECM Engine coolant temperature sensor trol valve Needle lift sensor Ignition timing For better startability under cool engine conditions the fuel injec tion timing is compensated according to the engine coolant tem perature Engine coolant temperature High 4 o c Q E o o o m 5 LL Engine rpm SEF651S EC 19 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Air Conditioning Cut Control INPUT OUTPUT SIGNAL LINE Air conditioner switch or ABS actuator Air conditioner signal and electric unit control unit Accelerator valve opening angle Accelerator position sensor Air ECM conditioner Vehicle speed relay Vehicle speed sensor Engine coolant temperature Engine coolant temperature sensor SYSTEM DESCRIPT
82. engine 8 Make sure that both cooling fans operate at low speed 660 p d 9 Turn ignition switch to LOCK position 4 SEC163BA 10 Push Air Conditioner switch and blower fan switch to OFF position 11 Disconnect engine coolant temperature sensor harness connector d m om 12 Connect 1500 resistor to engine coolant tempera 5222 ture sensor harness connector DISCONNECT 13 Restart engine and make sure that both cooling 6 fans operate at higher speed than low speed Be careful not to overheat engine Cooling fan 150Q resistor MEC475B EC 88 TROUBLE DIAGNOSIS 8 Cooling Fan Overheat Cont d EC COOL F 01 BATTERY lt 100A FUSE BLOCK J B Refer to EL POWER EE Detectable line for DTC 59 Non detectable line for DTC 40A 50 BR e B G W G COOLING COOLING COOLING FAN FAN FAN RELAY 3 RELAY 2 RELAY 1 E45 W L LG R TRIPLE COOLING PRESSURE FAN SWITCH MOTOR 1 REFER TO THE FOLLOWING E127 FUSE BLOCK Junction Box J B B YEC805 EC 89 TROUBLE DIAGNOSIS 8 Cooling fan relay 3 Cooling fan relay 1 YEC383 ACTIVE TEST COOLING FAN OFF MONITOR COOLAN TEMP S Cooling fan NEF809 ACTIVE TEST COOLINGFAN OFF MONITOR COOLAN TEMP S SEF111X Engine coolant temperature sensor harness connector DISCONNECT 150 resistor YEC384 Cooling Fan Overheat Cont d DIAG
83. er terminal 1 and 8 Check that MI lits on Repair or replace combi nation meter YEC121A Combination meter harness connector CHECK POWER SUPPLY Check the following 1 Turn ignition switch to ON position e Harness for open or 2 Check voltage between combination short circuit between meter terminal 1 and body combination meter and ground ignition switch Voltage Battery voltage e 10A fuse If NG repair or replace harness or fuse YEC122A EQ DISCONNECT Ecm m E 215 Combination meter harness connector CHECK GROUND CIRCUIT Check the following Turn ignition switch to LOCK posi e Harness connectors tion 50 Disconnect ECM harness connector If NG repair harness Check continuity between combina connectors tion meter connector terminal e Harness and connec and ECM connector terminal 215 tors for open or short Continuity should exist circuit between ECM If OK check harness for short cir and combination meter cuit YEC123A Disconnect and reconnect harness connectors in the circuit Then retest Trouble is not fixed Check ECM pin terminals for damage and check the connection of ECM har ness connector Reconnect ECM har ness connector and retest INSPECTION END EC 144 TROUBLE DIAGNOSES 20 Start Signal BATTERY WIG B Y 422 ANL E EC 145 EC S SIG 01 Refer to EL POWER IGNITION SWITCH
84. ess or connectors The ECM relay circuit is shorted e ECM relay e ECM DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1 Turn ignition switch to the position and select DATA MONITOR mode with CONSULT II 2 Turn ignition switch to the LOCK position and wait at least 5 seconds 3 Turn ignition switch to the ON position and wait at least 2 seconds DIAGNOSTIC PROCEDURE Refer to Trouble Diagnosis for Power Supply EC CD 59 for ECM relay circuit inspection EC 140 TROUBLE DIAGNOSES 19 Malfunction is detected when MI circuit is open or shorted amp Data Link Connectors Malfunction indicator circuit is monitored for open or short circuit If the circuit is malfunctioning MI can not report it but CONSULT II can Check Items Possible cause e Harness or connectors MI circuit is open or shorted e MI lamp e ECM DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1 Turn ignition switch to position and select DATA MONITOR mode with CONSULT II 2 Start engine and run it for at least 2 seconds at idle speed OR amp OVERALL FUNCTION CHECK 1 Turn ignition switch to ON position 2 Check that MI lits on EC 141 TROUBLE DIAGNOSES 19 MI Data Link Connectors Cont d IGNITION SWITCH EC MIL 01 ON or START BATTERY FUSE BLOCK Refer to EL POWER J B efer to O Detectable line for DTC Non detectable line for Models before VIN P11U05
85. functioning FUEL CUT S V 1 Fuel temperature sensor e An excessively high or low voltage from the sensor is detected by the ECM circuit FUEL TEMP SENSOR Accelerator position sensor e An excessively high or low voltage from the sensor is detected by the ECM circuit ACCEL POS SENSOR Crankshaft position sensor e An incorrect signal from the sensor is detected by the ECM during engine running and TDC cranking CRANK POS SEN TDC No failure No malfunction is detected by the ECM NO SELF DIAGNOSTIC FAILURE INDICATED Abbreviations for Quick Reference of DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE IGN ON Turning the ignition switch ON is required for checking the function of the sensor switch solenoid and circuit RUNNING Running engine is required for checking the function of the sensor switch solenoid and circuit LIFTING Lifting up the vehicle running engine and spinning wheels are required DRIVING Driving the vehicle in the specified pattern is required Abbreviations for Quick Reference of OVERALL FUNCTION CHECK IGN Turning the ignition switch ON is required for the ECM to detect a malfunction if one exists RUNNING Running engine is required for the ECM to detect a malfunction if one exists LIFTING Lifting up the vehicle running engine and spinning wheels are required for the ECM to detect a malfunction if one exists DRIVING Driving the vehicle in the specified pattern is req
86. ger lift timing mark Yellow painted mark Read plunger lift Plunger lift 0 89 0 08 mm 0 0350 0 0031 in at plunger lift timing mark When repeating the checking start with step 5 Adjusting 1 If plunger lift is not within the speci SEF662S fied value adjust by turning injec tion pump If indication is smaller than the specified value turn pump body away from engine If indication is larger than the specified value turn pump body towards engine Tighten injection pump securing bolts and nuts Nut 20 25 2 0 2 6 kg m 15 18 ft lb Bolt SEF657S 7 05 35 2 6 3 6 kg m 18 26 ft lb Remove dial gauge and install air bleeder with new washer Install injection tubes Flare nut 14 20 1 4 2 0 kg m 10 15 ft Ib 5 Bleed air from fuel system Refer to Water Draining Fuel Filter Check and Replacement of ENGINE MAINTENANCE in MA section EC 38 TROUBLE DIAGNOSIS General Description Diagnostic Trouble Chart ENGINE RELATED ITEMS Detected items Malfunction is detected when Screen terms for CONSULIT II SELF DIAG RESULTS mode Mass air flow sensor circuit e An excessively high or low voltage from the sensor is detected by the ECM MASS AIR FLOW SEN Engine coolant temperature e An excessively high or low voltage from the sensor is detected by the ECM sensor circuit COOLANT TEMP SEN Vehicle speed sensor circuit or e T
87. gging No 1 injection nozzle DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE NOTE Before diagnostic trouble confirmation be sure to check battery voltage is above 1 Turn ignition switch to ON position and select DATA MONITOR mode with CONSULT II 2 Start engine and run it for 2 seconds above 1 200 rpm EC 97 TROUBLE DIAGNOSIS 9 Needle Lift Sensor NLS Cont d NEEDLE EC NLS 01 LIFT SEN Detectable line for m Non detectable line for I 2 c A ge E oo gm D n E118 L BR mpre pe out poe no por ce e eoe ez A H S 314181513161317 ota 519 920 21 922 1823 824 925826 301 802 908 804 805 506 807 906 30948100511 3124313 YEC806 EC 98 TROUBLE DIAGNOSIS 9 ax Needle lift sensor harness connector SEF606S DISCONNECT DISCONNECT 5 Needle lift sensor ecm _folcowecton NEF206A Yn DISCONNECT DISCONNECT 24 connector CONNECTOR Needle lift sensor 333 Hilap NEF205A Needle Lift Sensor NLS Cont d DIAGNOSTIC PROCEDURE CHECK FOR AIR IN FUEL FILTER 1 Move priming pump up and down to purge air from fuel filter 2 Perform DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCE DURE CHECK INPUT SIGNAL CIRCUIT
88. h is required for the ECM to detect a malfunction if one exists RUNNING Running engine is required for the ECM to detect a malfunction if one exists E LIFTING eee the vehicle running engine and spinning wheels are required for the ECM to detect a malfunction if one exists DRIVING Driving the vehicle in the specified pattern is required for the ECM to detect a malfunction if one exists EC 45 Check Items Possible Cause TROUBLE DIAGNOSIS General Description Diagnostic Trouble Chart Cont d Not applicable 2 Confirmation Overall Func Reference Procedure tion Check Illumination Page Quick Ref e Harness or connectors The MI circuit is open or shorted IGN ON EC CD 141 e MI lamp e ECM 2 8 e Harness connectors The glow indicator lamp circuit is open or shorted IGN ON EC CD 118 Glow lamp 1 e This is Quick Reference of DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE Details are described in each specific TROUBLE DIAGNOSIS e The OVERALL FUNCTION CHECK is a simplified and effective way to inspect a component or circuit In some cases the OVERALL FUNCTION CHECK is used rather than a DIAGNOSTIC TROUBLE CONFIRMATION PRO CEDURE When no DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE is available the NG result of the OVERALL FUNCTION CHECK can be considered to mean the same as a malfunction item detection e During an NG OVERALL FUNCTION
89. harness connector Fuel temperature sensor 1 INSPECTION START CHECK POWER SUPPLY 1 Turn ignition switch to LOCK posi tion 2 Disconnect fuel temperature sensor harness connector 3 Turn ignition switch to ON position DISCONNECT 4 Check voltage between injection GA 6 pump connector terminal 6 and E ground with CONSULT II or voltage Injection pump tester N connector Voltage Approximately 5V Repair harness or con nectors CHECK GROUND CIRCUIT NEF819 1 Turn ignition switch to LOCK posi tion IE 0pm 2 Check harness continuity between p GA 54 injection pump connector terminal Injection pump 5 and ECM connector terminals connector 335 436 ECM O CONNECTOR Continuity should exist 335 436 2 If check harness for short cir cuit Repair harness or con nectors NEF208A CHECK COMPONENT Have the injection pump Fuel temperature sensor assembly serviced by an Refer to COMPONENT INSPECTION authorised service repre on next page sentative Disconnect and reconnect harness connectors in the circuits Then retest Trouble is not fixed Check ECM pin terminals for damage and check the connection of ECM har ness connector Reconnect ECM har ness connector and retest INSPECTION END EC 106 Yn DISCONNECT ale 6 5 QA TROUBLE DIAGNOSIS 11 YEC366 Fuel Temperature Sensor
90. harness or connectors Replace air conditioner relay TROUBLE DIAGNOSES 16 EGRC Solenoid Valve SYSTEM DESCRIPTION Camshaft position sensor TDC Engine speed Air conditioner switch Air conditioner signal EGRC solenoid valve Engine coolant temperature ECM Mass air flow The ECM receives signals sent from the engine coolant tempera ture sensor crankshaft position sensor TDC atmospheric pres sure sensor mass air flow sensor and air conditioner switch to determine engine speed and operating conditions Based on these signals the ECM controls the EGR control solenoid valve operation No EGR operation will take place when the engine coolant tem perature is below 70 C 158 F when idling at starting and dur ing a period of time after starting the engine 70 200 seconds depending on engine coolant temperature Engine coolant i temperature C F Load EGRC solenoid valve EGR valve Amount of EGR gas OFF ON Low load Open Fully open Large Above 70 158 High load Closed Fully closed em COMPONENT DESCRIPTION The EGR control solenoid valves control vacuum pressure act ing on the EGR valve The EGR control valve will then be fully opened or fully closed as required Thus intake air passages are opened or closed in relation to 221 exhaust gas and intake air Utilizing the relationship between exhaust gas pressure and intake air pressure control the amount of EGR exhaust gas recirc
91. he almost 0 km h 0 mph signal from the sensor is detected by the ECM even when ABS actuator and electric unit vehicle is being driven control unit circuit VEHICLE SPEED SEN Control sleeve position sensor e An excessively high or low voltage from the sensor is detected by the ECM circuit e An incorrect voltage signal from the sensor is detected by the ECM during engine run CONT SLEEV POS SEN ning Fuel injection feedback 2 e The fuel injection feedback system consists of the ECM electric governor and control F INJ F B 2 sleeve position sensor does not operate properly Fuel injection timing feedback e The fuel injection timing feedback system consists of the ECM fuel injection timing con F INJ TIMG F B trol valve and needle lift sensor does not operate properly Abbreviations for Quick Reference of DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE IGN ON Turning the ignition switch ON is required for checking the function of the sensor switch solenoid and circuit RUNNING Running engine is required for checking the function of the sensor switch solenoid and circuit LIFTING Lifting up the vehicle running engine and spinning wheels are required DRIVING Driving the vehicle in the specified pattern is required Abbreviations for Quick Reference of OVERALL FUNCTION CHECK IGN ON Turning the ignition switch ON is required for the ECM to detect a malfunction if one exists RUNNING Running engine is re
92. he control sleeve position sensor sig nal voltage is displayed BATTERY VOLT V power supply voltage of ECM 15 displayed START SIGNAL e Indicates ON OFF condition from the e After starting the engine OFF is dis ON OFF starter signal played regardless of the starter signal AIR COND SIG e Indicates ON OFF condition of the air ON OFF conditioner switch as determined by the air conditioner signal BRAKE SW Indicates ON OFF condition of the ON OFF stio lamp switch BRAKE SW2 e Indicates ON OFF condition of the ON OFF stio lamp switch 2 IGN SW e Indicates ON OFF condition from igni ON OFF tion switch MAS AIR FL SE V e he signal voltage of the mass air flow e When the engine is stopped a certain sensor 15 displayed value is indicated ACT INJ TIMG 9 e The actual injection timing angle deter mined by the ECM an approximate average angle between injection start and end from TDC is displayed TARGET F INJ e he target fuel injection quantity mm STROKE determined by the ECM according to the input signal is indicated NOTE Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically EC 29 Monitored item Unit FUEL CUT S V ON OFF AIR COND RLY ON OFF GLOW RLY ON OFF COOLING FAN LOW HI OFF EGRC SOL V ON OFF ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION ECM Main input Description CONSULT II
93. he idle control The ECM regulates the amount of fuel injected corresponding to changes in load applied to the engine to keep engine speed constant During the first 270s after a cold start the ECM also provides the system with a fast idle control in response to the engine coolant temperature NORMAL CONTROL Input output signal line Crankshaft position sensor TDC Engine speed m Control sleeve position Control sleeve position sensor ECM Electric Accelerator position sensor Accelerator position governor Vehicle speed sensor or ABS actuator Vehicle speed and electric unit control unit The amount of fuel injected under normal driving conditions is determined according to sensor signals The crankshaft position sensor TDC detects engine speed and the accelerator position sensor detects accelerator position These sensors send signals Accelerator to the ECM 4 The fuel injection data predetermined by correlation between various engine speeds and accelerator positions are stored in the ECM memory forming a map The ECM determines the optimal amount of fuel to be injected using the sensor signals in comparison with the map gt o D 5 LL Engine rpm 5 6495 16 Fuel Injection System Cont d FUEL TEMPERATURE COMPENSATION Input output signal line Fuel temperature sensor Fuel temperature Crankshaft position sensor TDC Engine speed ECM
94. heck the connection of ECM harness con nector Reconnect ECM harness connector and retest INSPECTION END EC 111 TROUBLE DIAGNOSIS 12 Accelerator Position Sensor amp Switch DATA MONITOR MONITORING NO FAIL CLSD THL P SW ON PEF123W DISCONNECT 59 ECM e CONNECTOR 435 426 DISCONNECT TS DISCONNECT Accelerator switch COn M68 nector 426 NEF212A DISCONNECT LI 1 5 switch connector DISCONNECT CONNECTOR 435 NEF211A Cont d DIAGNOSTIC PROCEDURE INSPECTION START Accelerator position switch CHECK OVERALL FUNCTION 1 Turn ignition switch to position 2 Check OFF ACCEL POS in DATA MONITOR mode with CONSULT II Accelerator pedal released ON Accelerator pedal depressed OFF OR Turn ignition switch to LOCK position Check continuity between ECM connector terminal and ground Continuity Accelerator pedal released No Accelerator pedal depressed Yes CHECK GROUND CIRCUIT 1 Disconnect accelerator switch harness connector 2 Check harness continuity between accelerator switch connector terminal and ECM connector terminal 426 Continuity should exist CHECK INPUT SIGNAL CIRCUIT Check harness continuity between ECM connector terminal and accelerator switch connector terminal 3 Continuity should exist CHECK COMPONENT Accelerator swit
95. ing Fan Overheat Cont d OVERALL FUNCTION CHECK Use this procedure to check the overall function of the cooling fan During this check a DTC might not be confirmed WARNING Never remove the radiator cap when the engine is hot Seri fo ous burns could be caused by high pressure fluid escaping from the radiator Wrap a thick cloth around the cap Carefully remove the cap by turning it a quarter turn to allow built up pressure to escape Then turn the cap all the way off 640 1 Check the coolant level in the reservoir tank and radiator Allow engine to cool before checking coolant level the coolant level in the reservoir tank and or radiator is COOLINGFAN OFF below the proper range skip the following steps and go to DIAGNOSTIC PROCEDURE EC CD 90 2 Confirm whether customer filled the coolant or not If cus __ tomer filled the coolant skip the following steps and go to 7 7 DIAGNOSTIC PROCEDURE EC CD 90 3 ignition switch to ON position 4 Perform COOLING FAN in ACTIVE TEST mode with CONSULT II LOW speed and HI speed OR 3 Start engine Be careful not to overheat engine Set temperature control switch to full cold position Push Air Conditioner switch to ON position Turn blower fan switch to position Run engine at idle for a few minutes with Air Con ditioner operating Be careful not to overheat
96. ing fan relays 1 2 3 Check continuity between terminals 3 and 5 Conditions Continuity 12V direct current supply between relay Ves terminals 1 and 2 No current supply No If NG replace cooling fan relay Cooling fan relay 2 Check continuity between terminals 3 4 Conditions Continuity No current supply Yes 12V direct current supply between relay terminals 1 2 Cooling fan motors 1 and 2 1 Disconnect cooling fan motor harness connectors 2 Supply cooling fan motor terminals with battery voltage and check operation Terminals Cooling fan motor should operate If NG replace cooling fan motor Cooling fan motor 1 and 2 EC 96 TROUBLE DIAGNOSIS 9 Nozzle holder Inductive pick up coli Nozzle NEF689 Malfunction is detected when Needle Lift Sensor NLS The needle lift sensor is built into the No 1 nozzle Its inductive pick up element senses the lifting of the injection nozzle needle and thus the start of injection The signal is evaluated by the ECM and compared with the target timing Deviations in timing for example caused by changes in fuel temperature are sensed by the ECM and corrected Check Items Possible Cause e An improper signal from the sensor is sent to ECM e Harness or connectors The sensor circuit is open or shorted e Needle lift sensor e fuel line Clo
97. ltage signal from the ECM The modified signal returns to the ECM as the fuel temperature input The sensor uses a thermistor which is sensi tive to the change in temperature The electrical resistance of the thermistor decreases as temperature increases The sensor is built into the inside electrical circuit of the injection pump TP Check Items Malfunction is detected when Possible Cause e An excessively high or low voltage from the sensor is e Harness or connectors detected by ECM The sensor circuit is open or shorted e Fuel temperature sensor DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1 Turn ignition switch to ON position 2 Select DATA MONITOR mode with CONSULT II 3 Wait at least 5 seconds EC 104 TROUBLE DIAGNOSIS 11 Fuel Temperature Sensor FTS Cont d EC FTS 01 INJECTION PUMP FUEL TEMPERATURE SENSOR F50 ENEN Detectable line for Non detectable line for ei 340 341 342 343 3441345 13461347 3481849 3501351 552 431 492 433 434 435 436 437438 439 440 9798 420 401 402 408404 405 406 407 406 409 410 31418151816 31713181819 o0 32 322 32318241825 926 S01 502 805 804 506 06 907 808 ate 101811 8121313 eee YEC808 EC 105 TROUBLE DIAGNOSIS 11 Fuel Temperature Sensor FTS Cont d DIAGNOSTIC PROCEDURE M9 B Electronic injection pump
98. n is detected when Possible Cause e Fuel cut solenoid valve circuit is malfunctioning e Harness or connectors The solenoid valve circuit is open or shorted e Fuel cut solenoid valve DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1 Turn ignition switch to ON position Select DATA MONITOR mode with CONSULT II otart engine If no start circuit is open Warm engine up sufficiently Turn ignition switch to LOCK position and wait at least 5 seconds Start engine and rev it up above 1 300 rpm Release pedal and wait at least 3 seconds 2 EC 100 TROUBLE DIAGNOSIS 10 Fuel Cut Solenoid Valve Cont d EC FCUT 01 BATTERY 15A Refer to EL POWER 36 E3 Detectable line for W R Non detectable line for INJECTION PUMP C FUEL CUT SOLE NOID VALVE 7 SB F49 MODULE RELAY E91 927 526 329 350 331 8821833 3435 896 937 238 09 314 ts 16 317 818 S19 920 S2 82213231824 826 826 Bu pe put oro pa prr pta Gio pt co os YEC807 EC 101 TROUBLE DIAGNOSIS 10 LTS Electronic injection pump harness connector ACTIVE TEST FUEL CUT SOL V MONITOR C2FCS01 EAO EA Electronic injection pump harness con nection ECM 349 226 Fuel Cut Solenoid Valve Cont d DIAGNOSTIC PROCEDURE INSPECTION START CHECK MAIN POWER SUPPLY Check
99. ne Possible but hard to start O Others 1 Idlin O No fast idle Unstable High idle 0 Low idle i 0 Others Stumble Surge Knock Lack of power O Driveability hers At the time of start O While idling Engine stall O While accelerating 0 While decelerating Just after stopping O While loading Incident occurrence Just after delivery Recently 0 In the morning O At night In the daytime All the time O Under certain conditions 1 Sometimes Weather conditions O Not affected Temperature Temperature 0 Hot O Warm 1 Cool Cold O Humid oF Startability 0 Cold O During warm up After warm up Engine conditions Engine speed Po 1 4 14 4 14 0 2 000 4 000 6 000 8 000 rpm Road conditions 0 In town In suburbs 0 Highway 0 Off road up down Not affected O At starting O While idling O At racing O While accelerating 0 While cruising Driving conditions O While decelerating While turning RH LH Vehicle speed 10 20 30 40 50 60 70 80 90 100 mph Malfunction indicator Turned on Not turned on EC 34 TROUBLE DIAGNOSIS Work Flow Work Flow CHECK IN Listen to customer complaints Get symptoms yi wm fun STEP Check print out or write down and erase Diagnostic Trouble malfunction item STEP
100. nector harness connector ter minal 1 and ECM connector terminal If NG repair harness connectors YEC378 CHECK GROUND CIRCUIT 1 Turn ignition switch to LOCK posi tion Check harness continuity between RDNT brake switch harness connec tor terminal and body ground Continuity should exist If OK check harness for short circuit Repair harness or con nectors CHECK COMPONENT RDNT brake switch Refer to COMPONENT INSPECTION on next page Disconnect and reconnect harness connectors in the circuit Then retest Trouble is not fixed Check ECM pin terminals for damage and check the connection of ECM har ness connector Reconnect ECM har ness connector and retest INSPECTION END EC 138 TROUBLE DIAGNOSES 17 Brake Switch Cont d COMPONENT INSPECTION Stop lamp switch and RDNT brake switch 1 Turn ignition switch to LOCK position 2 Disconnect switch harness connectors 3 Check continuity between terminals 1 and 2 Continuity Brake pedal Stop lamp switch RDNT brake switch Depressed Yes Yes If NG replace stop lamp switch or RDNT brake switch EC 139 TROUBLE DIAGNOSES 18 Malfunction is detected when ECM relay shut off time is too late ECM Relay The ECM Relay shuts off the main power supply to the ECM within 5 seconds after the ignition switch has turned to the LOCK position Check Items Possible cause e Harn
101. nnector termi nal 2 and cooling fan relay 2 con nector terminal 3 cooling fan motor 2 connector terminal 1 and cooling fan relay 3 connector termi nal 5 cooling fan relay 2 connec tor terminal s and ground Continuity should exist If OK check harness for short circuit Check harness continuity between cooling fan motor 2 terminal 2 and ground Repair harness or connec tors CHECK OUTPUT SIGNAL CIRCUIT 1 Disconnect ECM harness connector 2 Check harness continuity between ECM terminal and cooling fan relay 3 connector terminal 2 amp cooling fan short circuit between relay 2 connector terminal 2 cooling fan relay 2 3 and Continuity should exist ECM If OK check harness for short circuit If NG repair harness or connectors Check the following e Harness connectors 28 e Harness for open or CHECK COMPONENT Cooling fan relay 2 3 Replace cooling fan relays Refer to COMPONENT INSPECTION ECJ CD 96 CHECK COMPONENTS Cooling fan motors Refer to COMPONENT INSPECTION Replace cooling fan motors Disconnect and reconnect harness connec tors in the circuit Then retest Trouble is not fixed Check ECM pin terminals for damage and check the connection of ECM harness con nector Reconnect ECM harness connector and retest INSPECTION END EC 93 TROUBLE DIAGNOSIS 8 Cooling Fan Overheat Cont d Hose adapter CHECK COOL
102. nnectors in the circuit Then retest Trouble is not fixed Check ECM pin terminals for damage and check the connection of ECM har ness connector Reconnect ECM har ness connector and retest INSPECTION END EC 116 Q G PPP Tem sensor TDC HE nector TROUBLE DIAGNOSIS 13 Crankshaft Position Sensor Cont d COMPONENT INSPECTION Crankshaft position sensor TDC SEF620S 211 x oo Io Disconnect crankshaft position sensor TDC harness con nector Loosen the fixing bolt of the sensor Remove the sensor Visually check the sensor for chipping Check resistance between crankshaft position sensor TDC terminals 2 and 3 Resistance Approximately 1 2 1 5kQ at 25 C 77 If NG replace crankshaft position sensor TDC EC 117 TROUBLE DIAGNOSES 14 Glow Control System When coolant temperature is lower than 75 C 167 Ignition switch ON After ignition switch has been turned to ON the glow relay turns ON for a period of time depending on engine coolant temperature allowing current to flow through the glow plugs Starting After starting the engine current will flow through the glow plugs for 300 seconds or until the coolant temperature 40 20 0 20 40 60 exceeds 50 C 122 F 40 4 32 68 104 140 Engine coolant temperature gt F Time gt 1 5 Pre glow Time gt 40 20 0 20 4
103. o self control at its initial value Engine operation can vary slightly when the terminal is disconnected However this is not an indication of a problem Do not replace parts because of a slight variation When ECM is removed for inspection make sure to ground the ECM mainframe BATTERY Always use a 12 volt battery as power source Do not attempt to disconnect battery cables while engine is running ELECTRONIC FUEL INJECTOR PUMP ECM mainframe Do not disconnect pump harness connectors with engine running Do not disassemble or adjust electronic fuel injection pump except for the following parts Camshaft position sensor pump Injection timing control valve Fuel cut solenoid valve l ilia Creo ECM PARTS HANDLING e Handle mass air flow sensor carefully to avoid damage Do not disassemble mass air flow sensor Do not clean mass air flow sensor with any type of detergent Do not disassemble No 1 injection nozzle built WHEN STARTING in needle lift sensor Do not depress accelerator pedal when Even a slight leak in the air intake system can starting cause serious problems Immediately after starting do not rev up Do not shock or jar the camshaft position sensor engine unnecessarily TDC Do not rev up engine just prior to shut down EC 5 WIRELESS EQUIPMENT When installing C B ham radio or a mobile phone be sure to observe the following
104. on pump according to sensor signals to com pensate the amount of fuel injected to the preset value START CONTROL Input output signal line Engine coolant temperature Engine coolant temperature sensor Crankshaft position sensor TDC Engine speso ECM Electric governor 7 Control sleeve position Control sleeve position sensor When starting the ECM adapts the fuel injection system for the start control The amount of fuel injected at engine starting is a 2 preset program value in the ECM The program is determined by 4 the engine speed and engine coolant temperature For better startability under cool engine conditions the lower the coolant temperature becomes the greater the amount of fuel injected The ECM ends the start control when the engine speed reaches a coolant temperature dependent value gt o D LL Engine rpm SEF648S EC 15 Fuel Injection System Cont d IDLE CONTROL Input output signal line Engine coolant temperature Engine coolant temperature sensor Crankshaft position sensor TDC Engine swith Air conditioner operation Control sleeve position sensor Control sleeve position adi Accelerator position switch Idle position Vehicle speed sensor or ABS actuator Vehicle speed and electric unit control unit When the ECM determines that the engine speed is at idle the fuel injection system is adapted for t
105. on switch ON Brake released Ignition switch ON Battery voltage 11 14V lt 405 R G Stop lamp switch Brake pedal depressed Immobilizer communica ich ON BATTERY VOLTAGE tion 4 14V Ignition switch ON Battery voltage 410 Brake pedal released 11 14V Ignition switch ON D Brake pedal depressed 416 H B Brake switch 2 OV 0 Approximately 4 2V Engine 1 running Vehicle speed sensor or 417 OR W ABS actuator and elec tric unit control unit Lift up the vehicle In 2nd gear position Vehicle speed is 40 km h 25 mph SEF552S Approximately 4 9V idi Data link connector for CONSULT II Idle speed CONSULT II is connected and 415 G R turned on Approximately Accelerator position sen Engine 15 running 425 sor ground Approximately Idle speed Accelerator position sen iti itch ON A ly 5V 433 LG W sor power supply Ignition switch ON pproximately 5 Ignition switch ON 0 4 0 6V 434 W PU out Ignition switch ON Approximately 4 0V Accelerator pedal fully depressed EC 57 TROUBLE DIAGNOSIS General Description ECM Terminals and Reference Value Cont d TER WIRE DATA MINAL ITEM CONDITION DC Voltage and COLOR Pulse Signal NO Ignition switch ON E Approximately Accelerator position Accelerator pedal released 435 GY R t
106. onnector and retest INSPECTION END EC 73 TROUBLE DIAGNOSIS 4 Control Sleeve Position Sensor CSPS The control sleeve position sensor is installed on the electric governor It senses the position of control sleeve rotor angle while the control sleeve is being driven by the electric governor and feeds it back to the ECM Sensor coil 5 6415 Check Items Malfunction is detected when Possible cause e An excessively high or low voltage from the sensor 1 e Harness or connectors detected by ECM The control sleeve position sensor circuit is open or P shorted e An incorrect voltage signal from the sensor is detected by e Control sleeve position sensor ECM during engine running Electronic injection pump 7 DIAGNOSTIC TROUBLE CONFIRMATION harness connector control PROCEDURE sleeve position sensor Nl D 1 Turn ignition switch to ON position and select DATA 13 MONITOR mode with CONSULT II N ap 2 2 Start engine and run it for at least 2 seconds at idle UE mal NS 2 e D A j zY N NEF796 EC 74 TROUBLE DIAGNOSIS 4 Control Sleeve Position Sensor CSPS Cont d INJECTION PUMP CON EC CS PS 01 TROL SLEEVE POSITION SENSOR F50 Detectable line for m NOn detectable line for YEC802 EC 75 TROUBLE DIAGNOSIS 4 Control Sleeve Position Sensor CSPS
107. ontact Battery 40 Accidental contact of probes will cause a short circuit voltage ANN and damage the ECM power transistor SEF348N EC 8 ENGINE AND EMISSION CONTROL OVERALL SYSTEM Engine Control Module Component Parts Location Fuel cut solenoid valve EGRC solenoid valve Electric fuel injection pump Needle lift sensor built in No 1 nozzle Vacuum pump Engine coolant Fuel filter temperature sensor Mass air flow sensor Glow relay Cooling fan relay EGR valve Cooling fan motors Crankshaft position sensor TDC Glow plugs YEC133A EC 9 ENGINE AND EMISSION CONTROL OVERALL SYSTEM Engine Control Module Component Parts Location Cont d Fuel cut solenoid valve N ex p SA 9 at Ke al b CL E Js 10 iti DON fey Electric governor control sleeve position sensor XC t MY X CD 0 WS Ejection timing control valve fuel temperature sensor built in a tt Ls S N cer 2 Crankshaft position FOM sensor as Accelerator pedal LHD YEC134A EC 10 CD20T ENGINE AND EMISSION CONTROL OVERALL SYSTEM ircuit Diagram C pa d 5 av S93 1 7 Ld NIA 291 SAV SI PON BV 2055949109 B OSLEPSONL Ld NIA 22339 SI POW HN 2 5 n 3 HOLIMS da d 0D IE OSZ8PSONL Ld NIA 220339 S SPOW
108. ouble is not fixed Check ECM pin terminals for damage and check the connection of ECM har ness connector Reconnect ECM harness connector and retest INSPECTION END EC 146 SERVICE DATA AND SPECIFICATIONS SDS General Specifications Unit rpm Engine CD20T Maximum engine speed 5 400 A C ON 825 25 Idle speed A C OFF 825 25 Pump numbers number NP VE4 CD20T 16700 2J620 10E2200L736 Pump data is not yet available Refer to CALIBRATION STANDARD published by BOSCH Injection Nozzle INSPECTION AND ADJUSTMENT Injection nozzle assembly Unit kPa bar psi Initial injection pressure 14 423 15 651 144 2 156 5 Inspection and Adjustment bu 148 159 2 091 2 269 15 000 16 000 150 0 160 0 153 163 2 175 2 320 Plunger lift mm in 0 89 0 08 Injection timing at plunger lift timing mark MASS AIR FLOW SENSOR Supply voltage V 5 0V Output voltage V 1 9 2 3 Engine is warmed up sufficiently and idling under no load ENGINE COOLANT TEMPERATURE SENSOR Temperature C F Resistance kQ 20 68 24 28 50 122 0 68 1 00 90 194 0 236 0 260 CONTROL SLEEVE POSITION SENSOR Resistance at 25 C 77 Q 6 0 INJECTION TIMING CONTROL VALVE Resistance at 25 77 F Q Approximately 15 ELECTRIC GOVERNOR Resistance at 25 77 F Q 1 0 CRANKSHAFT POSITION SENSOR TDC Resistance at 25 C 77 Q Approximately 1 215 1
109. ound with a jump CHECK POWER SUPPLY I 1 Disconnect ECM harness connector 2 Turn ignition switch to ON position 3 Check voltage between ECM connector terminal and ground Voltage Battery voltage If NG check the following 10A fuse Harness connectors Harness for open short circuit between ECM and ignition switch If NG replace 10A fuse repair harness or connec tors Go to CHECK GROUND CIRCUIT on page wire 2 Check voltage between ECM terminals 10 108 and ground Voltage Battery voltage CHECK HARNESS CONTINUITY BETWEEN ENGINE CONTROL MODULE RELAY AND ECM Check harness continuity between ECM connector terminals 107 C108 and ECM relay connector terminal 5 Continuity should exist If OK check harness for short Check the following e Harness connectors ueo Harness for open or short circuit between ECM relay and ECM If NG repair harness connectors 24 ECM o CONNECTOR 325 107 108 109 DISCONNECT AE ME CM CONNECTOR ECM relay o connector 107 108 109 12 NEF187A NEF188A EC 60 TROUBLE DIAGNOSIS FOR POWER SUPPLY Main Power Supply and Ground Circuit Cont d ES DISCONNECT Ea ECM relay connector n CHECK VOLTAGE BETWEEN ENGINE 1 x 2 CONTROL MODULE RELAY AND GROUND Check voltage between ECM relay connec tor terminals 2 3
110. ph N Cooling fans do not operate NN Cooling fans operate at low speed Cooling fans operate at high speed NEF772 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 Check Items Malfunction is detected when Possible Cause e An excessive high engine coolant temperature sensor sig e Harness or connectors nal is detected by the ECM Overheat The cooling fan circuit is open or shorted Cooling fan Radiator hose Radiator Radiator cap Water pump Thermostat Fan belt Engine coolant temperature sensor For more information refer to 12 MAIN CAUSES OF OVERHEATING 95 CAUTION When a malfunction is indicated be sure to replace the coolant following the procedure in the MA section Changing Engine Coolant ENGINE MAINTENANCE Also replace the engine oil a 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 Anti freeze Coolant Mixture Ratio RECOMMENDED FLUIDS AND LUBRICANTS b After refilling coolant run engine to ensure that no water flow noise is emitted EC 87 TROUBLE DIAGNOSIS 8 Cool
111. posi ECM and accelerator tion sensor connector terminal 5 position sensor ground with CONSULT II or voltage If NG repair harness or tester connectors Accelerator position Voltage Approximately 5V sensor connector CHECK GROUND CIRCUIT Check the following 1 Turn ignition switch to LOCK position e Harness connectors 2 Check harness continuity between accel M50 erator position sensor connector terminal e Harness for open or 4 and engine ground short circuit between Continuity should exist ECM and accelerator If OK check harness for short circuit position sensor If NG repair harness or connectors NEF824 44 Accelerator position sensor connector CHECK INPUT SIGNAL CIRCUIT Check the following 1 Disconnect ECM harness connector Harness connectors 2 Check harness continuity between ECM 1150 terminal and accelerator position Harness for open or sensor connector terminal 2 short circuit between Continuity should exist ECM and accelerator If OK check harness for short circuit position sensor If NG repair harness or connectors NEF825 E 14 69 Accelerator position sensor connector m 434 CHECK COMPONENT Accelerator position sensor Refer to COMPONENT INSPECTION Replace accelerator pedal assembly Disconnect and reconnect harness connec tors in the circuit Then retest NEF209A Trouble is not fixed Check ECM pin terminals for damage and c
112. power supply Refer to EC CD 59 CHECK OUTPUT SIGNAL CIRCUIT Turn ignition switch to ON position Select FUEL CUT SOL V in ACTIVE TEST mode with CONSULT II Touch ON and OFF alter nately Check that operating sound is emitted Repair harness or con nectors OR Turn ignition switch to LOCK position Disconnect ECM harness con nector and electronic injection pump harness connector Check harness continuity between fuel cut solenoid valve connector terminal 1 and ECM connector terminal 349 Continuity should exist If OK check harness for short CHECK COMPONENT Fuel cut solenoid valve Refer to COMPONENT INSPECTION on next page Replace fuel cut solenoid valve Disconnect and reconnect harness connectors in the circuit Then retest Trouble is not fixed Check ECM pin terminals for damage and check the connection of ECM har ness connector Reconnect ECM har ness connector and retest INSPECTION END EC 102 TROUBLE DIAGNOSIS 10 Fuel Cut Solenoid Valve Cont d COMPONENT INSPECTION Fuel cut solenoid valve 1 Remove fuel cut solenoid valve 2 Check for lifting shaft when applying 12V direct current to terminals If NG replace fuel cut solenoid valve EC 103 TROUBLE DIAGNOSIS 11 Fuel Temperature Sensor FTS The fuel temperature sensor is used to detect the fuel tempera ture in the injection pump The sensor modifies a vo
113. quired for the ECM to detect a malfunction if one exists LIFTING Lifting up the vehicle running engine and spinning wheels are required for the ECM to detect a malfunction if one exists DRIVING Driving the vehicle in the specified pattern is required for the ECM to detect a malfunction if one exists EC 39 TROUBLE DIAGNOSIS General Description Diagnostic Trouble Chart Contd Check Items Possible Cause 2 Harness or connectors The sensor circuit is open or shorted Mass air flow sensor Harness or connectors The sensor circuit is open or shorted Engine coolant temperature sensor Harness or connectors The sensor circuit is open or shorted Vehicle speed sensor or ABS actuator and electric unit control unit Harness or connectors The sensor circuit is open or shorted Control sleeve position sensor Main power supply circuit ECM terminals C23 C45 and fuse Harness or connectors Electric governor and control sleeve position sensor cir cuit Electronic fuel injection pump ECM Electric governor Harness or connectors Injection timing control valve Needle lift sensor and Crankshaft position sensor TDC circuit Injection timing control valve Needle lift sensor Crankshaft position sensor Air in fuel line Details are described in each TROUBLE DIAGNOSIS 1 Confirmation Procedure Quick Ref IGN ON IGN ON RUNNING RUNNING DRIVING RUNNING DRIV
114. r DTC Non detectable line for DTC R TION TIMING CONTROL VALVE NZ YEC804 EC 83 TROUBLE DIAGNOSIS 6 Injection Timing Control Valve Cont d TEL s Priming pump ZA Ko E Fuel injection timing control valve harness connector Oo Injection timing control valve harness connector p NEF804 NEF201A AOE 4 Injection timing control valve harness connector __ O CONNECTOR 202 NEF202A DIAGNOSTIC PROCEDURE INSPECTION START CHECK FOR AIR IN FUEL FILTER 1 Move priming pump up and down to purge air from fuel filter 2 Perform DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCE DURE CHECK POWER SUPPLY Turn ignition switch to LOCK posi tion Disconnect injection timing control valve harness connector Turn ignition switch to ON position Check voltage between injection tim ing control valve connector terminal 3 and ground with CONSULT II or tester Voltage Battery voltage CHECK OUTPUT SIGNAL CIRCUIT 1 Turn ignition switch to LOCK posi tion 2 Disconnect ECM harness connector 3 Check harness continuity between injection timing control valve connec tor terminal 2 and ECM terminals 2 Continuity should exist If OK check harness for short cir cuit EC 84 Check the following e Harness connectors E89 Electronic injection pump harness connec tor 15A fuse Harness for open or short
115. r short cir Cuit CHECK COMPONENT Engine coolant temperature sensor Refer to COMPONENT INSPECTION on next page OK Disconnect and reconnect harness connectors in the circuit Then retest Trouble is not fixed Check ECM pin terminals for damage and check the connection of ECM har ness connector Reconnect ECM har ness connector and retest INSPECTION END EC 68 NG NG NG Repair harness or con 5 Repair harness 5 Replace engine coolant temperature sensor TROUBLE DIAGNOSIS 2 Engine Coolant Temperature ECT Sensor Cont d COMPONENT INSPECTION Engine coolant temperature sensor Check resistance as shown in the figure Temperature C F Resistance kQ 20 68 2 1 2 9 50 122 0 68 1 0 SEF152P 90 194 0 236 0 260 If NG replace engine coolant temperature sensor Acceptable Resistance 8 6 4 2 0 8 4 2 1 0 0 0 0 20 0 20 40 60 80 100 4 32 68 104 140 us 212 Temperature C F SEFO12P EC 69 TROUBLE DIAGNOSIS 3 Vehicle Speed Sensor VSS Models with vehicle speed sensor The vehicle speed sensor is installed in the transaxle It contains Vehicle speed a pulse generator which provides a vehicle speed signal to the e speedometer The speedometer then sends a signal to the ECM Models without vehicle speed sensor The ABS actuator and electric unit control unit provides a
116. rs in the circuit Then retest Check ECM pin terminals for damage and check the connection of ECM har ness connector Reconnect ECM har ness connector and retest INSPECTION END EC 121 Trouble is not fixed Check the following e 15A fuse e 80A fusible link e Harness continuity between glow relay and fuse If NG replace fuse or fusible link or repair har ness or connectors Check harness connec tors CF96 Repair harness or con nectors Replace glow plug or glow relay TROUBLE DIAGNOSES 14 Glow Control System Cont d HOO Models before VIN P11U0548750 Combination meter connector CHEHSETELHHH Models after VIN P11U0548750 Combination meter connector YEC119A Models before VIN P11U0548750 Combination meter ECM O CONNECTOR 221 ee E ES c Models after VIN P11U0548750 Combination meter ECM OT INSPECTION START Glow indicator lamp circuit CHECK POWER SUPPLY CIRCUIT Turn ignition switch to LOCK posi tion Disconnect combination meter har ness connector Turn ignition switch to ON position Check voltage between combination meter harness connector terminal 5 or 1 and body ground Voltage Battery voltage CHECK GROUND CIRCUIT Turn ignition switch to LOCK posi tion Disconnect ECM harness connector Check harness continuity between
117. should be performed Follow the Work Flow on the next page Before undertaking actual checks take a few minutes to talk with a customer who approaches with a driveability complaint The customer can supply good information about such problems especially intermittent ones Find out what symptoms are present and under what conditions they occur A Diagnostic Worksheet like the example on next page should be used Start your diagnosis by looking for conventional problems first This will help troubleshoot driveability problems on a vehicle with an electronically controlled engine EC 33 TROUBLE DIAGNOSIS Introduction Diagnostic Worksheet There are many operating conditions that lead to the malfunction of engine components A good grasp of such conditions can Vehicle amp engine model make troubleshooting faster and more accurate Date Frequencies In general each customer feels differently about a problem It is Road conditions important to fully understand the symptoms or conditions for a Operating conditions customer complaint Weather conditions Utilize a diagnostic worksheet like the one shown below in order Symptoms to organize all the information for troubleshooting KEY POINTS SEF907L WORKSHEET SAMPLE Incident Date Manuf Date In Service Date Impossible to start No combustion O Partial combustion 0 Partial combustion when warming up engine 0 Partial combustion when cooling down engi
118. sidered to mean the same as a malfunction item detection During an OVERALL FUNCTION CHECK the malfunction item might not be confirmed e This is Quick Reference of OVERALL FUNCTION CHECK Details are described in each specific TROUBLE DIAGNOSIS CONSULT II may not detect but self diagnostic results are available with MI Imaginary sensor which produces secondary engine revolution signal using needle lift sensor pulse he atmospheric pressure sensor is located inside the ECM and is not replaceable EC 44 TROUBLE DIAGNOSIS General Description Diagnostic Trouble Chart Cont d ENGINE RELATED ITEMS Detected items Screen terms for Malfunction is detected when CONSULT II SELF DIAG RESULTS mode MI e MI malfunction indicator circuit is open or shorted 3 GLOW LAMP CIRCUIT e Glow lamp circuit is open or shorted 3 Abbreviations for Quick Reference of DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE IGN Turning the ignition switch ON is required for checking the function of the sensor switch solenoid and circuit RUNNING Running engine is required for checking the function of the sensor switch solenoid and circuit LIFTING Lifting up the vehicle running engine and spinning wheels are required DRIVING Driving the vehicle in the specified pattern is required Abbreviations for Quick Reference of OVERALL FUNCTION CHECK IGN ON _ Turning the ignition switc
119. ss connector 208 220 Turn ignition switch to the LOCK position Disconnect EGRC solenoid valve A harness connector Turn ignition switch to the ON posi tion Check voltage between connector terminal and engine ground Voltage Battery voltage CHECK OUTPUT SIGNAL CIRCUIT Turn ignition switch to the LOCK position Disconnect ECM harness connector Check harness continuity between ECM harness connector terminal and EGRC solenoid valve A e Harness continuity between ECM relay and EGRC solenoid valve A connector If NG repair harness or connectors Check the following e Harness for open or short circuit between ECM and solenoid valve If NG repair harness or connectors connector terminal 1 Continuity should exist If OK check harness for short cir cuit CHECK COMPONENTS EGRC solenoid valve Refer to COMPONENT INSPECTION 135 Replace malfunctioning component s Disconnect and reconnect harness connectors in the circuit Then retest Trouble is not fixed Check ECM pin terminals for damage or the connection of ECM harness con nector Reconnect ECM harness con nector and retest INSPECTION END EC 132 TROUBLE DIAGNOSES 16 EGRC Solenoid Valve Cont d DIAGNOSTIC PROCEDURE INSPECTION START EGR CONTROL OPERATION CHECK OVERALL FUNCTION INSPECTION END 1 Start engine and warm
120. ss connec tors in the circuit Then retest Trouble is not fixed Check ECM pin terminals for damage and check the connection of ECM harness con nector Reconnect ECM harness connector and retest INSPECTION END EC 76 Yn DISCONNECT TROUBLE DIAGNOSIS 4 Control sleeve posi tion sensor electric governor amp fuel temperature sensor connector 1 and 3 NEF680 Control Sleeve Position Sensor CSPS Cont d COMPONENT INSPECTION Control sleeve position sensor 1 Disconnect electronic injection pump harness connector 2 Check continuity between terminals 1 3 and 3 Resistance Approximately 6 00 at 25 C 77 F If NG take proper action EC 77 TROUBLE DIAGNOSIS 5 Return spring Decrease Increase Control sleeve Magnet SEF633S Malfunction is detected when Electric Governor The electric governor is built into the fuel injection pump It moves the control sleeve to increase or decrease the amount of fuel injected When current flows through the coil a magnetic force is produced rotating the rotor The rotor shaft is installed to the control sleeve via a ball pin which is eccentrically situated in relation to the rotor shaft With this arrangement the control sleeve can be moved in relation to rotor rotation The rotor s rotating angle is determined by a balanced condition of magnetic force generated by current flow regulated by means
121. t CONSULIT II to the data link connector for CONSULT II and select ENGINE from the menu Refer to Ec CHECK IDLE SPEED Read engine idle speed in DATA MONITOR mode with CONSULT II 825 rpm 25 in N position OR Check idle speed using tachom eter tester 825 rpm 25 in position Go to next page EC 37 Turn ignition switch to the LOCK position wait 5 seconds and then start engine If engine fails to start check malfunction item TROUBLE DIAGNOSIS Basic Inspection Basic Inspection Cont d 9 CHECK INJECTION TIMING Set No 1 piston at TDC on its com pression stroke TDC Without painted mark Remove injection tubes and air bleeder on the back of injection pump Set dial gauge so its indicator points to somewhere between 1 0 and 2 0 mm 0 039 and 0 079 in on the scale Bleed air from fuel sys tem After this inspection unnecessary diagnostic trouble code No might be displayed Erase the stored memory in ECM Refer to ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Turn crankshaft 2 turns clockwise and check that dial gauge indicates OK the same value again Turn crankshaft counterclockwise about 100 degrees then turn crank shaft slowly clockwise and set dial gauge indicator to 0 mm at the posi tion it stops Turn crankshaft clockwise and set it at plunger lift timing mark using the mark on the crankshaft pulley plun
122. t or circuit In some cases the OVERALL FUNCTION CHECK is used rather than a DIAGNOSTIC TROUBLE CONFIRMATION PRO CEDURE Reference Page When no DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE is available the NG result of the OVERALL FUNCTION CHECK can be considered to mean the same as a malfunction item detection e During an OVERALL FUNCTION CHECK the malfunction item might not be confirmed e This is Quick Reference of OVERALL FUNCTION CHECK Details are described in each specific TROUBLE DIAGNOSIS EC 42 TROUBLE DIAGNOSIS General Description Diagnostic Trouble Chart Contd ENGINE RELATED ITEMS Detected items Screen terms for Malfunction is detected when CONSULT II SELF DIAG RESULTS mode Atmospheric pressure e An excessively high or low voltage from the sensor is detected by the ECM sensor 5 3 Glow relay circuit e Glow relay circuit is open or shorted GLOW RELAY ECM e ECM reference voltage 2 5V is excessively high or low 3 Air conditioner relay circuit e Air conditioner relay circuit is shorted 3 EGRC solenoid valve A e EGRC solenoid valve A is open or shorted EGR SYS Brake switch circuits e Brake switch circuits are open or shorted 3 ECM e ECM version number or switching function is not plausible 3 ECCS D relay circuit e ECCS D relay shut off time is too late 3 Ignition switch signal Ignition swit
123. the harness connectors Precautions for On Board Diagnostic OBD System of Engine 0003 The ECM has board diagnostic system It will light the malfunction indicator MI to warn the driver of a malfunction causing emission deterioration CAUTION sure to turn the ignition switch OFF and disconnect the negative battery terminal before any repair or inspection work The open short circuit of related switches sensors solenoid valves etc will cause the MI to light up e Be sure to connect and lock the connectors securely after work A loose unlocked connector will cause the MI to light up due to the open circuit Be sure the connector is free from water grease dirt bent terminals etc Certain systems and components especially those related to OBD may use a new style slide locking type harness connector For description and how to disconnect refer to EL section Description HARNESS CONNEC TOR sure to route and secure the harnesses properly after work The interference of the harness with a bracket etc may cause the MI to light up due to the short circuit sure to connect rubber tubes properly after work misconnected or disconnected rubber tube may cause the MI to light up due to the malfunction of the EGR system or fuel injection system etc Be sure to erase the unnecessary malfunction information repairs completed from the ECM before returning
124. the vehicle to the customer EC 6 PRECAUTIONS AND PREPARATION Precautions e Before connecting or disconnecting the ECM harness connector turn ignition switch OFF and disconnect negative battery terminal Failure to do so may damage the ECM because battery voltage is applied to ECM even if ignition switch is turned off SEF289H When connecting ECM harness connectors push both sides of the connector until you hear a click Fasten Loosen Maneuver the lever until you hear the three connectors on the inside click Refer to the figure at left SEF881Y Before replacing ECM perform Terminals and Reference Eram Value P and make sure ECM functions properly put output signal Refer to inspection before replacement e f MI illuminates or blinks irregularly during engine running water may have accumulated in fuel filter Drain water from fuel filter If this does not correct the problem perform specified trouble diagnostic procedures e After performing each TROUBLE DIAGNOSIS perform OVERALL FUNCTION CHECK or DTC Diagnostic Trouble Code CONFIRMATION PROCEDURE The DTC should not be displayed in the DTC CONFIR MATION PROCEDURE if the repair is completed The OVERALL FUNCTION CHECK should be a good result SAT652J if the repair is completed EC 7 PRECAUTIONS AND PREPARATION Precautions Cont d e When measuring ECM signals with a circuit tester never allow the two tester probes to c
125. ttention to engine coolant temperature gauge on the instru ment panel If the reading shows an abnormally high temperature another part may be malfunctioning 2 Stop vehicle and let engine idle Check the intake and exhaust systems for leaks by listening for noise or visually inspecting the components 3 Allow engine to cool and visually check for oil and coolant leaks Then perform OVERALL FUNCTION CHECK EC 94 TROUBLE DIAGNOSIS 8 Cooling Fan Overheat Cont d 12 MAIN CAUSES OF OVERHEATING Engine Step Inspection item Equipment Standard Reference page OFF Blocked radiator e Visual No blocking Blocked condenser Blocked radiator grille Blocked bumper Coolant mixture Coolant tester 50 5096 coolant mix See RECOMMENDED ture FLUIDS AND LUBRI CANTS in MA section Coolant level Coolant up to MAX level See Changing Engine in reservoir tank and Coolant ENGINE radiator filler neck MAINTENANCE in MA section Radiator cap Pressure tester 78 98 kPa See System Check 0 78 0 98 bar 0 8 ENGINE COOLING 1 0 kg cm 11 14 psi SYSTEM in LC section 59 98 kPa 0 59 0 98 bar 0 6 1 0 kg cm 9 14 psi Limit Coolant leaks Visual No leaks See System Check ENGINE COOLING SYSTEM in LC section ON 2 e Thermostat Touch the upper Both hoses should be See Thermostat and lower radiator hoses Radiator ENGINE COOLING SYSTEM in LC section
126. u have repaired the circuit or replaced a component you need to run the engine in the same condi tions and circumstances which resulted in the customer s initial complaint Perform the DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE and confirm the normal code is STEP VII detected If the incident 15 still detected in the final check perform STEP VI by using a different method from the previous one Before returning the vehicle to the customer be sure to erase the unnecessary already fixed malfunction item in ECM EC 36 TROUBLE DIAGNOSIS Basic Inspection SEF 142 Pm riming pump So DATA MONITOR MONITORING NO FAIL CMPS RPM REF XXX rpm Qer 2 PEF190P Basic Inspection Precaution Perform Basic Inspection without electrical or mechanical loads applied BE 1 Headlamp switch is off Air Conditioner switch is off Rear defogger switch is off Steering wheel is in the straight ahead position etc FORE STARTING Check service records for any recent repairs that may indicate a related problem or the current need for scheduled maintenance Open engine hood and check the following Harness connectors for faulty con nections Vacuum hoses for splits kinks or faulty connections Wiring for faulty connections pinches or cuts Using priming pump bleed air from fuel system Refer to Fuel Filter Check in MA section CONNECT CONSULT II TO THE VEHICLE Connec
127. uired for the ECM to detect a malfunction if one exists EC 41 TROUBLE DIAGNOSIS General Description Diagnostic Trouble Chart Cont d Check Items Possible Cause Harness or connectors The cooling fan circuit is open or shorted Cooling fan Radiator hose Radiator Radiator cap Water pump Thermostat Fan belt Engine coolant temperature sensor For more information refer to 12 MAIN CAUSES OF OVERHEATING 2 Harness or connectors The sensor circuit is open or shorted Needle lift sensor Air in fuel line Clogging No 1 injection nozzle Harness or connectors The solenoid valve circuit is open or shorted Fuel cut solenoid valve Harness or connectors The sensor circuit is open or shorted Fuel temperature sensor Harness or connectors The sensor circuit is open or shorted Accelerator position sensor Accelerator position switch Harness or connectors The sensor circuit is open or shorted Crankshaft position sensor TDC No failure Not applicable 1 Overall Function Check Confirmation Procedure Quick Ref Illumination IGN ON RUNNING 91119 up tating up gt un IGN ON RUNNING f RUNNING e This is Quick Reference of DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE Details are described in each specific TROUBLE DIAGNOSIS e The OVERALL FUNCTION CHECK is a simplified and effective way to inspect a componen
128. ulated is regulated in large or small signal volumes SEF240PH ion heck Item Malfunction is detected when C ee tems Possible cause e EGRC solenoid valve A circuit is shorted e Harness or connectors EGRC solenoid valve A circuit is open or shorted e EGRC solenoid valve A EC 129 TROUBLE DIAGNOSES 16 EGRC Solenoid Valve Cont d DIAGNOSTIC TROUBLE CONFIRMATION PROCEDURE 1 Turn ignition switch to the ON position 2 Select DATA MONITOR mode with CONSULT II 3 Wait at least 2 seconds EC 130 CD20T TROUBLE DIAGNOSES 16 EGRC Solenoid Valve Cont d EC EGRC V 01 lic kK LLI E gt 5t tnm 8 8 5 lt x 8 C 3 7 22 52 T LL nr mim oc LL s 3 Lo LL do 9 A E D oc HENG 617187 Gv BATTERY 5 W R m J c a YEC814 EC 131 TROUBLE DIAGNOSES 16 EGRC Solenoid Valve Cont d DIAGNOSTIC PROCEDURE INSPECTION START Circuit for EGRC solenoid valve A AEQ EGRC solenoid valve A harness connector L CHECK MAIN POWER SUPPLY Refer to Trouble Diagnosis for main power supply EC CD 59 NEF219A CHECK POWER SUPPLY Check the following Ex DISCONNECT 5 EGRC solenoid valve A harne
129. vailable perform the OVER ALL FUNCTION CHECK instead The malfunction item cannot be displayed by this check however this simplified check is an effective alternative The result of the OVERALL FUNCTION CHECK is the same as the DTC detection Take the appropriate action based on the results of STEP through IV If the malfunction code is indicated proceed to specific TROUBLE DIAGNOSIS for the malfunction item If the normal code is indicated proceed to the BASIC INSPECTION Refer to EC CD 37 Then perform inspections according to the Symptom Matrix Chart Refer to STEP V Identify where to begin diagnosis based on the relationship study between symptom and possible causes Inspect the system for mechanical binding loose connectors or wiring damage using tracing Harness Lay outs Gently shake the related connectors components or wiring harness with CONSULIT II set in DATA MONI TOR AUTO TRIG mode Check the voltage of the related ECM terminals or monitor the output data from the related sensors with CONSULT II Refer to The DIAGNOSTIC PROCEDURE in EC section contains a description based on open circuit inspection A short circuit inspection is also required for the circuit check in the DIAGNOSTIC PROCEDURE For details refer to GI section Circuit Inspection HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRI CAL INCIDENT Repair or replace the malfunctioning parts STEP VI Once yo
130. vehicle speed signal to the speedometer The speedometer than sends a signal to the ECM AEC110 Check Items Malfunction is detected when Possible Cause e The almost 0 km h 0 mph signal from vehicle speed sen Models with vehicle speed sensor sor or ABS actuator and electric unit control unit is sent e Harness or connector to ECM even when vehicle is being driven The vehicle speed sensor circuit is open or shorted e Vehicle speed sensor Models without vehicle speed sensor e Harness or connector The ABS actuator and electric unit control unit is open or shorted e ABS actuator and electric unit control unit OVERALL FUNCTION CHECK Use this procedure to check the overall function of the vehicle DATA MONITOR speed sensor circuit During this check a DTC might not be VHCL SPEED SE XXX km h confirmed 1 Jack up drive wheels 2 Start engine 3 Read vehicle speed sensor signal in DATA MONI TOR mode with CONSULT II The vehicle speed on CONSULT II should be able to exceed 10 km h 6 mph when rotating wheels with PEF651U suitable gear position OR E 22 4 24 Jack up drive wheels ECM CONNECTOR Start engine Rotate drive wheel by hand Check voltage between ECM connector terminal and ground with voltage tester TONNS Voltage should vary between approx 0 0 6V NEF194A EC 70 TROUBLE DIAGNOSIS 3 Vehicle Speed Sensor VSS Cont d MODELS BEFORE VIN P1

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