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SECTION EC
CONTENTS
EC
DIAGNOSTIC TROUBLE CODE INDEX.........................1 Malfunction Indicator Lamp (MIL)..............................31
Alphabetical & Numerical Index for DTC ....................1 CONSULT ..................................................................36
PRECAUTIONS AND PREPARATION............................2 TROUBLE DIAGNOSIS Introduction......................42
Special Service Tools ..................................................2 Introduction ................................................................42
Commercial Service Tool.............................................3 Diagnostic Worksheet................................................43
Supplemental Restraint System (SRS) AIR TROUBLE DIAGNOSIS Work Flow ........................44
BAG and SEAT BELT PRE-TENSIONER...............4 Work Flow..................................................................44
PRECAUTIONS AND PREPARATION............................5 Description for Work Flow .........................................45
Engine Fuel & Emission Control System ....................5 TROUBLE DIAGNOSIS Basic Inspection ..............46
Precautions ..................................................................6 Basic Inspection.........................................................46
ENGINE AND EMISSION CONTROL OVERALL TROUBLE DIAGNOSIS General Description ........48
SYSTEM...........................................................................8 Symptom Matrix Chart...............................................48
ECCS-D Component Parts Location ...........................8 CONSULT Reference Value in Data Monitor
Circuit Diagram ..........................................................11 Mode ..........................................................................51
System Diagram ........................................................12 Major Sensor Reference Graph in Data Monitor
Vacuum Hose Drawing ..............................................13 Mode ..........................................................................53
System Chart .............................................................14 ECM Terminals and Reference Value .......................54
ENGINE AND EMISSION BASIC CONTROL TROUBLE DIAGNOSIS FOR POWER SUPPLY..........63
SYSTEM DESCRIPTION ...............................................15 Main Power Supply and Ground Circuit....................63
Fuel Injection System ................................................15 TROUBLE DIAGNOSIS FOR CAM POS SEN
Fuel Injection Timing System ....................................18 (PUMP) (DTC 11).........................................................69
Air Conditioning Cut Control......................................19 Camshaft Position Sensor (CMPS) (PUMP) .............69
Fuel Cut Control (at no load & high engine TROUBLE DIAGNOSIS FOR MASS AIR FLOW
speed) ........................................................................20 SEN (DTC 12) ..............................................................74
CRANKCASE VENTILATION SYSTEM........................21 Mass Air Flow Sensor (MAFS) ..................................74
Description .................................................................21 TROUBLE DIAGNOSIS FOR COOLANT TEMP
Inspection...................................................................21 SEN (DTC 13) ..............................................................79
INJECTION NOZZLE.....................................................22 Engine Coolant Temperature (ECT) Sensor .............79
Removal and Installation ...........................................22 TROUBLE DIAGNOSIS FOR VEHICLE SPEED
Disassembly (No. 2 - 4 nozzles) ...............................22 SEN (DTC 14) ..............................................................83
Inspection (No. 2 - 4 nozzles) ...................................23 Vehicle Speed Sensor (VSS) ....................................83
Cleaning (No. 2 - 4 nozzles) .....................................23 TROUBLE DIAGNOSIS FOR CONT SLEEV POS
Assembly (No. 2 - 4 nozzles) ....................................24 SEN (DTC 15) ..............................................................87
Test and Adjustment ..................................................25 Control Sleeve Position Sensor (CSPS) ...................87
ELECTRONIC FUEL INJECTION PUMP......................27 TROUBLE DIAGNOSIS FOR ADJUST
Removal.....................................................................27 RESISTOR (DTC 17) ...................................................92
Installation..................................................................28 Adjustment Resistor...................................................92
Disassembly and Assembly.......................................29 TROUBLE DIAGNOSIS FOR F/INJ F/B 2
ON BOARD DIAGNOSTIC SYSTEM (DTC 18), F/INJ F/B (DTC 22), ELECTRIC
DESCRIPTION ...............................................................30 GOV (DTC 25)..............................................................96
DTC and MIL Detection Logic ...................................30 Electric Governor .......................................................96
Diagnostic Trouble Code (DTC) ................................30
TROUBLE DIAGNOSIS FOR F/INJ TIMG F/B TROUBLE DIAGNOSIS FOR ACCEL POS
(DTC 21).......................................................................101 SENSOR (DTC 43) ....................................................139
Injection Timing Control Valve .................................101 Accelerator Position Sensor ....................................139
TROUBLE DIAGNOSIS FOR ACCEL POS SW TROUBLE DIAGNOSIS FOR CRANK POS SEN
(F/C) (DTC 23) ...........................................................106 (TDC) (DTC 47)..........................................................144
Accelerator Switch (F/C)..........................................106 Crankshaft Position Sensor (TDC) ..........................144
TROUBLE DIAGNOSIS FOR ECM 1 (DTC 27), TROUBLE DIAGNOSIS FOR GOV CUT
ECM 2 (DTC 31).......................................................111 CIRCUIT (DTC 48).....................................................149
Engine Control Module (ECM)-ECCS-D Control Governor Cut Circuit................................................149
Module .....................................................................111 TROUBLE DIAGNOSES FOR NON-DETECTABLE
TROUBLE DIAGNOSIS FOR OVER HEAT ITEMS...........................................................................151
(DTC 28).......................................................................113 Glow Control System...............................................151
Cooling Fan (Overheat) ...........................................113 EGRC-Solenoid Valve A, B and Throttle Control
TROUBLE DIAGNOSIS FOR I/C INT/A TEMP Solenoid Valve .........................................................156
SEN (DTC 33) ............................................................122 Start Signal ..............................................................163
Charge Air Temperature Sensor..............................122 Accelerator Position Switch .....................................165
TROUBLE DIAGNOSIS FOR NEEDLE LIFT Park/Neutral Position Switch ...................................170
SEN (DTC 34) ............................................................126 A/T Control...............................................................175
Needle Lift Sensor (NLS) ........................................126 Charge Air Cooler Fan Control................................178
TROUBLE DIAGNOSIS FOR FUEL CUT S/V 1 Heat Up Switch........................................................183
(DTC 36), FCV SHORT (DTC 37), FUEL CUT Air Conditioner Control ............................................187
S/V 2 (DTC 38)...........................................................130 MIL & Data Link Connectors ...................................188
Fuel Cut Solenoid Valve ..........................................130 SERVICE DATA AND SPECIFICATIONS (SDS) ........189
TROUBLE DIAGNOSIS FOR FUEL TEMP General Specifications.............................................189
SENSOR (DTC 42) ....................................................135 Injection Nozzle .......................................................189
Fuel Temperature Sensor (FTS)..............................135 Inspection and Adjustment ......................................189
*1: When nothing is displayed or the meaningless symbol is displayed in the Self-diag result mode with CONSULT, perform Diagnostic Test Mode II
(Self-diagnostic results) with ECM. Refer to EC-32.
*2: Refer to NATS (Nissan Anti-Theft System) in EL section.
EC-1
PRECAUTIONS AND PREPARATION
NT570
NT647
KV11289004
Nozzle cleaning kit
V1 KV11290012
Box
V2 KV11290110
Brush
V3 KV11290122
Nozzle oil sump scraper
V KV11290140
4
Nozzle needle tip
V KV11290150
5
Nozzle seat scraper
V6 KV11290210
Nozzle holder
V7 KV11290220
Nozzle hole cleaning
needle
NT296
EC-2
PRECAUTIONS AND PREPARATION
Special Service Tools (Contd)
Tool number
Description
Tool name
KV11292010
Nozzle centering device
NT293
KV11100300
Nozzle holder socket
(For No. 2 - 4 injection
nozzles)
NT563
KV119E0010
No. 1 injection nozzle
holder socket
NT648
NT653
EC-3
PRECAUTIONS AND PREPARATION
EC-4
PRECAUTIONS AND PREPARATION
SEF656V
EC-5
PRECAUTIONS AND PREPARATION
Precautions
+ Before connecting or disconnecting the ECM harness
connector, turn ignition switch OFF and disconnect nega-
tive 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
SEF308Q
SEF291H
MEF040D
EC-6
PRECAUTIONS AND PREPARATION
Precautions (Contd)
+ When measuring ECM signals with a circuit tester, never
allow the two tester probes to contact.
Accidental contact of probes will cause a short circuit and
damage the ECM power transistor.
SEF348N
EC-7
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
SEF657V
EC-8
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
ECCS-D Component Parts Location (Contd)
SEF658V
EC-9
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
ECCS-D Component Parts Location (Contd)
SEF659V
EC-10
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
Circuit Diagram
TEC420
EC-11
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
System Diagram
SEF660V
EC-12
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
SEF661V
1
V Charge air cooler to vacuum gal- 5
V 3-way connector to throttle control 8
V 3-way connector to EGRC-sole-
lery solenoid valve noid valve B
2
V Throttle control valve to throttle 6
V 3-way connector to EGRC-sole- 9
V EGR valve and 3-way connector
control solenoid valve noid valve A
3
V Vacuum pump to 3-way connector 7
V 3-way connector to EGRC-sole-
4
V Vacuum gallery to wastegate valve noid valve A
actuator
EC-13
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
System Chart
Ignition switch EGR valve & throttle control c EGRC-solenoid valve A, B &
c
valve control throttle control solenoid valve
Battery voltage c
Mass air flow sensor c Air conditioning cut control c Air conditioner relay
Heat up switch c Charge air cooler fan control c Charge air cooler fan relay
EC-14
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
START CONTROL
Input/output signal line
Engine coolant temperature
Engine coolant temperature sensor c
Engine speed
Crankshaft position sensor (TDC) c
ECM Electric
c governor
Start signal
Ignition switch c
When the ECM receives a start signal from the ignition switch, the
ECM adapts the fuel injection system for the start control. The
amount of fuel injected at engine starting is a preset program value
in the ECM. The program is determined by 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 400 rpm (for M/T models), 600 rpm (for A/T models) and
shifts the control to the normal or idle control.
SEF648S
EC-15
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
Fuel Injection System (Contd)
IDLE CONTROL
Input/output signal line
Engine coolant temperature
Engine coolant temperature sensor c
Engine speed
Crankshaft position sensor (TDC) c
Gear position
Neutral position switch c
Battery voltage
Battery c
ECM
Control sleeve position Electric
Control sleeve position sensor c c governor
Idle position
Accelerator position switch c
Vehicle speed
Vehicle speed sensor c
When the ECM determines that the engine speed is at idle, the fuel injection system is adapted for the idle
control. The ECM regulates the amount of fuel injected corresponding to changes in load applied to the engine
to keep engine speed constant. The ECM also provides the system with a fast idle control in response to the
engine coolant temperature and heat up switch signal.
NORMAL CONTROL
Input/output signal line
Engine speed
Crankshaft position sensor (TDC) c
Vehicle speed
Vehicle speed sensor c
EC-16
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
Fuel Injection System (Contd)
FUEL TEMPERATURE COMPENSATION
Input/output signal line
Fuel temperature
Fuel temperature sensor c
The amount of fuel leaking at or around high-pressure parts inside fuel injection pump varies with fuel tem-
perature 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 tempera-
ture sensor which detects fuel temperature.
DECELERATION CONTROL
Input/output signal line
Accelerator position
Accelerator switch (F/C) c
Electric
ECM c governor
Engine speed
Camshaft position sensor (PUMP) c
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 switch (F/C) and camshaft
position sensor (PUMP).
EC-17
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
BASIC CONTROL
Input/output signal line
Engine speed
Crankshaft position sensor (TDC) c Injection
ECM c timing con-
Injection timing trol valve
Needle lift sensor c
SEF650S
Start signal
Ignition switch c
For better startability under cool engine conditions, the fuel injec-
tion timing is compensated according to the engine coolant tem-
perature.
timing compensation
Fuel injection
Engine coolant
temperature
Engine rpm
SEF651S
EC-18
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
Fuel Injection Timing System (Contd)
ENGINE COOLANT TEMPERATURE COMPENSATION (During driving)
Input/output signal line
Engine speed
Crankshaft position sensor (TDC) c
Injection timing
Needle lift sensor c
For better exhaust efficiency under cool engine conditions, the fuel
injection timing is controlled within a compensation range depend-
ing on the engine speed, engine coolant temperature and amount
of fuel injected.
SEF652S
SYSTEM DESCRIPTION
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 continues
until the coolant temperature returns to normal.
EC-19
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION
Neutral position
Neutral position switch c
Accelerator position
Accelerator position switch or Accelerator c
ECM Electric
switch (F/C) c
governor
Engine speed
Crankshaft position sensor (TDC) c
If the engine speed is above 3,000 rpm with no load (for example,
in neutral and engine speed over 3,000 rpm) fuel will be cut off after
some time. The exact time when the fuel is cut off varies based on
engine speed.
Fuel cut will operate until the engine speed reaches 1,500 rpm,
then fuel cut is cancelled.
NOTE:
This function is different from deceleration control and fuel cut
solenoid valve control listed under Fuel Injection System,
EC-15 and TROUBLE DIAGNOSIS FOR DTC 36, 37, 38,
EC-130.
EC-20
CRANKCASE VENTILATION SYSTEM
Description
In this system, blow-by gas is sucked into the air inlet pipe through
the control valve after oil separation by oil separator in the rocker
cover.
SEF456HA
Inspection
Blow-by control valve BLOW-BY CONTROL VALVE
Check control valve for clogging and abnormalities.
Intake
manifold
Rocker cover
SEC586B
VENTILATION HOSE
1. Check hoses and hose connections for leaks.
2. Disconnect all hoses and clean with compressed air.
If any hose cannot be freed of obstructions, replace.
SEC692
EC-21
INJECTION NOZZLE
CAUTION:
+ Do not disassemble No. 1 nozzle (with needle lift sensor
built-in). If NG, replace No. 1 injection nozzle.
+ Plug flare nut with a cap or rag so that no dust enters the
nozzle. Cover nozzle tip for protection of needle.
SEF662V
SEF669A
Nozzle needle
Nozzle body
Nozzle nut
SEF670A
EC-22
INJECTION NOZZLE
SEF830
SEF831
SEF832
EC-23
INJECTION NOZZLE
Cleaning (No. 2 - 4 nozzles) (Contd)
4. Clean spray hole of nozzle body by using Tool.
To prevent spray hole from canting, always clean it by start-
ing with inner side and working towards outside.
SEF833
SEF834
SEF835
SEF671A
EC-24
INJECTION NOZZLE
EF791A
2. 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
14,220 kPa (142.2 bar, 145 kg/cm2, 2,062 psi)
New
14,711 - 15,495 kPa (147.1 - 155.0 bar,
150 - 158 kg/cm2, 2,133 - 2,247 psi)
SEF672A
Always check initial injection pressure using a new nozzle.
SEF673A
LEAKAGE TEST
1. Maintain the pressure at about 981 to 1,961 kPa (9.8 to 19.6
bar, 10 to 20 kg/cm2, 142 to 284 psi) below initial injection
pressure.
2. Check that there is no dripping from the nozzle tip or around the
body.
SEF674A
EC-25
INJECTION NOZZLE
Test and Adjustment (Contd)
3. If there is leakage, clean, overhaul or replace nozzle.
EC-26
ELECTRONIC FUEL INJECTION PUMP
SEF663V
Removal
1. Remove battery.
Disconnect electronic injection pump harness connectors.
SEF664V
SEF665V
EC-27
ELECTRONIC FUEL INJECTION PUMP
Removal (Contd)
7. Remove injection pump assembly.
SEF666V
Installation
1. Install key on injection pump shaft, then install injection pump
sprocket.
+ Use alignment mark on sprocket.
2. Install injection pump timing belt.
Refer to EM section (Injection Pump Timing Belt).
SEF667V
EC-28
ELECTRONIC FUEL INJECTION PUMP
SEF668V
EC-29
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
SEF691S
EC-30
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
1. BULB CHECK : This function checks the MIL bulb for damage (blown, open circuit,
etc.).
2. MALFUNCTION : This is a usual driving condition. When a malfunction is detected, the
WARNING MIL will light up to inform the driver that a malfunction has been
detected.
3. SELF-DIAGNOSTIC : This function allows diagnostic trouble codes to be read.
RESULTS
EC-31
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Malfunction Indicator Lamp (MIL) (Contd)
HOW TO SWITCH DIAGNOSTIC TEST MODES
Turn ignition switch ON.
(Do not start engine.)
.
NG NG
Check MIL circuit. c
Repair harness or
c
Diagnostic Test Mode I BULB CHECK. (See EC-188.) connectors.
Refer to previous page.
MIL should come on. OK OK
c .
b
OK
Diagnostic Test
c
G c Mode I
Start engine. MALFUNC-
TION WARN-
ING.
Refer to previ-
ous page.
.
NG Check MIL circuit and data link connector for
c
CONSULT circuit. (See EC-188.)
OK NG
.
Data link connector for CONSULT
(Connect CHK and IGN terminals with a suitable Repair harness or
harness.) connectors.
MIL should go off.
OK
.
Wait at least 2 seconds. b .
.
DIAGNOSTIC TEST MODE II
SELF-DIAGNOSTIC RESULTS
.
B
j A
j
EC-32
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Malfunction Indicator Lamp (MIL) (Contd)
B
j A
j
m
.
+ Switching the modes is not possible when the engine
is running.
+ When ignition switch is turned off during diagnosis,
power to ECM will drop after approx. 5 seconds.
The diagnosis will automatically return to Diagnostic
Data link connector for CONSULT
Test Mode I.
(Connect CHK and IGN terminals with a suit-
able harness.)
.
Wait at least 2 seconds.
.
If the suitable harness is disconnected at this
time, the diagnostic trouble code will be
erased from the backup memory in the ECM.
EC-33
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Malfunction Indicator Lamp (MIL) (Contd)
DIAGNOSTIC TEST MODE IBULB CHECK
In this mode, the MALFUNCTION INDICATOR LAMP on the instrument panel should stay ON. If it remains
OFF, check the bulb. Refer to EL section (WARNING LAMPS AND CHIME) or see EC-188.
DIAGNOSTIC TEST MODE IMALFUNCTION WARNING
MALFUNCTION
Condition
INDICATOR LAMP
When the malfunction is detected or the ECMs CPU is malfunctioning. (Refer to MIL Illumination of the
ON
DIAGNOSTIC TROUBLE CODE INDEX, EC-1.)
OFF No malfunction.
+ These Diagnostic Trouble Code Numbers are clarified in Diagnostic Test Mode II (SELF-DIAGNOSTIC
RESULTS).
DIAGNOSTIC TEST MODE IISELF-DIAGNOSTIC RESULTS
In this mode, a diagnostic trouble code is indicated by the number of blinks of the MALFUNCTION INDICA-
TOR LAMP as shown below.
SEF212NA
Long (0.6 second) blinking indicates the number of ten digits, and short (0.3 second) blinking indicates the
number of single digits. For example, the malfunction indicator lamp blinks 4 times for 5 seconds (0.6 sec x
4 times) and then it blinks three times for about 1 second (0.3 sec x 3 times). This indicates the DTC 43
and refers to the malfunction of the accelerator position sensor circuit.
In this way, all the detected malfunctions are classified by their diagnostic trouble code numbers. The DTC
55 refers to no malfunction. (See DIAGNOSTIC TROUBLE CODE INDEX, EC-1.)
HOW TO ERASE DIAGNOSTIC TEST MODE II (Self-diagnostic results)
The diagnostic trouble code can be erased from the backup memory in the ECM when the diagnostic test mode
is changed from Diagnostic Test Mode II to Diagnostic Test Mode I. (Refer to HOW TO SWITCH DIAGNOS-
TIC TEST MODES on previous page.)
+ If the battery terminal is disconnected, the diagnostic trouble code will be lost from the backup
memory within 24 hours.
+ Be careful not to erase the stored memory before starting trouble diagnoses.
+ If the MIL blinks or NATS MALFUNCTION is displayed on
SELF-DIAG RESULTS screen, perform self-diagnostic
results mode with CONSULT using NATS program card
(NATS-E940). Refer to EL section.
+ Confirm no self-diagnostic results of NATS is displayed
before touching ERASE in SELF-DIAG RESULTS mode
with CONSULT.
+ When replacing ECM, initialisation of NATS V2.0 system
and registration of all NATS V2.0 ignition key IDs must be
carried out with CONSULT using NATS program card
(NATS-E940).
SEF288Q
Therefore, be sure to receive all keys from vehicle owner.
Regarding the procedures of NATS initialisation and NATS
ignition key ID registration, refer to CONSULT operation
manual, NATS V2.0.
EC-34
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
Malfunction Indicator Lamp (MIL) (Contd)
RELATIONSHIP BETWEEN MIL, DTC, CONSULT AND DRIVING PATTERNS
Driving Pattern
MIL ON
OFF
CONSULT
SELF-
DIAGNOSTIC DTC exists
RESULTS
SCREEN
& DTC does
DATA MONITOR not exist
(AUTO TRIG) SCREEN
SELF- COUNTER
DIAGNOSTIC
RESULTS
SCREEN
SEF659S
*1: When a malfunction is detected, MIL will light up. *5: The DTC will not be displayed any longer after vehicle is
*2: When the same malfunction is detected in two consecutive driven 40 times without the same malfunction.
driving patterns, MIL will stay lit up. (The DTC still remain in ECM.)
*3: MIL will go off after vehicle is driven three times without *6: Other screens except SELF-DIAGNOSTIC RESULTS &
any malfunctions. DATA MONITOR (AUTO TRIG) cannot display the mal-
*4: When a malfunction is detected for the first time, the DTC function. DATA MONITOR (AUTO TRIG) can display the
will be stored in ECM. malfunction at the moment it is detected.
EC-35
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT
CONSULT INSPECTION PROCEDURE
1. Turn off ignition switch.
2. Connect CONSULT to data link connector for CONSULT.
(Data link connector for CONSULT is located under the hood
opener.)
SEF669V
SEF895K
SEF660S
EC-36
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT (Contd)
ECCS COMPONENT PARTS/CONTROL SYSTEMS APPLICATION
DIAGNOSTIC TEST MODE
Item SELF-DIAG-
DATA ACTIVE
NOSTIC
MONITOR TEST
RESULTS
Camshaft position sensor (PUMP) X X
Engine coolant temperature sensor X X
Control sleeve position sensor X X
Fuel temperature sensor X X
Vehicle speed sensor X X
Accelerator position sensor X X X
Accelerator position switch X X
Accelerator switch (F/C) X X
ECCS COMPONENT PARTS
EC-37
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT (Contd)
SELF-DIAGNOSTIC MODE
Regarding items detected in SELF-DIAG RESULTS mode, refer to DIAGNOSTIC TROUBLE CODE
INDEX, EC-1.
DATA MONITOR MODE
Monitored item ECM
Main
[Unit] input Description Remarks
signals
signals
CKPSzRPM + The engine speed computed from the
(TDC) [rpm] j j crankshaft position sensor (TDC) signal
is displayed.
CKPSzRPM + The engine speed [determined by the
(REF) [rpm] time between pulses from the crankshaft
j j position sensor (TDC) signal] is dis-
played.
CMPSzRPM - + The engine speed computed from the
PUMP [rpm] j j camshaft position sensor (PUMP) signal
is displayed.
COOLAN TEMP/S + The engine coolant temperature (deter- + When the engine coolant temperature
[C] or [F] mined by the signal voltage of the engine sensor is open or short-circuited, ECM
j j coolant temperature sensor) is displayed. enters fail-safe mode. The engine cool-
ant temperature determined by the ECM
is displayed.
VHCL SPEED SE + The vehicle speed computed from the
[km/h] or [mph] j j vehicle speed sensor signal is displayed.
FUEL TEMP SEN + The fuel temperature (determined by the
[C] or [F] j j signal voltage of the fuel temperature
sensor) is displayed.
ACCEL POS SEN [V] + The accelerator position sensor signal
j j voltage is displayed.
FULL ACCEL SW + Indicates [ON/OFF] condition from the
[ON/OFF] j j accelerator position switch signal.
ACCEL SW (FC) + Indicates [OPEN/CLOSE] condition from
[OPEN/CLOSE] j j the accelerator switch (FC) signal.
OFF ACCEL SW + Indicates [ON/OFF] condition from the
[ON/OFF] j j accelerator position switch signal.
C/SLEEV POS/S [V] + The control sleeve position sensor signal
j j voltage is displayed.
BATTERY VOLT [V] + The power supply voltage of ECM is dis-
j j played.
P/N POSI SW + Indicates [ON/OFF] condition from the
[ON/OFF] j j park/neutral position switch signal.
START SIGNAL + Indicates [ON/OFF] condition from the + After starting the engine, [OFF] is dis-
[ON/OFF] j j starter signal. played regardless of the starter signal.
NOTE:
Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.
EC-38
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT (Contd)
Monitored item ECM
Main
[Unit] input Description Remarks
signals
signals
AIR COND SIG + Indicates [ON/OFF] condition of the air
[ON/OFF] j j conditioner switch as determined by the
air conditioner signal.
IGN SW + Indicates [ON/OFF] condition from igni-
[ON/OFF] j j tion switch signal.
MAS AIR/FL SE [V] + The signal voltage of the mass air flow + When the engine is stopped, a certain
j j sensor is displayed. value is indicated.
ACT INJ TIMG [] + The actual injection timing angle deter-
mined by the ECM (an approximate
j j average angle between injection start
and end from TDC) is displayed.
INJ TIMG C/V [%] + Indicates the duty ratio of fuel injection
timing control valve.
DECELER F/CUT + Indicates [ON/OFF] condition from decel- + When the accelerator pedal is released
[ON/OFF] j eration fuel cut signal. quickly with engine speed at 3,000 rpm
or more, ON is displayed.
FUEL CUT S/V + The control condition of the fuel cut sole- + When the fuel cut solenoid valve is not
[ON/OFF] noid valve (determined by ECM accord- operating, fuel is not supplied to injection
ing to the input signal) is indicted. nozzles.
j + OFF ... Fuel cut solenoid valve is not
operating.
ON ... Fuel cut solenoid valve is operat-
ing.
GLOW RLY [ON/OFF] + The glow relay control condition (deter-
j mined by ECM according to the input
signal) is displayed.
COOLING FAN + Indicates the control condition of the
[LOW/HI/OFF] cooling fans (determined by ECM
according to the input signal).
j + LOW ... Operates at low speed.
HI ... Operates at high speed.
OFF ... Stopped.
I/C FAN RLY + Indicates the control condition of the
[ON/OFF] j charge air cooler fan (determined by
ECM according to the input signals).
EGRC SOL/V A + The control condition of the EGRC-sole-
[ON/OFF] noid valve A (determined by ECM
according to the input signal) is indi-
cated.
+ OFF ... EGRC-solenoid valve A is not
operating.
ON ... EGRC-solenoid valve A is operat-
ing.
EGRC SOL/V B + The control condition of the EGRC-sole-
[ON/OFF] noid valve B (determined by ECM
according to the input signal) is indi-
cated.
+ OFF ... EGRC-solenoid valve B is not
operating.
ON ... EGRC-solenoid valve B is operat-
ing.
THROT RLY + The control condition of the throttle con-
[ON/OFF] trol solenoid valve (determined by ECM
according to the input signal) is indi-
cated.
+ OFF ... Throttle control solenoid valve is
not operating.
ON ... Throttle control solenoid valve is
operating.
EC-39
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT (Contd)
ACTIVE TEST MODE
TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY)
+ Ignition switch: ON
+ Operate the cooling fan at Cooling fan moves at LOW, HI + Harness and connector
COOLING FAN
LOW, HI speed and turn speed and stops. + Cooling fan motor
OFF using CONSULT.
OFF ACCEL PO + Clears the self-learning fully closed accelerator position, detected by accelerator position sensor, from the
SIG ECM.
+ Ignition switch: ON
+ Turn solenoid valve ON and Solenoid valve makes an operating + Harness and connector
FUEL CUT SOL/V
OFF with the CONSULT and sound. + Solenoid valve
listen to operating sound.
+ Ignition switch: ON
+ Turn solenoid valve ON and Solenoid valve makes an operating + Harness and connector
EGRC SOL/V A
OFF with the CONSULT and sound. + Solenoid valve
listen to operating sound.
+ Ignition switch: ON
+ Turn solenoid valve ON and Solenoid valve makes an operating + Harness and connector
EGRC SOL/V B
OFF with the CONSULT and sound. + Solenoid valve
listen to operating sound.
+ Ignition switch: ON
THROT CONT + Turn solenoid valve ON and Solenoid valve makes an operating + Harness and connector
SOL/V OFF with the CONSULT and sound. + Solenoid valve
listen to operating sound.
+ Ignition switch: ON (Engine
stopped)
Glow relay makes the operating + Harness and connector
GLOW RLY + Turn the glow relay ON and
sound. + Glow relay
OFF using CONSULT and
listen to operating sound.
+ Engine: Return to the original
trouble condition If trouble symptom disappears, see
INJ TIMING + Adjust initial injection timing
+ Retard the injection timing using CHECK ITEM.
CONSULT.
EC-40
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT (Contd)
REAL TIME DIAGNOSIS IN DATA MONITOR MODE
CONSULT has two kinds of triggers and they can be selected by touching SETTING in DATA MONITOR
mode.
1. AUTO TRIG (Automatic trigger):
+ The malfunction will be identified on the CONSULT screen in real time.
In other words, the 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, DATA
MONITOR cannot continue any longer after the malfunction detection.
2. MANU TRIG (Manual trigger):
+ The malfunction item will not be displayed automatically on CONSULT 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 DTC by performing the DTC CONFIRMATION PROCEDURE, be sure to
select to DATA MONITOR (AUTO TRIG) mode. You can confirm the malfunction at the moment it is
detected.
+ While narrowing down the possible causes, CONSULT 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 DTC 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
+ If the malfunction is displayed as soon as DATA MONITOR is selected, reset CONSULT 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.
SEF529Q
EC-41
TROUBLE DIAGNOSIS Introduction
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
drives electronic fuel injection pump. It is essential that both input
and output signals are proper 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 intermit-
tently rather than continuously. Most intermittent problems are
SEF858S caused by poor electric connections or improper wiring. In this
case, careful checking of suspected circuits may help prevent the
replacement of good parts.
A visual check only may not find the cause of the problems. A road
test with CONSULT or a circuit tester connected should be per-
formed. Follow the Work Flow, EC-44.
Before undertaking actual checks, take a few minutes to talk with
a customer who approaches with a driveability complaint. The cus-
tomer 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.
SEF233G Start your diagnosis by looking for conventional problems first.
This will help troubleshoot driveability problems on an electronically
controlled engine vehicle.
SEF234G
EC-42
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 make
troubleshooting faster and more accurate.
In general, each customer feels differently about a problem. It is
important to fully understand the symptoms or conditions for a
customer complaint.
Utilize a diagnostic worksheet like the one shown below in order to
organize all the information for troubleshooting.
SEF907L
WORKSHEET SAMPLE
Customer name MR/MS Model & Year VIN
Engine # Trans. Mileage
Incident Date Manuf. Date In Service Date
h Impossible to start h No combustion h Partial combustion
h Partial combustion when engine is warm
h Startability
h Partial combustion when engine is cool
h Possible but hard to start h Others [ ]
h No fast idle h Unstable h High idle h Low idle
h Idling
Symptoms h Others [ ]
h Stumble h Surge h Knock h Lack of power
h Driveability
h Others [ ]
h At the time of start h While idling
h Engine stall h While accelerating h While decelerating
h Just after stopping h While loading
h Just after delivery h Recently
Incident occurrence
h In the morning h At night h In the daytime
Frequency h All the time h Under certain conditions h Sometimes
Weather conditions h Not affected
Weather h Fine h Raining h Snowing h Others [ ]
Temperature h Hot h Warm h Cool h Cold h Humid F
h Cold h During warm-up h After warm-up
Vehicle speed
EC-43
TROUBLE DIAGNOSIS Work Flow
Work Flow
CHECK IN
.
CHECK INCIDENT CONDITIONS. ................................................. STEP I
Listen to customer complaints. (Get symptoms.)
.
Check and PRINT OUT (write down) Diagnostic Trouble Code (DTC).
Then clear. Also check related service bulletins for information. ........................................... STEP II
. .
INCIDENT CONFIRMATION *1
........................................... STEP IV
Verify the DTC by performing the DTC CONFIRMATION PROCEDURE.
.
Choose the appropriate action. ...........................................
c STEP V
*2
Malfunction Code (at STEP II or IV) Normal Code (at both STEP II and IV)
.
BASIC INSPECTION
. .
TROUBLE DIAGNOSIS FOR DTC XX. STEP VI
.
REPAIR/REPLACE
.
NG FINAL CHECK
Confirm that the incident is completely fixed by performing BASIC INSPECTION and
........................................... STEP VII
DTC CONFIRMATION PROCEDURE (or OVERALL FUNCTION CHECK). Then,
erase the unnecessary (already fixed) DTCs in ECM.
OK
.
CHECK OUT
*1: If the incident cannot be duplicated, refer to GI 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 POWER SUPPLY, EC-63.
EC-44
TROUBLE DIAGNOSIS Work Flow
EC-45
TROUBLE DIAGNOSIS Basic Inspection
Basic Inspection
Precaution:
Perform Basic Inspection without electrical or mechanical
loads applied;
+ Headlamp switch is OFF,
+ Air conditioner switch is OFF,
+ Rear defogger switch is OFF,
+ Steering wheel is in the straight-ahead position, etc.
BEFORE STARTING
SEF142I
1. Check service records for any recent
repairs that may indicate a related
problem, or the current need for sched-
uled maintenance.
2. Open engine hood and check the fol-
lowing:
+ Harness connectors for improper con-
nections
+ Vacuum hoses for splits, kinks, or
improper connections
+ Wiring for improper connections,
pinches, or cuts
3. Using priming pump, bleed air from fuel
SEF670V system. Refer to DRAINING WATER,
Checking and Replacing Fuel Filter
and Draining Water of ENGINE
MAINTENANCE in MA section.
.
CONNECT CONSULT TO THE VEHICLE.
Connect CONSULT to the data link con-
nector for CONSULT and select
ENGINE from the menu. Refer to
EC-36.
SEF669V
.
No
DOES ENGINE START? c
Turn ignition switch OFF,
wait 5 seconds and then
Yes start engine. If engine fails
to start, check diagnostic
trouble code (DTC).
.
Run engine for 10 minutes.
SEF714V
CHECK IDLE SPEED.
--------------------------------------------------------------------------------------------------------------------------------------------------------
Read engine idle speed in DATA
MONITOR mode with CONSULT.
------------------------------------------------------------------- OR -------------------------------------------------------------------
Check idle speed using tachom-
eter tester.
--------------------------------------------------------------------------------------------------------------------------------------------------------
77525 rpm
.
(Go to j
A on next page.)
SEF671V
EC-46
TROUBLE DIAGNOSIS Basic Inspection
Basic Inspection (Contd)
A
j
.
OK
CHECK INJECTION TIMING. c + Bleed air from fuel sys-
1. Set No. 1 piston at TDC on its com- tem.
pression stroke. + After this inspection,
2. Remove injection tubes and air bleeder unnecessary diagnostic
on the back of injection pump. trouble code No. might
3. Set dial gauge so its indicator points to be displayed.
somewhere between 1.0 and 2.0 mm Erase the stored
(0.039 and 0.079 in) on the scale. memory in ECM.
4. Turn crankshaft 1 turn clockwise and Refer to ON BOARD
SEF672V check that dial gauge indicates the DIAGNOSTIC SYSTEM
same value again. DESCRIPTION (EC-30)
5. Turn crankshaft counterclockwise about and HOW TO ERASE
100 degrees, then turn crankshaft DTC (EC-30).
clockwise slowly, and set dial gauge
indicator to 0 mm at the position it OK
stops. .
6. Turn crankshaft clockwise and set the INSPECTION END
injection timing mark on the crankshaft
pulley to the timing indicator.
7. Read plunger lift.
Plunger lift:
0.920.04 mm (0.03620.0016 in)
+ When repeating the checking, start
with step 5.
SEF664V
NG
.
ADJUSTING c Go to .
1. If plunger lift is not within the specified
value, adjust by turning injection pump.
+ If indication is smaller than the speci-
fied value, turn pump body away
from engine.
+ If indication is larger than the speci-
fied value, turn pump body towards
engine.
SEF673V
2. Tighten injection pump securing bolts
and nuts.
Nut:
: 16 - 21 Nzm
(1.6 - 2.1 kg-m, 12 - 15 ft-lb)
Bolt:
: 22 - 29 Nzm
(2.2 - 3.0 kg-m, 16 - 22 ft-lb)
3. Remove dial gauge and install air
bleeder with new washer.
4. Install injection tubes.
Flare nut:
: 22 - 25 Nzm
(2.2 - 2.5 kg-m, 16 - 18 ft-lb)
5. Bleed air from fuel system.
SEF666V Refer to DRAINING WATER, Check-
ing and Replacing Fuel Filter and
Draining Water of ENGINE MAINTE-
NANCE in MA section.
EC-47
TROUBLE DIAGNOSIS General Description
ENGINE STALL
POOR ACCELERATION
KNOCK/DETONATION
IDLING VIBRATION
DURING DRIVING
LACK OF POWER
BLACK SMOKE
WHITE SMOKE
LOW IDLE
Reference page
AT IDLE
HI IDLE
Fuel cut
Warranty symptom
AA AB AC AD AE AF AG AH AJ AK AL AM AP HA
code
EC-48
SYMPTOM
HI IDLE
Fuel cut
LOW IDLE
ENGINE STALL
HARD/NO START/
LACK OF POWER
IDLING VIBRATION
AT IDLE
EXCESSIVE FUEL CONSUMPTION
HESITATION/SURGING/FLAT SPOT
DEAD BATTERY (UNDER CHARGE)
Malfunction indicator lamp illuminates.
page
SYSTEM
Malfunction
Reference
Check point
ECCS system
DURING DRIVING
Feature of symptom
WHEN DECELERATING
BLACK SMOKE
EC-49
Engine coolant temperature sensor Compensation according to
circuit open, short j j j j j j j j EC-79 engine coolant temperature does
not function.
Vehicle speed sensor circuit open, short j j EC-83
Control sleeve position sensor circuit open, short j j j j j j EC-87
Adjustment resistor circuit open, short j j j j j j j j EC-92
open, ground short j j j j j j j
Electric governor circuit EC-96
short j j
open, short j j j Injection timing cannot be con-
Injection timing control valve circuit EC-101 trolled.
ground short j j
ECCS
open, short j j j
Accelerator switch (FC) circuit EC-106
ground short j j
Charge air temperature sensor circuit open, short j EC-122
Symptom Matrix Chart (Contd)
HI IDLE
Fuel cut
LOW IDLE
ENGINE STALL
HARD/NO START/
LACK OF POWER
IDLING VIBRATION
AT IDLE
EXCESSIVE FUEL CONSUMPTION
HESITATION/SURGING/FLAT SPOT
DEAD BATTERY (UNDER CHARGE)
Malfunction indicator lamp illuminates.
SYSTEM
Malfunction
Check point
ECCS system
Reference page
DURING DRIVING
Feature of symptom
WHEN DECELERATING
BLACK SMOKE
EC-50
Accelerator position switch (Idle) cir- EC-165
cuit short j j j j j Accelerator position sensor NG
signal is output.
Accelerator position switch (Full) cir- open, short j j j j j EC-165
cuit
open j j j j
Ignition switch circuit EC-63
short Engine does not stop.
open j j j
Power supply for ECM circuit EC-63
short j j
open, short Does not operate.
Throttle control solenoid valve circuit EC-156
ground short j j j Does not stop operating.
open, short
ECCS
EGRC-solenoid valve A, B circuit EC-156
ground short j Does not stop operating.
open j j j j j Glow lamp does not turn on.
Glow relay circuit EC-151
short Glow lamp does not turn off.
open j j j j
Symptom Matrix Chart (Contd)
TROUBLE DIAGNOSIS General Description
CKPSzRPM (TDC)
+ Tachometer: Connect Almost the same speed as the CON-
CKPSzRPM (REF)
+ Run engine and compare tachometer indication with the CONSULT value. SULT value.
CMPSzRPM-PUMP
+ Turn drive wheels and compare speedometer indication with the CONSULT Almost the same speed as
VHCL SPEED SE
value the CONSULT value
FUEL TEMP SEN + Engine: After warming up More than 40C (104 F)
Heat up switch: ON ON
WARM UP SW + Ignition switch: ON
Heat up switch: OFF OFF
INJ TIMG C/V + Engine: After warming up, idle the engine. Approx. 50%
Idle OFF
EC-51
TROUBLE DIAGNOSIS General Description
CONSULT Reference Value in Data Monitor
Mode (Contd)
MONITOR ITEM CONDITION SPECIFICATION
EC-52
TROUBLE DIAGNOSIS General Description
SEF663S
EC-53
TROUBLE DIAGNOSIS General Description
SEF519V
AEC913
SEF367I
SEF665S
EC-54
TROUBLE DIAGNOSIS General Description
ECM Terminals and Reference Value (Contd)
ECM HARNESS CONNECTOR TERMINAL LAYOUT
SEF064P
Ignition switch ON
Idle speed
SEF715V
5 Y/B Tachometer
Approximately 1.0 - 2.0V
SEF716V
EC-55
TROUBLE DIAGNOSIS General Description
ECM Terminals and Reference Value (Contd)
TER- DATA
WIRE
MINAL ITEM CONDITION (DC Voltage and Pulse
COLOR
NO. Signal)
Approximately 0 - 4.8V
10 P Fuel temperature sensor Engine is running. Output voltage varies with
fuel temperature.
Ignition switch ON
0 - 1.5V
Glow lamp is ON.
16 L/W Glow lamp
Ignition switch ON BATTERY VOLTAGE
Glow lamp is OFF. (11 - 14V)
Approximately 0 - 4.8V
Engine coolant tempera- Output voltage varies with
19 LG/R Engine is running.
ture sensor engine coolant tempera-
ture.
EC-56
TROUBLE DIAGNOSIS General Description
ECM Terminals and Reference Value (Contd)
TER- DATA
WIRE
MINAL ITEM CONDITION (DC Voltage and Pulse
COLOR
NO. Signal)
Ignition switch ON
Approximately 0V
Gear position is N or P (A/T models).
Inhibitor switch/ Gear position is Neutral (M/T models).
22 P/B
Neutral position switch
Ignition switch ON BATTERY VOLTAGE
Except the above gear position (11 - 14V)
Ignition switch ON
0.4 - 0.6V
Accelerator position sen- Accelerator pedal fully released
23 W
sor Ignition switch ON
Approximately 4.3V
Accelerator pedal fully depressed
Engine is running.
24 PU/W A/T signal No. 1 6 - 8V
Idle speed
0 - BATTERY VOLTAGE
(11 - 14V)
Engine is running.
SEF717V
Engine is running.
30 P A/T signal No. 3 Approximately 0V
Idle speed
Ignition switch ON
Approximately 0V
Accelerator position switch Accelerator pedal released
32 W/G
(Full) Ignition switch ON BATTERY VOLTAGE
Accelerator pedal fully depressed (11 - 14V)
EC-57
TROUBLE DIAGNOSIS General Description
ECM Terminals and Reference Value (Contd)
TER- DATA
WIRE
MINAL ITEM CONDITION (DC Voltage and Pulse
COLOR
NO. Signal)
Approximately 0V
Idle speed
SEF718V
34 W Needle lift sensor
Approximately 0V
SEF719V
Approximately 0 - 4.8V
Charge air temperature
36 LG Engine is running. Output voltage varies with
sensor
charge air temperature.
Engine is running.
37 P/B A/T signal No. 2 6 - 8V
Idle speed
Engine ground
39 Engine is running. (Probe this terminal with
B ECCS ground
43 Idle speed @ tester probe when
measuring.)
EC-58
TROUBLE DIAGNOSIS General Description
ECM Terminals and Reference Value (Contd)
TER- DATA
WIRE
MINAL ITEM CONDITION (DC Voltage and Pulse
COLOR
NO. Signal)
Approximately 0V
Idle speed
SEF720V
40 Crankshaft position sensor
L
44 (TDC) Approximately 0V
SEF721V
Approximately 0V
Idle speed
SEF722V
41 Camshaft position sensor
W
45 (PUMP) Approximately 0V
SEF723V
42 L/G Approximately 0V
Engine is running.
Data link connector for
64 Y/G Idle speed (CONSULT is connected and Approximately 0 - 12V
CONSULT
turned on)
65 Y/R Approximately 0 - 9V
Approximately 0 - 4.6V
(Voltage varies with part
46 Y Adjustment resistor Ignition switch ON
number of adjustment
resistor.)
EC-59
TROUBLE DIAGNOSIS General Description
ECM Terminals and Reference Value (Contd)
TER- DATA
WIRE
MINAL ITEM CONDITION (DC Voltage and Pulse
COLOR
NO. Signal)
Approximately 2.6V
SEF724V
56 BATTERY VOLTAGE
W Power supply for ECM Ignition switch ON
61 (11 - 14V)
Ignition switch ON
0V
Heat up switch is OFF.
59 BR/W Heat up switch
Ignition switch ON BATTERY VOLTAGE
Heat up switch is ON. (11 - 14V)
Approximately 2.6V
SEF725V
Approximately 2.6V
SEF726V
Ignition switch ON
0.4 - 0.6V
Accelerator position sen- Accelerator pedal fully released
68 B/W
sor signal to TCM Ignition switch ON
Approximately 4.3V
Accelerator pedal fully depressed
BATTERY VOLTAGE
70 BR Power supply (Back-up) Ignition switch OFF
(11 - 14V)
EC-60
TROUBLE DIAGNOSIS General Description
ECM Terminals and Reference Value (Contd)
TER- DATA
WIRE
MINAL ITEM CONDITION (DC Voltage and Pulse
COLOR
NO. Signal)
Approximately 10V
Engine is running.
Idle speed
SEF727V
102
G/Y Electric governor ground
108 Approximately 10V
Engine is running.
SEF728V
BATTERY VOLTAGE
(11 - 14V)
Idle speed
SEF729V
104 Injection timing control
L/W
110 valve BATTERY VOLTAGE
(11 - 14V)
SEF730V
EC-61
TROUBLE DIAGNOSIS General Description
ECM Terminals and Reference Value (Contd)
TER- DATA
WIRE
MINAL ITEM CONDITION (DC Voltage and Pulse
COLOR
NO. Signal)
EC-62
TROUBLE DIAGNOSIS FOR POWER SUPPLY
Ignition switch ON
Engine ground
39 Engine is running. (Probe this terminal with
B ECCS ground
43 Idle speed @ tester probe when
measuring.)
56 BATTERY VOLTAGE
W Power supply for ECM Ignition switch ON
61 (11 - 14V)
BATTERY VOLTAGE
70 BR Power supply (Back-up) Ignition switch OFF
(11 - 14V)
EC-63
TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
(Contd)
TEC421
EC-64
TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
(Contd)
TEC422
EC-65
TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
(Contd)
INSPECTION START
.
No
Start engine. c CHECK POWER SUP-
Is engine running? PLY-I.
1. Turn ignition switch
Yes ON.
2. Check voltage between
ECM terminal V 38 and
ground with CONSULT
SEF065P or tester.
Voltage: Battery volt-
age
If NG, check the following.
+ Harness connectors
M51 , F6
+ 10A fuse
+ Harness for open or
short between ECM and
fuse
If NG, repair harness or
connectors.
OK
.
Go to CHECK
SEF056R GROUND CIRCUIT on
EC-68.
.
NG
CHECK POWER SUPPLY-II. c Check the following.
1. Stop engine. + Harness connectors
2. Check voltage between ECM terminal E127 , M21
70 and ground with CONSULT or
+ Harness connectors
V M52 , F7
tester.
Voltage: Battery voltage + 7.5A fuse
+ Harness for open or
OK short between ECM and
battery
If NG, repair harness or
connectors.
SEF566S
.
OK
CHECK POWER SUPPLY-III. c Go to CHECK
1. Turn ignition switch ON and then GROUND CIRCUIT on
OFF. EC-68.
2. Check voltage between ECM terminals
V 56 , V
61 , 116 , 117 and ground with
CONSULT or tester.
Voltage: Case-1: Battery voltage does
After turning ignition switch OFF, not exist.
battery voltage will exist for a few Case-2: Battery voltage exists
seconds, then drop to approximately for more than a few
0V. seconds.
NG
SEF567S Case-2
Case-1 c Go to CHECK ECCS
RELAY on next page.
.
A
j
EC-66
TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
(Contd)
A
j
.
CHECK HARNESS CONTINUITY NG Check the following.
c
BETWEEN ECCS RELAY AND ECM. + Harness connectors
1. Disconnect ECM harness connector. M52 , F7
2. Disconnect ECCS relay. + Harness connectors
3. Check harness continuity between ECM M50 , F5
terminals V56 , V61 and relay terminal + Harness for open or
SEF513V V 7 , and ECM terminals 116 , 117 short between ECM and
and relay terminal V 5 . ECCS relay
Continuity should exist. If NG, repair open circuit or
If OK, check harness for short to short to ground or short to
ground and short to power. power in harness or con-
nectors.
OK
.
CHECK VOLTAGE BETWEEN ECCS NG Check the following.
c
RELAY AND GROUND. + Harness connectors
Check voltage between relay terminals E127 , M21
V1 , V3 , V6 and ground with CONSULT + 15A fuse
SEF569S or tester. + Harness for open or
Voltage: Battery voltage short between ECCS
relay and battery
OK
If NG, repair harness or
connectors.
.
CHECK OUTPUT SIGNAL CIRCUIT. NG Check the following.
c
Check harness continuity between ECM + Harness connectors
terminal V4 and relay terminal V 2 . M52 , F7
Continuity should exist. + Harness for open or
If OK, check harness for short to ground short between ECM and
SEF030S and short to power. ECCS relay
If NG, repair open circuit or
OK
short to ground or short to
power in harness or con-
nectors.
.
CHECK ECCS RELAY. NG Replace ECCS relay.
c
1. Apply 12V direct current between relay
terminals V1 and V 2 .
2. Check continuity between relay termi-
nals V3 and V 5 , V7 and V 6 .
OK
.
B
j
EC-67
TROUBLE DIAGNOSIS FOR POWER SUPPLY
Main Power Supply and Ground Circuit
(Contd)
B
j
.
CHECK GROUND CIRCUIT. NG Check the following.
c
1. Turn ignition switch OFF. + Joint connector F18
2. Disconnect ECM harness connector. + Harness for open or
3. Check harness continuity between ECM short between ECM and
terminals V 39 , V
43 , 106 , 112 , 118 ground
and engine ground. If NG, repair open circuit or
SEF570S Continuity should exist. short to ground or short to
If OK, check harness for short to power in harness or con-
ground and short to power. nectors.
OK
.
Check ECM pin terminals for damage and
check the connection of ECM harness
connector.
.
INSPECTION END
EC-68
TROUBLE DIAGNOSIS FOR CAM POS SEN (PUMP) (DTC 11)
Approximately 0V
Idle speed
SEF723V
EC-69
TROUBLE DIAGNOSIS FOR CAM POS SEN (PUMP) (DTC 11)
Camshaft Position Sensor (CMPS) (PUMP)
(Contd)
ON BOARD DIAGNOSIS LOGIC
Diagnostic
Check Items
Trouble Code Malfunction is detected when ....
(Possible cause)
No.
11 + An improper signal from the sensor is detected by + Harness or connectors
ECM during engine running. [The camshaft position sensor (PUMP) circuit is open
or shorted.]
+ Camshaft position sensor (PUMP)
EC-70
TROUBLE DIAGNOSIS FOR CAM POS SEN (PUMP) (DTC 11)
Camshaft Position Sensor (CMPS) (PUMP)
(Contd)
TEC423
EC-71
TROUBLE DIAGNOSIS FOR CAM POS SEN (PUMP) (DTC 11)
Camshaft Position Sensor (CMPS) (PUMP)
(Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
CHECK INPUT SIGNAL CIRCUIT. NG Repair open circuit or short
c
1. Turn ignition switch OFF. to ground or short to power
2. Disconnect electronic fuel injection in harness or connectors.
SEF675V pump harness connector and ECM har-
ness connector.
3. Check harness continuity between ter-
minal V 1 and ECM terminals V 41 , V
45 .
Continuity should exist.
If OK, check harness for short to
ground and short to power.
OK
.
CHECK GROUND CIRCUIT-I. NG Repair open circuit or short
c
1. Turn ignition switch OFF. to ground or short to power
2. Check harness continuity between ter- in harness or connectors.
SEF731V minal V 2 and ECM terminals V 28 , V
33 .
Continuity should exist.
If OK, check harness for short to
ground and short to power.
OK
.
NG
CHECK GROUND CIRCUIT-II. c
Check the following.
1. Loosen and retighten engine ground + Joint connector F19
screws. + Harness for open or
2. Check harness continuity between ter- short between electronic
minal V 3 and engine ground. fuel injection pump and
SEF732V Continuity should exist. engine ground
If OK, check harness for short to If NG, repair harness or
ground and short to power. connectors.
OK
.
CHECK COMPONENT NG Replace camshaft position
c
[Camshaft position sensor (PUMP)]. sensor (PUMP).
Refer to COMPONENT INSPECTION
on next page.
OK
.
Disconnect and reconnect harness connec-
SEF676V tors in the circuit. Then retest.
.
INSPECTION END
SEF733V
EC-72
TROUBLE DIAGNOSIS FOR CAM POS SEN (PUMP) (DTC 11)
Camshaft Position Sensor (CMPS) (PUMP)
(Contd)
COMPONENT INSPECTION
Camshaft position sensor (PUMP)
1. Disconnect electronic fuel injection pump harness connector.
2. Loosen the camshaft position sensor (PUMP).
3. Remove the sensor.
4. Visually check the sensor for chipping.
SEF573S
SEF677V
EC-73
TROUBLE DIAGNOSIS FOR MASS AIR FLOW SEN (DTC 12)
EC-74
TROUBLE DIAGNOSIS FOR MASS AIR FLOW SEN (DTC 12)
Mass Air Flow Sensor (MAFS) (Contd)
DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE
1) Turn ignition switch ON, and wait at least 6 seconds.
2) Select DATA MONITOR mode with CONSULT.
3) Start engine and wait at least 3 seconds.
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
1) Turn ignition switch ON, and wait at least 6 seconds.
2) Start engine and wait at least 3 seconds.
3) Turn ignition switch OFF, wait at least 5 seconds and
then turn ON.
SEF735V 4) Perform Diagnostic Test Mode II (Self-diagnostic
results) with ECM.
EC-75
TROUBLE DIAGNOSIS FOR MASS AIR FLOW SEN (DTC 12)
Mass Air Flow Sensor (MAFS) (Contd)
TEC424
EC-76
TROUBLE DIAGNOSIS FOR MASS AIR FLOW SEN (DTC 12)
Mass Air Flow Sensor (MAFS) (Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
NG
CHECK POWER SUPPLY. c Check the following.
1. Turn ignition switch OFF. + Harness connectors
2. Disconnect mass air flow sensor har- M52 , F7
ness connector. + Harness for open or
3. Turn ignition switch ON. short between mass air
4. Check voltage between terminal V 1 flow sensor and ECM
SEF713V and ground with CONSULT or tester. + Harness for open or
Voltage: Battery voltage short between mass air
flow sensor and ECCS
OK relay
If NG, repair harness or
connector.
.
NG
CHECK GROUND CIRCUIT. c Check the following.
1. Turn ignition switch OFF. + Harness connectors
2. Loosen and retighten engine ground E106 , M88
screws. + Harness connectors
3. Check harness continuity between ter- M51 , F6
minal V 2 and engine ground. + Harness for open or
SEF736V Continuity should exist. short between mass air
If OK, check harness for short to flow sensor and ECM
ground and short to power. + Harness for open or
short between mass air
OK flow sensor and TCM
If NG, repair open circuit or
short to ground or short to
power in harness or con-
nectors.
.
NG
CHECK INPUT SIGNAL CIRCUIT. c Repair open circuit or short
1. Disconnect ECM harness connector. to ground or short to power
2. Check harness continuity between ter- in harness or connectors.
SEF676V
minal V 3 and ECM terminal V 35 .
Continuity should exist.
If OK, check harness for short to
ground and short to power.
OK
.
NG
CHECK COMPONENT c Replace mass air flow sen-
(Mass air flow sensor). sor.
Refer to COMPONENT INSPECTION
on next page.
OK
.
Disconnect and reconnect harness con-
SEF737V nectors in the circuits. Then retest.
.
INSPECTION END
SEF738V
EC-77
TROUBLE DIAGNOSIS FOR MASS AIR FLOW SEN (DTC 12)
Mass Air Flow Sensor (MAFS) (Contd)
COMPONENT INSPECTION
Mass air flow sensor
1. Start engine and warm it up to normal operating temperature.
2. Check voltage between ECM terminal V 35 and ground under the
following condition.
Conditions Voltage V
Ignition switch ON (Engine stopped.) Less than 1.0
Idle (Engine is warmed-up sufficiently.) 1.0 - 1.7
SEF739V 2,500 rpm Approximately 2.1
Idle to about 4,000 rpm* 1.0 - 1.7 to Approx. 4.0
*: Check for linear voltage rise in response to increase to about 4,000 rpm in engine
speed.
3. If NG, remove mass air flow sensor from air duct. Check hot
wire for damage and dust.
SEF740V
EC-78
TROUBLE DIAGNOSIS FOR COOLANT TEMP SEN (DTC 13)
SEF594K
<Reference data>
Engine coolant tempera-
Voltage* Resistance
ture
(V) (k)
C (F)
10 (14) 4.4 7.0 - 11.4
20 (68) 3.5 2.1 - 2.9
50 (122) 2.3 0.68 - 1.00
90 (194) 1.0 0.236 - 0.260
SEF012P *: These data are reference values and measured between ECM terminal V 19
(Engine coolant temperature sensor) and ECM terminal V
43 (ECCS ground).
Diagnostic
Check Items
Trouble Code Malfunction is detected when ...
(Possible Cause)
No.
13 + An excessively high or low voltage from the sensor is + Harness or connectors
entered to ECM. (The sensor circuit is open or shorted.)
+ Engine coolant temperature sensor
EC-79
TROUBLE DIAGNOSIS FOR COOLANT TEMP SEN (DTC 13)
Engine Coolant Temperature (ECT) Sensor
(Contd)
TEC425
EC-80
TROUBLE DIAGNOSIS FOR COOLANT TEMP SEN (DTC 13)
Engine Coolant Temperature (ECT) Sensor
(Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
NG
CHECK POWER SUPPLY. c Check the following.
1. Turn ignition switch OFF. + Harness connectors
2. Disconnect engine coolant temperature E202 , E69
sensor harness connector. + Harness connectors
SEF678V 3. Turn ignition switch ON. E127 , M21
4. Check voltage between terminal V2 + Harness connectors
and ground with CONSULT or tester. M51 , F6
Voltage: + Harness for open or
Approximately 5V short between ECM and
engine coolant tempera-
OK ture sensor
If NG, repair harness or
connectors.
.
NG
CHECK GROUND CIRCUIT. c Check the following.
1. Turn ignition switch OFF. + Harness connectors
2. Check harness continuity between ter- E202 , E69
minal V 1 and engine ground. + Harness connectors
SEF541P
Continuity should exist. E127 , M21
If OK, check harness for short to + Harness connectors
ground and short to power. M50 , F5
+ Harness connectors
OK F6 , M51
+ Harness connectors
M88 , E106
+ Harness for open or
short between ECM and
engine coolant tempera-
ture sensor
+ Harness for open or
short between TCM and
engine coolant tempera-
SEF542P ture sensor
If NG, repair open circuit or
short to ground or short to
power in harness or con-
nectors.
.
NG
CHECK COMPONENT c Replace engine coolant
(Engine coolant temperature sensor). temperature sensor.
Refer to COMPONENT INSPECTION
on next page.
OK
.
Disconnect and reconnect harness con-
nectors in the circuit. Then retest.
.
INSPECTION END
EC-81
TROUBLE DIAGNOSIS FOR COOLANT TEMP SEN (DTC 13)
Engine Coolant Temperature (ECT) Sensor
(Contd)
COMPONENT INSPECTION
Engine coolant temperature sensor
Check resistance as shown in the figure.
SEF012P
EC-82
TROUBLE DIAGNOSIS FOR VEHICLE SPEED SEN (DTC 14)
AEC110
0 - BATTERY VOLTAGE
(11 - 14V)
Engine is running.
SEF717V
EC-83
TROUBLE DIAGNOSIS FOR VEHICLE SPEED SEN (DTC 14)
Vehicle Speed Sensor (VSS) (Contd)
OVERALL FUNCTION CHECK
Use this procedure to check the overall function of the vehicle
speed sensor circuit. During this check, a DTC might not be con-
firmed.
1) Jack up drive wheels.
2) Start engine.
3) Read vehicle speed sensor signal in DATA MONITOR
mode with CONSULT.
The vehicle speed on CONSULT should be able to
exceed 10 km/h (6 MPH) when rotating wheels with suit-
SEF941N able gear position.
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
1) Jack up drive wheels.
2) Start engine.
3) Rotate drive wheel by hand.
4) Check voltage between ECM terminal V 26 and ground
with tester.
Voltage should vary between 0V - battery voltage.
SEF811R
EC-84
TROUBLE DIAGNOSIS FOR VEHICLE SPEED SEN (DTC 14)
Vehicle Speed Sensor (VSS) (Contd)
TEC426
EC-85
TROUBLE DIAGNOSIS FOR VEHICLE SPEED SEN (DTC 14)
Vehicle Speed Sensor (VSS) (Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
CHECK INPUT SIGNAL CIRCUIT. NG Check the following.
c
1. Turn ignition switch OFF. + Harness connectors
2. Disconnect ECM harness connector M52 , F7
and combination meter harness con- + Joint connector M79
SEF742V nector. + Harness for open or
3. Check harness continuity between ECM short between ECM and
terminal V26 and meter terminal V 26 . combination meter
Continuity should exist. If NG, repair open circuit or
If OK, check harness for short to short to ground or short to
ground and short to power. power in harness or con-
nectors.
OK
.
CHECK SPEEDOMETER FUNCTION. NG Check the following.
c
Make sure that speedometer functions + Harness connectors
properly. M86 , E104 (LHD mod-
els)
OK
+ Harness connectors
M21 , E127 (RHD mod-
els)
+ Harness connectors
E70 , E201
+ Harness for open or
short between combina-
tion meter and vehicle
speed sensor
If NG, repair open circuit or
short to ground or short to
power in harness or con-
nectors.
Check vehicle speed sen-
sor and its circuit.
Refer to EL section.
.
Disconnect and reconnect harness con-
nectors in the circuit. Then retest.
.
INSPECTION END
EC-86
TROUBLE DIAGNOSIS FOR CONT SLEEV POS SEN (DTC 15)
SEF743V
Approximately 2.6V
SEF724V
Approximately 2.6V
SEF725V
Approximately 2.6V
SEF726V
EC-87
TROUBLE DIAGNOSIS FOR CONT SLEEV POS SEN (DTC 15)
Control Sleeve Position Sensor (CSPS) (Contd)
ON BOARD DIAGNOSIS LOGIC
Diagnostic
Check Items
Trouble Code Malfunction is detected when ....
(Possible cause)
No.
15 + An excessively high or low voltage from the sensor is + Harness or connectors
detected by ECM. (The control sleeve position sensor circuit is open or
........................................................................................... shorted.)
+ An improper voltage signal from the sensor is + Control sleeve position sensor
detected by ECM during engine running.
EC-88
TROUBLE DIAGNOSIS FOR CONT SLEEV POS SEN (DTC 15)
Control Sleeve Position Sensor (CSPS) (Contd)
TEC427
EC-89
TROUBLE DIAGNOSIS FOR CONT SLEEV POS SEN (DTC 15)
Control Sleeve Position Sensor (CSPS) (Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
CHECK POWER SUPPLY CIRCUIT. NG Repair open circuit or short
c
1. Turn ignition switch OFF. to ground or short to power
2. Disconnect ECM harness connector in harness or connectors.
and electronic fuel injection pump har-
ness connector.
SEF679V 3. Check harness continuity between ter-
minal V 2 and ECM terminals V 53 , V
57 .
Continuity should exist.
If OK, check harness for short to
ground and short to power.
OK
.
CHECK INPUT SIGNAL CIRCUIT. NG Repair open circuit or short
c
Check harness continuity between sensor to ground or short to power
terminal V3 and ECM terminals V 63 , V
67 . in harness or connectors.
Continuity should exist.
SEF744V If OK, check harness for short to ground
and short to power.
OK
.
CHECK GROUND CIRCUIT-I. NG Repair open circuit or short
c
Check harness continuity between sensor to ground or short to power
terminal V6 and ECM terminals V 62 , V
66 . in harness or connectors.
Continuity should exist.
If OK, check harness for short to ground
and short to power.
OK
SEF745V
.
CHECK GROUND CIRCUIT-II. NG Check the following.
c
1. Loosen and retighten engine ground + Joint connector F19
screws. + Harness for open or
2. Check harness continuity between ter- short between control
minal V 4 and engine ground. sleeve position sensor
Continuity should exist. and engine ground
If OK, check harness for short to If NG, repair open circuit or
ground and short to power. short to ground or short to
power in harness or con-
OK
nectors.
SEF746V .
A
j
SEF676V
EC-90
TROUBLE DIAGNOSIS FOR CONT SLEEV POS SEN (DTC 15)
Control Sleeve Position Sensor (CSPS) (Contd)
A
j
.
CHECK COMPONENT NG Take proper action.
c
(Control sleeve position sensor).
Refer to COMPONENT INSPECTION
below.
OK
.
Disconnect and reconnect harness connec-
SEF747V 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
COMPONENT INSPECTION
Control sleeve position sensor
1. Disconnect electronic fuel injection pump harness connector.
2. Check continuity between terminals V 2 and V
3 , V
2 and V 6 .
Resistance: Approximately 5.9 [at 23C (73F)]
If NG, take proper action.
SEF680V
EC-91
TROUBLE DIAGNOSIS FOR ADJUST RESISTOR (DTC 17)
Adjustment Resistor
The adjustment resistor is used to achieve uniform pump charac-
teristics.
SEF681V
Approximately 0 - 4.6V
(Voltage varies with part
46 Y Adjustment resistor Ignition switch ON
number of adjustment
resistor.)
EC-92
TROUBLE DIAGNOSIS FOR ADJUST RESISTOR (DTC 17)
Adjustment Resistor (Contd)
TEC428
EC-93
TROUBLE DIAGNOSIS FOR ADJUST RESISTOR (DTC 17)
Adjustment Resistor (Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
CHECK POWER SUPPLY. NG Repair harness or connec-
c
1. Turn ignition switch OFF. tors.
2. Disconnect electronic fuel injection
pump harness connector.
3. Turn ignition switch ON.
SEF682V
4. Check voltage between terminal V 2
and ground.
Voltage:
Approximately 5V
OK
.
CHECK GROUND CIRCUIT. NG Check the following.
c
1. Turn ignition switch OFF. + Harness connectors
2. Check harness continuity between ter- F6 , M51
minal V 6 and engine ground. + Harness connectors
Continuity should exist. M88 , E106
SEF749V
If OK, check harness for short to + Harness for open or
ground and short to power. short between ECM and
adjustment resistor
OK
+ Harness for open or
short between TCM and
adjustment resistor
If NG, repair open circuit or
short to ground or short to
power in harness or con-
nectors.
.
SEF750V
CHECK COMPONENT NG Replace adjustment resis-
c
(Adjustment resistor). tor.
Refer to COMPONENT INSPECTION
on next page.
OK
.
Disconnect and reconnect harness con-
nectors in the circuit. Then retest.
.
INSPECTION END
EC-94
TROUBLE DIAGNOSIS FOR ADJUST RESISTOR (DTC 17)
Adjustment Resistor (Contd)
COMPONENT INSPECTION
Adjustment resistor
Check resistance between terminals V 2 and V 6 .
Resistance: Approximately 0.2 - 15.0 k [at 25C
(77F)]
Resistance value varies with adjustment sensor num-
bers.
If NG, replace adjustment resistor.
Always replace adjustment resistor with a new one which has same
number on label.
SEF683V
EC-95
TROUBLE DIAGNOSIS FOR F/INJ F/B 2 (DTC 18),
F/INJ F/B (DTC 22), ELECTRIC GOV (DTC 25)
Electric Governor
The electric governor is built into the electronic 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 rotors rotating angle is determined by a balanced condition of
magnetic force (generated by current flow regulated by means of
the ECM) and tension of return spring (installed to rotor). The larger
the current flow through the coil, the greater the rotors 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 changing
the duty ratio which controls the ON-OFF operation of the electric
governor grounding circuit.
SEF632S
SEF633S
Ignition switch ON
EC-96
TROUBLE DIAGNOSIS FOR F/INJ F/B 2 (DTC 18),
F/INJ F/B (DTC 22), ELECTRIC GOV (DTC 25)
Electric Governor (Contd)
TER- DATA
WIRE
MINAL ITEM CONDITION (DC Voltage and Pulse
COLOR
NO. Signal)
Approximately 10V
Engine is running.
Idle speed
102 SEF727V
G/Y Electric governor ground
108 Approximately 10V
Engine is running.
SEF728V
EC-97
TROUBLE DIAGNOSIS FOR F/INJ F/B 2 (DTC 18),
F/INJ F/B (DTC 22), ELECTRIC GOV (DTC 25)
Electric Governor (Contd)
DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE
Note: If DTC 18, 22, 25 and DTC 15 are displayed, perform
TROUBLE DIAGNOSIS FOR DTC 15. (See EC-87.)
1) Turn ignition switch ON and select DATA MONITOR
mode with CONSULT.
2) Start engine and warm it up to normal operating tem-
perature.
3) Run engine for 2 seconds at 3,000 rpm. Return engine
speed to idle, then increase to 3,000 rpm under no load.
SEF751V ---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
1) Start engine and warm it up to normal operating tem-
perature.
2) Run engine for 2 seconds at 3,000 rpm. Return engine
speed to idle, then increase to 3,000 rpm under no load.
3) Turn ignition switch OFF, wait at least 5 seconds and
then turn ON.
4) Perform Diagnostic Test Mode II (Self-diagnostic
results) with ECM.
Note: If a malfunction occurs intermittently, conduct suitable
driving pattern for 10 minutes. This makes it possible to
determine DTC.
EC-98
TROUBLE DIAGNOSIS FOR F/INJ F/B 2 (DTC 18),
F/INJ F/B (DTC 22), ELECTRIC GOV (DTC 25)
Electric Governor (Contd)
TEC429
EC-99
TROUBLE DIAGNOSIS FOR F/INJ F/B 2 (DTC 18),
F/INJ F/B (DTC 22), ELECTRIC GOV (DTC 25)
Electric Governor (Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
CHECK POWER SUPPLY.
Refer to EC-63.
.
NG
CHECK POWER SUPPLY CIRCUIT. c
Repair open circuit or short
SEF679VA
1. Turn ignition switch OFF. to ground or short to power
2. Disconnect ECM harness connector in harness or connectors.
and electronic fuel injection pump har-
ness connector.
3. Check harness continuity between ter-
minal V 1 and ECM terminals 101 ,
107 .
Continuity should exist.
If OK, check harness for short to
ground and short to power.
OK
.
SEF752V NG
CHECK GROUND CIRCUIT. c
Repair open circuit or short
Check harness continuity between termi- to ground or short to power
nal V5 and ECM terminals 102 , 108 . in harness or connectors.
Continuity should exist.
If OK, check harness for short to ground
and short to power.
OK
.
NG
CHECK COMPONENT c
Take proper action.
(Electric governor).
Refer to COMPONENT INSPECTION
below.
SEF753V OK
.
Disconnect and reconnect harness connec-
tors in the circuit. Then retest.
.
INSPECTION END
COMPONENT INSPECTION
Electric governor
1. Disconnect electronic fuel injection pump harness connector.
2. Check continuity between terminals V 1 and V
5 .
Resistance: Approximately 0.68 [at 23C (73F)]
If NG, take proper action.
SEF684V
EC-100
TROUBLE DIAGNOSIS FOR F/INJ TIMG F/B (DTC 21)
INJ TIMG C/V + Engine: After warming up, idle the engine. Approx. 50%
BATTERY VOLTAGE
(11 - 14V)
Idle speed
SEF730V
EC-101
TROUBLE DIAGNOSIS FOR F/INJ TIMG F/B (DTC 21)
Injection Timing Control Valve (Contd)
ON BOARD DIAGNOSIS LOGIC
Diagnostic
Check Items
Trouble Code Malfunction is detected when ....
(Possible cause)
No.
21 + Injection timing feedback system does not operate + Harness or connectors
properly. (This system consists essentially of ECM, [Injection timing control valve, needle lift sensor,
injection timing control valve and needle lift sensor.) crankshaft position sensor (TDC) circuits]
+ Injection timing control valve
+ Needle lift sensor
+ Crankshaft position sensor (TDC)
+ Air in fuel line
EC-102
TROUBLE DIAGNOSIS FOR F/INJ TIMG F/B (DTC 21)
Injection Timing Control Valve (Contd)
TEC430
EC-103
TROUBLE DIAGNOSIS FOR F/INJ TIMG F/B (DTC 21)
Injection Timing Control Valve (Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
OK
CHECK FOR AIR IN FUEL FILTER. c
INSPECTION END
1. Move priming pump up and down to
purge air from fuel filter.
2. Perform DIAGNOSTIC TROUBLE
CODE CONFIRMATION PROCE-
SEF670V DURE.
NG
.
NG
CHECK POWER SUPPLY. c
Check the following.
1. Turn ignition switch OFF. + Harness connectors
2. Disconnect injection timing control valve M51 , F6
harness connector. + Electronic fuel injection
3. Turn ignition switch ON. pump harness connector
4. Check harness continuity between ter- F3
minal V 2 and ground with CONSULT or + 10A fuse
tester. + Harness for open or
Voltage: Battery voltage short between injection
SEF685V
timing control valve and
OK fuse
If NG, repair harness or
connectors.
.
NG
CHECK OUTPUT SIGNAL CIRCUIT. c
Check the following.
1. Turn ignition switch OFF. + Electronic fuel injection
2. Disconnect ECM harness connector. pump harness connector
3. Check harness continuity between ter- F3
minal V 1 and ECM terminals 104 , + Harness for open or
110 . short between injection
Continuity should exist. timing control valve and
SEF754V
If OK, check harness for short to ECM
ground and short to power. If NG, repair open circuit or
short to ground or short to
OK power in harness or con-
nectors.
.
CHECK COMPONENT NG Replace injection timing
c
(Injection timing control valve). control valve.
Refer to COMPONENT INSPECTION
on next page.
OK
.
Disconnect and reconnect harness connec-
SEF755V 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-104
TROUBLE DIAGNOSIS FOR F/INJ TIMG F/B (DTC 21)
Injection Timing Control Valve (Contd)
COMPONENT INSPECTION
Injection timing control valve
1. Reconnect injection timing control valve harness connector.
2. Disconnect electronic fuel injection pump harness connector.
3. Check resistance between terminals V 3 and V7 .
Resistance: Approximately 11 [at 20C (68F)]
If NG, replace injection timing control valve.
SEF686V
EC-105
TROUBLE DIAGNOSIS FOR ACCEL POS SW (F/C) (DTC 23)
SEF687V
EC-106
TROUBLE DIAGNOSIS FOR ACCEL POS SW (F/C) (DTC 23)
Accelerator Switch (F/C) (Contd)
DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE
1) Turn ignition switch ON and select DATA MONITOR
mode with CONSULT.
2) Depress and release accelerator pedal once for 15 sec-
onds.
3) Repeat step 2 for 26 times.
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
1) Turn ignition switch ON.
2) Depress and release accelerator pedal once for 15 sec-
SEF756V onds.
3) Repeat step 2 for 26 times.
4) Turn ignition switch OFF, wait at least 5 seconds and
then turn ON.
5) Perform Diagnostic Test Mode II (Self-diagnostic
results) with ECM.
EC-107
TROUBLE DIAGNOSIS FOR ACCEL POS SW (F/C) (DTC 23)
Accelerator Switch (F/C) (Contd)
TEC431
EC-108
TROUBLE DIAGNOSIS FOR ACCEL POS SW (F/C) (DTC 23)
Accelerator Switch (F/C) (Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
OK
CHECK OVERALL FUNCTION. c
INSPECTION END
1. Turn ignition switch ON.
2. Check ACCEL SW (F/C) in
DATA MONITOR mode with
CONSULT.
Accelerator pedal released:
OFF
SEF688V Accelerator pedal depressed:
ON
------------------------------------------------------------------- OR -------------------------------------------------------------------
1. Turn ignition switch ON.
2. Check voltage between ECM
terminal V 29 and ground.
Voltage:
Accelerator pedal released
Battery voltage
Accelerator pedal depressed
Approximately 0V
NG
.
NG
CHECK GROUND CIRCUIT. c Check the following.
SEF589S 1. Turn ignition switch OFF. + Harness connectors
2. Loosen and retighten engine ground M51 , F6 (RHD mod-
screws. els)
3. Disconnect accelerator switch (F/C) har- + Joint connector F18
ness connector. + Harness for open or
4. Check harness continuity between termi- short between accelera-
nal V3 and engine ground. tor switch (F/C) and
Continuity should exist. engine ground
If OK, check harness for short to ground If NG, repair open circuit or
and short to power. short to ground or short to
power in harness or con-
OK nectors.
.
NG
CHECK INPUT SIGNAL CIRCUIT. c
Check the following.
SEF590S 1. Disconnect ECM harness connector. + Harness connectors
2. Check harness continuity between ECM F6 , M51 (RHD mod-
terminal V
29 and terminal V 1 . els)
Continuity should exist. + Harness for open or short
If OK, check harness for short to ground between ECM and accel-
and short to power. erator switch (F/C)
If NG, repair open circuit or
OK short to ground or short to
power in harness or con-
nectors.
.
NG
CHECK COMPONENT c
Replace accelerator pedal
[Accelerator switch (F/C)]. assembly.
Refer to COMPONENT INSPECTION
on next page.
SEF591S
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
SEF592S
EC-109
TROUBLE DIAGNOSIS FOR ACCEL POS SW (F/C) (DTC 23)
Accelerator Switch (F/C) (Contd)
COMPONENT INSPECTION
Accelerator switch (F/C)
1. Disconnect accelerator switch (F/C) harness connector.
2. Check continuity between terminals V 1 and V3 .
Conditions Continuity
Accelerator pedal released No
Accelerator pedal depressed Yes
If NG, replace accelerator pedal assembly.
SEF689V
EC-110
TROUBLE DIAGNOSIS FOR ECM 1 (DTC 27), ECM 2 (DTC 31)
SEC220B
Diagnostic
Check Item
Trouble Code Malfunction is detected when ....
(Possible Cause)
No.
27, 31 + ECM calculation function is malfunctioning. + ECM
(ECCS-D control module)
EC-111
TROUBLE DIAGNOSIS FOR ECM 1 (DTC 27), ECM 2 (DTC 31)
Engine Control Module (ECM)-ECCS-D Control
Module (Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
1) Turn ignition switch ON.
2) Select SELF DIAG RESULTS
mode with CONSULT.
3) Touch ERASE.
------------------------------------------------------------------- OR -------------------------------------------------------------------
1) Turn ignition switch ON.
2) Erase the Diagnostic Test Mode
II (Self-diagnostic results)
memory.
.
PERFORM SELF-DIAGNOSIS.
Select SELF DIAG RESULTS
mode with CONSULT.
------------------------------------------------------------------- OR -------------------------------------------------------------------
PERFORM Diagnostic Test Mode
II (SELF-DIAGNOSTIC
RESULTS).
.
Is the DTC 27, 31 displayed again? Yes Replace ECM.
c
No
.
INSPECTION END
EC-112
TROUBLE DIAGNOSIS FOR OVER HEAT (DTC 28)
The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, air condi-
tioner system pressure and air conditioner ON signal. The control system has 2-step control [ON/OFF].
Operation
SEF757V
EC-113
TROUBLE DIAGNOSIS FOR OVER HEAT (DTC 28)
Cooling Fan (Overheat) (Contd)
TER- DATA
WIRE
MINAL ITEM CONDITION (DC Voltage and Pulse
COLOR
NO. Signal)
EC-114
TROUBLE DIAGNOSIS FOR OVER HEAT (DTC 28)
Cooling Fan (Overheat) (Contd)
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. Serious
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.
AEC640 1) Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to DIAG-
NOSTIC PROCEDURE, EC-117.
2) Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to DIAGNOS-
TIC PROCEDURE, EC-117.
3) Turn ignition switch ON.
4) Perform COOLING FAN in ACTIVE TEST mode with
CONSULT and make sure that cooling fan operates
when touching ON.
SEF758V
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
3) Disconnect engine coolant temperature sensor harness
connector.
4) Connect 150 resistor to engine coolant temperature
sensor harness connector.
5) Start engine and make sure that cooling fan operates.
Be careful not to overheat engine.
SEF979S
EC-115
TROUBLE DIAGNOSIS FOR OVER HEAT (DTC 28)
Cooling Fan (Overheat) (Contd)
TEC432
EC-116
TROUBLE DIAGNOSIS FOR OVER HEAT (DTC 28)
Cooling Fan (Overheat) (Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
CHECK COOLING FAN OPERATION. OK Go to CHECK COOL-
c
1. Turn ignition switch OFF. ING SYSTEM FOR LEAK,
2. Turn ignition switch ON. EC-119.
3. Perform COOLING FAN in
ACTIVE TEST mode with
SEF758V CONSULT and make sure that
cooling fan operates when touch-
ing ON.
------------------------------------------------------------------- OR -------------------------------------------------------------------
2. Disconnect engine coolant tem-
perature sensor harness connec-
tor.
3. Connect 150 resistor to engine
coolant temperature sensor har-
ness connector.
4. Start engine and make sure that
cooling fan operates.
SEF979S NG
.
CHECK POWER SUPPLY. NG Check the following.
c
1. Turn ignition switch OFF. + 10A fuse
2. Disconnect cooling fan relay-1. + 30A fusible link
3. Turn ignition switch ON. + Harness for open or short
4. Check voltage between terminals V
2 , between cooling fan
V5 and ground with CONSULT or tester. relay-1 and fuse
Voltage: Battery voltage + Harness for open or short
between cooling fan
OK
relay-1 and battery
If NG, repair harness or
SEF690V
connectors.
.
CHECK GROUND CIRCUIT. NG Repair open circuit or short
c
1. Turn ignition switch OFF. to ground or short to power
2. Disconnect cooling fan motor harness in harness or connectors.
connector.
3. Check harness continuity between
relay terminal V3 and motor termi-
nals V 1 , V
3 .
Continuity should exist.
If OK, check harness for short to
ground and short to power.
SEF759V 4. Check harness continuity between
motor terminals V 2 , V4 and body
ground.
Continuity should exist.
If OK, check harness for short to
ground and short to power.
OK
.
A
j
SEF691V
EC-117
TROUBLE DIAGNOSIS FOR OVER HEAT (DTC 28)
Cooling Fan (Overheat) (Contd)
A
j
.
CHECK OUTPUT SIGNAL CIRCUIT. NG Check the following.
c
1. Disconnect ECM harness connector. + Harness connectors
2. Check harness continuity between ECM E127 , M21
terminal V
14 and terminal V 1 . + Harness connectors
Continuity should exist. M52 , F7
If OK, check harness for short to ground + Harness for open or short
SEF760V and short to power. between cooling fan
relay-1 and ECM
OK
If NG, repair open circuit or
short to ground or short to
power in harness or con-
nectors.
.
CHECK COMPONENT NG Replace cooling fan relay.
c
(Cooling fan relay-1).
Refer to COMPONENT INSPECTION,
EC-121.
OK
SEF761V .
CHECK COMPONENT NG Replace cooling fan motor.
c
(Cooling fan motor-1).
Refer to COMPONENT INSPECTION,
EC-121.
OK
.
Disconnect and reconnect harness connec-
tors in the circuit. Then retest.
.
INSPECTION END
EC-118
TROUBLE DIAGNOSIS FOR OVER HEAT (DTC 28)
Cooling Fan (Overheat) (Contd)
SLC754AA
OK
.
CHECK RADIATOR CAP. NG Replace radiator cap.
c
Apply pressure to cap with a tester.
Radiator cap relief pressure:
78 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0
kg/cm2, 11 - 14 psi)
OK
.
CHECK THERMOSTAT. NG Replace thermostat.
c
1. Check valve seating condition at normal
room temperatures.
It should seat tightly.
SLC755AB 2. Check valve opening temperature and
valve lift.
Valve opening temperature:
82C (180F) [standard]
Maximum valve lift:
More than 10 mm/95C
(0.39 in/203F)
3. Check if valve is closed at 5C (9F)
below valve opening temperature.
For details, refer to LC section (Thermo-
stat).
OK
.
SLC343 Check engine coolant temperature sensor. NG Replace engine coolant
c
Refer to COMPONENT INSPECTION, temperature sensor.
EC-82.
OK
.
If the cause cannot be isolated, go to
MAIN 12 CAUSES OF OVERHEATING
on next page.
.
INSPECTION END
EC-119
TROUBLE DIAGNOSIS FOR OVER HEAT (DTC 28)
Cooling Fan (Overheat) (Contd)
MAIN 12 CAUSES OF OVERHEATING
Engine Step Inspection item Equipment Condition Reference page
OFF 1 + Blocked radiator + Visual No blocking
+ Blocked radiator grille
+ Blocked bumper
2 + Coolant mixture + Coolant tester 50 - 50% coolant mixture See RECOMMENDED
FLUIDS AND LUBRI-
CANTS in MA section.
3 + Coolant level + Visual Coolant up to MAX level See Changing Engine
in reservoir tank and Coolant, ENGINE
radiator filler neck MAINTENANCE in MA
section.
4 + Radiator cap + Pressure tester 78 - 98 kPa See System Check
(0.78 - 0.98 bar, 0.8 - 1.0 ENGINE COOLING
kg/cm2, 11 - 14 psi) SYSTEM in LC section.
ON*2 5 + Coolant leaks + Visual No leaks See System Check
ENGINE COOLING
SYSTEM in LC section.
ON*2 6 + Thermostat + Touch the upper and Both hoses should be hot See Thermostat and
lower radiator hoses Radiator, ENGINE
COOLING SYSTEM in
LC section.
ON*1 7 + Cooling fan + CONSULT Operating See TROUBLE DIAG-
NOSIS FOR DTC 28,
EC-113.
OFF 8 + Combustion gas leak + Color checker chemical Negative
tester 4 Gas analyzer
ON*3 9 + Coolant temperature + Visual Gauge less than 3/4
gauge when driving
+ Coolant overflow to res- + Visual No overflow during driving See Changing Engine
ervoir tank and idling Coolant, ENGINE
MAINTENANCE in MA
section.
OFF*4 10 + Coolant return from res- + Visual Should be initial level in See ENGINE MAINTE-
ervoir tank to radiator reservoir tank NANCE in MA section.
OFF 11 + Cylinder head + Straight gauge feeler 0.1mm (0.004 in) Maxi- See Inspection, CYL-
gauge mum distortion (warping) INDER HEAD in EM
section.
12 + Cylinder block and pis- + Visual No scuffing on cylinder See Inspection, CYL-
tons 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.
EC-120
TROUBLE DIAGNOSIS FOR OVER HEAT (DTC 28)
Cooling Fan (Overheat) (Contd)
COMPONENT INSPECTION
Cooling fan relay-1
Check continuity between terminals 3
V and 5 .
V
Conditions Continuity
12V direct current supply between
Yes
terminals V1 and V 2
No current supply No
SEF511P
If NG, replace relay.
Terminals
() (@)
Cooling fan motor 1 , V
V 3 2 , V
V 4
EC-121
TROUBLE DIAGNOSIS FOR I/C INT/A TEMP SEN (DTC 33)
SEF594K
<Reference data>
Charge air temperature Voltage Resistance
C (F) (V) (k)
10 (14) 4.4 7.0 - 11.4
20 (68) 3.5 2.1 - 2.9
50 (122) 2.3 0.68 - 1.00
90 (194) 1.0 0.236 - 0.260
110 (230) 0.64 0.143 - 0.153
SEF012P 150 (302) 0.30 0.050 - 0.065
Approximately 0 - 4.8V
Charge air temperature
36 LG Engine is running. Output voltage varies with
sensor
charge air temperature.
*1: When nothing is displayed or the meaningless symbol is displayed in the Self-diag result mode with CONSULT, perform Diagnostic Test Mode II
(Self-diagnostic results) with ECM. Refer to EC-32.
EC-122
TROUBLE DIAGNOSIS FOR I/C INT/A TEMP SEN (DTC 33)
Charge Air Temperature Sensor (Contd)
TEC438
EC-123
TROUBLE DIAGNOSIS FOR I/C INT/A TEMP SEN (DTC 33)
Charge Air Temperature Sensor (Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
NG
CHECK POWER SUPPLY. c
Repair harness or connec-
1. Turn ignition switch OFF. tors.
2. Disconnect charge air temperature sen-
sor harness connector.
3. Turn ignition switch ON.
SEF710V 4. Check voltage between terminal V 2
and ground with CONSULT or tester.
Voltage:
Approximately 5V
OK
.
CHECK GROUND CIRCUIT. NG Check the following.
c
1. Turn ignition switch OFF. + Harness connectors
2. Check harness continuity between ter- F6 , M51
minal V 1 and engine ground. + Harness connectors
Continuity should exist. M88 , E106
If OK, check harness for short to + Harness for open or
SEF764V ground and short to power. short between ECM and
charge air temperature
OK sensor
+ Harness for open or
short between TCM and
charge air temperature
sensor
If NG, repair open circuit or
short to ground or short to
power in harness or con-
nectors.
.
SEF765V CHECK COMPONENT NG Replace charge air tem-
c
(Charge air temperature sensor). perature sensor.
Refer to COMPONENT INSPECTION
on next page.
OK
.
Disconnect and reconnect harness con-
nectors in the circuit. Then retest.
.
INSPECTION END
EC-124
TROUBLE DIAGNOSIS FOR I/C INT/A TEMP SEN (DTC 33)
Charge Air Temperature Sensor (Contd)
COMPONENT INSPECTION
Charge air temperature sensor
Check resistance as shown in the figure.
SEF012P
EC-125
TROUBLE DIAGNOSIS FOR NEEDLE LIFT SEN (DTC 34)
Piezoelectric element
SEF604S
Approximately 0V
Idle speed
SEF718V
34 W Needle lift sensor
Approximately 0V
SEF719V
EC-126
TROUBLE DIAGNOSIS FOR NEEDLE LIFT SEN (DTC 34)
Needle Lift Sensor (NLS) (Contd)
DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE
1) Turn ignition switch ON and select DATA MONITOR
mode with CONSULT.
2) Start engine and run it for at least 10 seconds at idle
speed.
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
1) Start engine and run it for at least 10 seconds at idle
speed.
2) Turn ignition switch OFF, wait at least 5 seconds and
SEF714V then turn ON.
3) Perform Diagnostic Test Mode II (Self-diagnostic
results) with ECM.
EC-127
TROUBLE DIAGNOSIS FOR NEEDLE LIFT SEN (DTC 34)
Needle Lift Sensor (NLS) (Contd)
TEC433
EC-128
TROUBLE DIAGNOSIS FOR NEEDLE LIFT SEN (DTC 34)
Needle Lift Sensor (NLS) (Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
CHECK FOR AIR IN FUEL FILTER. OK INSPECTION END
c
1. Move priming pump up and down to
purge air from fuel filter.
2. Perform DIAGNOSTIC TROUBLE
CODE CONFIRMATION PROCEDURE.
SEF670V NG
.
Loosen and retighten engine ground
screws.
.
CHECK INPUT SIGNAL CIRCUIT. NG Repair open circuit or short
c
1. Turn ignition switch OFF. to ground or short to power
2. Disconnect ECM harness connector and in harness or connectors.
needle lift sensor harness connector.
3. Check harness continuity between termi-
nal V1 and ECM terminal V 34 .
SEF676V Continuity should exist.
If OK, check harness for short to ground
and short to power.
OK
.
CHECK GROUND CIRCUIT. NG Repair open circuit or short
c
Check resistance between terminal V 2 and to ground or short to power
engine ground. in harness or connectors.
Continuity should exist.
If OK, check harness for short to ground
and short to power.
OK
SEF692V .
CHECK NO. 1 INJECTION NOZZLE FOR NG Replace No. 1 injection
c
CLOGGING. nozzle.
Refer to SPRAY PATTERN TEST, Test
and Adjustment, INJECTION NOZZLE,
EC-26.
OK
.
Disconnect and reconnect harness connec-
tors in the circuit. Then retest.
SEF766V
Check ECM pin terminals for damage and
check the connection of ECM harness con-
nector. Reconnect ECM harness connector
and retest.
.
INSPECTION END
SEF767V
EC-129
TROUBLE DIAGNOSIS FOR FUEL CUT S/V 1 (DTC 36),
FCV SHORT (DTC 37), FUEL CUT S/V 2 (DTC 38)
SEF667S
Ignition switch ON
56 BATTERY VOLTAGE
W Power supply for ECM Ignition switch ON
61 (11 - 14V)
EC-130
TROUBLE DIAGNOSIS FOR FUEL CUT S/V 1 (DTC 36),
FCV SHORT (DTC 37), FUEL CUT S/V 2 (DTC 38)
Fuel Cut Solenoid Valve (Contd)
ON BOARD DIAGNOSIS LOGIC
Diagnostic
Check Items
Trouble Malfunction is detected when ...
(Possible Cause)
Code No.
36, 37, 38 + Fuel cut solenoid valve circuit is malfunctioning. + Main power supply circuit (ECM terminals 116 , 117 )
and fuse
+ Harness or connectors
(The solenoid valve circuit is open or shorted.)
+ Fuel cut solenoid valve
+ ECM
EC-131
TROUBLE DIAGNOSIS FOR FUEL CUT S/V 1 (DTC 36),
FCV SHORT (DTC 37), FUEL CUT S/V 2 (DTC 38)
Fuel Cut Solenoid Valve (Contd)
TEC434
EC-132
TROUBLE DIAGNOSIS FOR FUEL CUT S/V 1 (DTC 36),
FCV SHORT (DTC 37), FUEL CUT S/V 2 (DTC 38)
Fuel Cut Solenoid Valve (Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
CHECK POWER SUPPLY FOR ECM.
Check power supply circuit. Refer to
EC-63.
OK
.
SEF860S NG
CHECK OUTPUT SIGNAL CIRCUIT. Repair open circuit or short
c
1. Turn ignition switch ON. to ground or short to power
2. Select FUEL CUT SOL/V in in harness or connectors.
ACTIVE TEST mode with
CONSULT.
3. Touch ON and OFF alter-
nately.
4. Check that operating sound is
emitted.
------------------------------------------------------------------- OR -------------------------------------------------------------------
1. Turn ignition switch OFF.
2. Disconnect ECM harness con-
SEF682VA
nector and electronic fuel injec-
tion pump harness connector.
3. Check harness continuity
between terminal V 4 and ECM
terminals 113 , 115 .
Continuity should exist.
If OK, check harness for short to
ground and short to power.
OK
.
CHECK COMPONENT NG Replace fuel cut solenoid
c
(Fuel cut solenoid valve). valve.
SEF768V
Refer to COMPONENT INSPECTION
on next page.
OK
.
Disconnect and reconnect harness con-
nectors in the circuit. Then retest.
.
INSPECTION END
EC-133
TROUBLE DIAGNOSIS FOR FUEL CUT S/V 1 (DTC 36),
FCV SHORT (DTC 37), FUEL CUT S/V 2 (DTC 38)
Fuel Cut Solenoid Valve (Contd)
COMPONENT INSPECTION
Fuel cut solenoid valve
Fuse
1. Remove fuel cut solenoid valve.
2. Check shaft to see if it is lifted when applying 12V direct cur-
rent to terminals.
If NG, replace fuel cut solenoid valve.
Shaft SEF859S
EC-134
TROUBLE DIAGNOSIS FOR FUEL TEMP SENSOR (DTC 42)
SEF666S
<Reference data>
Engine coolant tempera-
Voltage Resistance
ture
(V) (k)
C (F)
20 (4) 4.6 13.67 - 16.37
20 (68) 3.5 2.306 - 2.568
60 (140) 1.8 0.538 - 0.624
80 (176) 1.2 0.289 - 0.344
SEF012P
Approximately 0 - 4.8V
10 P Fuel temperature sensor Engine is running. Output voltage varies with
fuel temperature.
EC-135
TROUBLE DIAGNOSIS FOR FUEL TEMP SENSOR (DTC 42)
Fuel Temperature Sensor (FTS) (Contd)
TEC435
EC-136
TROUBLE DIAGNOSIS FOR FUEL TEMP SENSOR (DTC 42)
Fuel Temperature Sensor (FTS) (Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
CHECK POWER SUPPLY. NG Repair harness or connec-
c
1. Turn ignition switch OFF. tors.
2. Disconnect electronic fuel injection
pump harness connector.
3. Turn ignition switch ON.
SEF682VB
4. Check voltage between terminal V 1
and ground with CONSULT or tester.
Voltage:
Approximately 5V
OK
.
CHECK GROUND CIRCUIT. NG Check the following.
c
1. Turn ignition switch OFF. + Harness connectors
2. Check harness continuity between ter- F6 , M51
minal V 5 and engine ground. + Harness connectors
Continuity should exist. M88 , E106
SEF769V If OK, check harness for short to + Harness for open or
ground and short to power. short between ECM and
electronic fuel injection
OK
pump
+ Harness for open or
short between TCM and
electronic fuel injection
pump
If NG, repair open circuit or
short to ground or short to
power in harness or con-
nectors.
SEF770V
.
CHECK COMPONENT NG Take proper action.
c
(Fuel temperature sensor).
Refer to COMPONENT INSPECTION
on next page.
OK
.
Disconnect and reconnect harness con-
nectors in the circuits. Then retest.
.
INSPECTION END
EC-137
TROUBLE DIAGNOSIS FOR FUEL TEMP SENSOR (DTC 42)
Fuel Temperature Sensor (FTS) (Contd)
COMPONENT INSPECTION
Fuel temperature sensor
Wait until fuel temperature sensor reaches room temperature.
Check resistance as shown in the figure.
SEF012P
EC-138
TROUBLE DIAGNOSIS FOR ACCEL POS SENSOR (DTC 43)
SEF861SA
Ignition switch ON
0.4 - 0.6V
Accelerator position sen- Accelerator pedal fully released
23 W
sor Ignition switch ON
Approximately 4.3V
Accelerator pedal fully depressed
EC-139
TROUBLE DIAGNOSIS FOR ACCEL POS SENSOR (DTC 43)
Accelerator Position Sensor (Contd)
ON BOARD DIAGNOSIS LOGIC
Diagnostic
Check Items
Trouble Malfunction is detected when ...
(Possible Cause)
Code No.
43 + An excessively low or high voltage from the sensor is + Harness or connectors
detected by the ECM. (The sensor circuit is open or shorted.)
+ Accelerator position sensor
+ Accelerator position switch
+ Accelerator switch (F/C)
EC-140
TROUBLE DIAGNOSIS FOR ACCEL POS SENSOR (DTC 43)
Accelerator Position Sensor (Contd)
TEC436
EC-141
TROUBLE DIAGNOSIS FOR ACCEL POS SENSOR (DTC 43)
Accelerator Position Sensor (Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
NG
CHECK POWER SUPPLY. c Check the following.
1. Turn ignition switch OFF. + Harness connectors
2. Disconnect accelerator position sensor F7 , M52 (RHD mod-
harness connector. els)
3. Turn ignition switch ON. + Harness for open or
4. Check voltage between terminal V 1 short between ECM and
SEF694V and ground with CONSULT or tester. accelerator position sen-
Voltage: Approximately 5V sor
If NG, repair harness or
OK connectors.
.
NG
CHECK GROUND CIRCUIT. c Check the following.
1. Turn ignition switch OFF. + Harness connectors
2. Loosen and retighten engine ground F7 , M52 (RHD mod-
screw. els)
3. Check harness continuity between ter- + Harness for open or
minal V 3 and engine ground. short between ECM and
Continuity should exist. accelerator position sen-
If OK, check harness for short to sor
SEF771V ground and short to power. If NG, repair open circuit or
short to ground or short to
OK power in harness or con-
nectors.
.
NG
CHECK INPUT SIGNAL CIRCUIT. c Check the following.
1. Disconnect ECM harness connector. + Harness connectors
2. Check harness continuity between ECM F7 , M52 (RHD mod-
terminal V
23 and terminal V 2 . els)
Continuity should exist. + Harness for open or
If OK, check harness for short to short between ECM and
ground and short to power. accelerator position sen-
SEF676V
sor
OK If NG, repair open circuit or
short to ground or short to
power in harness or con-
nectors.
.
NG
CHECK COMPONENT c Replace accelerator pedal
(Accelerator position sensor). assembly.
Refer to COMPONENT INSPECTION
on next page.
OK
.
Disconnect and reconnect harness con-
SEF772V nectors in the circuit. Then retest.
.
INSPECTION END
SEF773V
EC-142
TROUBLE DIAGNOSIS FOR ACCEL POS SENSOR (DTC 43)
Accelerator Position Sensor (Contd)
COMPONENT INSPECTION
Accelerator position sensor
1. Disconnect accelerator position sensor harness connector.
2. Make sure that resistance between terminals V 2 and 3
V
changes when depressing accelerator pedal manually.
Accelerator pedal conditions Resistance [at 25C (77F)]
Completely released Approximately 0.5 k
Partially depressed 0.5 - 4 k
CAUTION:
If accelerator position sensor or ECM connector is
disconnected, perform the following procedures:
Select OFF ACCEL PO SIG in ACTIVE TEST mode.
Touch CLEAR.
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
Start and warm up engine. After engine has warmed up,
idle for 10 minutes.
EC-143
TROUBLE DIAGNOSIS FOR CRANK POS SEN (TDC) (DTC 47)
SEF615S
Approximately 0V
Idle speed
SEF721V
EC-144
TROUBLE DIAGNOSIS FOR CRANK POS SEN (TDC) (DTC 47)
Crankshaft Position Sensor (TDC) (Contd)
DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE
Before performing the following procedure, confirm that bat-
tery voltage is more than 10V.
1) Turn ignition switch ON and select DATA MONITOR
mode with CONSULT.
2) Crank engine for at least 1 second.
3) Start engine and run it for at least 2 seconds at idle
speed.
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
SEF714V 1) Crank engine for at least 1 second.
2) Start engine and run it for at least 2 seconds at idle
speed.
3) Turn ignition switch OFF, wait at least 5 seconds and
then turn ON.
4) Perform Diagnostic Test Mode II (Self-diagnostic
results) with ECM.
EC-145
TROUBLE DIAGNOSIS FOR CRANK POS SEN (TDC) (DTC 47)
Crankshaft Position Sensor (TDC) (Contd)
TEC437
EC-146
TROUBLE DIAGNOSIS FOR CRANK POS SEN (TDC) (DTC 47)
Crankshaft Position Sensor (TDC) (Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
NG
CHECK INPUT SIGNAL CIRCUIT. c
Check the following.
1. Turn ignition switch OFF. + Harness connectors
2. Disconnect crankshaft position sensor F13 , EC4
(TDC) harness connector and ECM har- + Harness for open or
ness connector. short between ECM and
SEF696V 3. Check harness continuity between ECM crankshaft position sen-
terminals V 40 , V
44 and terminal V
1 . sor (TDC)
Continuity should exist. If NG, repair open circuit or
If OK, check harness for short to short to ground or short to
ground and short to power. power in harness or con-
nectors.
OK
.
NG
CHECK GROUND CIRCUIT-I. c
Check the following.
Check harness continuity between termi- + Harness connectors
nal V2 and ECM terminals V 47 , V
52 . F13 , EC4
Continuity should exist. + Harness for open or
If OK, check harness for short to ground short between crankshaft
SEF774V and short to power. position sensor (TDC)
and ECM
OK If NG, repair open circuit or
short to ground or short to
power in harness or con-
nectors.
.
NG
CHECK GROUND CIRCUIT-II. c
Check the following.
1. Loosen and retighten engine ground + Joint connector F19
screws. + Harness for open or
2. Disconnect harness connectors F13 , short between harness
EC4 . connector F13 and
3. Check harness continuity between ter- engine ground
SEF775V
minal V 3 and engine ground. If NG, repair open circuit or
Continuity should exist. short to ground or short to
If OK, check harness for short to power in harness or con-
ground and short to power. nectors.
OK
.
NG
CHECK COMPONENT c
Replace crankshaft posi-
[Crankshaft position sensor (TDC)]. tion sensor (TDC).
Refer to COMPONENT INSPECTION
on next page.
OK
.
SEF676V
Disconnect and reconnect harness connec-
tors in the circuit. Then retest.
.
INSPECTION END
SEF776V
EC-147
TROUBLE DIAGNOSIS FOR CRANK POS SEN (TDC) (DTC 47)
Crankshaft Position Sensor (TDC) (Contd)
COMPONENT INSPECTION
Crankshaft position sensor (TDC)
1. Disconnect crankshaft position sensor (TDC) harness connec-
tor.
2. Loosen the fixing bolt of the sensor.
3. Remove the sensor.
4. Visually check the sensor for chipping.
SEF620S
SEF697V
EC-148
TROUBLE DIAGNOSIS FOR GOV CUT CIRCUIT (DTC 48)
ECM Electric
c
Engine speed governor
Camshaft position sensor (PUMP) c
Diagnostic
Check Item
Trouble Code Malfunction is detected when ....
(Possible Cause)
No.
48 + Accelerator switch circuit is shorted. + Harness or connectors
+ Crankshaft position sensor (PUMP) or ECM is mal- [Accelerator switch (F/C) and camshaft position sen-
functioning. sor (PUMP) circuits]
+ Accelerator switch (F/C)
+ Camshaft position sensor (PUMP)
+ ECM
EC-149
TROUBLE DIAGNOSIS FOR GOV CUT CIRCUIT (DTC 48)
Governor Cut Circuit (Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
1) Turn ignition switch ON.
2) Select SELF DIAG RESULTS
mode with CONSULT.
3) Touch ERASE.
------------------------------------------------------------------- OR -------------------------------------------------------------------
1) Turn ignition switch ON.
2) Erase the diagnostic test mode
II (Self-diagnostic results)
memory.
.
PERFORM DIAGNOSTIC TROUBLE
CODE CONFIRMATION PROCEDURE.
See previous page.
.
Yes
Is the DTC 48 displayed again? c
Replace ECM.
No
.
INSPECTION END
EC-150
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
When engine coolant temperature is more than 90C (194F), the glow relay turns off, inactivating the quick-
glow control until coolant temperature drops below 70C (158F).
When coolant temperature is lower than 90C (194F):
+ Ignition switch ON
After ignition switch has turned to ON, the glow relay turns ON for a certain period of time in relation to
engine coolant temperature, allowing current to flow through glow plug.
+ Cranking
The glow relay turns ON, allowing current to flow through glow plug.
+ Starting
After engine has started, current continues to flow through glow plug (after-glow mode) for a certain period
in relation to engine coolant temperature.
When engine speed exceeds 2,400 rpm, current flow through glow plug is interrupted.
The glow lamp turns ON for a certain period of time in relation to engine coolant temperature at the time glow
relay is turned ON.
COMPONENT DESCRIPTION
Glow plug
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
Ignition switch ON
0 - 1.5V
Glow lamp is ON.
16 L/W Glow lamp
Ignition switch ON BATTERY VOLTAGE
Glow lamp is OFF. (11 - 14V)
EC-151
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Glow Control System (Contd)
TEC441
EC-152
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Glow Control System (Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
NG
Check fuel level, fuel supplying system, c
Correct.
starter motor, etc.
OK
.
NG
Check that all glow plug connecting plate c
Install properly.
SEF698V
nuts are installed properly.
OK
.
CHECK OVERALL FUNCTION. OK CHECK COMPONENT
c
Check entire glow control system. (Refer (Glow plug).
to System Operation Check on next See page EC-155.
page.)
NG
.
CHECK VOLTAGE BETWEEN GLOW NG Check the following.
c
RELAY AND GROUND. + 100A fusible link
SEF699V 1. Turn ignition switch OFF. + Harness for open or
2. Disconnect glow relay. short between glow
3. Check voltage between terminals V
1 , relay and battery
V3 and ground with CONSULT or If NG, repair harness or
tester. connectors.
Voltage: Battery voltage
OK
.
NG
CHECK OUTPUT SIGNAL CIRCUIT. c
Check the following.
1. Disconnect ECM harness connector. + Harness connectors
2. Check harness continuity between ECM E127 , M21
terminal 111 and terminal V 2 . + Harness connectors
SEF777V
Continuity should exist. M51 , F6
If OK, check harness for short to + Harness for open or
ground and short to power. short between glow
relay and ECM
OK If NG, repair open circuit or
short to ground or short to
power in harness or con-
nectors.
.
CHECK HARNESS CONTINUITY NG Check the following.
c
BETWEEN GLOW RELAY AND GLOW + Harness connectors
PLUG. E65 , E204
SEF778V
1. Disconnect glow plug harness connec- + Harness for open or
tor. short between glow
2. Check harness continuity between glow relay and glow plug
relay terminal V
5 and glow plug har- If NG, repair open circuit or
ness connector. short to ground or short to
Continuity should exist. power in harness or con-
If OK, check harness for short to nectors.
ground and short to power.
.
OK
A
j
SEF779V
EC-153
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Glow Control System (Contd)
A
j
.
CHECK COMPONENTS NG Replace malfunctioning
c
(Glow relay, Glow plug). component(s).
Refer to COMPONENT INSPECTION,
EC-155.
OK
.
Disconnect and reconnect harness connec-
tors in the circuit. Then retest.
.
INSPECTION END
SEF700V
EC-154
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Glow Control System (Contd)
3. After-glow system
a. Connect S terminal to starter motor.
b. Start engine and read voltage.
Voltage:
Battery voltage for 5* minutes
* Engine coolant temperature is lower than 50C
(122F).
SEF781V
COMPONENT INSPECTION
Glow relay
1. Check relay for coil continuity.
Continuity should exist.
2. Check relay for proper operation.
SEC564B
Glow plug
1. Remove glow plug connecting plate.
2. Check each glow plug for continuity.
Continuity should exist:
Approximately 0.8 [at 25C (77F)]
+ If NG, replace glow plug.
SEF701V
SEC565B
EC-155
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Accelerator position
Accelerator position sensor EGRC-solenoid valve B
c c
ECM
Engine coolant temperature (ECCS-D
Engine coolant temperature sensor Throttle control solenoid valve
c control c
module)
Start signal
Ignition switch
c
The ECM receives signals sent from the engine coolant tempera-
ture sensor, crankshaft position sensor (TDC), ignition switch, mass
air flow sensor and accelerator position sensor to determine engine
speed and operating conditions. Based on these signals, the ECM
controls EGR control solenoid valve (A and B) operation and
throttle control solenoid valve operation.
Engine coolant EGRC-solenoid valve Throttle control Throttle control Amount of EGR
temperature Load EGR valve
A B solenoid valve valve gas
C (F)
OFF OFF OFF
Below 70 (158) Any Fully closed Fully open
(Closed) (Closed) (Closed)
ON ON ON
Low load Fully open Closed Large
(Open) (Open) (Open)
ON ON OFF
Medium load-1 Fully open Fully open Medium
(Open) (Open) (Closed)
Above 70 (158)
ON OFF OFF
Medium load-2 Half open Fully open Small
(Open) (Closed) (Closed)
OFF OFF OFF
High load Fully closed Fully open
(Closed) (Closed) (Closed)
COMPONENT DESCRIPTION
The EGRC-solenoid valves A and B control vacuum pressure act-
ing on the EGR valve. The EGR control valve will then be fully
opened, half-opened or fully closed, as required.
The throttle control solenoid valve controls vacuum pressure acting
on the throttle chamber. Thus, intake air passages are opened or
closed in relation to exhaust gas and intake air. Utilizing the rela-
tionship between exhaust gas pressure and intake air pressure
control, the amount of EGR (exhaust gas recirculated) is regulated
in three stages large, medium, small.
SEF784V
EC-156
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
EGRC-Solenoid Valve A, B and Throttle Control
Solenoid Valve (Contd)
CONSULT REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Specification data are reference values.
MONITOR ITEM CONDITION SPECIFICATION
+ Engine: After warming up Idle ON
+ Air conditioner switch: OFF
EGRC SOL/V A Revving engine from idle to 3,750
+ Shift lever: N OFF
+ No-load rpm
+ Engine: After warming up Idle ON
+ Air conditioner switch: OFF
EGRC SOL/V B Revving engine from idle to 2,600
+ Shift lever: N OFF
+ No-load rpm
+ Engine: After warming up Idle ON
+ Air conditioner switch: OFF
THROT RLY Revving engine from idle to 2,500
+ Shift lever: N OFF
+ No-load rpm
EC-157
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
EGRC-Solenoid Valve A, B and Throttle Control
Solenoid Valve (Contd)
TEC442
EC-158
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
EGRC-Solenoid Valve A, B and Throttle Control
Solenoid Valve (Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
CHECK OVERALL FUNCTION. OK INSPECTION END
c
1. Start engine and warm it up to normal
operating temperature.
SEF702V 2. Perform diagnostic test mode II (Self-
diagnostic results).
Make sure that diagnostic trouble code
No. 55 is displayed.
3. Make sure that EGR valve spring
moves up and down (Use your finger)
under the following conditions.
At idle:
Spring moves up and down.
Revving engine from idle to 3,800
rpm:
Spring does not move.
SEF703V 4. Make sure that throttle control valve rod
moves up and down under the following
conditions.
At idle:
Rod moves up and down.
Revving engine from idle to 2,500
rpm:
Rod does not move.
NG
.
CHECK VACUUM SOURCES TO EGR OK CHECK COMPONENTS
c
SEF704V VALVE AND THROTTLE CONTROL (EGR valve and throttle
VALVE. control valve).
1. Disconnect vacuum hose to EGR valve. (See page EC-162.)
2. Make sure that vacuum exists under
NG
the following conditions.
At idle:
Vacuum should exist.
Revving engine from idle to 3,800
rpm:
Vacuum should not exist.
3. Disconnect vacuum hose to throttle
.
control valve.
SEF705V 4. Make sure that vacuum exists under Replace malfunctioning
the following conditions. component(s).
At idle:
Vacuum should exist.
Revving engine from idle to 2,500
rpm:
Vacuum should not exist.
NG
.
A
j
EC-159
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
EGRC-Solenoid Valve A, B and Throttle Control
Solenoid Valve (Contd)
A
j
.
CHECK CONTROL FUNCTION. OK CHECK VACUUM HOSE.
c
1. Stop engine. Check vacuum hose for
2. Turn ignition switch ON. clogging, cracks or
3. Turn EGRC-solenoid valve A, B improper connection.
and throttle control solenoid
SEF682S valve ON and OFF in
ACTIVE TEST mode with
CONSULT and check operating
sound.
------------------------------------------------------------------- OR -------------------------------------------------------------------
1. Check voltage between ECM
terminal 103 and ground under
the following conditions.
Voltage:
At idle
0 - 1V
Revving engine from idle to
3,800 rpm
SEF683S
Battery voltage
2. Check voltage between ECM
terminal 109 and ground under
the following conditions.
Voltage:
At idle
0 - 1V
Revving engine from idle to
2,600 rpm
Battery voltage
3. Check voltage between ECM
terminal V 1 and ground under
SEF816F
the following conditions.
Voltage:
At idle
0 - 1V
Revving engine from idle to
2,500 rpm
Battery voltage
NG
.
B
j
EC-160
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
EGRC-Solenoid Valve A, B and Throttle Control
Solenoid Valve (Contd)
B
j
.
CHECK POWER SUPPLY. NG Check the following.
c
1. Turn ignition switch OFF. + Harness connectors
2. Disconnect EGRC-solenoid valve A, B M21 , E127
and throttle control solenoid valve har- + 10A fuse
ness connector. + Harness for open or
SEF706V 3. Turn ignition switch ON. short between EGRC-
4. Check voltage between terminal V 1 solenoid valve A, B and
and ground with CONSULT or tester. fuse
Voltage: Battery voltage + Harness for open or
short between throttle
OK
control solenoid valve
and fuse
If NG, repair harness or
connectors.
.
CHECK OUTPUT SIGNAL CIRCUIT. NG Check the following.
c
SEF782V 1. Turn ignition switch OFF. + Harness connectors
2. Disconnect ECM harness connector. E127 , M21
3. Check harness continuity between + Harness connectors
ECM terminal V 1 and terminal V 2 , M50 , F5
ECM terminal 103 and terminal V 2 , + Harness for open or
ECM terminal 109 and terminal V 2 . short between EGRC-
Continuity should exist. solenoid valve A, B and
If OK, check harness for short to ECM
ground and short to power. + Harness for open or
short between throttle
OK
control solenoid valve
and ECM
SEF783V If NG, repair open circuit or
short to ground or short to
power in harness or con-
nectors.
.
CHECK COMPONENTS NG Replace malfunctioning
c
(EGRC-solenoid valve A, B and throttle component(s).
control solenoid valve).
Refer to COMPONENT INSPECTION
on next page.
OK
.
Disconnect and reconnect harness connec-
tors in the circuit. Then retest.
.
INSPECTION END
EC-161
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
EGRC-Solenoid Valve A, B and Throttle Control
Solenoid Valve (Contd)
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.
MEF137D
SEF707V
EC-162
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Start Signal
TEC443
EC-163
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Start Signal (Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
CHECK OVERALL FUNCTION. OK INSPECTION END
c
1. Turn ignition switch ON.
2. Check START SIGNAL in
DATA MONITOR mode with
CONSULT.
SEF625S
IGN ON OFF
IGN START ON
------------------------------------------------------------------- OR -------------------------------------------------------------------
1. Turn ignition switch to START.
2. Check voltage between ECM
terminal V 20 and ground.
Voltage:
Ignition switch START
Battery voltage
Except above
Approximately 0V
SEF109P NG
.
CHECK INPUT SIGNAL CIRCUIT. NG Check the following.
c
1. Turn ignition switch OFF. + Harness connectors
2. Disconnect ECM harness connector and M52 , F7
ignition switch harness connector. + 7.5A fuse
3. Check harness continuity between ECM + Fuse block M3 , E112
terminal V20 and terminal V 6 . + Harness for open or short
Continuity should exist. between ECM and igni-
If OK, check harness for short to ground tion switch
and short to power. If NG, repair open circuit or
short to ground or short to
OK power in harness or con-
SEF785V nectors.
.
Disconnect and reconnect harness connec-
tors in the circuit. Then retest.
.
INSPECTION END
EC-164
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
SEF708V
Ignition switch ON
Approximately 0V
Accelerator position switch Accelerator pedal released
32 W/G
(Full) Ignition switch ON BATTERY VOLTAGE
Accelerator pedal fully depressed (11 - 14V)
EC-165
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Accelerator Position Switch (Contd)
TEC444
EC-166
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Accelerator Position Switch (Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
OK
CHECK OVERALL FUNCTION. c
INSPECTION END
1. Turn ignition switch ON.
2. Select FULL ACCEL SW and
OFF ACCEL SW in DATA
MONITOR mode with CON-
SEF626S SULT.
3. Check FULL ACCEL SW and
OFF ACCEL SW signal under
the following conditions.
OFF ACCEL SW:
Accelerator pedal released
ON
Accelerator pedal
depressed OFF
FULL ACCEL SW:
Accelerator pedal released
OFF
Accelerator pedal fully
SEF627S depressed ON
------------------------------------------------------------------- OR -------------------------------------------------------------------
1. Turn ignition switch ON.
2. Check voltage between ECM
terminal V 31 and ground under
the following conditions.
Voltage:
Accelerator pedal released
Battery voltage
Accelerator pedal
depressed
Approximately 0V
3. Check voltage between ECM
terminal V 32 and ground under
SEF708V
the following conditions.
Voltage:
Accelerator pedal released
Approximately 0V
Accelerator pedal fully
depressed
Battery voltage
NG
.
CHECK POWER SUPPLY. NG Check the following.
c
1. Turn ignition switch OFF. + Harness connectors
SEF786V 2. Disconnect accelerator position switch M52 , F7 (LHD mod-
harness connector. els)
3. Turn ignition switch ON. + Harness for open or
4. Check voltage between terminal V 5 short between accelera-
and ground with CONSULT or tester. tor position switch and
Voltage: Battery voltage ECCS relay
+ Harness for open or
OK short between accelera-
tor position switch and
ECM
If NG, repair harness or
connectors.
.
A
j
EC-167
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Accelerator Position Switch (Contd)
A
j
.
CHECK INPUT SIGNAL CIRCUIT-I. NG Check the following.
c
1. Turn ignition switch OFF. + Harness connectors
2. Disconnect ECM harness connector. M52 , F7 (RHD mod-
3. Check harness continuity between ter- els)
minal V 6 and ECM terminal V 31 . + Harness for open or
Continuity should exist. short between ECM and
If OK, check harness for short to accelerator position
SEF787V
ground and short to power. switch
If NG, repair open circuit or
OK
short to ground or short to
power in harness or con-
nectors.
.
CHECK INPUT SIGNAL CIRCUIT-II. NG Check the following.
c
Check harness continuity between termi- + Harness connectors
nal V4 and ECM terminal V 32 . M52 , F7 (RHD mod-
Continuity should exist. els)
If OK, check harness for short to ground + Harness for open or
SEF788V and short to power. short between ECM and
accelerator position
OK
switch
If NG, repair open circuit or
short to ground or short to
power in harness or con-
nectors.
.
CHECK COMPONENT NG Replace accelerator pedal
c
(Accelerator position switch). assembly.
Refer to COMPONENT INSPECTION
on next page.
OK
.
Disconnect and reconnect harness con-
nectors in the circuits. Then retest.
.
INSPECTION END
EC-168
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Accelerator Position Switch (Contd)
COMPONENT INSPECTION
Accelerator position switch
1. Disconnect accelerator position switch harness connector.
2. Check continuity between terminals V 5 and V 6 .
Conditions Continuity
Accelerator pedal released Yes
Accelerator pedal depressed No
Conditions Continuity
Accelerator pedal released No
Accelerator pedal fully depressed Yes
CAUTION:
If accelerator position sensor or ECM connector is
disconnected, perform the following procedures:
Select OFF ACCEL PO SIG in ACTIVE TEST mode.
Touch CLEAR.
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
Start and warm up engine. After engine has warmed up,
idle for 10 minutes.
EC-169
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
TEC445
EC-170
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Park/Neutral Position Switch (Contd)
When the gear position is in N, neutral position switch is ON.
The ECM detects the position because the continuity of the line (the
ON signal) exists.
CONSULT REFERENCE VALUE IN DATA MONITOR MODE
Remarks: Specification data are reference values.
MONITOR ITEM CONDITION SPECIFICATION
Shift lever: Neutral/Park ON
P/N POSI SW + Ignition switch: ON
Except above OFF
DIAGNOSTIC PROCEDURE
M/T models
INSPECTION START
.
CHECK OVERALL FUNCTION. OK INSPECTION END
c
1. Turn ignition switch ON.
2. Select P/N POSI SW in
SEF963N
DATA MONITOR mode with
CONSULT.
3. Check P/N POSI SW signal
under the following conditions.
Neutral position: ON
Except neutral position: OFF
------------------------------------------------------------------- OR -------------------------------------------------------------------
2. Check voltage between ECM
terminal V 22 and ground under
the following conditions.
Voltage:
Neutral position
SEF622S
Approximately 0V
Except neutral position
Battery voltage
NG
.
A
j
SEF789V
EC-171
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Park/Neutral Position Switch (Contd)
A
j
.
CHECK GROUND CIRCUIT. NG Check the following.
c
1. Turn ignition switch OFF. + Harness connectors
2. Disconnect neutral position switch har- E202 , E69
ness connector. + Harness for open or short
3. Check harness continuity between termi- between neutral position
2 and body ground.
nal V switch and body ground
AEC750
Continuity should exist. If NG, repair open circuit or
If OK, check harness for short to short to ground or short to
ground and short to power. power in harness or con-
nectors.
OK
.
CHECK INPUT SIGNAL CIRCUIT. NG Check the following.
c
1. Disconnect ECM harness connector. + Harness connectors
2. Check harness continuity between ECM F7 , M52
22 and terminal V
terminal V 1 . + Harness connectors
Continuity should exist. M21 , E127
If OK, check harness for short to + Harness connectors
SEF624S
ground and short to power. E70 , E201
+ Harness for open or short
OK
between ECM and neu-
tral position switch
If NG, repair open circuit or
short to ground or short to
power in harness or con-
nectors.
.
CHECK COMPONENT NG Replace neutral position
c
(Neutral position switch). switch.
Refer to MT section.
OK
.
Disconnect and reconnect harness connec-
tors in the circuit. Then retest.
.
INSPECTION END
EC-172
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Park/Neutral Position Switch (Contd)
A/T models
INSPECTION START
.
CHECK OVERALL FUNCTION. OK INSPECTION END
c
1. Turn ignition switch ON.
2. Select P/N POSI SW in
DATA MONITOR mode with
SEF963N
CONSULT.
3. Check P/N POSI SW signal
under the following conditions.
P or N position: ON
Except above positions: OFF
------------------------------------------------------------------- OR -------------------------------------------------------------------
2. Check voltage between ECM
terminal V 22 and ground under
the following conditions.
Voltage:
P or N position
Approximately 0V
SEF622S
Except above positions
Battery voltage
NG
.
CHECK POWER SUPPLY. NG Check the following.
c
1. Turn ignition switch OFF. + 7.5A fuse
2. Disconnect inhibitor switch harness con- + Harness for open or short
nector. between inhibitor switch
3. Turn ignition switch ON. and fuse
4. Check voltage between terminal V 3 and If NG, repair harness or
ground with CONSULT or tester. connectors.
SEF790V
Voltage: Battery voltage
OK
.
A
j
SEF791V
SEF792V
EC-173
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Park/Neutral Position Switch (Contd)
A
j
.
CHECK INPUT SIGNAL CIRCUIT-I. NG Check the following.
c
1. Turn ignition switch OFF. + Diode E103
2. Disconnect TCM harness connector. + Harness continuity
3. Check harness continuity between TCM between inhibitor switch
terminal V36 and terminals V 7 , V
9 . and TCM
Continuity should exist. If NG, repair open circuit or
SEF793V If OK, check harness for short to ground short to ground or short to
and short to power. power in harness or con-
OK nectors.
.
CHECK INPUT SIGNAL CIRCUIT-II. NG Check the following.
c
1. Disconnect ECM harness connector. + Harness connectors
2. Check harness continuity between ECM F7 , M52
terminal V
22 and TCM terminal V 14 . + Harness connectors
Continuity should exist. M21 , E127
If OK, check harness for short to ground + Harness for open or short
and short to power. between ECM and TCM
SEF794V If NG, repair open circuit or
OK
short to ground or short to
power in harness or con-
nectors.
.
CHECK COMPONENT NG Replace inhibitor switch.
c
(Inhibitor switch).
Refer to AT section.
OK
.
Disconnect and reconnect harness connec-
tors in the circuit. Then retest.
.
INSPECTION END
EC-174
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
A/T Control
These circuit lines are used to control the smooth shifting up and
down of A/T during the hard acceleration/deceleration.
Voltage signals are exchanged between ECM and TCM.
ECM TERMINALS AND REFERENCE VALUE
Remarks: Specification data are reference values and are measured between each terminal and 43
V (ECCS
ground) with a voltmeter.
TER- DATA
WIRE
MINAL ITEM CONDITION (DC Voltage and Pulse
COLOR
NO. Signal)
Engine is running.
24 PU/W A/T signal No. 1 6 - 8V
Idle speed
Engine is running.
30 P A/T signal No. 3 Approximately 0V
Idle speed
Engine is running.
37 P/B A/T signal No. 2 6 - 8V
Idle speed
EC-175
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
A/T Control (Contd)
TEC440
EC-176
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
A/T Control (Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
CHECK OVERALL FUNCTION. OK INSPECTION END
c
1. Start engine and let it idle.
2. Check voltage between ECM terminals
V24 , V
30 , V
37 and ground with CON-
SULT or tester.
SEF792V
Terminal Voltage
30
V and ground Approximately 0V
37
V and ground 6 - 8V
NG
.
CHECK INPUT SIGNAL CIRCUIT-I. NG Check the following.
c
1. Turn ignition switch OFF. + Harness connectors
SEF795V 2. Disconnect ECM harness connector M51 , F6
and TCM harness connector. + Harness connectors
3. Check harness continuity between E106 , M88
ECM terminal V 24 and terminal V
5 , + Harness continuity
ECM terminal V 30 and terminal V
7 , between ECM and TCM
ECM terminal V 37 and terminal V
6 . If NG, repair harness or
Continuity should exist. connectors.
OK
.
CHECK INPUT SIGNAL CIRCUIT-II. NG Check the following.
c
Check harness continuity between ECM + Harness connectors
SEF796V terminal V
24 and ground, ECM terminal E106 , M88
V30 and ground, ECM terminal V 37 and + Harness connectors
ground. M51 , F6
Continuity should not exist. + Harness for short
If OK, check harness for short to power. between ECM and TCM
If NG, repair short to
OK
ground or short to power in
harness or connectors.
.
Disconnect and reconnect harness con-
nectors in the circuit. Then retest.
.
INSPECTION END
EC-177
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Charge air temperature sensor Charge air temperature ECM c Charge air cooler fan relay
c
The ECM controls the charge air cooler fan operation corresponding to the engine speed, the charge air tem-
perature and the start signal. The control system has 2-step control [ON/OFF]. The ECM does not directly drive
the charge air cooler fan. It controls the ON/OFF charge air cooler fan relay, which in turn controls the charge
air cooler fan.
When the charge air temperature is above 67C (153F) and engine speed is more than 1,600 rpm, the charge
air cooler fan operates.
EC-178
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Charge Air Cooler Fan Control (Contd)
TEC439
EC-179
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Charge Air Cooler Fan Control (Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
CHECK OVERALL FUNCTION. OK INSPECTION END
c
1. Turn ignition switch OFF.
2. Disconnect charge air temperature sen-
sor harness connector.
3. Connect 150 resistor to charge air
SEF710V
temperature sensor harness connector.
4. Start engine and keep engine speed at
2,000 rpm.
5. Make sure that charge air cooler fan
operates.
NG
.
CHECK POWER SUPPLY. NG Check the following.
c
1. Stop engine. + Harness connectors
2. Disconnect charge air cooler fan relay. M21 , E127
.
CHECK GROUND CIRCUIT. NG Check the following.
c
SEF712V 1. Turn ignition switch OFF. + Harness connectors
2. Disconnect charge air cooler fan motor E127 , M21
harness connector. + Harness connectors
3. Check harness continuity between relay M50 , F5
terminal V 3 and motor terminal V 1 , + Harness for open or
motor terminal V 2 and engine ground. short between charge air
Continuity should exist. cooler fan relay and
If OK, check harness for short to charge air cooler fan
ground and short to power. motor
+ Harness for open or
OK
short between charge air
cooler fan motor and
SEF799V engine ground
If NG, repair open circuit or
short to ground or short to
power in harness or con-
nectors.
.
A
j
SEF711V
EC-180
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Charge Air Cooler Fan Control (Contd)
A
j
.
CHECK OUTPUT SIGNAL CIRCUIT. NG Check the following.
c
1. Disconnect ECM harness connector. + Harness connectors
2. Check harness continuity between ECM E127 , M21
terminal V8 and relay terminal V 1 . + Harness connectors
Continuity should exist. M52 , F7
If OK, check harness for short to + Harness for open or
SEF800V ground and short to power. short between ECM and
charge air cooler fan
OK
relay
If NG, repair open circuit or
short to ground or short to
power in harness or con-
nectors.
.
CHECK COMPONENT NG Replace charge air cooler
c
(Charge air cooler fan relay). fan relay.
Refer to COMPONENT INSPECTION
on next page.
SEF801V
OK
.
CHECK COMPONENT NG Replace charge air cooler
c
(Charge air cooler fan motor). fan motor.
Refer to COMPONENT INSPECTION
on next page.
OK
.
Disconnect and reconnect harness con-
nectors in the circuit. Then retest.
.
INSPECTION END
EC-181
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Charge Air Cooler Fan Control (Contd)
COMPONENT INSPECTION
Charge air cooler fan relay
Check continuity between terminals 3
V and 5 .
V
Conditions Continuity
12V direct current supply between
Yes
terminals V1 and V 2
No current supply No
SEF802V
EC-182
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Heat Up Switch
The heat up switch is located on the lower side of the instrument
panel. This switch is used to speed up the heaters operation when
the engine is cold.
When the ECM received the heat up switch ON signal, the ECM
increases the engine idle speed to 1,100 - 1,200 rpm to warm up
engine quickly.
This system works when all conditions listed below are met.
Heat up switch ON
SEF803V
Engine coolant temperature Below 70C (158F)
Shift lever P or N
Accelerator pedal Fully released
Vehicle speed Below 4 km/h (2 MPH)
Ignition switch ON
0V
Heat up switch is OFF.
59 BR/W Heat up switch
Ignition switch ON BATTERY VOLTAGE
Heat up switch is ON. (11 - 14V)
EC-183
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Heat Up Switch (Contd)
TEC447
EC-184
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Heat Up Switch (Contd)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
CHECK OVERALL FUNCTION. OK INSPECTION END
c
1. Turn ignition switch ON.
2. Check WARM UP SW signal
in DATA MONITOR mode with
CONSULT.
SEF804V
Heat up switch is ON: ON
Heat up switch is OFF: OFF
------------------------------------------------------------------- OR -------------------------------------------------------------------
2. Check voltage between ECM
terminal V 59 and ground under
the following condition.
Voltage:
Heat up switch is ON
Battery voltage
Heat up switch is OFF
Approximately 0V
SEF805V NG
.
CHECK POWER SUPPLY. NG Check the following.
c
1. Turn heat up switch OFF. + Fuse block M3
2. Turn ignition switch OFF. + 10A fuse
3. Disconnect heat up switch harness con- + Harness for open or
nector. short between heat up
4. Turn ignition switch ON. switch and fuse
5. Check voltage between terminal V6 If NG, repair harness or
and ground with CONSULT or tester. connectors.
Voltage: Battery voltage
SEF806V OK
.
CHECK INPUT SIGNAL CIRCUIT. NG Check the following.
c
1. Turn ignition switch OFF. + Harness connectors
2. Disconnect ECM harness connector. M51 , F6
3. Check harness continuity between ECM + Harness for open or
terminal V59 and terminal V 5 . short between heat up
Continuity should exist. switch and ECM
If OK, check harness for short to If NG, repair open circuit or
ground and short to power. short to ground or short to
power in harness or con-
OK
SEF807V nectors.
.
A
j
EC-185
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
Heat Up Switch (Contd)
A
j
.
CHECK COMPONENT NG Replace heat up switch.
c
(Heat up switch).
Refer to COMPONENT INSPECTION
below.
OK
.
Disconnect and reconnect harness con-
nectors in the circuit. Then retest.
.
INSPECTION END
COMPONENT INSPECTION
Heat up switch
1. Disconnect heat up switch harness connector.
2. Check continuity between terminals V
5 and V 6 .
Condition Continuity
Heat up switch ON Yes
Heat up switch OFF No
EC-186
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
TEC446
EC-187
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS
TEC448
EC-188
SERVICE DATA AND SPECIFICATIONS (SDS)
General Specifications
Unit: rpm Injection pump numbers
Engine RD28ETi
Pump assembly
Engine Part number
Idle speed 77525 number
Injection Nozzle
INSPECTION AND ADJUSTMENT Adjusting shims
Injection nozzle assembly Thickness mm (in) Parts No.
2
Unit: kPa (bar, kg/cm , psi) 0.50 (0.0197) 16613-V0700
Initial injection pressure 0.54 (0.0213) 16613-V0702
Used 14,220 (142.2, 145, 2,062) 0.58 (0.0228) 16613-V0704
14,711 - 15,495 (147.1 - 155.0, 0.62 (0.0244) 16613-V0706
New
150 - 158, 2,133 - 2,247)
0.66 (0.0260) 16613-V0708
EC-189
SERVICE DATA AND SPECIFICATIONS (SDS)
Inspection and Adjustment (Contd)
ADJUSTMENT RESISTOR ACCELERATOR POSITION SENSOR
Resistance [at 25C (77F)] k 0.2 - 15.0 Resistance k
Throttle valve conditions
[at 25C (77F)]
GLOW PLUG
Resistance [at 25C (77F)] 0.8
EC-190