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ENGINE CONTROL SYSTEM SECTION EC

1. j oc O Ki Q LU Z cc o E y SYSTEM amp O i i gt Basic engine n d ES control system a d Ojo m oO z oo 5 2 z z DI w Lu 3 0 z a O z z B5 Ae E J 0 0 BIC d SEE z RE df ol ES vd a z cS E zZz u z 0 5 Ele E w5 uj i O16 z ololZ o olle BIS EAEAE O E EIS JO Z asa a 3 Elle E E z u 9 o SEA x POS c ziz 2 o O lalele SEA O rl u 9 SES 9 S Em tc zZ u o 3 w 2 E Ilplol5d zi EIS e lalo zu PIE IEI 2lOo e ju s O z z EI E amp 2u l2l95 g i uw xIx 5 20 4 w lco Io Ly 3 L o pEjuulojolr cis z E Ele a oj u c lo am az 2 2 z z ic Wi o cx jojo IZ QOlu O ui 09 556 lt S 5 lt I EJE o OG iEl2ot al x ziulol o o amp 9 a aja zZz l clo is e zimj uu OIlS gt oio x zZz OlIr cle c UIloglol oljo z 2 5 o u oloxic c2 a a olo 2 zz u lziailo oOj lOigH a lz x x a ziu isls9 o 5 Z z r cr a z ri e 3 a 3 S 0 0 0 mlzosg5 els 9 Saje o 5 3 3 Warranty symptom Slelg 2 E bei o coda AA AB AC AD AF AM lsle 2 E Injection Advanced O e O EC 47 timin 9 Retarded EC 47 Electric injection pump O mainframe Injection nozzle EC 22 Glow system EC 151 Engine body EM sec tion EGR system EC 156 tion High Possibility Item O Low Possibility Item 1 Insufficient or excess amount Governor malfunction may be the cause 2 Depends on open valve pressure and
2. W L O O CONNECT mE O CONNECTOR ECM 56 61 116 117 Co Es SEF566S RK DISCONNECT En Y DISCONNECT A E 48 ECM O CONNECTOR 56 61 116 117 112 SEF567S Cont d INSPECTION START Start engine Is engine running No Yes CHECK POWER SUP PLY I 1 Turn ignition switch ON 2 Check voltage between ECM terminal 6 and ground with CONSULT or tester Voltage Battery volt age If NG check the following e Harness connectors e fuse e Harness for open or short between ECM and fuse If NG repair harness or connectors x Go to CHECK GROUND CIRCUIT on EC 68 1 Turn ignition switch ON and then OFF 2 Check voltage between ECM terminals E 6 C116 and ground with CONSULT or tester Voltage After turning ignition switch OFF battery voltage will exist for a few oe then drop to approximately NG Case 2 Ei X NG CHECK POWER SUPPLY II Check the following 1 Stop engine e Harness connectors 2 Check voltage between ECM terminal Cun CAD and ground with CONSULT or e Harness connectors tester E ED Voltage Battery voltage e Harness for open or OK short between ECM and battery If NG repair harness or connectors OK CHECK POWER SUPPLY III L Go to CHECK GROUND CIRCUIT on EC 68
3. EC 81 SEF152P Resistance kQ 18 6 4 Acceptable 2 1 0 0 8 0 4 0 2 0 1 20 0 20 40 60 80 100 4 32 68 104 140 176 212 Temperature C F SEF012P TROUBLE DIAGNOSIS FOR COOLANT TEMP SEN DTC 13 Engine Coolant Temperature ECT Sensor Cont d COMPONENT INSPECTION Engine coolant temperature sensor Check resistance as shown in the figure Temperature C F Resistance kQ 20 68 21229 50 122 0 68 1 0 90 194 0 236 0 260 If NG replace engine coolant temperature sensor EC 82 TROUBLE DIAGNOSIS FOR VEHICLE SPEED SEN DTC 14 Vehicle Speed Sensor VSS The vehicle speed sensor is installed in the transaxle It contains a pulse generator which provides a vehicle speed signal to the Vehicle speed speedometer The speedometer then sends a signal to the ECM sensor AEC110 ECM TERMINALS AND REFERENCE VALUE Remarks Specification data are reference values and are measured between each terminal and ECCS ground with a voltmeter TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR NO Signal 0 BATTERY VOLTAGE 11 14V Engine is running 26 L OR Vehicle speed sensor Lift up the vehicle In 1st gear position L Vehicle speed is 40 km h 25 MPH SEF717V ON BOARD DIAGNOSIS LOGIC Diagnostic Trouble Code Malfunction is detected when Ghee items Possib
4. 9 r Air conditioner switch is OFF 9 T Air conditioner switch is ON I LL LL 2 9 PO SS I e PERI 054 cz E c E 0 PSS RON KR Noes 500 PTOS Gee teta eta n Qs Ee a te e BSG CS SOLIS d SES E PIS POSO RI ISI ISI POCOS o SSRS o ORO KK 2 SS 2 SS L POS OS OO E 96 205 5 96 205 Eeer E amp BOO O IO o Q SEISIS o o PROS OSOS SOS SS SOS o o Meets so tote e e e SSI ENN o 2 PERRIS 20 80 20 80 D D c c Ww 12 50 Ww 12 50 Vehicle speed km h MPH Vehicle speed km h MPH L Cooling fan does not operate ERR Cooling fan operates SEF757V CONSULT REFERENCE VALUE IN DATA MONITOR MODE Remarks Specification data are reference values MONITOR ITEM CONDITION SPECIFICATION Se f Air conditioner switch OFF OFF e Engine After warming up idle AIR COND SIG the engine Air conditioner switch ON ON Compressor operates e When cooling fan is stopped OFF COOLING FAN e When cooling fan operates ON ECM TERMINALS AND REFERENCE VALUE Remarks Specification data are reference values and are measured between each terminal and ECCS ground with a voltmeter TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR NO Signal Engine is running BATTERY VOLTAGE L Cooling fan is not operating 11 14V 14 L Cooling fan relay Engine is running Cooling fan is operating EC 113 TROUBLE DIAGNOSIS FOR OVER HEAT
5. lt TCM TRANSMISSION 8 CONTROL E69 MODULE B E101 E102 lt A gt B B B L L E25 E I 2 3 4 5 e v s o Io4 ros to6 Ino ri 112 a4 45 46 57 58 59 60 116117 118 TEC445 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS Park Neutral Position Switch Cont d 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 Except above OFF P N POSI SW e Ignition switch ON ECM TERMINALS AND REFERENCE VALUE Remarks Specification data are reference values and are measured between each terminal and ECCS ground with a voltmeter TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR NO Signal Ignition switch ON Inhibi itch Gear position is N or P A T models Approximately OV 22 P B nhibitor switc L Gear position is Neutral M T models Neutral position switch Ignition switch ON BATTERY VOLTAGE L Except the above gear position 11 14V DIAGNOSTIC PROCEDURE yx MONITOR x NOFAIL M T models P N POSI SW ON INSPECTION START CHECK OVERALL FUNCTION OK INSPECTION END RECORD 1 Turn ignit
6. Neza aide Removal and Installation gt 1 Remove fuel injection tube and spill tube 2 Remove injection nozzle assembly Also remove gasket from nozzle end Pp 3 Install injection nozzle in the reverse order of removal CN J Injection nozzle to engine C 59 69 N m 6 0 7 0 kom 43 51 ft Ib Combustion chamber side Injection nozzle to tube 3 22 25 N m 22 2 5 kg m 16 18 ft Ib Spill tube REFUS 39 49 N m 4 0 5 0 kg m 29 36 ft Ib a Always clean the nozzle holes b Always use new injection nozzle gasket c Note that small washer should be installed in specified direction d Bleed air from fuel system Disassembly No 2 4 nozzles Do not disassemble No 1 nozzle with needle lift sensor 1 Loosen nozzle nut while preventing nozzle top from turning SEF669A Holder 2 Arrange all disassembled parts in the order shown at left Adjusting shim Nozzle spring Push rod d Distance piece Nozzle needle Ze Nozzle body C Ki wor Nozzle nut SEF670A EC 22 INJECTION NOZZLE Inspection No 2 4 nozzles Thoroughly clean all disassembled parts with fresh kerosene or solvent e f nozzle needle is damaged or fused replace nozzle assem bly with a new one e f end of nozzle needle is seized or excessively discolored replace nozzle assembly e Check nozzle body and distance piece for proper contact If excessively worn or damaged replace nozzle ass
7. DTC 28 Cooling Fan Overheat Cont d TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR NO Signal Engine is running BATTERY VOLTAGE L Air conditioner switch is OFF Est 15 YIL Air conditioner relay Engine is running L_ Both air conditioner switch and blower fan 0 1V switch are ON Compressor is operating ON BOARD DIAGNOSIS LOGIC This diagnosis continuously monitors the engine coolant temperature If the cooling fan or another component in the cooling system malfunctions engine coolant temperature will rise When the engine coolant temperature reaches an abnormally high temperature condition a malfunction is indicated Diagnostic Trouble m Check Items Code No Malfunction is detected when Possible Cause 28 e Cooling fan does not operate properly Overheat e Harness or connectors e Cooling fan system does not operate properly Over The cooling fan circuit is open or shorted heat e Cooling fan e Engine coolant was not added to the system using e Radiator hose the proper filling method e Radiator e Radiator cap e Water pump e Thermostat e Fan belt e Engine coolant temperature sensor For more information refer to MAIN 12 CAUSES OF OVERHEATING EC 120 CAUTION When a malfunction is indicated be sure to replace the coolant following the procedure in the MA section Changing Engine Coolant ENGINE MAINTENANCE Al
8. ENGINE COOLING SYSTEM in LC section ON 6 e Thermostat Touch the upper and Both hoses should be hot See Thermostat and lower radiator hoses Radiator ENGINE COOLING SYSTEM in LC section ON 7 e Cooling fan e CONSULT Operating See TROUBLE DIAG NOSIS FOR DTC 28 EC 113 OFF 8 e Combustion gas leak e Color checker chemical Negative tester 4 Gas analyzer ON 9 e Coolant temperature e Visual Gauge less than 3 4 gauge when driving e Coolant overflow to res e Visual No overflow during driving See Changing Engine ervoir tank and idling Coolant ENGINE MAINTENANCE in MA section OFF 10 e Coolant return from res e Visual Should be initial level in See ENGINE MAINTE ervoir tank to radiator reservoir tank NANCE in MA section OFF 11 Cylinder head e Straight gauge feeler 0 1mm 0 004 in Maxi See Inspection CYL gauge mum distortion warping INDER HEAD in EM section 12 e Cylinder block and pis e Visual No scuffing on cylinder See Inspection CYL tons 1 Turn the ignition switch ON 2 Engine running at 3 000 rpm for 10 minutes 8 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 walls or piston INDER BLOCK in EM section TROUBLE DIAGNOSIS FOR OVER HEAT DTC 28 Cooling Fan
9. Josues ainyeiedwe jugjooo euifu3 JeBjeuooqun Jousef iv Le JOSUSS MOJ Im SSEW Jejooo 11e aBleyo E J0jsise1 juawysnipy Si dINNd 1o0sues uonisod yeysweg amp SABA JOJ uO2 Josues einjejeduje a Buiu uonoefu jm ebieyo i D OGL 10sues gt uonisod o yeusxyuelo5 plougjos ejnpoui ma any 03102 4 8993 MOE ul ying ele sosuas ojnjejeduiga on osuas uonisod eAee s 0 JUOD 10u1eA0D 21u126 3 dund uonoefur anj 91U01193 3 fianeg OO youms 19414 any ei LI g SAJen dund piouejos 5u93 lt a winnoe V Salen pious os 0HO3 SAJEA piouejos JO4JUOD y SAJEA 0J uoo moiy L ejzzou uonoefui L ON out ya Josues UU ejpeeN Q Ue 13 009 Je ofieu5 lt gt Tt ug Buijoo5 Josuas paeds y Cal 9 3 youms youms uonisod jenneN Joje19 ooov EZ DL eB SEX youms uonisod Joyeiajso0y Josuas uonisod 10je19 229y NWIWI S LWN o ue MO e dure 101eoipur uonoungely jeuBis youms ug youms dn Sou SEF660V EC 12 ENGINE AND EMISSION CONTROL OVERALL SYSTEM Vacuum Hose Drawing Charge air cooler Cr SS Throttle control valve SS Vacuum pump Y E ff a Charge air Ld temperature Z sensor Rocker cover Ge o 3 way connector 3 way connector A EGRC solenoid valve B EGRC solenoid Intake manifold valve A Throttle control solenoid valve Wastegate valve actuator SEF661V Charge
10. pe 57 sensor power supply L ide speed SEF724V Approximately 2 6V Oe iiit Nats A 62 B Control sleeve position Engine is running S 66 sensor ground D Idle speed SEF725V Approximately 2 6V V 4l 63 B Control sleeve position Engine is running d pe 67 sensor M Idle speed SEF726V EC 87 TROUBLE DIAGNOSIS FOR CONT SLEEV POS SEN DTC 15 Control Sleeve Position Sensor CSPS Cont d ON BOARD DIAGNOSIS LOGIC Diagnostic Check Items Trouble Code Malfunction is detected when Possible cause No 15 e An excessively high or low voltage from the sensor is e Harness or connectors detected by ECM The control sleeve position sensor circuit is open or SE shorted e An improper voltage signal from the sensor is e Control sleeve position sensor detected by ECM during engine running DIAGNOSTIC TROUBLE CODE CONFIRMATION x MONITOR x NOFAIL PROCEDURE o 1 Turn ignition switch ON and select DATA MONITOR EA i mode with CONSULT 2 Start engine and run it for at least 2 seconds at idle speed OQR _ E 1 Start engine and run it for at least 2 seconds at idle D speed RECORD 2 Turn ignition switch OFF wait at least 5 seconds and then ON SEF714V 3 Perform Diagnostic Test Mode l Self diagnostic results with ECM EC 88 TROUBLE DIAGNOSIS FOR CONT SLEEV POS SEN DTC 15 Control Sleeve Position Sensor C
11. snssnssnssneineenennene 189 e Read Gl section HOW TO READ WIRING DIAGRAMS e See EL section POWER SUPPLY ROUTING for power distribution circuit When you perform trouble diagnoses read Gl section HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES and HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT DIAGNOSTIC TROUBLE CODE INDEX Alphabetical amp Numerical Index for DTC ALPHABETICAL INDEX FOR DTC NUMERICAL INDEX FOR DTC X Applicable X Applicable Not applicable Not applicable Items DTC MIL Reference DTC l MIL l Items Reference CONSULT screen terms illumination page illumination CONSULT screen terms page ACCEL POS SENSOR 43 X EC 139 11 X CAM POS SEN PUMP EC 69 ACCEL POS SW F C 23 X EC 106 12 MAS AIR FLOW SEN EC 74 ADJUST RESISTOR 17 EC 92 13 X COOLANT TEMP SEN EC 79 CAM POS SEN PUMP 11 X EC 69 14 VEHICLE SPEED SEN EC 83 CONT SLEEV POS SEN 15 X EC 87 15 X CONT SLEEV POS SEN EC 87 COOLANT TEMP SEN 13 X EC 79 17 ADJUST RESISTOR EC 92 CRANK POS SEN TDC 47 X EC 144 18 X F INJ F B 2 EC 96 ECM 1 27 X EC 111 21 F INJ TIMG F B EC 101 ECM 2 31 x EC 111 22 X F INJ F B EC 96 ELECTRIC GOV 25 X EC 96 23 X ACCEL POS SW F C EC 106 FCV SHORT 37 X EC 130 25 X ELECTRIC GOV EC 96 FUEL CUT S V 1 36 X EC 130 27 X ECM 1 EC 111 FUEL CUT S V 2 38 X EC 130 28 X OVER HEAT EC 113 FUEL TEMP SENSOR 42 EC 135 31 X ECM 2 EC 111 F INJ F B 22 X EC 96 83 1 I C INT
12. Idle speed 11 14V Approximately 0 4 8V 19 LG R Engine coolant tempera iaa Output voltage varies with ture sensor Engine ds running engine coolant tempera ture Ignition switch ON Approximately OV 20 RAW Start signal BATTERY VOLTAGE Ignition switch START 11 14V engine ts munning BATTERY VOLTAGE L Air conditioner switch is OFF 11 14V 21 LG B Air conditioner switch Engine is running L Both air conditioner switch and blower fan switch are ON Compressor is operating EC 56 Approximately 0V TROUBLE DIAGNOSIS General Description ECM Terminals and Reference Value Cont d TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR f NO Signal Ignition switch ON Gear position is N or P A T models Approximately OV Inhibitor switch L Gear position is Neutral M T models 22 P B e d Neutral position switch Ignition switch ON BATTERY VOLTAGE L Except the above gear position 11 14V Ignition switch ON 0 4 0 6V Accelerator position sen L Accelerator pedal fully released sor Ignition switch ON Approximately 4 3V L_ Accelerator pedal fully depressed Engine is running 24 PU W A T signal No 1 6 8V L_ Idle speed 0 BATTERY VOLTAGE
13. KV11290150 Nozzle seat scraper KV11290210 Nozzle holder 2 KV11290220 Nozzle hole cleaning needle NT296 EC 2 PRECAUTIONS AND PREPARATION Special Service Tools Cont d Tool number Pas 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 Commercial Service Tool Tool name Description Fuel filler cap adapter Checking fuel tank vacuum relief valve opening pressure NT653 EC 3 PRECAUTIONS AND PREPARATION Supplemental Restraint System SRS AIR BAG and SEAT BELT PRE TENSIONER The Supplemental Restraint System such as AIR BAG and SEAT BELT PRE TENSIONER used along with a seat belt helps to reduce the risk or severity of injury to the driver and front passenger in a frontal collision The SRS system composition which is available to NISSAN MODEL Y61 is as follows The composition var ies according to the destination Driver air bag module located in the center of the steering wheel front passenger air bag module located on the instrument panel on passenger side seat belt pre tensioner a diagnosis sensor unit warning lamp wiring harness and spiral cable Information necessary to service the system safely is included in the RS section of this Service Manual WARNING e To avoid rendering the SRS inoperative which could increase the
14. N Fuel cut solenoid valve AX Y S Q Injection timing control valve Accelerator position sensor Accelerator position switch Accelerator switch F C eg L P Engine coolant temperature sensor harness connector eee a 9 SIE yi VEZ Is E B SN US 410 a NSS Adjustment resistor p Se N ES ED B vA Camshaft position sensor PUMP T EGRC solenoid valve B SVN connector Zz ff Y LX miS EGRC solenoid valve A PA LN A GN 0 S harness connector X y De Throttle control solenoid valve Ki harness connector ve wy J SS Pee Ke SIT amp S IE a EE E CE Zu S Crankshaft position gt 4 D sensor TDC e 3 4 E M he bud M Q gt SEF658V EC 9 ENGINE AND EMISSION CONTROL OVERALL SYSTEM ECCS D Component Parts Location Cont d A Z d Cooling fan motor harness connector Z4 A v LME OME Needle lift sensor harness connector LG 7 a EN E ECCS control module FO A A Per adi Driver s side instrument lower cover removed Driver s side instrument lower cover removed SEF659V EC 10 TEC420 ENGINE AND EMISSION CONTROL OVERALL SYSTEM ircuit Diagram C Cv HOLIMS T STIL wersAs SLYN ui IM YN
15. ON EGRC solenoid valve A is operat ing EGRC SOL V B ON OFF The control condition of the EGRC sole 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 ON OFF The control condition of the throttle con 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 Cont d ACTIVE TEST MODE TEST ITEM CONDITION JUDGEMENT CHECK ITEM REMEDY e Ignition switch ON COOLING FAN e Operate the cooling fan at Cooling fan moves at LOW HI e Harness and connector LOW HI speed and turn Speed and stops e Cooling fan motor OFF ACCEL PO SIG OFF using CONSULT Clears the self learning fully closed accelerator position detected by accelerator position sensor from the EOM Ignition switch ON e Turn solenoid valve ON and Solenoid valve makes an operating Harness and connector FUEL CUT SOL OFF with the CONSULT and sound e Solenoid valve listen to operating sound e lgnition switch ON EGRC SOL V A e Turn solenoid valve ON and Solenoid valve makes an operating Harness and connector OFF with the CONSULT and sound e Solen
16. 0 68 1 00 90 194 0 236 0 260 110 230 0 143 0 153 150 302 0 050 0 065 ECM TERMINALS AND REFERENCE VALUE Remarks Specification data are reference values and are measured between each terminal and ECCS ground with a voltmeter TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR t NO Signal Approximately 0 4 8V 36 LG narge almtemperature Engine is running Output voltage varies with sensor A charge air temperature Engine is running Warm up condition 50 B Sensors ground C Approximately OV Idle speed ON BOARD DIAGNOSIS LOGIC Diagnostic Trouble Code No 33 1 entered to ECM Malfunction is detected when e An excessively high or low voltage from the sensor is Check Items Possible Cause e Harness or connectors The sensor circuit is open or shorted e Charge air temperature sensor 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 DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE ER 2 3 then turn ON Perform results with ECM EC 122 Diagnostic Test Mode I Turn ignition switch ON and wait at least 5 seconds Turn ignition switch OFF wait at least 5 seconds and Self diagnostic IATS 01 EC TEC438 Charge Air Temperature Sensor Cont d T
17. 11 14V Engine is running 26 L OR Vehicle speed sensor Lift up the vehicle In 1st gear position L Vehicle speed is 40 km h SEF717V 28 Camshaft position sensor Engine is running Warm up condition B Approximately OV 33 PUMP ground _ Idle speed Ignition switch ON BATTERY VOLTAGE L Accelerator pedal fully released 11 14V 29 R L Accelerator switch F C Ignition switch ON Approximately 0V L_ Accelerator pedal depressed Engine is running 30 P A T signal No 3 Approximately OV L Idle speed Ignition switch ON BATTERY VOLTAGE 11 14V a Accelerator position switch L Accelerator pedal fully released Idle Ignition switch ON Approximately OV L Accelerator pedal depressed Ignition switch ON Approximately 0V Accelerator position switch Accelerator pedal released 32 W G Full Ignition switch ON BATTERY VOLTAGE L Accelerator pedal fully depressed EC 57 11 14V TROUBLE DIAGNOSIS General Description ECM Terminals and Reference Value Cont d TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR NO Signal Approximately OV Engine is running Warm up condition L Idle speed SEF718V 34 W Needle lift sensor Approximately OV Engine is running Warm up condition IB Engine speed is 2 000 rpm SEF719V Engine is running Warm up condition 35 R Mass air flow sensor C 1 6 2 0V Idl
18. 12V direct current supply between Yes terminals 1 and 2 No current supply No If NG replace relay Charge air cooler fan motor 1 Disconnect charge air cooler fan motor harness connector 2 Supply charge air cooler fan motor terminals with battery volt age and check operation Charge air cooler fan motor should operate If NG replace charge air cooler fan motor EC 182 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS Heat Up Switch Heat up po The heat up switch is located on the lower side of the instrument panel This switch is used to speed up the heater s operation when Lenz 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 S id Heat up switch ON Engine coolant temperature Below 70 C 158 F Shift lever P or N Fully released Below 4 km h 2 MPH Accelerator pedal Vehicle speed CONSULT REFERENCE VALUE IN DATA MONITOR MODE Remarks Specification data are reference values MONITOR ITEM CONDITION SPECIFICATION Heat up switch ON ON WARM UP SW e lgnition switch ON Heat up switch OFF OFF ECM TERMINALS AND REFERENCE VALUE Remarks Specification data are reference values and are measured between each terminal and ECCS ground with a voltmeter TER WIRE DA
19. CKPSSRPEM TDC uim 2 Select DATA MONITOR mode with CONSULT 3 Wait at least 5 seconds OR E 1 Turn ignition switch ON and wait at least 5 seconds c 2 Turn ignition switch OFF wait at least 5 seconds and then turn ON RECORD 3 Perform Diagnostic Test Mode l Self diagnostic SEF748V results with ECM EC 92 TROUBLE DIAGNOSIS FOR ADJUST RESISTOR DTC 17 Adjustment Resistor Cont d EC ADJRES 01 INJECTION PUMP ADJUSTMENT RESISTOR Rm Detectable line for DTC Non detectable line for DTC lt A gt A T models gm mB gt 106 oo ceo 8 Di N ta E TCM SENS TRANSMISSION CONTROL MODULE E102 GND N E B lr TEC428 EC 93 TROUBLE DIAGNOSIS FOR ADJUST RESISTOR DTC 17 Adjustment Resistor Cont d injection pump ug harness connector Adjustment resistor SEF682V DIAGNOSTIC PROCEDURE INSPECTION START MENE oo AEO M7lel5 SEF750V CHECK POWER SUPPLY Sech Repair harness or connec 1 Turn ignition switch OFF tors 2 Disconnect electronic fuel injection pump harness connector 3 Turn ignition switch ON 4 Check voltage between terminal 2 and ground Voltage Approximately 5V CHECK GROUND CIRCUIT bis Check the following 1 Turn ignition switch OFF e Harness connectors 2 Check harness continuity between ter CE
20. OINT CONNECTOR 4 M51 l 2 7 e CONTROL MODULE o e Q o w Refer to last page Foldout page TEC424 EC 76 TROUBLE DIAGNOSIS FOR MASS AIR FLOW SEN DTC 12 Mass Air Flow Sensor MAFS Cont d DIAGNOSTIC PROCEDURE Mass air flow sensor harness connector N INSPECTION START NG R CHECK POWER SUPPLY Check the following 1 Turn ignition switch OFF e Harness connectors Disconnect mass air flow sensor har un ness connector e Harness for open or Turn ignition switch ON short between mass air Check voltage between terminal 1 flow sensor and ECM and ground with CONSULT or tester e Harness for open or Voltage Battery voltage short between mass air flow sensor and ECCS OK relay If NG repair harness or connector B NG CHECK GROUND CIRCUIT sl Check the following 1 Turn ignition switch OFF e Harness connectors 2 Loosen and retighten engine ground E106 screws e Harness connectors 3 Check harness continuity between ter u51 minal and engine ground e Harness for open or Continuity should exist short between mass air If OK check harness for short to flow sensor and ECM ground and short to power e 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 ae CHECK INPUT SIGNAL CIRCUIT Repair open circuit or
21. ground and short to power Check harness continuity between motor terminals 2 4 and body ground Continuity should exist If OK check harness for short to ground and short to power y OK 9 4 EC 117 TROUBLE DIAGNOSIS FOR OVER HEAT DTC 28 Cooling Fan Overheat Cont d Be DISCONNECT Ga ris DISCONNECT 1 f SEF760V DISCONNECT E SEF761V p DISCONNECT En Y DISCONNECT f 5 1 EcM JO CONNECTOR e Deh SEF762V l CHECK OUTPUT SIGNAL CIRCUIT NG Check the following 1 Disconnect ECM harness connector Pe Harness connectors 2 Check harness continuity between ECM E127 M21 terminal and terminal 1 e Harness connectors Continuity should exist M52 If OK check harness for short to ground e Harness for open or short and short to power between cooling fan OK relay 1 and ECM 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 Cooling fan relay 1 CP Refer to COMPONENT INSPECTION EC 121 CHECK COMPONENT NG Replace cooling fan motor gt Cooling fan motor 1 Refer to COMPONENT INSPECTION EC 121 d 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 R
22. m Engine ground 39 B EORR ound Engine is running Probe this terminal with 43 9 B Idle speed tester probe when measuring 56 TAX BATTERY VOLTAGE 61 Ww Power supply for ECM Ignition switch ON 11 14V 70 BR Power supply Back up Ignition switch OFF ee NOLTAGE 106 Engine is running 112 B ECCS ground C Approximately OV 118 Idle speed jos Ww Power supply for ECM Ignition switch ON BATTERY VOLTAGE 117 EC 63 11 14V EC MAIN 01 Main Power Supply and Ground Circuit TROUBLE DIAGNOSIS FOR POWER SUPPLY Cont d o o H amp o e o E 3 amp a o T Os 2 d EOS ic o S ele ES 2 SE Qui D o o 9 D o 1 2 E ais a pu 0zZ0 GIN r 270 69009 e Su 82 muo OQ x E 8 2 Ae I o Q ox m az D m pies Om x 2st 10A B Y B Y IGNITION SWITCH ON or START E BATTERY BR Ei BR I e TEC421 EC 64 TROUBLE DIAGNOSIS FOR POWER SUPPLY Main Power Supply and Ground Circuit EC MAIN 02 Cont d NEN Detectable line for DTC Non detectable line for DTC ECM ECCS D CONTROL MODULE w INT 11 d CONNECTOR 3 E w L e Oo gH o e EI LI GEI m DEEEE EC 65 TEC422 TROUBLE DIAGNOSIS FOR POWER SUPPLY Main Power Supply and Ground Circuit CONNECT ECM O CONNECTOR y ri f e SS i O O ER SEFO65P CONNECT EG ECM O CONNECTOR f M
23. 3 Turn ignition switch ON 4 Check voltage between terminal 1 and ground with CONSULT or tester Voltage Approximately 5V OK E CHECK GROUND CIRCUIT Sech Check the following 1 Turn ignition switch OFF e Harness connectors 2 Check harness continuity between ter CES st minal and engine ground e Harness connectors Continuity should exist 88 If OK check harness for short to e Harness for open or ground and short to power short between ECM and OK electronic fuel injection pump e 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 x NG CHECK COMPONENT eech Take proper action TROUBLE DIAGNOSIS FOR FUEL TEMP SENSOR DTC 42 DISCONNECT Electronic fuel injection pump 20 18 6 a 4 Acceptable ME o 2 S 1 0 08 e E 04 0 2 0 1 L 4 82 E eh 4 Qu T Temperature C SEF012P Fuel Temperature Sensor FTS Cont d COMPONENT INSPECTION Fuel temperature sensor Wait until fuel temperature sensor reaches room temperature Check resistance as shown in the figure Temperature C F Resistance kQ 20 68 2 306 2 568 60 140 0 538 0 624 80 176 0 289 0 344 If NG take proper action EC 138 TROUBLE DIAGNOSIS FOR ACCEL POS SENSOR DTC 43 Accelerator Position Sensor The accelerator position sensor is installed on the upper end
24. 45 PUMP Approximately OV Engine is running Warm up condition L Engine speed is 2 000 rpm SEF723V EC 69 TROUBLE DIAGNOSIS FOR CAM POS SEN PUMP DTC 11 Camshaft Position Sensor CMPS PUMP Cont d ON BOARD DIAGNOSIS LOGIC Diagnostic Trouble Code No Malfunction is detected when Check Items Possible cause 11 ECM during engine running e An improper signal from the sensor is detected by e Harness or connectors The camshaft position sensor PUMP circuit is open or shorted e Camshaft position sensor PUMP DIAGNOSTIC TROUBLE CODE CONFIRMATION x MONITOR x NOFAIL L PROCEDURE CKPS RPM TDC 775rpm 1 2 RECORD 1 SEF714V Turn ignition switch ON and select DATA MONITOR mode with CONSULT Start engine and run it for at least 2 seconds at idle speed If engine does not run turn ignition switch to START for at least 2 seconds O Start engine and run it for at least 2 seconds at idle speed If engine does not run turn ignition switch to START for at least 2 seconds Turn ignition switch OFF wait at least 5 seconds and then ON Perform Diagnostic Test Mode l Self diagnostic results with ECM EC 70 TROUBLE DIAGNOSIS FOR CAM POS SEN PUMP DTC 11 Camshaft Position Sensor CMPS PUMP Cont d EC CMPS 01 ECM ECCS D CONTROL MODULE Rm Detectable line for DTC F8 Non detecta
25. CONTROL VALVE Refer to last page Foldout page This connector is not shown in HARNESS LAYOUT EL section TEC430 EC 103 TROUBLE DIAGNOSIS FOR F INJ TIMG F B DTC 21 Injection Timing Control Valve Cont d Priming pum pos Injection timing control valve SEF754V DISCONNECT AE O A ECH O CONNECTOR 104 110 SEF755V DIAGNOSTIC PROCEDURE INSPECTION START CHECK FOR AIR IN FUEL FILTER 1 Move priming pump up and down to purge air from fuel filter 2 Perform DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCE DURE OK INSPECTION END CHECK POWER SUPPLY NG Check the following 1 Turn ignition switch OFF e Harness connectors 2 Disconnect injection timing control valve M51 harness connector e Electronic fuel injection 3 Turn ignition switch ON pump harness connector 4 Check harness continuity between ter minal 2 and ground with CONSULT or e 10A fuse tester e Harness for open or Voltage Battery voltage short between injection timing control valve and OK fuse If NG repair harness or connectors CHECK OUTPUT SIGNAL CIRCUIT A Check the following 1 Turn ignition switch OFF e Electronic fuel injection 2 Disconnect ECM harness connector pump harness connector 3 Check harness continuity between ter CES minal 1 and ECM terminals 102 e Harne
26. DTC iS BR TEC433 EC 128 TROUBLE DIAGNOSIS FOR NEEDLE LIFT SEN DTC 34 Needle Lift Sensor NLS Cont d DIAGNOSTIC PROCEDURE INSPECTION START SS Priming pump CHECK FOR AIR IN FUEL FILTER OK INSPECTION END 1 Move priming pump up and down to purge air from fuel filter 2 Perform DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE y NG Loosen and retighten engine ground Screws a CHECK INPUT SIGNAL CIRCUIT 1 Turn ignition switch OFF 2 Disconnect ECM harness connector and needle lift sensor harness connector 3 Check harness continuity between termi nal and ECM terminal a Continuity should exist If OK check harness for short to ground and short to power Repair open circuit or short to ground or short to power in harness or connectors OK CHECK GROUND CIRCUIT NG Repair open circuit or short Check resistance between terminal 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 CHECK NO 1 INJECTION NOZZLE FOR NG Replace No 1 injection CLOGGING nozzle p y N E Y Rd ume Refer to SPRAY PATTERN TEST Test HS i TS and Adjustment INJECTION NOZZLE EC 26 ECM Jo conwectoR an 34 OK Disconnect and reconnect harness connec tors in the circ
27. M34 LAN W G ae GC 1G LAN m LG B ak ES Tei LAN LG B W G E221 L W LG B ECM GLOW ECCS D PLUG CONTROL MODULE Reter to last page Foldout page ve i27 E204 E221 B B TEC441 EC 152 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS Glow Control System Cont d DIAGNOSTIC PROCEDURE INSPECTION START Check fuel level fuel supplying system starter motor etc plate nuts 2 7 3 5 Nem OK E 0 28 0 36 kg m NA pe SEF698V Check that all glow plug connecting plate Install properly nuts are installed properly inn Glow lay 1 OK o CHECK OVERALL FUNCTION OK CHECK COMPONENT Check entire glow control system Refer Glow plug to System Operation Check on next See page EC 155 page NG B CHECK VOLTAGE BETWEEN GLOW NS Check the following RELAY AND GROUND e 100A fusible link 1 Turn ignition switch OFF e Harness for open or 2 Disconnect glow relay short between glow 3 Check voltage between terminals 1 relay and battery 3 and ground with CONSULT or If NG repair harness or tester connectors Voltage Battery voltage CHECK OUTPUT SIGNAL CIRCUIT NG Check the following 1 Disconnect ECM harness connector e Harness connectors 2 Check harness continuity between ECM E127 M21 terminal 111 and terminal e Harness connectors Continuity should e
28. N n o This connector is not shown in HARNESS LAYOUT EL section TEC437 EC 146 TROUBLE DIAGNOSIS FOR CRANK POS SEN TDC DTC 47 Crankshaft Position Sensor TDC Cont d Zeg from under vehicle DIAGNOSTIC PROCEDURE Crank pulley INSPECTION START e Zeg gt position sensor CHECK INPUT SIGNAL CIRCUIT aad Check the following ROCA harness 1 Turn ignition switch OFF e Harness connectors connector T 2 Disconnect crankshaft position sensor EN NS TDC harness connector and ECM har e Harness for open or P Oil pan ness connector short between ECM and 7 N SEF696V 3 Check harness continuity between ECM crankshaft position sen terminals and terminal 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 nad NES A DISCONNECT ground and short to power power in harness or con EE rector T S H S E 40 44 CHECK GROUND CIRCUIT I NG Check the following Check harness continuity between termi e Harness connectors nal 2 and ECM terminals 2 2 EN Continuity should exist e Harness for open or If OK check harness for short to ground short between crankshaft sEr774v and short to power position sensor TDC and ECM El If NG repair open circuit or short to ground or short to power in harness o
29. O az on o E Y HOSN3S 3univu3 a E y H3dWil E MIV 308VHO s19pow L W CW NOISSIM de SNYUL HOSN3S 3B lvH3dWil suspen ERO Y WoL 1Nv1002 3NIDN3 YOSNIS 38NLY3AN3L IIN ANA NOI 123 NI O HoLIMS T YOLS1S38Y LNAWLSAP AV NOILISOd Fee n o oe dNnd NO1123PNI TVH1n3N YN QWAT vayowoyoey oF SLYN HOLS IWYSHL HOSN3S 9 4 HOLIMS 7 JossaJduoo o e 801v831399V Fo s MU BIY S wars As O y OL AT y TE 9v 3unss3ud vna de m ez dv IOYLNOO sonazaoo 91419373 a AS EDD dWnd No1123nNI Lu 2 E NODIS EI ET ue a s bes T HOSN3S ema Q LE u01V331322V z2 d foe GC 1411 371033N y F 28 of 382 QO a g OI uOSN3S ES 4 z OT NOI LISOd Jer 8 l Z zz Zi Wee O YOLVYS TION 8v Q SLL gy E eg uo ujunj a ai los g EM IMYA Q10N330S nt Qux D HOSN3S z9 g ind 13104 oJ ET No 330 NOLLISOd Je 2 dWnd NOILO3PNI oc 59 MOL IAS 33315 OY 1NO9 Joe 8 L dn LV3H dad NOILO3PNI ba o JAVA GIONS 10S LS Cr JOHINOO 3 1LLONH 9nd MO19 sch 8 3ATVA ee EE RNC IG1 MDENIS QI0N310S 2993 NOILISOd 7 V 3ATVA H H H H H H LJVHSXNYN2 E QI0N310S 2493 JAYA OH LNO2 Cid SOS ONIWIL NOILOSPNI AYILLVA isiunag ea Ga dad NOI123PNI Z No79 llo dnd NOILOSCNI YOSNIS a P L CN E N3L3N 8317113 1303 s gt SE CT lt SAA ONO ec EE AI EE N ls x ag 3 Luvis J0 NO O HE SJ LANSNOD N04 HOLIMS NOILINSI SE dNV1 NOLVOIONI Ki H0 153NN02 gt NOTLONN 31V XNIT Viva EC 11 ENGINE AND EMISSION CONTROL OVERALL SYSTEM
30. Overheat Cont d COMPONENT INSPECTION Cooling fan relay 1 Check continuity between terminals 3 and Conditions Continuity 12V direct current supply between Yes terminals 1 and 2 No current supply No SEF511P If NG replace relay Cooling fan motor 1 1 Disconnect cooling fan motor harness connector 2 Supply cooling fan motor terminals with battery voltage and check operation Terminals Cooling fan motor OO seF763v Cooling fan motor should operate If NG replace cooling fan motor EC 121 TROUBLE DIAGNOSIS FOR I C INT A TEMP SEN DTC 33 Terminal Sensor SEF594K no o 18 6 a 4 Acceptable ME 8 2 1 0 08 e E 04 0 2 0 1 20 0 20 40 60 80 100 4 32 68 104 140 176 212 Temperature C F SEF012P Charge Air Temperature Sensor The charge air temperature sensor is used to detect the charge air temperature The sensor modifies a voltage signal from the ECM The modified signal returns to the ECM as the charge air tempera ture input The sensor uses a thermistor which is sensitive to the change in temperature The electrical resistance of the thermistor decreases as temperature increases The ECM uses this signal for the charge air cooler control lt Reference data gt Charge air temperature Voltage Resistance C F V kQ 10 14 4 4 7 0 11 4 20 68 3 5 2 1 2 9 50 122
31. Refer to EC 36 Data link connector S e e for CONSULT _ 5 ITA Te Es SEF669V DOES ENGINE START x MONITOR x NOFAIL Yes Turn ignition switch OFF wait 5 seconds and then start engine If engine fails to start check diagnostic trouble code DTC CKPS RPM TDC 775rpm Run engine for 10 minutes RECORD SEF714V CHECK IDLE SPEED N Read engine idle speed in DATA SSA AS MONITOR mode with CONSULT y OS Diesel tacho OR lk SE E Check idle speed using tachom x m LY A By eter tester d EE TELA 7 775 25 rpm x NG SS ES 7 OS SSSA T AOS NO XR Go to on next page ZA TS n J page 2 v AR SX 7 LOSS SZ SEF671V EC 46 TROUBLE DIAGNOSIS Basic Inspection Basic Inspection Cont d a CHECK INJECTION TIMING iir e Bleed air from fuel sys 1 Set No 1 piston at TDC on its com tem pression stroke e 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 check that dial gauge indicates the DIAGNOSTIC SYSTEM same value again DESCRIPTION EC 30 5 Turn crankshaft counterclo
32. Turn ignition switch OFF wait at least 5 seconds and then turn ON 3 Perform Diagnostic Test Mode l Self diagnostic results EC 149 TROUBLE DIAGNOSIS FOR GOV CUT CIRCUIT DTC 48 Governor Cut Circuit Cont d DIAGNOSTIC PROCEDURE INSPECTION START 1 Turn ignition switch ON 2 Select SELF DIAG RESULTS mode with CONSULT 3 Touch ERASE OR E 1 Turn ignition switch ON 2 Erase the diagnostic test mode Il Self diagnostic results memory PERFORM DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE See previous page Is the DTC 48 displayed again Yes Replace ECM INSPECTION END EC 150 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS Glow Control System SYSTEM DESCRIPTION Engine speed Crankshaft position sensor TDC Glow relay Glow plugs gt Engine coolant temperature Engine coolant temperature sensor gt Glow lamp When engine coolant temperature is more than 90 C 194 F the glow relay turns off inactivating the quick glow control until coolant temperature drops below 70 C 158 F When coolant temperature is lower than 90 C 194 F e 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 e Cranking The glow relay turns ON allowing current to flow through g
33. Wait at least 2 seconds 3 Turn ignition switch OFF wait at least 5 seconds and X RECORD aa E RECORD 4 Perform Diagnostic Test Mode l Self diagnostic SEF748V a results with ECM EC 111 TROUBLE DIAGNOSIS FOR ECM 1 DTC 27 ECM 2 DTC 31 Engine Control Module ECM ECCS D Control Module Cont d DIAGNOSTIC PROCEDURE INSPECTION START 1 Turn ignition switch ON 2 Select SELF DIAG RESULTS mode with CONSULT 3 Touch ERASE OR E 1 Turn ignition switch ON 2 Erase the Diagnostic Test Mode ll Self diagnostic results memory PERFORM SELF DIAGNOSIS Select SELF DIAG RESULTS mode with CONSULT OR E PERFORM Diagnostic Test Mode amp y I SELF DIAGNOSTIC RESULTS Is the DTC 27 31 displayed again Yes Replace ECM No INSPECTION END EC 112 TROUBLE DIAGNOSIS FOR OVER HEAT DTC 28 Cooling Fan Overheat SYSTEM DESCRIPTION Vehicle speed sensor Vehicle speed ECM Eos Geen ECCS D Engine coolant temperature sensor delia dad control Cooling fan mod relay ule Air conditioner switch Air conditioner ON signal 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
34. air cooler to vacuum gal 3 way connector to throttle control 3 way connector to EGRC sole lery solenoid valve noid valve B Throttle control valve to throttle 3 way connector to EGRC sole 9 EGR valve and 3 way connector control solenoid valve noid valve A Vacuum pump to 3 way connector _ 3 way connector to EGRC sole Vacuum gallery to wastegate valve noid valve A GG a actuator Refer to System Diagram EC 12 for vacuum control system EC 13 ENGINE AND EMISSION CONTROL OVERALL SYSTEM System Chart Camshaft position sensor PUMP Fuel injection control Electric governor Crankshaft position sensor TDC Control sleeve position sensor gt Fuel injection timing control Injection timing control valve Fuel temperature sensor Engine coolant temperature sensor Fuel cut control I Fuel cut solenoid valve Needle lift sensor Accelerator position sensor Accelerator postion sensor pl Glow control system Glow relay 8 glow lamp Accelerator position switch Malfunction indicator lamp On the instrument panel ECCS p On board diagnostic system control module Accelerator switch F C Ka Neutral position switch pps e Y EGR valve amp throttle control EGRC solenoid valve A B amp Ignition switch 9 valve control throttle control solenoid valve Battery volt
35. complaint Perform the DTC CONFIRMATION PROCEDURE and confirm the normal code Diagnostic trouble code No 55 STEP VII is detected If the incident is still detected in the final check perform STEP VI by using a different method from the previous one Before returning the vehicle to the customer be sure to erase the unnecessary already fixed DTC in ECM Refer to EC 30 EC 45 TROUBLE DIAGNOSIS Basic Inspection Basic Inspection Precaution Perform Basic Inspection without electrical or mechanical loads applied e Headlamp switch is OFF e Air conditioner switch is OFF e Rear defogger switch is OFF e e Steering wheel is in the straight ahead position etc Z BEFORE STARTING 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 e Harness connectors for improper con nections e Vacuum hoses for splits kinks or improper connections e 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 LS JOP and Draining Water of ENGINE e Fuse MWA MAINTENANCE in MA section cover 77 7 SB D S 2 Hood opener CONNECT CONSULT TO THE VEHICLE S A Connect CONSULT to the data link con nector for CONSULT and select ENGINE from the menu
36. fan relay Charge air cooler fan relay X X X X X X X X X LTD X X m X X SpA X X X X X Applicable EC 37 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION SELF DIAGNOSTIC MODE CONSULT Cont d Regarding items detected in SELF DIAG RESULTS mode refer to DIAGNOSTIC TROUBLE CODE INDEX EC 1 DATA MONITOR MODE Monitored item ECM Mal Unit input sianals Description Remarks signals 9 CKPS RPM The engine speed computed from the TDC rpm O O crankshaft position sensor TDC signal is displayed CKPS RPM The engine speed determined by the REF rpm CMPS RPM PUMP rpm time between pulses from the crankshaft position sensor TDC signal is dis played The engine speed computed from the camshaft position sensor PUMP signal is displayed COOLAN TEMP S C or F VHCL SPEED SE km h or mph FUEL TEMP SEN C or F The engine coolant temperature deter mined by the signal voltage of the engine coolant temperature sensor is displayed The vehicle speed computed from the vehicle speed sensor signal is displayed The fuel temperature determined by the signal voltage of the fuel temperature sensor is displayed e When the engine coolant temperature sensor is open or short circuited ECM enters fail safe mode The engine cool ant temperature determined by the ECM is displayed ACCEL POS SEN V The accelerator position sensor sig
37. initial injection pressure Refer to SDS for adjusting shim EC 189 Adjusting shim Lv SEF673A LEAKAGE TEST 1 Maintain the pressure at about 981 to 1 961 kPa 9 8 to 19 6 bar 10 to 20 kg cm 142 to 284 psi below initial injection pressure 2 Checkthat there is no dripping from the nozzle tip or around the body A 6 Good Faulty SEF674A EC 25 INJECTION NOZZLE Test and Adjustment Cont d 3 If there is leakage clean overhaul or replace nozzle SPRAY PATTERN TEST A B C D 1 Check spray pattern by pumping tester handle one full stroke per second e f main spray angle is within 30 degrees as shown injec uL tion nozzle is good A 80 A e itis still normal even if a thin stream of spray deviates from D fu kul the main spray pattern B m E UM PM 2 f the spray pattern is not correct disassemble and clean hia Hi Pu nozzle Sa 3 Test again and if spray pattern is not corrected replace nozzle r EC 26 ELECTRONIC FUEL INJECTION PUMP SEC 135 186 Front Injection pump pulley 3 54 64 7 5 5 6 5 40 47 9 16 21 9 16 21 1 6 2 1 12 1 6 2 1 12 15 Se e B t 22 29 2 2 3 0 16 22 2 2 3 0 16 22 o fy 6 3 8 3 0 64 0 85 55 6 73 8 Wel Nam kg m in Ib 8 O Nem kg m ft lb SEF663V Removal 1 Remove battery Disconnect electronic injection pump harness connectors 2 Set No
38. malfunction can be A malfunction can not be displayed on DATA displayed on DATA MONITOR screen MONITOR screen automatically if detected automatically even if detected SEF529Q EC 41 TROUBLE DIAGNOSIS Introduction Sensors Injection pump fi SEF858S 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 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 w
39. nozzles sssesssssss 23 Assembly No 2 4 nozzlesl 24 Test and Adjustment esee 25 ELECTRONIC FUEL INJECTION PUMP 27 Removal nennen 27 Installaton ner nennnnetnnnnnnnneeennneeenen 28 Disassembly and Assembly ssss 29 ON BOARD DIAGNOSTIC SYSTEM DESCHIDTION 30 DTC and MIL Detection Logic 30 Diagnostic Trouble Code DTC 30 Malfunction Indicator Lamp MIL CONSULT T 36 TROUBLE DIAGNOSIS Introduction 42 JptrogO Hop Age UE 42 Diagnostic Worksheet esee 43 TROUBLE DIAGNOSIS Work Flow 44 Work POW si E ee M 44 Description for Work Flow eene 45 TROUBLE DIAGNOSIS Basic Inspection 46 Basic Inispection e et cete 46 TROUBLE DIAGNOSIS General Description 48 Symptom Matrix Chart 48 CONSULT Reference Value in Data Monitor ejos 51 Major Sensor Reference Graph in Data Monitor Mode x ee utt reae m m died 53 ECM Terminals and Reference Value 54 TROUBLE DIAGNOSIS FOR POWER SUPPLY 63 Main Power Supply and Ground Circuit 63 TROUBLE DIAGNOSIS FOR CAM POS SEN PUMP DTC 11 1 dede 69 Camshaft Position Sensor CMPS PUMP 69 TROUBLE DIA
40. on Check MIL circuit NG Repair harness or See EC 188 connectors ES OK NG Data link connector for CONSULT Connect CHK and IGN terminals with a suitable harness MIL should go off e Wait at least 2 seconds Data link connector for CONSULT Disconnect the suitable harness between CHK and IGN terminals SE DIAGNOSTIC TEST MODE II SELF DIAGNOSTIC RESULTS q EC 32 b C Diagnostic Test m Mode Start engine MALFUNC TION WARN ING Refer to previ ous page Check MIL circuit and data link connector for CONSULT circuit See EC 188 OK NG Repair harness or connectors gt erased from the backup memory in the ECM ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Malfunction Indicator Lamp MIL Cont d Data link connector for CONSULT Connect CHK and IGN terminals with a suit able harness A Wait at least 2 seconds A a CHK IGN E LLL ee Es Data link connector for CONSULT Disconnect the suitable harness between CHK and IGN terminals Y If the suitable harness is disconnected at this time the diagnostic trouble code will be e Switching the modes is not possible when the engine is running e When ignition switch is turned off during diagnosis power to ECM will drop after approx 5 seconds The diagnosis will auto
41. released CLOSE ACCEL SW FC Enoi d Engine stopped Accelerator pedal slightly open OPEN m ie Accelerator pedal released ON OFF ACCEL SW e c Switch ON Engine stopped Accelerator pedal slightly open OFF C SLEEV POS S e Engine After warming up 1 0 3 5V BATTERY VOLT Ignition switch ON Engine stopped 11 14V Shift lever Neutral Park ON P N POSI SW e Ignition switch ON Except above OFF START SIGNAL e Ignition switch ON START gt ON OFF gt ON gt OFF Air conditioner switch OFF OFF e Engine After warming up idle the AIR COND SIG engine Air conditioner switch ON ON Compressor operates IGN SW e Ignition switch ON gt OFF ON 3 OFF Heat up switch ON ON WARM UP SW e Ignition switch ON Heat up switch OFF OFF e Engine After warming up MAS AIR FL SE e EES OFF Idle 16 20V e Shift lever N e No load e Engine After warming up Idle 9 5 to 12 0 ACT INJ TIMG e Ar conditioner switch OFF e Shift lever N e No load 2 000 rpm 10 0 to 15 5 INJ TIMG C V e Engine After warming up idle the engine Approx 5096 Idle OFF DECELER F CUT le Engine After warming up When accelerator pedal is released quickly with engine speed at 3 000 rpm ON or more FUEL CUT S V e Ignition switch ON gt OFF ON gt OFF GLOW RLY e Refer to EC 151 EC 51 TROUBLE DIAGNOSIS General Description CONSULT Reference Value in Data Monitor Mode Cont d MONITOR ITEM CONDITION SPECIFICATION e When coolin
42. retest Trouble is not fixed Check ECM pin terminals for damage and check the connection of ECM harness connector Reconnect ECM harness con nector and retest INSPECTION END EC 168 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS Accelerator lt a position switch ES DISCONNECT Accelerator Position Switch Cont d COMPONENT INSPECTION Accelerator position switch 1 Disconnect accelerator position switch harness connector 2 Check continuity between terminals and Conditions Continuity Accelerator pedal released Yes Accelerator pedal depressed No 3 Check continuity between terminals 4 and Conditions Continuity Accelerator pedal released No Accelerator pedal fully depressed Yes If NG replace accelerator pedal assembly 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 DU E Start and warm up engine After engine has warmed up JS idle for 10 minutes EC 169 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS Park Neutral Position Switch EC PNP SW 01 NEN Detectable line for DTC Non detectable line for DTC IGNITION SWITCH ON or START FUSE BLOCK lt A gt AT models J B Refer to EL POWER MAIN En m ECM CONTROL T MODULE F8 NEUT Cre INHIBITOR
43. sensor Injection timing trol valve The optimal fuel injection timing data predetermined in proportion BTDC to engine speeds and amount of fuel injected are stored in the C ES ECM memory The ECM uses the data to control the fuel injection A Y Fuel injection timing Engine rpm SEF650S ENGINE COOLANT TEMPERATURE COMPENSATION When starting Input output signal line Crankshaft position sensor TDC Engine coolant temperature sensor Engine coolant temperature g p Injection timing con Ignition timing trol valve Engine speed Needle lift sensor Ignition switch Start signal For better startability under cool engine conditions the fuel injec tion timing is compensated according to the engine coolant tem 1 perature CG S Ee 5 2 Engine coolant SS Ge HESE Ea Sg E PE Engine rom SEF651S EC 18 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Fuel Injection Timing System Cont d ENGINE COOLANT TEMPERATURE COMPENSATION During driving Input output signal line Crankshaft position sensor TDC Engine speed Injection timing con trol valve Engine coolant temperature Engine coolant temperature sensor Injection timing Needle lift sensor For better exhaust efficiency under cool engine conditions the fuel injection ti
44. short 1 Disconnect ECM harness connector Check harness continuity between ter minal and ECM terminal gt Continuity should exist If OK check harness for short to ground and short to power CS to ground or short to power in harness or connectors CHECK COMPONENT Mass air flow sensor Refer to COMPONENT INSPECTION on next page Disconnect and reconnect harness con SEF737V nectors in the circuits Then retest DISCONNECT w DISCONNECT AE a gt lt Ecm o coNNECTOR SEKR 35 Check ECM pin terminals for damage and check the connection of ECM harness connector Reconnect ECM harness con nector and retest Trouble is not fixed INSPECTION END Ca SEF738V EC 77 NG a Replace mass air flow sen sor TROUBLE DIAGNOSIS FOR MASS AIR FLOW SEN DTC 12 CONNECT 24 R 35 d Da LN SEF739V SEF740V Mass Air Flow Sensor MAFS Cont d COMPONENT INSPECTION Mass air flow sensor 1 Start engine and warm it up to normal operating temperature 2 Check voltage between ECM terminal 3 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 Approximately 2 1 1 0 1 7 to Approx 4 0 2 500 rpm Idle to about 4 000 rpm Check for linear voltage rise in respon
45. this check however this simplified check is an effective alternative The NG result of the OVERALL FUNCTION CHECK is the same as the DTC detection Take the appropriate action based on the results of STEP through IV STEP V If the malfunction code is indicated proceed to TROUBLE DIAGNOSIS FOR DTC XX If the normal code is indicated proceed to the BASIC INSPECTION Refer to EC 46 Then perform inspections according to the Symptom Matrix Chart Refer to EC 48 Identify where to begin diagnosis based on the relationship study between symptom and possible causes Inspect the system for mechanical binding loose connectors or wiring damage using tracing Harness Layouts Gently shake the related connectors components or wiring harness with CONSULT set in DATA MONITOR AUTO TRIG mode STEP VI Check the voltage of the related ECM terminals or monitor the output data from the related sensors with CON SULT Refer to EC 54 The DIAGNOSTIC PROCEDURE in EC section contains a description based on open circuit inspection A short circuit inspection is also required for the circuit check in the DIAGNOSTIC PROCEDURE For details refer to Gl section Circuit Inspection HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT Repair or replace the malfunction parts Once you have repaired the circuit or replaced a component you need to run the engine in the same conditions and circumstances which resulted in the customer s initial
46. 1 piston at TDC on its compression stroke TDC Crankshaft pulley notch without painted mark 3 Remove fuel hoses supply return and spill and injection tubes Crankehraft 4 Remove air duct and injection pump timing belt cover pulley 5 Remove injection pump timing belt TDC Refer to EM section Injection Pump Timing Belt timing mark Injection timing mark SEF664V 6 Remove injection pump sprocket with Tool e Remove key from injection pump shaft and store safely EC 27 ELECTRONIC FUEL INJECTION PUMP Removal Cont d 7 Remove injection pump assembly Installation 1 Install key on injection pump shaft then install injection pump sprocket e Use alignment mark on sprocket 2 Install injection pump timing belt Refer to EM section Injection Pump Timing Belt 3 Adjust injection timing Refer to Basic Inspection EC 46 4 Install all parts removed EC 28 ELECTRONIC FUEL INJECTION PUMP Fuel cut solenoid valve 9 20 25 2 0 2 5 14 18 O ring Camshaft position sensor PUMP 0 20 25 2 0 2 5 14 18 O ring CO w og ake 61 87 A zu 9 Injection timing control valve Wei N m kg m in Ib O N m kg m ft lb SEF668V Disassembly and Assembly CAUTION e Do not disassemble the parts not shown in the illustration above e Before installing injection timing control valve liberally apply a coat of diesel fuel to O ring and its m
47. 1V Cooling Fan Overheat Cont d DIAGNOSTIC PROCEDURE INSPECTION START CHECK COOLING FAN OPERATION 1 Turn ignition switch OFF 2 Turn ignition switch ON 3 Perform COOLING FAN in ACTIVE TEST mode with CONSULT and make sure that cooling fan operates when touch ing ON OK Goto A CHECK COOL ING SYSTEM FOR LEAK EC 119 OR Disconnect engine coolant tem perature sensor harness connec tor Connect 150 resistor to engine coolant temperature sensor har ness connector Start engine and make sure that cooling fan operates CHECK POWER SUPPLY NG Check the following 1 Turn ignition switch OFF e 10A fuse 2 Disconnect cooling fan relay 1 e 30A fusible link 3 Turn ignition switch ON e Harness for open or short 4 Check voltage between terminals 2 between cooling fan and ground with CONSULT or tester relay 1 and fuse Voltage Battery voltage e Harness for open or short OK between cooling fan relay 1 and battery If NG repair harness or connectors CHECK GROUND CIRCUIT NG Repair open circuit or short 1 Turn ignition switch OFF r to ground or short to power 2 Disconnect cooling fan motor harness in harness or connectors connector 3 Check harness continuity between relay terminal 3 and motor termi nals O Continuity should exist If OK check harness for short to
48. 2 E 3 E 2 gs Eg E 26 2 ae S So af o Oo BIN ge S iy o o m oz oo d x a kat o E ae Hae og ETS 323 G amp zuim 8 5999 P ESOS WU 1 1 I I 1 1 D I a 1 1 1 1 2 I I I Li am D 1 1 om o Su amp amp 3 2 1 1 T cals 1 1 Ww ek LI I 1 o a test e a Se Se tc T 1 i i Y 1 1 O i I fe a 1 1 a Oo 1 1 m en z RIR Be Be GB 88 a 1 1 En B lt i I En En ED G Sa S A zo M50 Ww EIS L3 4 5 6 TEC442 EC 158 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS EGRC Solenoid Valve A B and Throttle Control Solenoid Valve Cont d DIAGNOSTIC PROCEDURE INSPECTION START CHECK OVERALL FUNCTION OK INSPECTION END 1 Start engine and warm it up to normal operating temperature 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 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 CHECK VACUUM SOURCES TO EGR PES CHECK COMPONENTS VALVE AND THROTTLE CONTROL EGR valve and throttle VALVE c
49. 400 at 25 C 77 F If NG replace camshaft position sensor PUMP EC 73 TROUBLE DIAGNOSIS FOR MASS AIR FLOW SEN DTC 12 EE O I O O SEF734V Mass Air Flow Sensor MAFS COMPONENT DESCRIPTION The mass air flow sensor is placed in the stream of intake air lt measures the intake air flow rate by measuring a part of the entire intake air flow It consists of a hot wire that is supplied with electric current from the ECM The temperature of the hot wire is controlled by the ECM a certain amount The heat generated by the hot wire is reduced as the intake air flows around it The more air the greater the heat loss Therefore the ECM must supply more electric current to the hot wire as air flow increases This maintains the temperature of the hot wire The ECM detects the air flow by means of this current change CONSULT REFERENCE VALUE IN DATA MONITOR MODE Remarks Specification data are reference values MONITOR ITEM CONDITION SPECIFICATION MAS AIR FL SE Engine After warming up Air conditioner switch OFF 1 6 2 0V Shift lever N No load ECM TERMINALS AND REFERENCE VALUE Remarks Specification data are reference values and are measured between each terminal and ECCS ground with a voltmeter TER WIRE DATA MINAL COLOR ITEM CONDITION DC voltage NO Engine is running Warm up condition 35 R Mass air flow sensor C 1 6 2 0V Idle spe
50. 9 The actual injection timing angle deter mined by the ECM an approximate average angle between injection start and end from TDC is displayed Indicates the duty ratio of fuel injection timing control valve DECELER F CUT Indicates ON OFF condition from decel e When the accelerator pedal is released ON OFF 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 e 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 OFF Fuel cut solenoid valve is not operating ON Fuel cut solenoid valve is operat ing nozzles GLOW RLY ON OFF The glow relay control condition deter mined by ECM according to the input signal is displayed COOLING FAN LOW HI OFF Indicates the control condition of the cooling fans determined by ECM according to the input signal LOW Operates at low speed HI Operates at high speed OFF Stopped VC FAN RLY ON OFF Indicates the control condition of the charge air cooler fan determined by ECM according to the input signals EGRC SOL V A ON OFF The control condition of the EGRC sole noid valve A determined by ECM according to the input signal is indi cated OFF EGRC solenoid valve A is not operating
51. A TEMP SEN EC 122 F INJ F B 2 18 EC 96 34 NEEDLE LIFT SEN EC 126 F INJ TIMG F B 21 EC 101 36 X FUEL CUT S V 1 EC 130 GOV CUT CIRCUIT 48 X EC 149 37 x FCV SHORT EC 130 UC INT A TEMP SEN 33 1 EC 122 38 X FUEL CUT S V 2 EC 130 MAS AIR FLOW SEN 12 EC 74 42 FUEL TEMP SENSOR EC 135 NATS MALFUNCTION 141 148 X EL section 43 x ACCEL POS SENSOR EC 139 NEEDLE LIFT SEN 34 SS EC 126 47 x CRANK POS SEN TDO EC 144 ES pd En 55 eg 48 X GOV CUT CIRCUIT EC 149 OVER HEAT 28 X EC 113 55 a Ee VEHICLE SPEED SEN 14 EC 83 141 148 X NATS MALFUNCTION EL section 2 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 Special Service Tools FOR DIESEL ENGINE INJECTION PUMP Tool number WE EA Description KV11229352 Measuring plunger lift Measuring device NEN Si 4 KV11229350 d Holder E l G KV11229360 A Nut 3 KV11229370 Pin KV11254410 Dial gauge NT570 KV11102900 Removing injection pump sprocket Pulley puller ET NT647 FOR DIESEL ENGINE INJECTION NOZZLE Tool number Description Tool name P KV11289004 Nozzle cleaning kit D KV11290012 Box 2 KV11290110 Brush 3 KV11290122 Nozzle oil sump scraper KV11290140 Nozzle needle tip
52. C Diagnostic heck Trouble Code Malfunction is detected when S Se tems Possible Cause No 47 e An improper signal from the sensor is detected by e Harness or connectors ECM during engine running and cranking The sensor circuit is open e Crankshaft position sensor TDC EC 144 TROUBLE DIAGNOSIS FOR CRANK POS SEN TDC DTC 47 Crankshaft Position Sensor TDC Cont d DIAGNOSTIC TROUBLE CODE CONFIRMATION MONITOR x NOFAIL O 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 CKPS RPM TDC 775rpm 2 Crank engine for at least 1 second 3 Start engine and run it for at least 2 seconds at idle speed OR RECORD SEF714V E 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 l Self diagnostic results with ECM EC 145 TROUBLE DIAGNOSIS FOR CRANK POS SEN TDC DTC 47 Crankshaft Position Sensor TDC Cont d EC CKPS 01 NENNEN Detectable line for DTC Non detectable line for DTC OINT ONNECTOR 4 Bp gn dh 1 D 1 L er i i a es 4 l ll o EN y I J g E E SENSOR TDC e ECS n a
53. C 36 FCV SHORT DTC 37 FUEL CUT S V 2 DTC 38 Fuel Cut Solenoid Valve sessseeeseeeeseeeeeenn eenen TROUBLE DIAGNOSIS FOR FUEL TEMP SENSOR DTC A3 Fuel Temperature Sensor FTS When you read wiring diagrams TROUBLE DIAGNOSIS FOR ACCEL POS SENSOR DTO A3 139 Accelerator Position Sensor ssnnnenneneennneneeeeeeeae 139 TROUBLE DIAGNOSIS FOR CRANK POS SEN TDG DTC 47 oett eee ods 144 Crankshaft Position Sensor TDO 144 TROUBLE DIAGNOSIS FOR GOV CUT CIRCUIT DTC 468 sese 149 Governor Gut CILCUll eoe desees tere dente tono ture nhoda 149 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS 151 Glow Control System eee 151 EGRC Solenoid Valve A B and Throttle Control Solenoid Valve oocccccccccccccccccococonenoneceninininininonos 156 Sc erga 163 Accelerator Position Switch sssnnnnaeneeeennnaeeeneeeee 165 Park Neutral Position Switch essosnnnnnaeneeeenaeaanae 170 AA A 175 Charge Air Cooler Fan Control 178 Heat Up Switch ct ient tees 183 Air Conditioner Control 187 MIL amp Data Link Connectors 188 SERVICE DATA AND SPECIFICATIONS SDS 189 General Specifications sess 189 Injection Nozzle eee 189 Inspection and Adjustment
54. C solenoid valve Load Throttle control EGR valve Throttle control Amount of EGR temperature C F A B solenoid valve valve gas Below 70 158 Any A id a Fully closed Fully open Low load E Ee SC Fully open Closed Large Medium load 1 Ko Weg Fully open Fully open Medium Medium load 2 EEN TM Half open Fully open Small High load PAM EET DEF Fully closed Fully open Closed Closed Closed COMPONENT DESCRIPTION TEE valve 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 Blind cap control the amount of EGR exhaust gas recirculated is regulated in three stages large medium small Vacuum signal 4 SEF784V EC 156 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS EGRC Solenoid Valve A B and Throttle Control Solenoid Valve Cont d CONSULT REFERENCE VALUE IN DATA MONITOR MODE Remarks Specification data are reference values MONITOR ITEM CONDITION SPECIFICATION e Engine After warming up Idle ON e Air conditioner switch OFF EGRC SOL V A e Shift lever N Revving engine f
55. CES ECM terminal and terminal e Harness for open or ECM terminal and terminal short between EGRC 1 108 109 Continuity should exist solenoid valve A B and If OK check harness for short to ECM ground and short to power e Harness for open or short between throttle d control solenoid valve and ECM SEF783V If NG repair open circuit or short to ground or short to power in harness or con nectors Y CHECK COMPONENTS NG Replace malfunctioning EGRC solenoid valve A B and throttle component s control solenoid valve Refer to COMPONENT INSPECTION on next page Disconnect and reconnect harness connec tors in the circuit Then retest Trouble is not fixed Check ECM pin terminals for damage or the connection of ECM harness connector Reconnect ECM harness connector and retest INSPECTION END EC 161 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS BATTERY EGRC Solenoid Valve A B and Throttle Control Solenoid Valve Cont d COMPONENT INSPECTION EGR valve Apply vacuum to EGR vacuum port with a hand vacuum pump EGR valve spring should lift If NG replace EGR valve Throttle control valve Apply vacuum to throttle control valve vacuum port with a hand vacuum pump Throttle control valve should close If NG replace throttle control valve EGRC solenoid valve A B and throttle control solenoid valve Check air passage c
56. CTABLE ITEMS A T Control Cont d EC AT C 01 z O ER TRANSMISSION CONTROL MODULE Rm Detectable line for DTC Non detectable line for DTC MEE TEC440 EC 176 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS A T Control Cont d DIAGNOSTIC PROCEDURE INSPECTION START Check harness continuity between ECM terminal and ground ECM terminal and ground ECM terminal and ground Continuity should not exist If OK check harness for short to power DISCONNECT e E 24 30 37 OK Disconnect and reconnect harness con nectors in the circuit Then retest SEF797V Trouble is not fixed Check ECM pin terminals for damage and check the connection of ECM harness connector Reconnect ECM harness con nector and retest INSPECTION END EC 177 CHECK OVERALL FUNCTION OK INSPECTION END 1 Start engine and let it idle 2 Check voltage between ECM terminals Gi 89 6 and ground with CON SULT or tester Terminal Voltage and ground 6 8V and ground Approximately 0V G and ground 6 8V NG B CHECK INPUT SIGNAL CIRCUIT I NG Check the following 1 Turn ignition switch OFF e Harness connectors 2 Disconnect ECM harness connector ust and TCM harness connector e Harness connectors 3 Check harness continuity between E106 ECM terminal and terminal e Harness continuity E
57. Case 1 EC 66 Case 1 Battery voltage does not exist Case 2 Battery voltage exists for more than a few seconds Go to CHECK ECCS RELAY on next page TROUBLE DIAGNOSIS FOR POWER SUPPLY Main Power Supply and Ground Circuit RHD models amp ae ME ECM O CONNECTOR z 4 5 7 L SEC202B Cont d Boi CHECK HARNESS CONTINUITY haa Check the following BETWEEN ECCS RELAY AND ECM e Harness connectors 1 Disconnect ECM harness connector 52 2 Disconnect ECCS relay e Harness connectors 3 Check harness continuity between ECM 50 F5 terminals 8 and relay terminal e Harness for open or and ECM terminals 116 short between ECM and and relay terminal 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 OK nectors CHECK VOLTAGE BETWEEN ECCS INS Check the following RELAY AND GROUND e Harness connectors Check voltage between relay terminals E127 M21 D and ground with CONSULT e 15A fuse or tester e Harness for open or Voltage Battery voltage short between ECCS OK relay and battery If NG repair harness or connectors CHECK OUTPUT SIGNAL CIRCUIT S Check the following Check harness continuity between ECM e Harness
58. E Remarks Specification data are reference values and are measured between each terminal and ECCS ground with a voltmeter TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR NO Signal Engine is running BATTERY VOLTAGE Charge air cooler fan L Charge air cooler fan is not operating 11 14V 8 G OR relay Engine is running D 0 1V Charge air cooler fan is operating EC 178 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS Charge Air Cooler Fan Control Cont d EC IC FAN 01 IGNITION SWITCH ON or START 9 10A SE BLOCK 15A Refer to EL POWER Gu eg G R Rm Detectable line for DTC Non detectable line for DTC G R G R CHARGE AIR COOLER FAN RELAY NEM G OR eee 11 G OR G OR r ECM Ke ECCS D FAN CONTROL MODULE Va Den L B TEC439 EC 179 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS Charge Air Cooler Fan Control Cont d Charge air temperature sensor harness connector Pd Y ay DIAGNOSTIC PROCEDURE INSPECTION START Charge air cooler fan DISCONNECT Charge air temperature sensor 1500 resistor SEF798V ae ids Charge air cooler fan relay amp L SEF799V 1 Turn ignition switch OFF 2 Disconnect charge air cooler fan motor harness connector 3 Check harness continuity between relay terminal 3 and motor
59. ECM The ECM uses the signal to control the fuel cut switch F C Operation at deceleration for better fuel efficiency SEF687V CONSULT REFERENCE VALUE IN DATA MONITOR MODE Remarks Specification data are reference values MONITOR ITEM CONDITION SPECIFICATION ACCEL SW FC e Ignition switch ON Accelerator pedal released CLOSE Engine stopped Accelerator pedal slightly open OPEN Idle OFF DECELER F CUT e Engine After warming up When accelerator pedal is released quickly with engine ON speed at 3 000 rpm or more ECM TERMINALS AND REFERENCE VALUE Remarks Specification data are reference values and are measured between each terminal and ECCS ground with a voltmeter TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR NO Signal Ignition switch ON BATTERY VOLTAGE L Accelerator pedal fully released 11 14V 29 R L Accelerator switch F C Ignition switch ON C Approximately 0V Accelerator pedal depressed ON BOARD DIAGNOSIS LOGIC Diagnostic Check Items Trouble Code Malfunction is detected when f Possible cause No 23 e The OFF signal short is sent to the ECM for a cer e Harness or connectors tain period of time even when the accelerator pedal is The switch circuit is shorted not being depressed e Accelerator switch F C EC 106 TROUBLE DIAGNOSIS FOR ACCEL POS SW F C DTC 23 Accelerator Switch F C Cont d DIA
60. EF800V DISCONNECT AE DISCONNECT JAE Ea DE SEF801V Charge Air Cooler Fan Control Cont d e CHECK OUTPUT SIGNAL CIRCUIT NG Check the following 1 Disconnect ECM harness connector e Harness connectors 2 Check harness continuity betveen ECM E127 terminal and relay terminal 1 e Harness connectors Continuity should exist M52 If OK check harness for short to e Harness for open or ground and short to power short between ECM and OK charge air cooler fan 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 y Charge air cooler fan relay fan relay Refer to COMPONENT INSPECTION on next page NG CHECK COMPONENT Charge air cooler fan motor Refer to COMPONENT INSPECTION on next page OK Disconnect and reconnect harness con nectors in the circuit Then retest I Trouble is not fixed Check EOM pin terminals for damage and check the connection of ECM harness connector Reconnect ECM harness con nector and retest INSPECTION END EC 181 Replace charge air cooler fan motor TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS SEF511P SEF802V Charge Air Cooler Fan Control Cont d COMPONENT INSPECTION Charge air cooler fan relay Check continuity between terminals 3 and Conditions Continuity
61. EL SW and OFF ACCEL SW in DATA MONITOR mode with CON 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 depressed ON OR Turn ignition switch ON 2 Check voltage between ECM terminal 6 and ground under the following conditions Voltage Accelerator pedal released Battery voltage Accelerator pedal depressed Approximately 0V 3 Check voltage between ECM terminal G and ground under the following conditions Voltage Accelerator pedal released Approximately 0V Accelerator pedal fully depressed Battery voltage RECORD SEF626S Mee Im m Q o CONNECTOR 31 32 SEF627S DEI D gt switch harness connector L A role SEF708V M Ki OK INSPECTION END m b CHECK POWER SUPPLY 1 Turn ignition switch OFF sEr78ev 2 Disconnect accelerator position switch harness connector 3 Turn ignition switch ON 4 Check voltage between terminal and ground with CONSULT or tester Voltage Battery voltage EC 167 NG Check the following e Harness connectors M52 LHD mod els e Harness for open or short between accelera tor position switch and ECCS relay e Harness for open or short between accelera tor
62. ENGINE CONTROL SYSTEM SECTION CONTENTS DIAGNOSTIC TROUBLE CODE INDEX 1 Alphabetical amp Numerical Index for DTC 1 PRECAUTIONS AND PREPARATION 2 Special Service Tools isuri iii i 2 Commercial Service Tool 3 Supplemental Restraint System SRS AIR BAG and SEAT BELT PRE TENSIONER 4 PRECAUTIONS AND PREPARATION 5 Engine Fuel amp Emission Control System 5 ege Le 6 ENGINE AND EMISSION CONTROL OVERALL SYSTEM oio eo D eo 8 ECCS D Component Parts Location 8 Circuit Diagram cra eR terit 11 System Diagraim eH recette deeer 12 Vacuum Hose Drawing ooooccocccocccnoccccnnnnononncnanncnnn cnn 13 System Ch LIt e 14 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION 1 iicet ens 15 Fuel Injection System eese 15 Fuel Injection Timing System 18 Air Conditioning Cut Control 19 Fuel Cut Control at no load amp high engine Speedy rece dete eet tete 20 CRANKCASE VENTILATION SYSTEM 21 Description xen ee ettet aede 21 ee EE 21 INJECTION NOZZLE sese 22 Removal and Installation sseesssse 22 Disassembly No 2 4 nozzles 22 Inspection No 2 4 noszesi 23 Cleaning No 2 4
63. GNOSIS FOR MASS AIR FLOW SEN DIC 12 een e tede 74 Mass Air Flow Sensor MAFS eeen 74 TROUBLE DIAGNOSIS FOR COOLANT TEMP SEN DIG 13 eddie em E HR 79 Engine Coolant Temperature ECT Sensor 79 TROUBLE DIAGNOSIS FOR VEHICLE SPEED SEN DIC Kees eeh ente a 83 Vehicle Speed Sensor VE 83 TROUBLE DIAGNOSIS FOR CONT SLEEV POS SEN DIC 15 eiecti dete idus 87 Control Sleeve Position Sensor CSPS 87 TROUBLE DIAGNOSIS FOR ADJUST RESISTOR DTC 17 atte eren 92 Adjustment Resistor iinitan 92 TROUBLE DIAGNOSIS FOR F INJ F B 2 DTC 18 F INJ F B DTC 22 ELECTRIC GOV DTC 25 96 Electric Govermor anaannnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnne 96 TROUBLE DIAGNOSIS FOR F INJ TIMG F B DIC 21 555 e hd e ek e ns Injection Timing Control Valve TROUBLE DIAGNOSIS FOR ACCEL POS SW F C DTC A iid vede Accelerator Switch EICH TROUBLE DIAGNOSIS FOR ECM 1 DTC 27 ECMi2 DIG 31 etc ee eae Ee Engine Control Module ECM ECCS D Control TROUBLE DIAGNOSIS FOR OVER HEAT A te teen Cooling Fan Overheat c ren TROUBLE DIAGNOSIS FOR I C INT A TEMP SEN DIC eegener eet Ciel Charge Air Temperature Sensor TROUBLE DIAGNOSIS FOR NEEDLE LIFT SEN DTC J4 nee en Needle Lift Sensor NLS TROUBLE DIAGNOSIS FOR FUEL CUT S V 1 DT
64. GNOSTIC TROUBLE CODE CONFIRMATION x MONITOR x NOFAIL L PROCEDURE y 1 Turn ignition switch ON and select DATA MONITOR HU gs SE mode with CONSULT SEN er E 2 em and release accelerator pedal once for 15 sec onds 3 Repeat step 2 for 26 times OR E 1 Turn ignition switch ON RECORD Depress and release accelerator pedal once for 15 sec SEF756V onds 3 Repeat step 2 for 26 times Turn ignition switch OFF wait at least 5 seconds and then turn ON 5 Perform Diagnostic Test Mode ll Self diagnostic results with ECM EC 107 TROUBLE DIAGNOSIS FOR ACCEL POS SW F C DTC 23 Accelerator Switch F C Cont d EC ACC SW 01 ECM ECCS D CONTROL MODULE Rm Detectable line for DTC Non detectable line for DTC lt 1 LHD models lt P gt RHD models ACCELERATOR SWITCH F C DEPRESSED KL RELEASED CONNECTOR 3 B pe ee B JOINT TEC431 EC 108 TROUBLE DIAGNOSIS FOR ACCEL POS SW F C DTC 23 Accelerator Switch F C Cont d MONITOR NOFAIL ACCEL SW FC OFF RECORD SEF589S CONNECTOR SEF591S CONNECTOR SEF592S DIAGNOSTIC PROCEDURE INSPECTION START CHECK OVERALL FUNCTION EM INSPECTION END 1 Turn ignition switch ON a 2 Check ACCEL SW F C
65. IC SYSTEM DESCRIPTION Malfunction Indicator Lamp MIL Cont d RELATIONSHIP BETWEEN MIL DTC CONSULT AND DRIVING PATTERNS This driving pattern does not satisfy NG Detection self diagnostic condition This driving pattern satisfies self diagnostic condition Driving Pattern Engine RUN ON GN STOP OFF e i pa UIU UU OFF ra ECM Diagnostic DISPLAY trouble i 5 code NO 4 DISPLAY i CONSULT SELF a i DIAGNOSTIC DTC exists j RESULTS SCREEN amp DTC does H DATA MONITOR NOt exist 39 AUTO TRIG SCREEN 4 3 2 SELF 0 o to io o I DIAGNOSTIC COUNTER 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 4 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 t m cover 7 B di CONSULT CONSULT INSPECTION PROCEDURE 1 Turn off ignition swi
66. IN 12 CAUSES OF OVERHEATING on next page Y INSPECTION END Perform FINAL CHECK by the following procedure after repair is completed 1 Warm up engine Run the vehicle for at least 20 minutes Pay attention to engine coolant temperature gauge on the instrument panel If the reading shows an abnormally high temperature another part may be malfunctioning 2 Stop vehicle and let engine idle Check the intake and exhaust systems for leaks by listening for noise or visually inspecting the components 3 Allow engine to cool and visually check for oil and coolant leaks Then perform OVERALL FUNCTION CHECK EC 119 TROUBLE DIAGNOSIS FOR OVER HEAT DTC 28 Cooling Fan Overheat Cont d MAIN 12 CAUSES OF OVERHEATING Engine Step Inspection item Equipment Condition Reference page OFF 1 e Blocked radiator e Visual No blocking e Blocked radiator grille e Blocked bumper 2 e Coolant mixture e Coolant tester 50 50 coolant mixture See RECOMMENDED FLUIDS AND LUBRI CANTS in MA section 3 e Coolant level e Visual Coolant up to MAX level See Changing Engine in reservoir tank and Coolant ENGINE radiator filler neck MAINTENANCE in MA section 4 e Radiator cap e Pressure tester 78 98 kPa See System Check 0 78 0 98 bar 0 8 1 0 ENGINE COOLING kg cm 11 14 psi SYSTEM in LC section ON 5 e Coolant leaks e Visual No leaks See System Check
67. N Voltage ves WIN pat number of adjustment resistor iti Engine is running Warm up condition 47 B W Crankshaft position sensor C Approximately OV 52 TDC ground Idle speed 48 G R AGRIS position sen Ignition switch ON Approximately 5V sor power supply 49 G R Sensors power Signal t0 Ignition switch ON Approximately 5V TCM EC 59 TROUBLE DIAGNOSIS General Description ECM Terminals and Reference Value Cont d TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR NO Signal Engine is running Warm up condition 50 B Sensors ground Approximately 0V L Idle speed iti Engine is running Warm up condition 51 UW Accelerator position sen Approximately OV sor ground L Idle speed Approximately 2 6V v A NN 53 w Control sleeve position Engine is running o 57 sensor power supply D Idle speed SEF724V 56 BATTERY VOLTAGE 61 Ww Power supply for ECM Ignition switch ON 11 14V Ignition switch ON oV L Heat up switch is OFF 59 BR W Heat up switch Ignition switch ON BATTERY VOLTAGE L Heat up switch is ON 11 14V Approximately 2 6V v E R A E a 62 E Control sleeve position Engine is running 66 sensor ground B Idle speed SEF725V Approximately 2 6V v Po ut dm b Wo deo 63 Control sleeve p
68. NSPECTION END SES COMPONENT INSPECTION p Es Control sleeve position sensor 1 Disconnect electronic fuel injection pump harness connector 2 Check continuity between terminals 2 and and Resistance Approximately 5 90 at 23 C 73 F If NG take proper action Ci Electronic fuel EC 91 TROUBLE DIAGNOSIS FOR ADJUST RESISTOR DTC 17 Adjustment Resistor Adjustment resistor The adjustment resistor is used to achieve uniform pump charac teristics SEF681V ECM TERMINALS AND REFERENCE VALUE Remarks Specification data are reference values and are measured between each terminal and ECCS ground with a voltmeter TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR t NO Signal Approximately 0 4 6V i a Ae Voltage varies with part 46 Y Adjustment resistor Ignition switch ON number of adjustment resistor Engine is running Warm up condition 50 B Sensors ground C Approximately 0V Idle speed ON BOARD DIAGNOSIS LOGIC Diagnostic Trouble Code No Check Items Malfunction is detected when Possible Cause 17 e An excessively high or low voltage from the resistor is e Harness or connectors detected by ECM The adjustment resistor circuit is open or shorted e Adjustment resistor DIAGNOSTIC TROUBLE CODE CONFIRMATION ye MONITOR yx NOFAIL O PROCEDURE 1 Turn ignition switch ON
69. OFF 0 1 5V L For a few seconds after turning ignition switch 4 B Y ECCS relay Self shutoff OFF Ignition switch OFF E BATTERY VOLTAGE A few seconds passed after turning ignition 11 14V switch OFF 56 es BATTERY VOLTAGE 61 Ww Power supply for ECM Ignition switch ON 11 14V Ignition switch OFF Approximately OV Ss R W Fuel cut solenoid valve BATTERY VOLTAGE Ignition switch ON 11 14V LTAGE Se W Power supply for ECM Ignition switch ON BATTERY NOBIS 117 A 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 Cont d ON BOARD DIAGNOSIS LOGIC Diagnostic Trouble Malfunction is detected when Check Items Possible Cause Code No 36 37 38 Fuel cut solenoid valve circuit is malfunctioning e Main power supply circuit ECM terminals 16 17 and fuse e Harness or connectors The solenoid valve circuit is open or shorted e Fuel cut solenoid valve e ECM DIAGNOSTIC TROUBLE CODE CONFIRMATION ye MONITOR yx NOFAIL O PROCEDURE 1 Turn ignition switch ON il e dogm 2 GC DATA MONITOR mode with CONSULT 3 Start engine 4 Turn ignition switch OFF wait at least 5 seconds and then turn ON OR E 1 Start engine Turn ignition switch OFF wait at least 5 seconds and RECORD SEF748V then turn ON 3 Perform Diagnostic Te
70. OM terminal and terminal between ECM and TCM ECM terminal 8 and terminal If NG repair harness or Continuity should exist connectors OK CHECK INPUT SIGNAL CIRCUIT II NG Check the following e Harness connectors ED uas e Harness connectors ust e Harness for short between ECM and TCM If NG repair short to ground or short to power in harness or connectors TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS Charge Air Cooler Fan Control SYSTEM DESCRIPTION Crankshaft position sensor TDC Engine speed gt Charge air temperature sensor Charge air temperature ECM Charge air cooler fan relay Ignition switch Start signal gt 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 67 C 153 F and engine speed is more than 1 600 rpm the charge air cooler fan operates CONSULT REFERENCE VALUE IN DATA MONITOR MODE Remarks Specification data are reference values MONITOR ITEM CONDITION e When charge air cooler fan is stopped OFF UC FAN RLY e When charge air cooler fan operates ON SPECIFICATION ECM TERMINALS AND REFERENCE VALU
71. RASE DTC The diagnostic trouble code can be erased by the following methods e If the battery terminal is disconnected the diagnostic trouble code will be lost within 24 hours e When you erase the DTC using CONSULT is easier and quicker than switching the diagnostic test modes HOW TO ERASE DTC With CONSULT 1 If the ignition switch stays ON after repair work be sure to turn ignition switch OFF once Wait at least 5 seconds and then turn it ON Engine stopped again Turn CONSULT ON and touch ENGINE Touch SELF DIAG RESULTS Touch ERASE The DTC in the ECM will be erased y SELECT SYSTEM ly seiecroiaamoDE O E SELF DIAG RESULTS L ENGINE h SELF DIAG RESULTS h FUEL CUT S V 1 0 ZA p gt gt Bom FCV SHORT 0 bh Aa PoE LERasE PRNT 1 Touch ENGINE 2 Touch SELF DIAG RESULTS 3 Touch ERASE The DTC in the ECM will be erased E HOW TO ERASE DTC No Tools 1 If the ignition switch stays ON after repair work be sure to turn ignition switch OFF once Wait at least 5 seconds and then turn it ON again 2 Change the diagnostic test mode from Mode II to Mode I Refer to EC 32 EC 30 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Malfunction Indicator Lamp MIL 1 The malfunction indicator lamp will light up when the ignition a A switch is turned ON without the engine running This is a bulb check H CHECK e If the m
72. RMINALS AND REFERENCE VALUE Remarks Specification data are reference values and are measured between each terminal and ECCS ground with a voltmeter TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR i NO Signal Ignition switch ON BATTERY VOLTAGE 11 14V m Di Accelerator position switch Accelerator pedal fully released Idle Ignition switch ON Approximately OV L_ Accelerator pedal depressed Ignition switch ON Approximately OV sk ma Accelerator position switch Accelerator pedal released Full Ignition switch ON BATTERY VOLTAGE L_ Accelerator pedal fully depressed 11 14V EC 165 Hab 316 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS Accelerator Position Switch Cont d EC ACL SW 01 BATTERY mm Detectable line for DTC Refer to EL POWER 7 5A Non detectable line for DTC D LHD models RD RHD models L To EC MAIN MAFS wap GOVNR FCUT ACCELERATOR POSITION SWITCH ED v29 lt B gt MODULE Refer to last page Foldout page 20 E127 Ka GED W Ce BR F1 GY GY PAS EEE TEC444 EC 166 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS Accelerator Position Switch Cont d DIAGNOSTIC PROCEDURE INSPECTION START yx MONITOR NOFAIL OFF ON FULL ACCEL SW OFF ACCEL SW CHECK OVERALL FUNCTION 1 Turn ignition switch ON 2 Select FULL ACC
73. ROUBLE DIAGNOSIS FOR I C INT A TEMP SEN DTC 33 E o D ES a o ss o 2 sig S 5 8 E z Do A Z E g ELA Di E E S zn A ex 8roo 2 FEOS uy SIS gt lu Ba cono en 2 ZS no m 7 5 8 O ru 6 E D e UI tn pil a ze lt lt WW or Ou es V OF EE DE GIS AS E E We fea Gs CIS EC 123 TROUBLE DIAGNOSIS FOR I C INT A TEMP SEN DTC 33 Charge Air Temperature Sensor Cont d N P di N Charge air temperature sensor harness connector v DIAGNOSTIC PROCEDURE INSPECTION START CHECK POWER SUPPLY NG Repair harness or connec 1 Turn ignition switch OFF tors 2 Disconnect charge air temperature sen sor harness connector 3 Turn ignition switch ON 4 Check voltage between terminal 2 and ground with CONSULT or tester Voltage Approximately 5V OK CHECK GROUND CIRCUIT m Check the following 1 Turn ignition switch OFF e Harness connectors 2 Check harness continuity between ter CES ist minal and engine ground e Harness connectors Continuity should exist WEN If OK check harness for short to e Harness for open or ground and short to power short between ECM and charge air temperature OK sensor e 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 Y CHECK COMPONENT Na Replace charge air t
74. S st minal ei and engine ground e Harness connectors Continuity should exist 88 If OK check harness for short to e Harness for open or ground and short to power short between ECM and adjustment resistor OK e 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 Y CHECK COMPONENT e Replace adjustment resis Adjustment resistor tor Refer to COMPONENT INSPECTION on next page Disconnect and reconnect harness con nectors in the circuit Then retest OK Trouble is not fixed Check ECM pin terminals for damage and check the connection of ECM harness connector Reconnect ECM harness connector and retest INSPECTION END EC 94 TROUBLE DIAGNOSIS FOR ADJUST RESISTOR DTC 17 Adjustment Resistor Cont d COMPONENT INSPECTION Adjustment resistor Check resistance between terminals 2 and Resistance Approximately 0 2 15 0 kQ at 25 C 77 F 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 DISCONNECT Electronic fuel injection pump 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 electroni
75. SPS Cont d EC CSPS 01 Rm Detectable line for DTC Non detectable line for DTC OINT ONNECTOR 4 INJECTION PUMP CONTROL SLEEVE POSITION SENSOR Ox L co dk m o n N NA a LI Dee ED F19 CEt ED ar EC 89 TEC427 TROUBLE DIAGNOSIS FOR CONT SLEEV POS SEN DTC 15 Electronic fuel injection pump harness connector Control sleeve position sensor Ze XS uw A SEF679V KA CONNECTOR ATID Seel D 53 57 a ECM SEF744V Le DISCONNECT dE O AE KA arm 63 67 SEF745V DISCONNECT amp x DISCONNECT AE O MES Ka Ecm o coNNECTOR ATID SAA 66 SEF746V Control Sleeve Position Sensor CSPS Cont d DIAGNOSTIC PROCEDURE INSPECTION START CHECK POWER SUPPLY CIRCUIT 1 Turn ignition switch OFF 2 Disconnect ECM harness connector and electronic fuel injection pump har ness connector 3 Check harness continuity between ter minal 2 and ECM terminals 3 Continuity should exist If OK check harness for short to ground and short to power Repair open circuit or short to ground or short to power in harness or connectors CHECK INPUT SIGNAL CIRCUIT Check harness continuity between sensor terminal 3 and ECM terminals 63 6 Continuity should exist If OK check harness for short to ground and short to power Repair open ci
76. TA MINAL ITEM CONDITION DC Voltage and Pulse COLOR l NO Signal Ignition switch ON C oV Heat up switch is OFF 59 BR W Heat up switch Ignition switch ON BATTERY VOLTAGE L Heat up switch is ON 11 14V EC 183 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS Heat Up Switch Cont d EC HEATUP 01 IGNITION SWITCH ON or START 2 10A FUSE BLOCK Refer to EL POWER J B MEE Detectable line for DTC Non detectable line for DTC WB QD LHD models lt R gt RHD models Fee L B p To EL ILL L B W B W 5 BR W BR W B B ECM o LL L MODULE lt gt M3 n Refer to last page Foldout page EC 184 TEC447 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS x NOFAIL O yx MONITOR WARM UP SW OFF RECORD Heat Up Switch Cont d DIAGNOSTIC PROCEDURE INSPECTION START SEF804V CONNECT KI amp 59 DISCONNECT HOL oja ro Le eo CHECK OVERALL FUNCTION 1 Turn ignition switch ON 2 Check WARM UP SW signal in DATA MONITOR mode with CONSULT Heat up switch is ON ON Heat up switch is OFF OFF OR Check voltage between ECM terminal and ground under the following condition Voltage Heat up switch is ON Battery voltage Heat up switch is OFF Approximately 0V Po CHECK POWER SUPPLY 1 Turn heat up switch OFF 2 Turn i
77. age Vehicle speed sensor Cooling fan control Cooling fan relay Air conditioner switch Mass air flow sensor gt Air conditioning cut control Air conditioner relay Charge air temperature sensor Heat up switch a Charge air cooler fan control Charge air cooler fan relay EC 14 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Fuel Injection System SYSTEM DESCRIPTION Three types of fuel injection control are provided to accommodate engine operating conditions normal control idle control and start control The ECM determines the appropriate fuel injection control Under each control the amount of fuel injected is compensated to improve engine performance The ECM performs duty control on the electric governor built into the fuel injection pump according to sensor signals to compensate the amount of fuel injected to the preset value START CONTROL Input output signal line Engine coolant temperature Engine coolant temperature sensor Crankshaft position sensor TDC Engine speed Electric governor Ignition switch Ce Control sleeve position Control sleeve position sensor When the ECM receives a start signal from the ignition switch the ECM adapts the fuel injection system for the start control The Engine coolant amount of fuel injected at engine starting is a preset program value Emmet ii in the ECM The pr
78. aiz Le e 2 I L z VIS 85 Reha Es e ELO m do DE EZ GIS zo DE GIS Ee TEC448 EC 188 SERVICE DATA AND SPECIFICATIONS SDS General Specifications Unit rpm Injection pump numbers E SEN Engine Part number ibo Maximum engine speed 5 400 RD28ETi 16700 VB300 104721 2000 Injection Nozzle INSPECTION AND ADJUSTMENT Adjusting shims Injection nozzle assembly Thickness mm in Parts No 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 New 14 711 15 495 147 1 155 0 0 62 0 0244 16613 V0706 Eeer 0 66 0 0260 16613 V0708 0 70 0 0276 16613 V0710 0 74 0 0291 16613 V0712 0 78 0 0307 16613 V0714 0 82 0 0323 16613 V0716 0 86 0 0339 16613 V0718 0 90 0 0354 16613 V0720 0 94 0 0370 16613 V0722 0 98 0 0386 16613 V0724 1 00 0 0394 16613 V0760 Inspection and Adjustment Bits E edel E TEMPERATURE Temperature C F Resistance kQ 20 68 21 29 CAMSHAFT POSITION SENSOR PUMP 50 122 0 68 1 00 Resistance at 25 C 77F Q 1 360 1 840 90 194 0 236 0 260 CONTROL SLEEVE POSITION SENSOR Resistance at 23 C 73 F Q 5 9 EC 189 SERVICE DATA AND SPECIFICATIONS SDS Inspection and Adjustment Cont d ADJUSTMENT RESISTOR ACCELERATOR POSITION SENSOR Resistance at 25 C 77 F KQ 0 2 15 0 Resistance kQ Throttle valve conditions at 25 C 77 F Completely c
79. alfunction indicator lamp does not light up refer to EL section WARNING LAMPS AND CHIME or see EC 188 S x 2 When the engine is started the malfunction indicator lamp J N should go off If the lamp remains on the on board diagnostic system has detected an engine system malfunction serosip If MIL illuminates or blinks irregularly after starting engine water may have accumulated in fuel filter Drain water from fuel filter ON BOARD DIAGNOSTIC SYSTEM FUNCTION The on board diagnostic system has the following three functions 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 Refer to HOW TO SWITCH DIAGNOSTIC TEST MODES on next page Diagnostic Diagnostic Condition Test Mode Test Mode II Engine stopped SELF DIAGNOSTIC BULB CHECK Ignition switch RESULTS in ON posi A tion Engine CA running MALFUNCTION 8 i WARNING EC 31 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Malfunction Indicator Lamp MIL Cont d HOW TO SWITCH DIAGNOSTIC TEST MODES ES Turn ignition switch ON Do not start engine A NG Diagnostic Test Mode BULB CHECK Refer to previous page gt MIL should come
80. an ECM system malfunction due to receiving external noise degraded operation of ICs etc e Keep ECM parts and harnesses dry e Before removing parts turn off ignition switch and then disconnect battery ground cable SEF656V EC 5 PRECAUTIONS AND PREPARATION Precautions e 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 Tightened ES e When connecting ECM harness connector tighten secur ing bolt until the gap between orange indicators disap pears wei 3 0 5 0 N m 0 3 0 5 kg m 26 43 in Ib SEF308Q e When connecting or disconnecting pin connectors into or from ECM take care not to damage pin terminals bend or break Make sure that there are not any bends or breaks on ECM pin terminal when connecting pin connectors m MN e Before replacing ECM perform Terminals and Reference Perform EGM in Value inspection and make sure ECM functions properly put output signal inspection before Refer to EC 54 replacement S EIE Do E O MEF040D e If MIL illuminates or blinks irregularly when engine is running water may have accumulated in fuel filter Drain 7 water from fuel filter If this does not correct the problem nS Pd perform specified
81. art and warm up engine After engine has warmed up JS idle for 10 minutes EC 143 TROUBLE DIAGNOSIS FOR CRANK POS SEN TDC DTC 47 Crankshaft Position Sensor TDC The crankshaft position sensor TDC monitors engine speed by means of signals from the sensing plate with two protrusions installed to the crankshaft pulley The datum signal output is detected at ATDC 70 and sent to the ECM The sensor signal is used for fuel injection control and fuel injection timing control CONSULT REFERENCE VALUE IN DATA MONITOR MODE Remarks Specification data are reference values MONITOR ITEM CONDITION SPECIFICATION e Tachometer Connect TES Almost the same speed as the CKPS RPM TDC o de reli and compare tachometer indication with the CONSULT CONSULT value ECM TERMINALS AND REFERENCE VALUE Remarks Specification data are reference values and are measured between each terminal and ECCS ground with a voltmeter TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR NO Signal Approximately OV Engine is running Warm up condition ES Idle speed 40 L Crankshaft position sensor SEF720V 44 TDC Approximately OV Engine is running Warm up condition E Engine speed is 2 000 rpm SEF721V T Engine is running Warm up condition 47 B W Crankshaft position sensor Approximately OV 52 TDC ground Idle speed ON BOARD DIAGNOSIS LOGI
82. ater the retard angle This means that chang ing the ON OFF duty ratio makes it possible to achieve an optimal advance angle and accurately control fuel injection timing CONSULT REFERENCE VALUE IN DATA MONITOR MODE Remarks Specification data are reference values MONITOR ITEM CONDITION SPECIFICATION e Air conditioner switch OFF dii l ACT INJ TIMG A e Shift lever N e No load 2 000 rpm 10 0 to 15 5 INJ TIMG C V e Engine After warming up idle the engine Approx 50 ECM TERMINALS AND REFERENCE VALUE Remarks Specification data are reference values and are measured between each terminal and ECCS ground with a voltmeter TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR NO Signal BATTERY VOLTAGE 11 14V Engine is running Warm up condition L Idle speed 104 uw Injection timing control SEF729V 110 valve BATTERY VOLTAGE 11 14V Engine is running Warm up condition L Engine speed is 2 000 rpm SEF730V EC 101 TROUBLE DIAGNOSIS FOR F INJ TIMG F B DTC 21 Injection Timing Control Valve Cont d ON BOARD DIAGNOSIS LOGIC Diagnostic Check Items Trouble Code Malfunction is detected when No Possible cause 21 e Injection timing feedback system does not operate e Harness or connectors properly This system consists essentially of ECM Injection timing control valve needle lift sensor injection timing control valv
83. ating area Insert injection timing control valve straight into bore in fuel pump body After properly positioning injection timing control valve visually check that fuel does not leak e After assembling the parts erase Diagnostic Trouble Code DTC and perform DTC CONFIRMATION PROCEDURE or OVERALL FUNCTION CHECK EC 29 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION DTC and MIL Detection Logic When a malfunction is detected for the first time the malfunction DTC is stored in the ECM memory The MIL will light up each time the ECM detects malfunction However if the same malfunction is experienced in two consecutive driving patterns and the engine is still running the MIL will stay lit up For diagnostic items causing the MIL to light up refer to DIAGNOSTIC TROUBLE CODE INDEX EC 1 Diagnostic Trouble Code DTC HOW TO READ DTC The diagnostic trouble code can be read by the following methods 1 The number of blinks of the malfunction indicator lamp in the Diagnostic Test Mode II Self Diagnostic Results Examples 11 13 14 etc These DTCs are controlled by NISSAN 2 CONSULT Examples CAM POS SEN PUMP etc e Output of the trouble code means that the indicated circuit has a malfunction However in the Mode Il it does not indicate whether the malfunction is still occurring or occurred in the past and returned to normal CONSULT can identify them Therefore using CONSULT if available is recommended HOW TO E
84. ble line for DTC OINT ONNECTOR 4 INJECTION PUMP CAMSHAFT POSITION SENSOR PUMP B B B F9 e dk o SE N o cus o L E NI 11111 Go BE GY GY 24es as 5selsolod TEC423 EC 71 TROUBLE DIAGNOSIS FOR CAM POS SEN PUMP DTC 11 Camshaft Position Sensor CMPS PUMP Cont d VW H CH SE e gt DIAGNOSTIC PROCEDURE XA Do T 4 ex OH eh A C TS JA INSPECTION START ASW EA Fe aos A Electronic fuel US lt lt lt injection pump SEPT harness connector AES c SC NG Camshaft position gt CHECK INPUT SIGNAL CIRCUIT Repair open circuit or short sensor PUMP E 1 Turn ignition switch OFF to ground or short to power 2 SE E A A 2 Disconnect electronic fuel injection in harness or connectors X P peer SEF675V pump harness connector and ECM har ness connector 3 Check harness continuity between ter DISCONNECT DISCONNECT minal 1 and ECM terminals o En Continuity should exist HS TS If OK check harness for short to Ka round and short to power ECM o connector 41 45 OK es CHECK GROUND CIRCUIT I NA Repair open circuit or short 1 Turn ignition switch OFF to ground or short to power 2 Check harness continuity between ter in harness or connectors SE minal 2 and ECM terminals 3 CNET GE Continuity should ex
85. c fuel injection pump It moves the control sleeve to increase or decrease the amount of fuel injected When current flows through the coil a magnetic force is produced rotating the rotor The rotor shaft is installed to the control sleeve via a ball pin which is eccentrically situated in relation to the rotor shaft With this arrangement the control sleeve can be moved in relation to rotor rotation The rotor s rotating angle is determined by a balanced condition of magnetic force generated by current flow regulated by means of the ECM and tension of return spring installed to rotor The larger the current flow through the coil the greater the rotor s rotating angle This means that the control sleeve moves to the right increasing the amount of fuel injected Return spring SCH 8 QQ The ECM regulates the current flow through the coil by changing S the duty ratio which controls the ON OFF operation of the electric governor grounding circuit RN YY Decrease Increase Control sleeve SEF632S ECM TERMINALS AND REFERENCE VALUE Remarks Specification data are reference values and are measured between each terminal and ECCS ground with a voltmeter TER WIRE DATA MINAL COLOR ITEM CONDITION DC Voltage and Pulse NO Signal Ignition switch ON Ignition switch OFF 0 1 5V L For a few seconds after turning ignition switch 4 B Y ECCS relay S
86. ccelerator position sen sor OK If NG repair open circuit or short to ground or short to DISCONNECT power in harness or con p BJ GA nectors 312 CHECK COMPONENT NA 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 Trouble is not fixed DISCONNECT Yn DISCONNECT i 24 y Check ECM pin terminals for damage and check the connection of ECM harness ED connector Reconnect ECM harness con SS nector and retest INSPECTION END SEF773V EC 142 TROUBLE DIAGNOSIS FOR ACCEL POS SENSOR DTC 43 gt DISCONNECT NI af Accelerator Position Sensor Cont d COMPONENT INSPECTION Accelerator position sensor 1 Disconnect accelerator position sensor harness connector 2 Make sure that resistance between terminals 2 and 3 changes when depressing accelerator pedal manually Accelerator pedal conditions Resistance at 25 C 77 F Completely released Approximately 0 5 kQ 0 5 4kQ Partially depressed Completely depressed Approximately 4 kQ If NG replace accelerator pedal assembly 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 DU uss E St
87. ckwise 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 i OK stops 6 Turn crankshaft clockwise and set the INSPECTION END nna i injection timing mark on the crankshaft Timing indicator pulley to the timing indicator Ge 7 Read plunger lift amp d timing mark Plunger lift Injection 0 92 0 04 mm 0 0362 0 0016 in timing mark When repeating the checking start with step 5 SEF664V HS NIncrease Ge A ADJUSTING L wl Goto AY 1 If plunger lift is not within the specified value adjust by turning injection pump e If indication is smaller than the speci fied value turn pump body away from engine e If indication is larger than the speci fied value turn pump body towards engine 2 Tighten injection pump securing bolts and nuts Nut o 16 24 N m 1 6 2 1 kg m 12 15 ft Ib Bolt o 22 29 Nm 2 2 3 0 kg m 16 22 ft Ib 3 Remove dial gauge and install air bleeder with new washer 4 Install injection tubes Flare nut o 22 25 Nm 2 2 2 5 kg m 16 18 ft lb 5 Bleed air from fuel system SEF66ev 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 Symptom Matrix Chart SYMPTOM HARD NO START RESTART EXCP HA
88. connectors terminal and relay terminal WEN Continuity should exist e Harness for open or If OK check harness for short to ground short between ECM and and short to power ECCS relay OK If NG repair open circuit or short to ground or short to power in harness or con nectors CHECK ECCS RELAY ouo Replace ECCS relay 1 Apply 12V direct current between relay terminals and 2 2 Check continuity between relay termi nals 3 and and 12V O applied Continuity exists No voltage applied No continuity y OK EC 67 TROUBLE DIAGNOSIS FOR POWER SUPPLY Main Power Supply and Ground Circuit E Cont d DISCONNECT h MEA ECM O CONNECTOR 89 43 106 112 118 CHECK GROUND CIRCUIT ke Check the following 1 Turn ignition switch OFF e Joint connector 2 Disconnect ECM harness connector e Harness for open or 3 Check harness continuity between ECM short between ECM and terminals 106 112 ground 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 dE 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 Camshaft Position Sensor CMPS PUMP The camsha
89. e Approximately 0 8 1 2 kQ at 25 C 77 F If NG replace crankshaft position sensor TDC 21 7 Ee sensor p n uu STS E gei 7 E EC 148 TROUBLE DIAGNOSIS FOR GOV CUT CIRCUIT DTC 48 Governor Cut Circuit ON BOARD DIAGNOSIS LOGIC This diagnostic procedure checks whether or not fuel cut is being performed during deceleration Signals from the accelerator switch and camshaft position sensor PUMP are sent to the ECM The ECM uses these signals to control the electric governor operation 5 Accelerator position Accelerator switch F C Electric Engine speed governor Camshaft position sensor PUMP Diagnostic Check Item Trouble Code Malfunction is detected when Possible Cause No 48 Accelerator switch circuit is shorted e Harness or connectors e Crankshaft position sensor PUMP or ECM is mal Accelerator switch F C and camshaft position sen functioning sor PUMP circuits Accelerator switch F C e Camshaft position sensor PUMP e ECM DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE Note If both DTC 48 and 11 or 23 are displayed perform TROUBLE DIAGNOSIS FOR DTC 11 or 23 See EC 69 or 106 1 Turn ignition switch ON 2 Select DATA MONITOR mode with CONSULT 3 Startengine and run it to 3 000 rpm then quickly release accelerator pedal E E 1 Start engine and run it to 3 000 rpm then quickly release 3 accelerator pedal 2
90. e and needle lift sensor crankshaft position sensor TDC circuits e Injection timing control valve Needle lift sensor e Crankshaft position sensor TDC e Air in fuel line DIAGNOSTIC TROUBLE CODE CONFIRMATION x MONITOR sx NOFAIL Cl PROCEDURE Note If both DTC 21 and 34 or 47 are displayed perform TROUBLE DIAGNOSIS FOR DTC 34 or 47 See EC 126 or EC 144 1 Turn ignition switch ON and select DATA MONITOR 2 CKPS RPM TDC 3000rpm COOLAN TEMP S 80 C mode with CONSULT Start engine and warm it up to normal operating tem perature RECORD 3 Run engine for 2 seconds at 3 000 rpm Return engine SEF751V speed to idle then increase to 3 000 rpm under no load E 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 Tur ignition switch OFF wait at least 5 seconds and then turn ON 4 Perform Diagnostic Test Mode l 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 102 TROUBLE DIAGNOSIS FOR F INJ TIMG F B DTC 21 Injection Timing Control Valve Cont d EC TCV 01 Rm Detectable line for DTC Non detectable line for DTC IGNITION SWITCH ON or START FUSE BLOCK E JB Refer to EL POWER INJECTION PUMP INJECTION TIMING
91. e speed Approximately O 4 8V 36 LG Charge air temperature Engine is running Output voltage varies with sensor f charge air temperature Engine is running 37 P B A T signal No 2 E 6 8V Idle speed Ignition switch OFF DV 38 B Y Ignition switch BATTERY VOLTAGE Ignition switch ON 11 14V Engine ground Engine is running P hi inal with 39 B ECCS ground ah is bus wit 43 Idle speed O tester probe when EC 58 measuring TROUBLE DIAGNOSIS General Description ECM Terminals and Reference Value Cont d TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR NO Signal Approximately OV Engine is running Warm up condition L Idle speed 40 Crankshaft position sensor SEPT ES TDC Approximately OV Engine is running Warm up condition D Engine speed is 2 000 rpm SEF721V Approximately OV Engine is running Warm up condition L Idle speed 41 w Camshaft position sensor SEF 722V 45 PUMP Approximately 0V Engine is running Warm up condition L Engine speed is 2 000 rpm SEF723V 42 L G Engine is running Approximately OV Data link connector for f 64 YG CONSULT L ide speed CONSULT is connected and Approximately 0 12V 65 Y R turned on Approximately 0 9V Approximately 0 4 6V 46 Y Adjustment resistor Ignition switch O
92. econnect ECM harness connector and retest INSPECTION END EC 118 TROUBLE DIAGNOSIS FOR OVER HEAT DTC 28 Cooling Fan Overheat Cont d CHECK COOLING SYSTEM FOR LEAK NO Check the following for Apply pressure to the cooling system with gt leak a tester and check if the pressure drops e Hose Testing pressure e Radiator 157 kPa 1 57 bar 1 6 kg cm 23 psi e Water pump Pressure should not drop Refer to LC section Water CAUTION Pump Higher than the specified pressure may cause radiator damage CHECK RADIATOR CAP NG Replace radiator cap Apply pressure to cap with a tester Radiator cap relief pressure 78 98 kPa 0 78 0 98 bar 0 8 1 0 kg cm 11 14 psi ikg CHECK THERMOSTAT NG Replace thermostat 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 82 C 180 F standard Maximum valve lift More than 10 mm 95 C 0 39 in 203 F 3 Check if valve is closed at 5 C 9 F below valve opening temperature For details refer to LC section Thermo stat 1 OK SLC343 Check engine coolant temperature sensor NG Replace engine coolant Refer to COMPONENT INSPECTION temperature sensor EC 82 If the cause cannot be isolated go to MA
93. ecurely pp e Do not bump glow plug heating element If it is bumped replace glow plug with new one If glow plug is dropped Glow harness from a height of 10 cm 3 94 in replace with new one Connecting plate e If glow plug installation hole is contaminated with carbon remove using a reamer or suitable tool Washer e Hand tighten glow plug by turning it two to three times Spring washer then tighten using a tool to specified torque 3 15 20 N m 1 5 2 0 kg m 11 14 ft lb Glow plug SEC565B EC 155 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS EGRC Solenoid Valve A B and Throttle Control Solenoid Valve SYSTEM DESCRIPTION Camshaft position sensor TDC Engine speed gt EGRC solenoid valve A Accelerator position sensor Accelerator position gt EGRC solenoid valve B ECM ECCS D Engine coolant temperature sensor Engine coolant temperature gt control Throttle control solenoid valve module Ignition switch Start signal gt Mass air flow sensor EE gt 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 EGR
94. ed Engine is running Warm up condition 50 B Sensors ground Approximately 0V ON BOARD DIAGNOSIS LOGIC Diagnostic Trouble Code No Malfunction is detected when E Idle speed Check Items Possible Cause e An excessively high or low voltage from the sensor is e Harness or connectors sent to ECM The sensor circuit is open or shorted e Mass air flow sensor EC 74 TROUBLE DIAGNOSIS FOR MASS AIR FLOW SEN DTC 12 Mass Air Flow Sensor MAFS Cont d DIAGNOSTIC TROUBLE CODE CONFIRMATION MONITOR ze NOFAIL LI PROCEDURE CKPS RPM TDC 780rpm 1 Turn ignition switch ON and wait at least 6 seconds MAS AIR FL SE 1 95V 2 Select DATA MONITOR mode with CONSULT Start engine and wait at least 3 seconds OR _ Turn ignition switch ON and wait at least 6 seconds Start engine and wait at least 3 seconds Turn ignition switch OFF wait at least 5 seconds and RECORD Ger RECORD 4 Perform Diagnostic Test Mode l Self diagnostic SEF735V 1 results with ECM EC 75 TROUBLE DIAGNOSIS FOR MASS AIR FLOW SEN DTC 12 Mass Air Flow Sensor MAFS Cont d e 0 Ed p E gt o DH EE I O o O 5 LLI o 2 3 oo 22 Ss o o UD 9c o az ke LL z o D a LL 2 o Kg tr SE BATTERY lt A gt A T models CONTROL MODULE TRANSMISSION E102 TCM SENS GND B I E106 5
95. ed 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 ll 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 Il to Diagnostic Test Mode Refer to HOW TO SWITCH DIAGNOS TIC TEST MODES on previous page e If the battery terminal is disconnected the diagnostic trouble code will be lost from the backup memory within 24 hours e Be careful not to erase the stored memory before starting trouble diagnoses e Ifthe MIL blinks or NATS MALFUNCTION is displayed on E sELF DiaG RESULTS ML SELF DIAG RESULTS screen perform self diagnostic FAILURE DETECTED TIME results mode with CONSULT using NATS program card NATS MALFUNCTION 0 NATS E940 Refer to EL section e Confirm no self diagnostic results of NATS is displayed before touching ERASE in SELF DIAG RESULTS mode with CONSULT e When replacing ECM initialisation of NATS V2 0 system and registration of all NATS V2 0 ignition key IDs must be ERASE PRINT faces CONSULT using NATS program card Se 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 DIAGNOST
96. elf shutoff OFF Ignition switch OFF C BATTERY VOLTAGE A few seconds passed after turning ignition 11 14V switch OFF 101 Engine is running BATTERY VOLTAGE R B Electric governor C 41 14V 107 Idle speed Vie EC 96 TROUBLE DIAGNOSIS FOR F INJ F B 2 DTC 18 F INJ F B DTC 22 ELECTRIC GOV DTC 25 Electric Governor Cont d TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR NO Signal Approximately 10V Engine is running D Idle speed 102 SEF727V G Y Electric governor ground 108 Approximately 10V Engine is running L Engine speed is 2 000 rpm SEF728V 116 A BATTERY VOLTAGE 117 Ww Power supply for ECM Ignition switch ON 11 14V ON BOARD DIAGNOSIS LOGIC Diagnostic heck I Trouble Code Malfunction is detected when 7 FS teme Possible cause No 18 22 25 e Fuel injection feedback system does not operate prop e Main power supply circuit ECM terminals 116 117 erly This system consists essentially of ECM electric and fuse governor and control sleeve position sensor e Harness or connectors Electric governor and control sleeve position sensor circuit e Electric governor e Electronic fuel injection pump e ECM EC 97 TROUBLE DIAGNOSIS FOR F INJ F B 2 DTC 18 F INJ F B DTC 22 ELECTRIC GOV DTC 25 Electric Governor Cont d DIAGNOSTIC TROUBLE CODE CONFIRMATION
97. em Charge air temperature sensor perature sensor Refer to COMPONENT INSPECTION on next page KS Disconnect and reconnect harness con nectors in the circuit Then retest Trouble is not fixed Check ECM pin terminals for damage and check the connection of ECM harness connector Reconnect ECM harness con nector and retest INSPECTION END EC 124 TROUBLE DIAGNOSIS FOR I C INT A TEMP SEN DTC 33 SEF152P Resistance kQ o Oo 0 O gt m 2 m BR OO wm ROOO 100 212 Acceptable 20 0 20 40 60 80 4 32 68 104 140 176 Temperature C F SEF012P Charge Air Temperature Sensor Cont d COMPONENT INSPECTION Charge air temperature sensor Check resistance as shown in the figure Temperature C F Resistance kQ 20 68 21 29 50 122 0 68 1 0 90 194 0 236 0 260 If NG replace charge air temperature sensor EC 125 TROUBLE DIAGNOSIS FOR NEEDLE LIFT SEN DTC 34 Needle Lift Sensor NLS The needle lift sensor is built into the No 1 injection nozzle Its piezoelectric element senses changes in fuel injection timing caused by fuel temperature etc This change of fuel injection tim ing is sent as a pulse signal to the ECM Piezoelectric element SEF604S ECM TERMINALS AND REFERENCE VALUE Remarks Specification data are reference values and are measured between each terminal and ECCS ground wit
98. embly or dis tance piece e Check distance piece and nozzle holder for proper contact If excessively worn or damaged replace distance piece or nozzle holder e Check nozzle spring for excessive wear or damage If exces sively worn or damaged replace it with a new spring Cleaning No 2 4 nozzles a Do not touch the nozzle mating surface with your fingers b To wash the nozzles use a wooden stick and brass brush with clean diesel fuel 1 Remove any carbon from exterior of nozzle body except wrap s ping angle portion by using Tool LA D d e SEF830 2 Clean oil sump of nozzle body using Tool KV11290122 SEF831 3 Clean nozzle seat by using Tool This job should be performed with extra precautions since efficiency of nozzle depends greatly on a good nozzle seat SEF832 EC 23 INJECTION NOZZLE Cleaning No 2 4 nozzles Cont d 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 5 Decarbonate nozzle needle tip by using Tool KV11290140 SEF834 6 Check needle sinking 1 Pull needle about halfway out from body and then release it 2 Needle should sink into body very smoothly from just its own weight 3 Repeat this test and rotate needle slightly each time If needle fails to sink smoothly from any position
99. en ECM C OZ terminal and TCM terminal 3 e Harness connectors Continuity should exist 21 If OK check harness for short to ground e Harness for open or short and short to power between ECM and TCM OK If NG repair open circuit or short to ground or short to power in harness or con nectors CHECK COMPONENT NG Replace inhibitor switch H Inhibitor switch Refer to AT section Disconnect and reconnect harness connec tors in the circuit Then retest i Trouble is not fixed Check ECM pin terminals for damage or the connection of ECM harness connector Reconnect ECM harness connector and retest INSPECTION END EC 174 ground with a voltmeter 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 ECCS TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR NO Signal Engine is running 24 PU W A T signal No 1 6 8V L Idle speed Engine is running 30 P A T signal No 3 Approximately OV L Idle speed Engine is running 37 P B A T signal No 2 L Idle speed EC 175 6 8V TROUBLE DIAGNOSES FOR NON DETE
100. 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 Electric governor CRANKCASE VENTILATION SYSTEM Description Baffle plate In this system blow by gas is sucked into the air inlet pipe through Rocker cover Blow by control valve the control valve after oil separation by oil separator in the rocker Intake manifold cover Blow by gas lt Fresh air SEF456HA Inspection eege BLOW BY CONTROL VALVE a Check control valve for clogging and abnormalities eN ME Intake e 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 e Do not disassemble No 1 nozzle with needle lift sensor built in If NG replace No 1 injection nozzle e Plug flare nut with a cap or rag so that no dust enters the nozzle Cover nozzle tip for protection of needle
101. erature increases SEF666S m lt Reference data gt 1 i 8 engine gra temper Voltage Resistance 4 3 f Acceptable C F V kQ o 19 20 4 4 6 13 67 16 37 Ss 20 68 3 5 2 306 2 568 0 2 60 140 1 8 0 538 0 624 20 0 20 40 60 80 100 80 176 1 2 0 289 0 344 4 32 68 104 140 176 212 Temperature C F SEFO12P ECM TERMINALS AND REFERENCE VALUE Remarks Specification data are reference values and are measured between each terminal and ECCS ground with a voltmeter TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR NO Signal Approximately O 4 8V 10 P Fuel temperature sensor Engine is running Output voltage varies with fuel temperature Engine is running Warm up condition 50 B Sensors ground E Approximately OV Idle speed ON BOARD DIAGNOSIS LOGIC Diagnostic Trouble Code No Check Items Malfunction is detected when Possible Cause 42 e An excessively high or low voltage from the sensor is e Harness or connectors detected by ECM The sensor circuit is open or shorted e Fuel temperature sensor DIAGNOSTIC TROUBLE CODE CONFIRMATION x MONITOR x NOFAIL L PROCEDURE 1 Turn ignition switch ON CKPS RPM TDC Orpi Select DATA MONITOR mode with CONSULT Wait at least 5 seconds pf oo e _ E 1 Turn ignition switch ON and wait at least 5 seconds Turn ig
102. ess connector and retest INSPECTION END COMPONENT INSPECTION y PA Heat up switch p 1 Disconnect heat up switch harness connector 2 Check continuity between terminals and Condition Continuity Yes Heat up switch ON Er Heat up switch OFF sersosv If NG replace heat up switch No EC 186 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS Air Conditioner Control EC A CCUT 01 IGNITION SWITCH ON FUSE BLOCK Refer to EL POWER J B ve Er MEE Detectable line for DTC THERMISTOR Non detectable line for DTC With A C e CONTROL R R L CONDITIONER To RELAY L G gt HAACM DD ge YL YB B Y B gt To COMPRESSOR NORMAL DUAL PRESSURE SWITCH ED lt A gt O HIGH ECM ACRLY ECOS D MODULE Refer to last page Foldout page TEC446 EC 187 MIL amp Data Link Connectors TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS 01 E H gt bg g 18 o Ol s a 206 z gell aug Oo 5 a Ez a E 3 2 LOO E Zz 0 m gt a OO OQ E 1 E 5 50 S o 2 uy als LUI o g S lu 58 2 9705 EC a9 2 lai 3 nom els o c 7 oOo os OED amp 2 S928 2 2277 Quos DC l l l l l l l l l l l Sz gt g i e f ya al ice 2 QI 5 1 Ed l m fa l a ER ea e Ge o s bs 8 5 CIS 88 3 E Gs Ee T Zug a Az E OS L gt lu 5 d Lal H Ma 55 o r
103. ft position sensor PUMP is located on the electronic fuel injection pump The sensor consists of a permanent magnet core and coil When engine is running gap between sensor and drive shaft rotat ing plate will periodically change Permeability near the sensor also changes Due to the permeability change the magnetic flux near the core is Camshaft position h d Th f th It ted in th ili sensor PUMP changed Therefore the voltage signal generated in the coil is changed seF674v The ECM receives the voltage signal 6 pulses 2 engine revolu tions These signals are used for tachometer indication CONSULT REFERENCE VALUE IN DATA MONITOR MODE Remarks Specification data are reference values MONITOR ITEM CONDITION SPECIFICATION CKPS RPM REF e Tachometer Connect Almost the same speed as the CONSULT value e Run engine and compare tachometer indication with the CONSULT CKPS RPM PUMP value ECM TERMINALS AND REFERENCE VALUE Remarks Specification data are reference values and are measured between each terminal and ECCS ground with a voltmeter TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR t NO Signal 28 Camshaft position sensor Engine is running Warm up condition B C Approximately 0V 33 PUMP ground Idle speed Approximately OV Engine is running Warm up condition B Idle speed 41 w Camshaft position sensor SEF722V
104. 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 Control sleeve position sensor Control sleeve position Accelerator switch F C Meco Breton postion ECM Electric governor Engine speed Camshaft position sensor PUMP 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 Fuel Injection Timing System SYSTEM DESCRIPTION The fuel injection timing system provides the optimal fuel injection timing for the target amount of fuel injected according to engine speed The timing is compensated when the vehicle is being driven or when starting depending on the engine coolant temperature The ECM performs duty control on the timing control valve allowing the valve to provide optimal fuel injection timing The ECM also performs feedback control on the timing control valve using the signal from the needle lift sensor which detects the actual fuel injection timing BASIC CONTROL Input output signal line Engine speed Crankshaft position sensor TDC m t ECM timing con Needle lift
105. g engine from idle to 2 600 rpm Battery voltage 3 Check voltage between ECM terminal CO and ground under the following conditions Voltage At idle 0 1V Revving engine from idle to 2 500 rpm Battery voltage OK CHECK VACUUM HOSE Check vacuum hose for clogging cracks or improper connection y NG EC 160 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS EGRC Solenoid Valve A B and Throttle Control Solenoid Valve Cont d EGRC solenoid valve B harness connector SNO Y ONES Y EGRC solenoid valve A harness connector C LL xq CHECK POWER SUPPLY NG Check the following Throttle control 1 Turn ignition switch OFF e Harness connectors Fox wave 2 Disconnect EGRC solenoid valve A B MD f N7 and throttle control solenoid valve har e 10A fuse ness connector e Harness for open or 3 Turn ignition switch ON short between EGRC 4 Check voltage between terminal 1 solenoid valve A B and and ground with CONSULT or tester fuse Voltage Battery voltage e 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 1 Turn ignition switch OFF e Harness connectors 2 Disconnect ECM harness connector E127 M21 DISCONNECT Ge PA 3 Check harness continuity between e Harness connectors GA ECM terminal 1 and terminal 2 M50
106. g fan is stopped OFF COOLING FAN e When cooling fan operates ON e When charge air cooler fan is stopped OFF I C FAN RLY e When charge air cooler fan operates ON e Engine After warming up Idle ON cancsouva ie e No load i Revving engine from idle to 3 750 rpm OFF e Engine After warming up Idle ON EGROBDUNE e E e No load i Revving engine from idle to 2 600 rpm OFF e Engine After warming up Idle ON pe i e No load i Revving engine from idle to 2 500 rpm OFF EC 52 TROUBLE DIAGNOSIS General Description Major Sensor Reference Graph in Data Monitor Mode The following are the major sensor reference graphs in DATA MONITOR mode Select HI SPEED in DATA MONITOR with CONSULT ACCEL POS SEN C SLEEV POS S ACT INJ TIMG Below is the data for ACCEL POS SEN C SLEEV POS S and ACT INJ TIMG when revving engine quickly up to 3 000 rpm under no load after warming up engine sufficiently Each value is for reference the exact value may vary 00 09 04 95 x0 1V 16 06 00 09 x0 1V 04 95 13 26 38 51 16 06 00 09 04 95 32 32 64 16 06 96 SEF663S EC 53 TROUBLE DIAGNOSIS General Description ECM Terminals and Reference Value PREPARATION 1 ECM is located behind the instrument lower panel For this inspection remove the driver s side instrument lower cover Drivers side instrument lower cover removed NOME gt SEF519V 2 Remove ECM harness p
107. gnition switch OFF 3 Disconnect heat up switch harness con nector 4 Turn ignition switch ON 5 Check voltage between terminal Ce and ground with CONSULT or tester Voltage Battery voltage SEF806V DISCONNECT amp Y DISCONNECT AE 00 24 115 5 Ecm jo coNNECTOR 59 SEF807V OK OK INSPECTION END NG Check the following e Fuse block M3 e 10A fuse e Harness for open or short between heat up switch and fuse If NG repair harness or connectors CHECK INPUT SIGNAL CIRCUIT 1 Turn ignition switch OFF 2 Disconnect ECM harness connector 3 Check harness continuity between ECM terminal and terminal Continuity should exist If OK check harness for short to ground and short to power EC 185 NG Check the following e Harness connectors WED e Harness for open or short between heat up switch and ECM If NG repair open circuit or short to ground or short to power in harness or con nectors TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS Heat Up Switch Cont d 0 CHECK COMPONENT NG Replace heat up switch Heat up switch Refer to COMPONENT INSPECTION below Disconnect and reconnect harness con nectors in the circuit Then retest Trouble is not fixed Check ECM pin terminals for damage or the connection of ECM harness connector Reconnect ECM harn
108. gnostic Trouble Code DTC Then clear Also check related service bulletins for information 2 Jqvvveeeesjeeeeeeeeeee STEP II Symptoms No symptoms except MIL collected lights up or Malfunction Code exists at STEP Il Verify the symptom by driving in the condition the cus tomer described E O AT STEP Ill Normal Code Malfunction Code at STEP Il at STEP Il INCIDENT CONFIRMATION Verify the DTC by performing the DTC CONFIRMATION PROCEDURE Choose the appropriate action T0000 eee reer ree STEP V Malfunction Code at STEP II or IV Normal Code at both STEP II and IV BASIC INSPECTION SYMPTOM BASIS at STEP or III Perform inspections according to Symptom Matrix Chart TROUBLE DIAGNOSIS FOR DTC XX STEP VI REPAIR REPLACE FINAL CHECK Confirm that the incident is completely fixed by performing BASIC INSPECTION and ii PR RARE STEP VII DTC CONFIRMATION PROCEDURE or OVERALL FUNCTION CHECK Then erase the unnecessary already fixed DTCs in ECM 1 98 CHECK OUT 1 If the incident cannot be duplicated refer to Gl 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 Description for Work F
109. gt lt o 2 2 uw 8 O o Hs o o u izi li a wlajrz Ok slo 2 0 E loli lo z ajw lt o xI lt ul zt e 2 5 a O u u r Z 2 O cz aH ct x O C z S 3 sis gEZ amp lg2aelSeesise8 2 za rjoj jo lt jojojo O e tT jao S S lt zt D Ia WOLdWAS EC 50 TROUBLE DIAGNOSIS General Description CONSULT Reference Value in Data Monitor Mode Remarks e Specification data are reference values e Specification data are output input values which are detected or supplied by the ECM at the connector Specification data may not be directly related to their components signals values operations MONITOR ITEM CONDITION SPECIFICATION CKPS RPM TDC e Tachometer Connect Almost the same speed as the CON SRPSIHPMARER e Run engine and compare tachometer indication with the CONSULT value SULT value CMPS RPM PUMP COOLAN TEMP S e Engine After warming up More than 70 C 158 F VHCL SPEED SE e Turn drive wheels and compare speedometer indication with the CONSULT Almost the same speed as value the CONSULT value FUEL TEMP SEN e Engine After warming up More than 40 C 104 F m itch Accelerator pedal released 0 40 0 60V ACCEL POS SEN e Ignition Switch ON Engine stopped Accelerator pedal depressed Approx 4 0V m oh Accelerator pedal depressed ON FULL ACCEL SW e Ignition Switch ON Engine stopped Except above OFF e Ignition switch ON Accelerator pedal
110. h a voltmeter TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR t NO Signal Approximately 0V Engine is running Warm up condition B Idle speed SEF718V 34 W Needle lift sensor Approximately OV Engine is running Warm up condition L Engine speed is 2 000 rpm SEF719V ON BOARD DIAGNOSIS LOGIC Diagnostic heck I Trouble Code Malfunction is detected when 6 ln tems Possible Cause No 34 e An improper signal from the sensor is sent to ECM e Harness or connectors The sensor circuit is open or shorted Needle lift sensor Air in fuel line Clogging No 1 injection nozzle EC 126 TROUBLE DIAGNOSIS FOR NEEDLE LIFT SEN DTC 34 Needle Lift Sensor NLS Cont d DIAGNOSTIC TROUBLE CODE CONFIRMATION x MONITOR x NOFAIL Cl PROCEDURE 1 Turm ignition switch ON and select DATA MONITOR SEET MNT mode with CONSULT 2 Start engine and run it for at least 10 seconds at idle speed A A 3 o E 1 Start engine and run it for at least 10 seconds at idle speed RECORD 2 Tur ignition switch OFF wait at least 5 seconds and SEF714V then turn ON 3 Perform Diagnostic Test Mode Il Self diagnostic results with ECM EC 127 TROUBLE DIAGNOSIS FOR NEEDLE LIFT SEN DTC 34 Needle Lift Sensor NLS Cont d EC NLS 01 ECM CONTROL MODULE ECCS D NEN Detectable line for DTC Non detectable line for
111. hat conditions they occur A Diagnostic Worksheet like the example on next page should be used Start your diagnosis by looking for conventional problems first This will help troubleshoot driveability problems on an electronically controlled engine vehicle EC 42 TROUBLE DIAGNOSIS Introduction Diagnostic Worksheet KEY POINTS There are many operating conditions that lead to the malfunction of engine components A good grasp of such conditions can make WHAT Vehicle amp engine model troubleshooting faster and more accurate WHEN Date Frequencies In general each customer feels differently about a problem It is WHERE Road conditions important to fully understand the symptoms or conditions for a HOW Operating conditions customer complaint Weather conditions Utilize a diagnostic worksheet like the one shown below in order to Symptoms organize all the information for troubleshooting SEF907L WORKSHEET SAMPLE Customer name MR MS Model amp Year VIN Engine Trans Mileage Incident Date Manuf Date In Service Date Impossible to start No combustion Partial combustion Partial combustion when engine is warm Partial combustion when engine is cool Possible but hard to start Others No fast idle Unstable High idle Low idle O Idling Symptoms Others Stumble Lack of power Others At the time of start While idling Engine stall While accelerating While decelerating Just af
112. in DATA MONITOR mode with CONSULT Accelerator pedal released OFF Accelerator pedal depressed ON OR E 1 Turn ignition switch ON By 2 Check voltage between ECM terminal and ground Voltage Accelerator pedal released Battery voltage Accelerator pedal depressed Approximately 0V I NG B CHECK GROUND CIRCUIT NG Check the following 1 Turn ignition switch OFF e Harness connectors 2 Loosen and retighten engine ground RHD mod screws els 3 Disconnect accelerator switch F C har e Joint connector ness connector e Harness for open or 4 Check harness continuity between termi short between accelera nal 3 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 CHECK INPUT SIGNAL CIRCUIT des Check the following 1 Disconnect ECM harness connector e Harness connectors 2 Check harness continuity between ECM al M51 RHD mod terminal and terminal 1 els Continuity should exist e 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 CHECK COMPONENT NS Replace accelerator pedal Accelerator switch F C assembly Refer to COMPONENT INSPECTION on nex
113. ion switch ON es 2 Select P N POSI SW in 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 and ground under the following conditions Voltage Neutral position Approximately ON Except neutral position Battery voltage y NG 0 DISCONNECT AE NO ECM O CONNECTOR 22 O L Propeller shaft Ss A SUE Neutral position switch harness connector __ m is SEF789V EC 171 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS A 9 GI AEC750 DISCONNECT pL E ECM O CONNECTOR DISCONNECT GI 22 SEF6248 CN e Park Neutral Position Switch Cont d CHECK GROUND CIRCUIT NG Check the following 1 Turn ignition switch OFF le Harness connectors 2 Disconnect neutral position switch har E202 ness connector e Harness for open or short 3 Check harness continuity between termi between neutral position nal 2 and body ground switch and body ground 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 CHECK INPUT SIGNAL CIRCUIT NG Check the following 1 D
114. 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 SS le Es Electric governor ma DISCONNECT P S oi H Electronic fuel cy cy 1 Disconnect electronic fuel injection pump harness connector injection pump um 2 Check continuity between terminals 1 and connector TR STA Resistance Approximately 0 680 at 23 C 73 F HEN If NG take proper action SEF684V EC 100 TROUBLE DIAGNOSIS FOR F INJ TIMG F B DTC 21 Timer piston Injection Timing Control Valve The injection timing control valve is built into the electronic fuel Mie 9 os High OT I Low injection pump It controls the timer piston to change the fuel injec Rise gt pressure tion timing y en d Er D PAK The timing control valve is a solenoid valve located in the line between high pressure chamber and low pressure chamber It changes fuel pressure in the high pressure chamber When current flows through the solenoid the solenoid turns ON the timing control valve opens advancing fuel injection timing Fuel injection timing When current does not flow through it the timing control valve control valve SEFeses Closes retarding injection timing The ECM emits an ON OFF duty signal The longer the OFF duration the greater the advance angle The longer the ON duration the gre
115. isconnect ECM harness connector e Harness connectors 2 Check harness continuity betveen ECM CEP 52 terminal 22 and terminal 1 e Harness connectors Continuity should exist 2r If OK check harness for short to e Harness connectors ground and short to power E70 OK e Harness for open or short 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 Y CHECK COMPONENT NG Replace neutral position Neutral position switch A switch Refer to MT section Disconnect and reconnect harness connec tors in the circuit Then retest i 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 172 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS Park Neutral Position Switch Cont d vx MONITOR x NOFAIL A T models P N POSI SW ON INSPECTION START CHECK OVERALL FUNCTION oK INSPECTION END 1 Turn ignition switch ON 2 Select P N POSI SW in ee DATA MONITOR mode with CONSULT 3 Check P N POSI SW signal under the following conditions y ys P or N position ON yo GA Except above positions OFF OR _ E 2 Check voltage between ECM A terminal and ground under the followi
116. ist D p Es If OK check harness for short to HS TS ground and short to power KA di OK 28 33 i i CHECK GROUND CIRCUIT II iid Check the following 1 Loosen and retighten engine ground e Joint connector screws e Harness for open or 2 Check harness continuity between ter short between electronic minal 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 Engine ground ground and short to power connectors S CHECK COMPONENT MEX Replace camshaft position Camshaft position sensor PUMP sensor PUMP Refer to COMPONENT INSPECTION on next page Disconnect and reconnect harness connec ye SEF676V tors in the circuit Then retest d Trouble is not fixed SS DISCONNECT KR GA Check ECM pin terminals for damage or the connection of ECM harness connector KA 3 Reconnect ECM harness connector and retest EI INSPECTION END SEF733V EC 72 TROUBLE DIAGNOSIS FOR CAM POS SEN PUMP DTC 11 e Za SEF573S Camshaft Position Sensor CMPS PUMP Cont d COMPONENT INSPECTION Camshaft position sensor PUMP 1 Disconnect electronic fuel injection pump harness connector Loosen the camshaft position sensor PUMP Remove the sensor Visually check the sensor for chipping AN 5 Check resistance between terminals 1 and 2 Resistance Approximately 1 360 1 8
117. jou saog NOO SAJEA piousjos 041uoo epioJu L ayesado jou saog poys uedo n9119 NDA 10 Ajddns J8MOY dois jou saop euifu3 usdo N3119 uoyws uoniub yno toys uedo 119 IN 4 yo ms uonisod 10219299Y jndino si jeubis ON Josues uonisod JojeJojeooy yous ino 110 ep Vous uonisod 101819622 poys DUnOID uedo poys punolb ou ada UND yoyms uonisod jeanaN Symptom Matrix Chart Cont d TROUBLE DIAGNOSIS General Description lt poys uedo jnour euis yels apo uojdw s AjueJeM uonouny JOU SBOP 0J1u09 uelis WV TV DVI PV HV SV dv dv av ov av lt T ai lt a EIA oo r o aja lu Ww wy Ww zz NC NE O O oyo iu zZz g9 283 T u u s s 2 slg n 0N E z E E 2 SEHE SIS m E g Z E E zd jo MEI 9 o m ulz tilz i iz E SE g E ds x x z z 5 ES o ul E E Z EI gt 9 E OI oo o se oo g c z ma E Ele zs gt x 9 i zZ lt Ela Ojo mi c o uo o9 S wc ziola 9 g EE IZ E S HN 30 BE SIEIS o amp zja g g o s 58 E 3 2 8 s amp 3 S a amp a 9 9 i Sju 2leg 5121212 T 9 s a 9 215 Se z zig o 2 zit ES o E Z w O OlGles E E 9015 f 2 9 2 x Zlz o x 2 3 Oj s mi it c S o f er Fa EAR ciu zx t Eo BISI E IR DI S E EIE u lzizig 4 co Slelua 6 O rj u zj u m 6 2 3 EX SJ zle gt jufuje c ulo iz lt pa elec E e Ool amp u E e alsi gt
118. lain leie GY 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 Cont d DIAGNOSTIC PROCEDURE INSPECTION START CHECK POWER SUPPLY Refer to EC 63 pump harness connector ES EES gem CHECK POWER SUPPLY CIRCUIT NG Repai ircuit or sh S ied pair open circuit or short de wi aw 1 Turn ignition switch OFF to ground or short to power 2 Disconnect ECM harness connector in harness or connectors US PANA amor and electronic fuel injection pump har AE OA ES ness connector I 3 Check harness continuity between ter GEIER minal and ECM terminals 101 ECM GE EE Gir 01 107 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 Check harness continuity between termi to ground or short to power SEENEN nal and ECM terminals 102 108 in harness or connectors p Es e Continuity should exist HS TS If OK check harness for short to ground SA d short t A aT Semer ABEN and short to power V Ivle 5 l OK 102 108 NG CHECK COMPONENT Take proper action Electric governor Refer to COMPONENT INSPECTION below SEF753V 1 OK Disconnect and reconnect harness connec tors in the circuit Then retest Trouble
119. le 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 Trouble is not fixed Check ECM pin terminals for damage and check the connection of ECM harness connector Reconnect ECM harness con nector and retest INSPECTION END EC 86 TROUBLE DIAGNOSIS FOR CONT SLEEV POS SEN DTC 15 Control Sleeve Position Sensor CSPS Electric governor The control sleeve position sensor is installed on the electric gov Control sleeve ernor It senses the position of control sleeve rotor angle while the Position sensor control sleeve is being driven by the electric governor and feeds it Fuel temperature back to the ECM sensor acK to the Built in electronic fuel injection pump SEF743V CONSULT REFERENCE VALUE IN DATA MONITOR MODE Remarks Specification data are reference values MONITOR ITEM CONDITION SPECIFICATION C SLEEV POS S e Engine After warming up 1 0 3 5V ECM TERMINALS AND REFERENCE VALUE Remarks Specification data are reference values and are measured between each terminal and ECCS ground with a voltmeter TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR NO Signal Approximately 2 6V V 4 bs 538 yy Control sleeve position Engine is running
120. le Cause No 14 e The almost 0 km h 0 MPH signal from vehicle speed e Harness or connector sensor is sent to ECM even when vehicle is being The vehicle speed sensor circuit is open or shorted driven e Vehicle speed sensor EC 83 TROUBLE DIAGNOSIS FOR VEHICLE SPEED SEN DTC 14 Vehicle Speed Sensor VSS Cont d OVERALL FUNCTION CHECK SO xz NOFAIL Use this procedure to check the overall function of the vehicle VHCL SPEED SE 20km h speed sensor circuit During this check a DTC might not be con P N POSI SW OFF 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 RECORD exceed 10 km h 6 MPH when rotating wheels with suit SEF941N able gear position OR SS e 1 Jack up drive wheels y Es 2 Start engine cy ed 3 Rotate drive wheel by hand Ecm O CONNECTOR 4 Check voltage between ECM terminal and ground with tester ri Voltage should vary between OV battery voltage eoo SEF811R EC 84 TROUBLE DIAGNOSIS FOR VEHICLE SPEED SEN DTC 14 Vehicle Speed Sensor VSS Cont d EC VSS 01 BATTERY Rm Detectable line for DTC FUSE BLOCK Refer to EL POWER Non detectable line for DTC J B D LHD models RD RHD models KA ER D R W B 55K lt R gt x 3 lt D gt 67K lt p gt UNIFIED METER CONTROL UNIT With speedometer a
121. losed Approximately 0 5 0 5 4 INJECTION TIMING CONTROL VALVE Partially open Completely open Approximately 4 Resistance at 20 C 68 F Q Approximately 11 FUEL TEMPERATURE SENSOR Resistance kQ ELECTRIC GOVERNOR Temperature C F Resistance at 23 C 73 F Q 0 68 20 4 13 67 16 37 20 68 2 306 2 568 CRANKSHAFT POSITION SENSOR TDC 60140 Hadr Ope 80 176 0 289 0 344 Resistance at 25 C 77 F KQ Approximately 0 8 1 2 GLOW PLUG Resistance at 25 C 77 F Q 0 8 EC 190
122. low STEP DESCRIPTION STEP Get detailed information about the conditions and the environment when the incident symptom occurred using the DIAGNOSTIC WORKSHEET as shown on EC 43 Before confirming the concern check and write down print out using CONSULT the Diagnostic Trouble Code STEP II DTC then erase the code Refer to EC 30 Study the relationship between the cause specified by DTC and the symptom described by the customer The Symptom Matrix Chart will be useful Refer to EC 48 Try to confirm the symptom and under what conditions the incident occurs The DIAGNOSTIC WORK SHEET is useful to verify the incident Connect CONSULT to the vehicle in DATA STEP III MONITOR AUTO TRIG mode and check real time diagnosis results If the incident cannot be verified perform INCIDENT SIMULATION TESTS Refer to Gl section If the malfunction code is detected skip STEP IV and perform STEP V Try to detect the Diagnostic Trouble Code DTC by driving in or performing the DTC CONFIRMATION PROCE DURE Check and read the DTC by using CONSULT During the DTC verification be sure to connect CONSULT to the vehicle in DATA MONITOR AUTO TRIG mode STEP IV and check real time diagnosis results If the incident cannot be verified perform INCIDENT SIMULATION TESTS Refer to Gl section In case the DTC CONFIRMATION PROCEDURE is not available perform the OVERALL FUNCTION CHECK instead The DTC cannot be displayed by
123. low plug e 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 Ceramic heater Resistor SEF857S ECM TERMINALS AND REFERENCE VALUE Remarks Specification data are reference values and are measured between each terminal and ECCS ground with a voltmeter TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR NO Signal Ignition switch ON C 0 1 5V Glow lamp is ON 16 L W Glow lamp Ignition switch ON BATTERY VOLTAGE iu Glow lamp is OFF 11 14V 111 LG B Glow relay Refer to SYSTEM DESCRIPTION EC 151 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS Glow Control System Cont d BATTERY 100A Refer to EL POWER EC GLOW 01 IGNITION SWITCH ON or START ral ll BLOCK M3 03 B NINE Detectable line for DTC Non detectable line for DTC COMBINATION METER O Desh M32
124. matically return to Diagnostic Test Mode l EC 33 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION Malfunction Indicator Lamp MIL Cont d DIAGNOSTIC TEST MODE I BULB 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 I MALFUNCTION WARNING MALFUNCTION INDICATOR LAMP Enden ON When the malfunction is detected or the ECM s CPU is malfunctioning Refer to MIL Illumination of the DIAGNOSTIC TROUBLE CODE INDEX EC 1 OFF No malfunction e These Diagnostic Trouble Code Numbers are clarified in Diagnostic Test Mode Il SELF DIAGNOSTIC RESULTS DIAGNOSTIC TEST MODE II SELF 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 Example Diagnostic trouble code No 12 and code No 43 0 6 0 3 0 6 0 3 Code No 12 Code No 43 Unit second 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 detect
125. ming is controlled within a compensation range depend ing on the engine speed engine coolant temperature and amount Engine coolant n of fuel injected temperature Low Fuel injection timing compensation Engine rpm gt SEF652S Air Conditioning Cut Control INPUT OUTPUT SIGNAL LINE Air conditioner switch Air conditioner ON signal A Accelerator valve opening angle Accelerator position sensor Air ECM conditioner a Vehicle speed relay Vehicle speed sensor Engine coolant temperature Engine coolant temperature sensor 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 Fuel Cut Control at no load amp high engine speed INPUT OUTPUT SIGNAL LINE Vehicle speed sensor Vehicle speed Neutral position switch Neutral position m E Accelerator position Accelerator position switch or Accelerator H switch F C Engin lant temperatur Engine coolant temperature sensor gine conan temperature Crankshaft position sensor TDC Engine spsed If the
126. n switch ON b Read voltage Voltage Battery voltage for about 20 seconds Engine coolant temperature is lower than 90 C 194 F It is lower than 70 C 158 F after warm up Repeating ignition switch ON and OFF may 90 C change the time 194 CF 2 Quick glow Cranking system Coolant temperature SEF780V a Disconnect S terminal for starter motor to prevent engine from cranking b Read voltage when ignition switch is turned to START Voltage Battery voltage For about 20 seconds after returning ignition switch to ON N e Quick pre heating time e EC 154 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS Glow Control System Cont d 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 50 C 122 Se 9 o o 2 o z ES o o COMPONENT INSPECTION Glow relay 1 Check relay for coil continuity Continuity should exist 2 Check relay for proper operation Coil voltage Continuity Contact point oy No OFF 12V Yes ON el Hg Ohmmeter SEC564B Glow plug 1 Remove glow plug connecting plate 2 Check each glow plug for continuity Continuity should exist Approximately 0 80 at 25 C 77 F e f NG replace glow plug Glow nut 3 Install glow plug connecting plate s
127. nal voltage is displayed FULL ACCEL SW Indicates ON OFF condition from the ON OFF accelerator position switch signal ACCEL SW FC Indicates OPEN CLOSE condition from OPEN CLOSE the accelerator switch FC signal OFF ACCEL SW Indicates ON OFF condition from the ON OFF accelerator position switch signal C SLEEV POS S V The control sleeve position sensor signal voltage is displayed BATTERY VOLT V The power supply voltage of ECM is dis played P N POSI SW ON OFF Indicates ON OFF condition from the park neutral position switch signal START SIGNAL ON OFF NOTE ooooooooDo oo o lo OI OOOOOO OO O JO Indicates ON OFF condition from the starter signal e After starting the engine OFF is dis played regardless of the starter signal 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 Cont d Monitored item ECM Unit input Description Remarks signals AIR COND SIG Indicates ON OFF condition of the air ON OFF conditioner switch as determined by the air conditioner signal IGN SW Indicates ON OFF condition from igni ON OFF tion switch signal MAS AIR FL SE V The signal voltage of the mass air flow sensor is displayed e When the engine is stopped a certain value is indicated ACT INJ TIMG 4 INJ TIMG C V
128. nd odo trip meter COMBINATION METER VEHICLE SPEED SENSOR E209 1 Refer to last page Foldout page 27 28 2o so el EU EES i34 35 36 37 38439 40 41 42 i 2 3 4 5 1617181 9 10 HHH W i3 s alal lalalalalala TEC426 EC 85 TROUBLE DIAGNOSIS FOR VEHICLE SPEED SEN DTC 14 Vehicle Speed Sensor VSS Cont d DISCONNECT AE o cowwecron H ECM D 26 ks N LITT TTT it Be T S DISCONNECT SEF742V DIAGNOSTIC PROCEDURE INSPECTION START CHECK INPUT SIGNAL CIRCUIT 1 Turn ignition switch OFF 2 Disconnect ECM harness connector and combination meter harness con nector 3 Check harness continuity between ECM terminal and meter terminal 2 Continuity should exist If OK check harness for short to ground and short to power OK CHECK SPEEDOMETER FUNCTION Make sure that speedometer functions properly NG Check the following e Harness connectors wz e Joint connector e Harness for open or short between ECM and combination meter If NG repair open circuit or short to ground or short to power in harness or con nectors NG OK Y Check the following e Harness connectors s6 LHD mod els e Harness connectors MD RHD mod els e Harness connectors ED e Harness for open or short between combina tion meter and vehic
129. ndition 0 1V L_ Idle speed 109 BR Y EGRC solenoid valve B Engine is running Warm up condition BATTERY VOLTAGE 11 14V L Engine is revving from idle up to 2 600 rpm EC 61 TROUBLE DIAGNOSIS General Description ECM Terminals and Reference Value Cont d TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR NO Signal 111 LG B Glow relay Refer to Glow Control System EC 151 Ignition switch OFF Approximately OV 113 115 R W Fuel cut solenoid valve CA vi BATTERY VOLTAGE EE 11 14V 116 BATTERY VOLTAGE 117 Ww Power supply for ECM Ignition switch ON 11 14V EC 62 TROUBLE DIAGNOSIS FOR POWER SUPPLY Main Power Supply and Ground Circuit ECM TERMINALS AND REFERENCE VALUE Remarks Specification data are reference values and are measured between each terminal and ECCS ground with a voltmeter TER WIRE DATA MINAL COLOR ITEM CONDITION DC Voltage and Pulse NO Signal Ignition switch ON Ignition switch OFF D 1 5V Es For a few seconds after turning ignition switch 4 B Y ECCS relay Self shutoff OFF Ignition switch OFF C BATTERY VOLTAGE A few seconds passed after turning ignition 11 14V switch OFF Ignition switch OFF DV 38 B Y Ignition switch BATTERY VOLTAGE Ignition switch ON 11 14V
130. ng conditions Voltage D P or N position Approximately 0V Except above positions Battery voltage NG CHECK POWER SUPPLY NG Check the following gt 1 Turn ignition switch OFF 2 Disconnect inhibitor switch harness con nector 3 Turn ignition switch ON 4 Check voltage between terminal 3 and ground with CONSULT or tester Voltage Battery voltage e 7 5A fuse e Harness for open or short between inhibitor switch and fuse If NG repair harness or connectors l OK 44 QO SEDE SEF792V EC 173 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS Park Neutral Position Switch Cont d E c G DISCONNECT P 6 5 4 3Y 9 8 7 SEF793V DISCONNECT 44 ES Ol CONNECTOR ECM l CHECK INPUT SIGNAL CIRCUIT I NG Check the following 1 Turn ignition switch OFF ee Diode 2 Disconnect TCM harness connector e Harness continuity 3 Check harness continuity between TCM between inhibitor switch terminal and terminals 7 and TCM Continuity should exist If NG repair open circuit or 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 a CHECK INPUT SIGNAL CIRCUIT II NG Check the following 1 Disconnect ECM harness connector M e Harness connectors 2 Check harness continuity betwe
131. nition switch OFF wait at least 5 seconds and then turn ON 3 Perform Diagnostic Test Mode Il Self diagnostic PELOD results with ECM SEF748V EC 135 TROUBLE DIAGNOSIS FOR FUEL TEMP SENSOR DTC 42 Fuel Temperature Sensor FTS Cont d EC FTS 01 Non detectable line for DTC D A T models EE Detectable line for DTC gm 1 m B FUEL TEMPERATURE SENSOR gt a 5 a z Q E o 0 2 Z SE lu a at E TCM SENS TRANSMISSION CONTROL MODULE E102 GND TEC435 EC 136 TROUBLE DIAGNOSIS FOR FUEL TEMP SENSOR DTC 42 Fuel Temperature Sensor FTS Cont d injection pump e harness connector Fuel temperature sensor IET A SEF682VB NA Afel Ile eo 44 O KA 23 2115 V Izlels SEF770V DIAGNOSTIC PROCEDURE Fuel temperature sensor Refer to COMPONENT INSPECTION on next page OK Disconnect and reconnect harness con nectors in the circuits Then retest Trouble is not fixed Check ECM pin terminals for damage and check the connection of ECM harness connector Reconnect ECM harness con nector and retest INSPECTION END EC 137 INSPECTION START CHECK POWER SUPPLY NG Repair harness or connec 1 Turn ignition switch OFF tors 2 Disconnect electronic fuel injection pump harness connector
132. of the accelerator pedal assembly The sensor detects the accelerator position and sends a signal to the ECM The ECM uses the signal to determine the amount of fuel to be injected Supply voltage 5V Applied between terminal No 1 and 3 Off accelerator position switch Output voltage between 4 Full terminal No 2 and 3 x 5 fos accelerator D t position 1 switch 1 Accelerator I 2 2 position 3 3 sensor 0 45 90 135 Output voltage between terminal No 2 and 3 V Throttle valve opening angle deg SEF861SA CONSULT REFERENCE VALUE IN DATA MONITOR MODE Remarks Specification data are reference values MONITOR ITEM CONDITION SPECIFICATION iti ith Accelerator pedal released 0 40 0 60V ACCEL POS SEN e anion SE H Engine stopped Accelerator pedal depressed Approx 4 0V ECM TERMINALS AND REFERENCE VALUE Remarks Specification data are reference values and are measured between each terminal and ECCS ground with a voltmeter TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR t NO Signal Ignition switch ON 0 4 0 6V L Accelerator pedal fully released 23 w Accelerator position sen sor Ignition switch ON Approximately 4 3V L_ Accelerator pedal fully depressed 48 G R EE EES Ignition switch ON Approximately 5V sor power supply T Engine is running Warm up condition 51 UW Accelerator po
133. ogram 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 Start signal Amount of fuel injected Engine rpm gt SEF648S EC 15 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Fuel Injection System Cont d IDLE CONTROL Input output signal line Engine coolant temperature sensor Engine coolant temperature Crankshaft position sensor TDC Neutral position switch Gear position Engine speed Battery Battery voltage Control sleev iliam sensor Control sleeve position Electric ontrol sleeve position senso governor Accelerator position switch Vehicle speed sensor Islas Air conditioner signal Idle position Air conditioner switch Heat up switch Heat up switch signal 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 temperat
134. oid valve listen to operating sound e Ignition switch ON EGRC SOL V B e Turn solenoid valve ON and Solenoid valve makes an operating Harness and connector OFF with the CONSULT and sound e Solenoid valve listen to operating sound e Ignition switch ON THROT CONT e Turn solenoid valve ON and Solenoid valve makes an operating Harness and connector SOL V OFF with the CONSULT and sound e Solenoid valve listen to operating sound e Ignition switch ON Engine stopped Glow relay makes the operating e Harness and connector GLOW RLY e Turn the glow relay ON and ound e Glow rela OFF using CONSULT and i y listen to operating sound e Engine Return to the original INJ TIMING trouble condition If trouble symptom disappears see Adjust initial injection timing Retard the injection timing using CONSULT CHECK ITEM EC 40 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT Cont d 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 e 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 Man
135. ontinuity Air passage Air passage Condition continuity continuity between and between and 12V direct current supply between terminals 1 Yes No and 2 No supply No Yes If NG replace solenoid valve s EC 162 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS Start Signal BATTERY EC S SIG 01 Refer to EL POWER IGNITION SWITCH NENNEN Detectable line for DTC Non detectable line for DTC FUSE BLOCK J B us Er R W rapes R W R W o STSW ECM ECCS D CONTROL MODULE CES to last page Foldout page E114 4 2 W E112 TEC443 EC 163 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS Start Signal Cont d DIAGNOSTIC PROCEDURE MONITOR x NOFAIL INSPECTION START START SIGNAL OFF CHECK OVERALL FUNCTION OK INSPECTION END 1 Turn ignition switch ON s 2 Check START SIGNAL in DATA MONITOR mode with RECORD CONSULT SEF625S IGN ON OFF IGN START ON m CONNECT Ew on EG 20 OR 4 E 1 Turn ignition switch to START 2 Check voltage between ECM terminal and ground Voltage Ignition switch START Battery voltage Except above Approximately 0V KS CHECK INPUT SIGNAL CIRCUIT NG Check the following 1 Turn ignition switch OFF e Harness connectors DISCONNECT x Sa DISCONNECT 2 Disconnect ECM harness connecto
136. ontinuity should exist If OK check harness for short to ground and short to power s NG Repair open circuit or short to ground or short to power in harness or connectors CHECK COMPONENT Fuel cut solenoid valve Refer to COMPONENT INSPECTION on next page i OK Disconnect and reconnect harness con nectors in the circuit Then retest Trouble is not fixed Check EOM pin terminals for damage and check the connection of ECM harness connector Reconnect ECM harness con nector and retest INSPECTION END EC 133 NG Replace fuel cut solenoid valve 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 Cont d COMPONENT INSPECTION Fuel cut solenoid valve 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 EC 134 TROUBLE DIAGNOSIS FOR FUEL TEMP SENSOR DTC 42 Fuel Temperature Sensor FTS The fuel temperature sensor is used to detect the fuel temperature in the injection pump The sensor modifies a voltage signal from the zs c ECM The modified signal returns to the ECM as the fuel tempera ture input The sensor uses a thermistor which is sensitive to the change in temperature The electrical resistance of the thermistor decreases as temp
137. ontrol valve 1 Disconnect vacuum hose to EGR valve See page EC 162 2 Make sure that vacuum exists under the following conditions At idle Vacuum should exist Revving engine from idle to 3 800 rpm C H NA A Vacuum should not exist KA GY tinct control 3 Disconnect vacuum hose to throttle NG Glo vee control valve A oZ esi 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 y NG 0 EC 159 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS EGRC Solenoid Valve A B and Throttle Control ACTIVE TEST BI EGRC SOL V A MONITOR CKPS RPM TDC SEF682S CONNECT ECAA ECM O connector 1 103 109 oo SEF683S gt ES Improper connection SEF816F Solenoid Valve Cont d CHECK CONTROL FUNCTION 1 Stop engine 2 Turn ignition switch ON 3 Turn EGRC solenoid valve A B and throttle control solenoid valve ON and OFF in ACTIVE TEST mode with CONSULT and check operating sound OR Check voltage between ECM terminal and ground under the following conditions Voltage At idle 0 1V Revving engine from idle to 3 800 rpm Battery voltage Check voltage between ECM terminal and ground under the following conditions Voltage At idle 0 1V Revvin
138. or harness connector e Harness connectors 3 Turn ignition switch ON E127 M21 4 Check voltage between terminal 2 e Harness connectors and ground with CONSULT or tester M51 Voltage e Harness for open or Approximately 5V short between ECM and engine coolant tempera OK ture sensor If NG repair harness or connectors E NG CHECK GROUND CIRCUIT sl Check the following 1 Turn ignition switch OFF e Harness connectors 2 Check harness continuity between ter E202 minal and engine ground e Harness connectors Continuity should exist E127 M21 If OK check harness for short to e Harness connectors B DISCONNECT ground and short to power M50 CP p e Harness connectors EN CES M51 em dp e Gies a M88 e Harness for open or short between ECM and engine coolant tempera ture sensor Es e Harness for open or short between TCM and engine coolant tempera ture sensor If NG repair open circuit or short to ground or short to power in harness or con nectors E N CHECK COMPONENT 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 Trouble is not fixed Check EOM pin terminals for damage and check the connection of ECM harness connector Reconnect ECM harness con nector and retest INSPECTION END
139. osition Engine is running S E 67 sensor D Idle speed SEF726V Ignition switch ON 0 4 0 6V Se Ei Accelerator position sen L Accelerator pedal fully released sor signal to TCM Ignition switch ON Approximately 4 3V L_ Accelerator pedal fully depressed 70 BR Power supply Back up Ignition switch OFF AAA VOLTAGE 11 14V 101 Engine is running BATTERY VOLTAGE R B Electric governor 107 L ide speed 11 14V EC 60 TROUBLE DIAGNOSIS General Description ECM Terminals and Reference Value Cont d TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR NO Signal Approximately 10V Engine is running L Idle speed 102 SEF727V 1 G Y Electric governor ground 08 Approximately 10V Engine is running D Engine speed is 2 000 rpm SEF728V Engine is running Warm up condition 0 1V L Idle speed 103 L Y EGRC solenoid valve A Engine is running Warm up condition BATTERY VOLTAGE L Engine is revving from idle up to 3 750 rpm 11 14V BATTERY VOLTAGE 11 14V Engine is running Warm up condition B Idle speed 104 UW Injection timing control SEF729V 110 valve BATTERY VOLTAGE 11 14V Engine is running Warm up condition L Engine speed is 2 000 rpm SEF730V 106 Engine is running 112 B ECCS ground Approximately OV 118 L Idle speed Engine is running Warm up co
140. osition Sensor Cont d DIAGNOSTIC PROCEDURE Accelerator position sensor harness connector INSPECTION START CHECK POWER SUPPLY SC Check the following 1 Turn ignition switch OFF e Harness connectors 2 Disconnect accelerator position sensor CEN N52 RHD mod harness connector els 3 Turn ignition switch ON e Harness for open or 4 Check voltage between terminal 1 short between ECM and and ground with CONSULT or tester accelerator position sen Voltage Approximately 5V sor oa If NG repair harness or En E connectors MES j CHECK GROUND CIRCUIT NS Check the following 1 Turn ignition switch OFF e Harness connectors 2 Loosen and retighten engine ground CEN 52 RHD mod screw els 3 Check harness continuity between ter e Harness for open or 60 minal 3 and engine ground short between ECM and Continuity should exist accelerator position sen If OK check harness for short to sor ground and short to power If NG repair open circuit or short to ground or short to power in harness or con nectors NG CHECK INPUT SIGNAL CIRCUIT sl Check the following 1 Disconnect ECM harness connector e Harness connectors 2 Check harness continuity between ECM CFT 52 RHD mod terminal and terminal 2 els Continuity should exist e Harness for open or If OK check harness for short to short between ECM and ground and short to power a
141. position switch and ECM If NG repair harness or connectors TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS Accelerator Position Switch Cont d DISCONNECT DISCONNECT Ae E 24 HS TS 6 CHECK INPUT SIGNAL CIRCUIT I NG Check the following 31 1 Turn ignition switch OFF e Harness connectors 2 Disconnect ECM harness connector M52 RHD mod 3 Check harness continuity between ter els minal and ECM terminal 8 e Harness for open or Continuity should exist short between ECM and If OK check harness for short to accelerator position ground and short to power switch If NG repair open circuit or s OK D p short to ground or short to DISCONNECT DISCONNECT PLANY O P nectors VN a mw Ressel ED 7 CHECK INPUT SIGNAL CIRCUIT II P Check the following Check harness continuity between termi e Harness connectors nal and ECM terminal 52 RHD mod Continuity should exist els If OK check harness for short to ground e Harness for open or and short to power short between ECM and OK accelerator position switch If NG repair open circuit or short to ground or short to power in harness or con nectors Y CHECK COMPONENT NG Replace accelerator pedal Accelerator position switch assembly Refer to COMPONENT INSPECTION on next page Disconnect and reconnect harness con nectors in the circuits Then
142. r and OSC ignition switch harness connector e 7 5A fuse ECH O CONNECTOR 3 Check harness continuity between ECM e Fuse block M3 E112 20 terminal and terminal e 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 OK short to ground or short to power in harness or con nectors Disconnect and reconnect harness connec tors in the circuit Then retest Trouble is not fixed Check ECM pin terminals for damage and check the connection of ECM harness con nector Reconnect ECM harness connector and retest INSPECTION END EC 164 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS CSS Accelerator Position Switch Accelerator position The accelerator position switch detects OFF accelerator switch sig R nal and Full accelerator switch signal and send these signals to the ECM The ECM will then determine engine idle conditions These signals are also used for diagnosing the accelerator position sen sor CONSULT REFERENCE VALUE IN DATA MONITOR MODE Remarks Specification data are reference values MONITOR ITEM CONDITION SPECIFICATION Em Ae S e Ignition switch ON Accelerator pedal depressed ON Engine stopped Except above OFF BEEAGBELSN e Ignition switch ON Accelerator pedal released ON Engine stopped Accelerator pedal slightly open OFF ECM TE
143. r con gt DISCONNECT 8 DISCONNECT nectors TS Si H S P lt ER CHECK GROUND CIRCUIT II Nm Check the following 1 Loosen and retighten engine ground e Joint connector screws e Harness for open or 2 Disconnect harness connectors F13 short between harness ES Genf connector F13 and 3 Check harness continuity between ter engine ground emia minal 3 and engine ground If NG repair open circuit or Continuity should exist short to ground or short to Engine ground If OK check harness for short to power in harness or con gt ground and short to power nectors NG CHECK COMPONENT Replace crankshaft posi Crankshaft position sensor TDC tion sensor TDC Refer to COMPONENT INSPECTION on next page fe SEF676V Disconnect and reconnect harness connec tors in the circuit Then retest Es 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 tal INSPECTION END SEF776V EC 147 TROUBLE DIAGNOSIS FOR CRANK POS SEN TDC DTC 47 Crankshaft Position Sensor TDC Cont d 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 5 Check resistance between terminals 1 and 2 Resistanc
144. r is e Harness or connectors The sensor circuit is open or shorted e Engine coolant temperature sensor DIAGNOSTIC TROUBLE CODE CONFIRMATION PROCEDURE 1 Turn ignition switch ON 2 Select DATA MONITOR mode with CONSULT 3 Wait at least 5 seconds OR Turn ignition switch ON and wait at least 5 seconds Turn ignition switch OFF wait at least 5 seconds and then turn ON 3 Perform Diagnostic Test Mode l Self diagnostic results with ECM SG WH y 2 EC 79 Engine Coolant Temperature ECT Sensor EC ECTS 01 TROUBLE DIAGNOSIS FOR COOLANT TEMP SEN DTC 13 Cont d O 5 E O c D EOS kj Do 5 2 S E o o o o 3 3 o 2 238 2204 Hi 25 8 sea Y 9 5 zE2 E o 7 IZA a ela B c z D oO Je Ka SS E O T Giu ol 8 e o A CONTROL MODULE Lr E Es zi Q Q el UI o z UI TEMPERATURE SENSOR ECCS D E219 50 l I L 1 I ofi E I 1 I I l x TEC425 EC 80 TROUBLE DIAGNOSIS FOR COOLANT TEMP SEN DTC 13 Engine Coolant Temperature ECT Sensor Cont d E N d DIAGNOSTIC PROCEDURE A INSPECTION START Engine coolant temperature sensor harness CHECK POWER SUPPLY um Check the following connector 1 Turn ignition switch OFF e Harness connectors 2 Disconnect engine coolant temperature E202 sens
145. rcuit or short to ground or short to power in harness or connectors NG CHECK GROUND CIRCUIT I Check harness continuity between sensor terminal and ECM terminals 69 Continuity should exist If OK check harness for short to ground and short to power Repair open circuit or short to ground or short to power in harness or connectors s NG Check the following gt S e Joint connector e Harness for open or short between control sleeve position sensor and engine ground If NG repair open circuit or short to ground or short to CHECK GROUND CIRCUIT II 1 Loosen and retighten engine ground screws 2 Check harness continuity between ter minal 4 and engine ground Continuity should exist If OK check harness for short to ground and short to power Engine ground SEF676V power in harness or con nectors ya EC 90 TROUBLE DIAGNOSIS FOR CONT SLEEV POS SEN DTC 15 Control Sleeve Position Sensor CSPS Cont d CHECK COMPONENT NG Take proper action 7 615 Control sleeve position sensor Refer to COMPONENT INSPECTION below E Jo Disconnect and reconnect harness connec tors in the circuit Then retest SEF747V i 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 I
146. replace both needle and body as a unit SEF835 Assembly No 2 4 nozzles Assemble in the reverse order of disassembly observing the fol lowing SEF671A If nozzle body is not installed properly Tool cannot be removed and nozzle body may be damaged Holder to nozzle nut EX 78 98 N m 8 0 10 0 kg m 58 72 ft Ib EC 24 INJECTION NOZZLE Test and Adjustment WARNING When using nozzle tester be careful not to allow diesel fuel sprayed from nozzle to contact your hands or body and make sure your eyes are properly protected with goggles INJECTION PRESSURE TEST 1 Install nozzle to injection nozzle tester and bleed air from flare nut EF791A 2 Pumpthe 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 y Used 14 220 kPa 142 2 bar 145 kg cm 2 062 psi New 14 711 15 495 kPa 147 1 155 0 bar 150 158 kg cm 2 133 2 247 psi Always check initial injection pressure using a new nozzle SEF672A 4 To adjust injection pressure change adjusting shims No 2 4 nozzles a Increasing the thickness of adjusting shims increases ini tial injection pressure Decreasing thickness reduces ini tial pressure b A shim thickness of 0 04 mm 0 0016 in corresponds approximately to a difference of 471 kPa 4 71 bar 4 8 kg cm 68 psi in
147. risk of personal injury or death in the event of a collision which would result in air bag inflation all maintenance must be performed by an authorized NISSAN dealer e Improper maintenance including incorrect removal and installation of the SRS can lead to per sonal injury caused by unintentional activation of the system For removal of Spiral Cable and Air Bag Module see the RS section e Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual Spiral cable and wiring harnesses covered with yellow insulation either just before the harness connectors or for the complete harness are related to the SRS EC 4 PRECAUTIONS AND PREPARATION Engine Fuel amp Emission Control System ECM ECCS D control module WIRELESS EQUIPMENT e Do not disassemble ECM e When installing C B ham radio or a e If a battery terminal is disconnected mobile phone be sure to observe the the memory will return to the ECM following as it may adversely affect value electronic control systems depending The ECM will now start to self control on its installation location at its initial value Engine operation can 1 Keep the antenna as far as possible vary slightly when the terminal is away from the ECM BATTERY disconnected However this is not an 2 Keep the antenna feeder line more than e Always use a 12 volt battery as power indication of a problem Do not replace 20 cm 7 9 in away from the harness so
148. rm up condition L Idle speed SEF715V 5 Y B Tachometer Approximately 1 0 2 0V Engine is running Warm up condition L Engine speed is 2 000 rpm EC 55 SEF716V TROUBLE DIAGNOSIS General Description ECM Terminals and Reference Value Cont d TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR NO Signal Engine is running BATTERY VOLTAGE L Charge air cooler fan is not operating 11 14V 8 G OR n air cooler fan did Engine is running 0 1V L_ Charge air cooler fan is operating Approximately 0 4 8V 10 P Fuel temperature sensor Engine is running Output voltage varies with a fuel temperature Engine is running BATTERY VOLTAGE L Cooling fan is not operating 11 14V 14 E Cooling fan relay Engine is running 0 1V L Cooling fan is operating Engine is running BATTERY VOLTAGE L_ Air conditioner switch is OFF 11 14V 15 YA Air conditioner relay Engine is running L Both air conditioner switch and blower fan D 1V switch are ON Compressor is operating Ignition switch ON 0 1 5V L Glow lamp is ON 16 L W Glow lamp Ignition switch ON BATTERY VOLTAGE L_ Glow lamp is OFF 11 14V Ignition switch ON 0 1 5V 18 G Malfunction indicator lamp Engine is running BATTERY VOLTAGE
149. rom idle to 3 750 OFF e No load rpm e Engine After warming up Idle ON e Air conditioner switch OFF EGRC SOL V B e Shift lever N Revving engine from idle to 2 600 OFF e No load rpm e Engine After warming up Idle ON e Air conditioner switch OFF THROT RLY e Shift lever N Revving engine from idle to 2 500 OFF e No load rpm ECM TERMINALS AND REFERENCE VALUE Remarks Specification data are reference values and are measured between each terminal and ECCS ground with a voltmeter TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR NO Signal Engine is running Warm up condition Approximately 0 4V A W Throttle control solenoid Idle speed valve Engine is running Warm up condition BATTERY VOLTAGE L_ Revving engine from idle to 2 500 rpm 11 14V Engine is running Warm up condition 0 1V L Idle speed 103 L Y EGRC solenoid valve A Engine is running Warm up condition BATTERY VOLTAGE L Revving engine from idle up to 3 750 rpm 11 14V Engine is running Warm up condition 0 1V L Idle speed 109 BR Y EGRC solenoid valve B Engine is running Warm up condition BATTERY VOLTAGE 11 14V L_ Revving engine from idle up to 2 600 rpm EC 157 EGRC Solenoid Valve A B and Throttle Control TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS Solenoid Valve Cont d EC EGRO V 01 D SE 5
150. rotector ECM harness protector 2 AEC913 3 Perform all voltage measurements with the connector con nected Extend tester probe as shown to perform tests easily e Open harness securing clip to make testing easier e Use extreme care not to touch 2 pins at one time e Data is for comparison and may not be exact Thin wire Tester probe SEF3671 Be sure ECM unit is properly grounded before checking ECM harness protector SEF665S EC 54 TROUBLE DIAGNOSIS General Description ECM Terminals and Reference Value Cont d ECM HARNESS CONNECTOR TERMINAL LAYOUT SEFO64P ECM INSPECTION TABLE Remarks Specification data are reference values and are measured between each terminal and ECCS ground with a voltmeter TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR NO Signal Engine is running Warm up condition ea Approximately 0 4V 1 W Throttle control solenoid Idle speed valve Engine is running Warm up condition BATTERY VOLTAGE L_ Revving engine from idle to 2 500 rpm 11 14V Ignition switch ON Ignition switch OFF 0 1 5V E For a few seconds after turning ignition switch 4 B Y ECCS relay Self shutoff OFF Ignition switch OFF E BATTERY VOLTAGE A few seconds passed after turning ignition 11 14V switch OFF Approximately 1 0 2 0V Engine is running Wa
151. se 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 EC 78 TROUBLE DIAGNOSIS FOR COOLANT TEMP SEN DTC 13 Terminal Sensor SEF594K o Acceptable Resistance kQ h A OO wv 2000 oo o Of 20 0 20 40 60 80 100 4 32 68 104 140 176 212 Temperature C F SEF012P Diagnostic Trouble Code No Malfunction is detected when Engine Coolant Temperature ECT Sensor The engine coolant temperature sensor is used to detect the engine coolant temperature The sensor modifies a voltage signal from the ECM The modified signal returns to the ECM as the engine cool ant temperature input The sensor uses a thermistor which is sen sitive to the change in temperature The electrical resistance of the thermistor decreases as temperature increases lt Reference data gt Engine coolant tempera gei Voltage Resistance c F V Ko 10 14 4 4 7 0 11 4 20 68 3 5 24 29 50 122 2 3 0 68 1 00 90 194 1 0 0 236 0 260 These data are reference values and measured between ECM terminal Engine coolant temperature sensor and ECM terminal ECCS grouna Check Items Possible Cause 13 entered to ECM ze MONITOR x NOFAIL O CKPS RPM TDC Orpm COOLAN TEMP S 25 C RECORD SEF741V e An excessively high or low voltage from the senso
152. sition sen C Approximately 0V sor ground Idle speed EC 139 TROUBLE DIAGNOSIS FOR ACCEL POS SENSOR DTC 43 Accelerator Position Sensor Cont d ON BOARD DIAGNOSIS LOGIC Diagnostic Check Items Trouble Malfunction is detected when Possible Cause Code No 43 e An excessively low or high voltage from the sensor is e Harness or connectors detected by the ECM The sensor circuit is open or shorted e Accelerator position sensor e Accelerator position switch e Accelerator switch F C DIAGNOSTIC TROUBLE CODE CONFIRMATION yx MONITOR x NOFAIL O PROCEDURE 1 Turn ignition switch ON OKPSREM TDO SE Select DATA MONITOR mode with CONSULT Wait at least 2 seconds QR Turn ignition switch ON and wait at least 2 seconds KEN Q8 Turn ignition switch OFF wait at least 5 seconds and then turn ON 3 Perform Diagnostic Test Mode Il Self diagnostic RECORD results with ECM SEF748V EC 140 TROUBLE DIAGNOSIS FOR ACCEL POS SENSOR DTC 43 Accelerator Position Sensor Cont d EC APS 01 ECM ECCS D CONTROL MODULE MEE Detectable line for DTC Non detectable line for DTC lt gt LHD models O B RHD models CONNECTOR 4 JOINT a eS 1 Cm Sl Ca W oc a 3 Bs al e TEC436 EC 141 TROUBLE DIAGNOSIS FOR ACCEL POS SENSOR DTC 43 Accelerator P
153. so replace the engine oil a Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute Be sure to use coolant with the proper mixture ratio Refer to MA section Anti freeze Coolant Mixture Ratio RECOMMENDED FLUIDS AND LUBRICANTS b After refilling coolant run engine to ensure that no water flow noise is emitted EC 114 TROUBLE DIAGNOSIS FOR OVER HEAT DTC 28 MAX lo MIN AEC640 B ACTIVE TEST BN COOLING FAN OFF MONITOR COOLAN TEMP S 85 C 7 Cooling fan DISCONNECT Engine coolant temperature sensor 150Q resister SEF979S Cooling Fan Overheat Cont d OVERALL FUNCTION CHECK Use this procedure to check the overall function of the cooling fan During this check a DTC might not be confirmed WARNING Never remove the radiator cap when the engine is hot 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 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 cu
154. spray pattern 8 Caused mainly by insufficient compression pressure 4 Symptom varies depending on off position of air duct etc EC 48 TROUBLE DIAGNOSIS General Description EC 49 ss Ol LEE E EL E PEEL peyote T A T ee pino uoys uedo 4 OGL 40sues uonisod Yeysquelo 6 1 03 poys uedo WOU JOSUSS uoiisod 10218 3994 uonounj jou seop aunjejad wa any 0 Buipioooe pajosfur nous usado n3119 Josues eJnjejeduuej any Jen jo junowe 10 uornesueduioo uf Buiuum 13 s dd euis yous 148 Suum 18148 uo suni oU noo SAJEA prougjos 1no any uoys punolb usado gt OSS AA AAA AAA uous uedo noii JOSUOS yj eipeoN po O poys uedo yno 1osues eJnjejeduue e abreyo ous punojB e OUS udo n3119 94 YIIMS 101eJo eoov 3 O uoys punoJ6 B wea pejoa O uous uedo No SAA joauoo Buruy uonoeful Q u09 eq jouues Buu uonos u Y E G OJO 2245 INDIO JOUJBAOB 91149913 i O O O yous punoib uedo PEN i O 36 93 19419 J0 SIS3J jueunsn py 18 03 n3119 JOSUSS uoijisod e ee s ONUOD gt 8 04 jnoJiro Josues peeds open ipd nouo a 229P Pd tee et eres 6723 Josuas aunjesedua juejooo euifu3 ous iiis HA totor to TEC ET poys puo uedo PURO OJO O OjOJO esiou uno 9 uonounjpeul Jojeulouoe OO uous uedo 119 dINNd 10sues uonisod yeysweg o vH dv JWAv 1v piv rv Hv 9v dv av _ av ov av YY apoo
155. ss for open or m short between injection Continuity should exist timing control valve and 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 gt Injection timing control valve Refer to COMPONENT INSPECTION control valve on next page i OK Disconnect and reconnect harness connec tors in the circuit Then retest d 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 ES Electronic fuel injection pump TS SEF686V Injection Timing Control Valve Cont d 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 3 and 7 Resistance Approximately 110 at 20 C 68 F If NG replace injection timing control valve EC 105 TROUBLE DIAGNOSIS FOR ACCEL POS SW F C DTC 23 Accelerator Switch F C The accelerator switch is installed to the accelerator pedal assem bly The switch senses accelerator position and sends an ON OFF E Accelerator signal to the
156. st Mode Il Self diagnostic results with 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 Cont d EC FCUT 01 BATTERY Rm Detectable line for DTC Refer to EL POWER SOLENOID VALVE INJECTION FUEL CUT Non detectable line for DTC PUMP CONTROL MODULE ECCS D z o uw Refer to last page Foldout page E127 KA alain Ill 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 Cont d B ACTIVE TEST BI FUEL CUT SOL V MONITOR CKPS RPM TDC SEF860S DIAGNOSTIC PROCEDURE INSPECTION START CHECK POWER SUPPLY FOR ECM Check power supply circuit Refer to EC 63 injection pump harness connector Fuel cut solenoid valve YESA SEF682VA 140048 KA ECM CONNECTOR 4131211 O CONNECTOR BOP 113 115 end SEF768V CHECK OUTPUT SIGNAL CIRCUIT 1 Turn ignition switch ON 2 Select FUEL CUT SOL V in ACTIVE TEST mode with CONSULT 3 Touch ON and OFF alter nately 4 Check that operating sound is emitted OR Turn ignition switch OFF Disconnect ECM harness con nector and electronic fuel injec tion pump harness connector 3 Check harness continuity between terminal Co and ECM terminals 113 115 C
157. stomer 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 n O E 3 Disconnect engine coolant temperature sensor harness connector 4 Connect 1504 resistor to engine coolant temperature sensor harness connector 5 Start engine and make sure that cooling fan operates Be careful not to overheat engine EC 115 TROUBLE DIAGNOSIS FOR OVER HEAT DTC 28 Cooling Fan Overheat Cont d EC COOL F 01 mmm Detectable line for DTC Non detectable line for DTC IGNITION SWITCH ON Refer to EL POWER FUSE BLOCK 30A e En We With A C AIR CONDITIONER RELAY To Y B EC FICD gt HA A C M A C A COOLING FAN MOTOR 1 E36 L E E B ECM ECCS D CONTROL AL MODULE Refer to last page Foldout page HE at 2 E127 pq ES Es lalo BR L GY 113 114 115 TEC432 EC 116 TROUBLE DIAGNOSIS FOR OVER HEAT DTC 28 B ACTIVE TEST Bl OFF COOLING FAN 85 C MONITOR COOLAN TEMP S DISCONNECT Cooling fan Engine coolant temperature sensor 150Q resister SEF979S O e Cooling fan relay 1 AEA SEF759V release lever PA SEF69
158. t page y OK Disconnect and reconnect harness connec tors in the circuit Then retest Y 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 109 TROUBLE DIAGNOSIS FOR ACCEL POS SW F C DTC 23 Accelerator Switch F C Cont d COMPONENT INSPECTION Accelerator switch F C 1 Disconnect accelerator switch F C harness connector 2 Check continuity between terminals y and 3 Ss S SS DISCONNECT 5 A 1 Conditions Continuity Accelerator pedal released No Accelerator pedal depressed Yes If NG replace accelerator pedal assembly EC 110 TROUBLE DIAGNOSIS FOR ECM 1 DTC 27 ECM 2 DTC 31 Engine Control Module ECM ECCS D Control Module The ECM consists of a microcomputer and connectors for signal input and output and for power supply The unit controls the engine SEC220B Diagnostic Check Item Trouble Code Malfunction is detected when No Possible Cause 27 31 e ECM calculation function is malfunctioning e ECM ECCS D control module DIAGNOSTIC TROUBLE CODE CONFIRMATION ye MONITOR yx NoFAIL O PROCEDURE 1 Turn ignition switch ON IRA SERM 2 Select DATA MONITOR mode with CONSULT 3 Wait at least 2 seconds OR E 1 Turn ignition switch ON BY 2
159. tch 2 Connect CONSULT to data link connector for CONSULT Data link connector for CONSULT is located under the hood opener e4 Hood opener u Turn on ignition switch Touch START Touch ENGINE Perform each diagnostic test mode according to each service procedure For further information see the CONSULT Operation Manual m a ENGINE o og RO p SELECTDIAGMODE Il SELF DIAG RESULTS DATA MONITOR ACTIVE TEST ECM PART NUMBER li EC 36 ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CONSULT Cont d ECCS COMPONENT PARTS CONTROL SYSTEMS APPLICATION DIAGNOSTIC TEST MODE SELF DIAG NOSTIC RESULTS Camshaft position sensor PUMP X DATA ACTIVE MONITOR TEST Engine coolant temperature sensor Control sleeve position sensor Fuel temperature sensor Vehicle speed sensor Accelerator position sensor X X X x x x gt ox Accelerator position switch i Accelerator switch F C Crankshaft position sensor TDC Needle lift sensor Ignition switch start signal Neutral position switch Battery voltage Air conditioner switch Heat up switch o LE lt a E H z O a Q o o o o ul Mass air flow sensor Charge air temperature sensor Injection timing control valve Fuel cut solenoid valve Glow relay OUTPUT EGRC solenoid valve A B amp throttle control solenoid valve Cooling
160. ter stopping While loading Startability Driveability Just after delivery O Recently In the morning O At night O In the daytime Incident occurrence Frequency All the time Under certain conditions Sometimes Weather conditions Not affected Weather Fine Raining Snowing Others Temperature Hot Warm Cool Cold Cold During warm up After warm up Engine conditions Engine speed l 1 0 2 000 4 000 6 000 8 000 rpm Road conditions In town In suburbs Highway Off road up down Not affected At starting While idling At racing While accelerating While cruising While decelerating While turning RH LH Driving conditions Vehicle speed 10 20 30 40 Malfunction indicator lamp Turned on Not turned on EC 43 TROUBLE DIAGNOSIS Work Flow Work Flow CHECK IN CHECK INCIDENT CONDITIONS EE EE STEP l Listen to customer complaints Get symptoms Check and PRINT OUT write down Dia
161. terminal 1 motor terminal 2 and engine ground Continuity should exist If OK check harness for short to ground and short to power SEF711V OK O EC 180 CHECK OVERALL FUNCTION OK INSPECTION END 1 Turn ignition switch OFF 2 Disconnect charge air temperature sen sor harness connector 3 Connect 15090 resistor to charge air 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 B CHECK POWER SUPPLY NG Check the following 1 Stop engine e Harness connectors 2 Disconnect charge air cooler fan relay MD 3 Turn ignition switch ON e 10A fuse 4 Check voltage between terminals 2 e 15A fuse amp and ground with CONSULT or e Fuse block M2 tester e Harness for open or Voltage Battery voltage short between charge air OK cooler fan relay and fuses If NG repair harness or connectors N CHECK GROUND CIRCUIT ech Check the following e Harness connectors ED Q1 e Harness connectors w CFS e Harness for open or short between charge air cooler fan relay and charge air cooler fan motor e Harness for open or short between charge air cooler fan motor and engine ground If NG repair open circuit or short to ground or short to power in harness or con nectors TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS Le DISCONNECT AE DISCONNECT AE a S
162. trouble diagnostic procedures e After performing each TROUBLE DIAGNOSIS perform CHECK OVERALL FUNCTION CHECK or DTC Diagnostic p a Trouble Code CONFIRMATION PROCEDURE E N The DTC should not be displayed in the DTC CONFIRMA TION PROCEDURE if the repair is completed The OVER ALL FUNCTION CHECK should be a good result if the repair is completed SEF051P EC 6 PRECAUTIONS AND PREPARATION Precautions Cont d e 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 Battery voltage Circuit tester SEF348N EC 7 ENGINE AND EMISSION CONTROL OVERALL SYSTEM ECCS D Component Parts Location Throttle control valve Glow plug Vacuum pump Charge air temperature sensor EGR valve Engine coolant temperature sensor Mass air flow sensor Fuel filter EGRC solenoid valve B Fuel filter switch EGRC solenoid valve A Glow relay Throttle control solenoid valve Cooling fan motor Charge air cooler fan Needle lift sensor built into No 1 nozzle Charge air cooler Crankshaft position sensor TDC Electronic fuel injection pump SEF657V EC 8 ENGINE AND EMISSION CONTROL OVERALL SYSTEM ECCS D Component Parts Location Cont d Electric governor Control sleeve position sensor Fuel temperature sensor Built in electronic fuel injection pump
163. ual trigger e 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 e 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 e 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 Gl section Incident Simulation Tests in HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT 2 MANU TRIG e lf 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 lj SET RECORDING COND AUTO TRIG UU TO LONG TIME SET RECORDING COND AUTO TRIG MANU TRIG I I SETTING START O E SETTING AUTO TRIG MANU TRIG A
164. uit Then retest kal Trouble is not fixed ser766v Check ECM pin terminals for damage and check the connection of ECM harness con nector Reconnect ECM harness connector and retest HE K re 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 Fuel Cut Solenoid Valve When the ignition switch is OFF the ECM turns the fuel cut sole noid valve OFF under this condition no current flows through the fuel cut solenoid valve shutting off fuel supply Ignition When the engine is not operating due to trouble the fuel cut sole Switch noid valve may or may not be OFF even when the ignition switch is ON Fuel cut solenoid valve SEF667S CONSULT REFERENCE VALUE IN DATA MONITOR MODE Remarks Specification data are reference values MONITOR ITEM CONDITION SPECIFICATION Idle OFF DECELER F CUT Engine After warming up When accelerator pedal is released quickly with engine speed at 3 000 ON rpm or more FUEL CUT S V e Ignition switch ON gt OFF ON gt OFF ECM TERMINALS AND REFERENCE VALUE Remarks Specification data are reference values and are measured between each terminal and ECCS ground with a voltmeter TER WIRE DATA MINAL ITEM CONDITION DC Voltage and Pulse COLOR NO Signal Ignition switch ON Ignition switch
165. urce parts because of a slight variation of electronic controls Do not attempt to disconnect battery e When ECM is removed for inspection Do not let them run parallel for a long cables while engine is running make sure to ground the ECM mainframe X distance 3 Adjust the antenna and feeder line so that the standing wave ratio can be kept smaller ELECTRONIC FUEL INJECTION PUMP KF 4 Be sure to ground the radio to vehicle ES EZ p e Do not disconnect pump harness body connectors with engine running e Do not disassemble electronic fuel injection pump except for the following parts Camshaft position sensor pump Injection timing control valve Fuel cut solenoid valve If NG take proper action ECM PARTS HANDLING e Do not disassemble No 1 injection nozzle with needle lift sensor built in e If NG replace No 1 injection nozzle YA co e Even a slight leak in the air intake WHEN STARTING ECM HARNESS HANDLING system can cause serious problems e Do not depress accelerator pedal when e Securely connect ECM harness e Do not shock or jar the crankshaft starting connectors position sensor TDC e Immediately after starting do not rev up A poor connection can cause an engine unnecessarily extremely high surge voltage to e Do not rev up engine just prior to develop in coil and condenser thus shutdown resulting in damage to ICs e Keep ECM harness at least 10 cm 3 9 in away from adjacent harnesses to prevent
166. ure and heat up switch signal NORMAL CONTROL Input output signal line Crankshaft position sensor TDC Engine speed Control sleeve position sensor Control sleeve position Electric governor Accelerator position sensor Vehicle speed sensor venicle speed Accelerator position The amount of fuel injected under normal driving conditions is determined according to sensor signals The crankshaft position o E sensor TDC detects engine speed and the accelerator position E sensor detects accelerator position These sensors send signals to 9 Accelerator the ECM v opening larger The fuel injection data predetermined by correlation between vari E ous engine speeds and accelerator positions are stored in the 3 ECM memory forming a map The ECM determines the optimal E S amount of fuel to be injected using the sensor signals in compari Engine rpm son with the map SEF649S EC 16 ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION Fuel Injection System Cont d FUEL TEMPERATURE COMPENSATION Input output signal line Fuel Fuel temperature sensor ue tomperature Engine speed Crankshaft position sensor TDC Electric governor 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
167. woiduiAs uenem E a Ela ojo gt I o oo IE w Ww EES SIS ES SE u 22 s KEE 5 l ltsis oo E o lei E ux E z w a sys SIS ih E S S 5 z 5 m oc g IMC bes Se i dE cicls s E E o E 2 ES 2 E o r o n T 5 no a T a Elke gt 95 8 a Z Eu olo 5 a x E o zZ lt a tc po og 28 wc Eifel fe O 9 RE EI lt lt a HN ge 2 o EIE Sle l Slzl Z alaoal5 5 z LO 30 E EJES ajo MO ula mc 2 nO 3 EISEN REISE S s 3j s ejS S n ela 2225 fo z 8 5 2 9 218 2 P z z 2 z 2e 8 8 S Ulzlz 2 E EO SE 21 O E o c Es z l3E lelzlSlelelz GEIER ES Liz lt D slale 5 OP lzl elela lole2 z G SEI l2 2is lo 2 B u SIE uo t OE S5lo 9 d T gio iP z oz alu lo zik ul zt apa S lo O uiuic z g olcia lxisel o E z OC SEIEIREREIEIEIEIEUAEARIEIEIEIEANE za l 3 d ojolB E 9 z amp 8 S c D Ic INOLdWAS 310M JOU seop 1euonipuoo Jg poys Bunesodo mu yms Jeuonipuoo 1Y dois 1ou seop 1euoinipuoo Jv poys punoJD uedo Bune1edo dois Jou seop jeuonipuoo JN yous rou ee 1euonipuoo aly eje1edo jou seop 1euonipuoo ANY uedo uoys uedo no 101280005 WO O O O O O O O dois 0 ejqeun euiDue seyew oys punog no yoinus jjes ee S993 YO UN Jou seop dwej mojo UO uan JOU SAOP du MOE nouo Aejas MOIE uado poys punoJ6 poys uedo Bunejedo dos jou saog n0119 g V eA E A piousjos 2HDO3 yoys puno ECCS Bunejedo dois
168. xist OSC dm If OK check harness for short to e Harness for open or ground and short to power short between glow u relay and ECM ECM o CONNECTOR If NG repair open circuit or am e short to ground or short to Sc power in harness or con nectors ES CHECK HARNESS CONTINUITY y Check the following BETWEEN GLOW RELAY AND GLOW e Harness connectors SEF778V PLUG E85 1 Disconnect glow plug harness connec e Harness for open or s tor short between glow 2 Check harness continuity between glow relay and glow plug 5d Wc 4 aul relay terminal and glow plug har If NG repair open circuit or TS 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 y OK SEF779V EC 153 TROUBLE DIAGNOSES FOR NON DETECTABLE ITEMS Glow Control System Cont d 0 CHECK COMPONENTS NG Replace malfunctioning Glow relay Glow plug componeni s Refer to COMPONENT INSPECTION EC 155 d ER 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 SYSTEM OPERATION CHECK Set voltmeter between glow plug and engine body 1 Quick glow Pre glow system l a Turn ignitio
169. ye MONITOR x Nora LI 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 2 CKPS RPM TDC 3000rpm COOLAN TEMP S 80 C mode with CONSULT Start engine and warm it up to normal operating tem perature 3 Run engine for 2 seconds at 3 000 rpm Return engine RECORD speed to idle then increase to 3 000 rpm under no load 3875141 o OR MH Start engine and warm it up to normal operating tem perature Run engine for 2 seconds at 3 000 rpm Return engine speed to idle then increase to 3 000 rpm under no load 3 Tur ignition switch OFF wait at least 5 seconds and then turn ON 4 Perform Diagnostic Test Mode l 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 F INJ F B DTC 22 ELECTRIC GOV DTC 25 TROUBLE DIAGNOSIS FOR F INJ F B 2 DTC 18 Electric Governor Cont d EC GOVNR 01 BATTERY NENNEN Detectable line for DTC Non detectable line for DTC Refer to EL POWER INJECTION PUMP ELECTRIC GOVERNOR ECM ECCS D CONTROL MODULE F8 Refer to last page Foldout page v21 11142 E127 18114115 E GIS E D mm M50 W EIS 3 4 516 BR 316 KA a

ENGINE CONTROL SYSTEM SECTION EC

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