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'94 Mazda RX-7 Factory Service Manual

Contents

1. F 120 TROUBLESHOOTING GUIDE F 178 CHECK VALVE SPLIT AIR paa ace F 120 QUICK DIAGNOSIS CHART F 178 CHECK VALVE MR danis F 120 RELATIONSHIP F 182 AIR PUMP F 121 USING THIS 184 AIR PUMP DRIVE BELT F 122 DIAGNOSTIC INDEX 186 AIR PUMP RELAY 123 PRECAUTION F 189 SOLENOID VALVE RELIEF2 F 123 SYMPTOM TROUBLESHOOTING F 190 POSITIVE CRANKCASE VENTILATION PCV SERVICE POINTS F 218 SYSTEM F 124 OUTLINE aenean rrr rni F 218 POV VALVE F 124 WIRING DIAGRAM F 224 EXHAUST GAS RECIRCULATION EGR F 125 ELECTRICAL DIAGNOSIS SUPPORT F 228 F INDEX INDEX Intake Air System 1 Fresh air duct Removal Inspection Installation page F 76 2 Resonance chamber Removal Inspection Installation page F 76 3 Air cleaner housing Inspection page F 16 4 Air bypass valve Inspection page F 77 5 Charge air cooler Removal inspection Installation
2. REPAIR REPLACE No DETERMINE IF TROUBLE HAS BEEN ELIMINATED Yes CHECK OUT Diagnostic index TROUBLESHOOTING GUIDE DIAGNOSTIC INDEX Each troubleshooting item is assigned a number Witt start in other than P and N ranges TROUBLESHOOTING ITEM There are 58 troubleshooting items supe colg Choose the item that most closely corresponds to the actual symptom Afer z Engine tials 184 shows indication of fring Sul wil nol run when engine is Enging will not continue sunning when warm when IGN wich retumed kom STA to KG position Cranks normally but Any angine temp Starter cranks engine at normal speed but engine ie hard to start quires excessive cranking fime belore starting al any engine lemperature AN UM aS POM temperature When engine cold ee M SUNT Quire amp exceb v cranking tne dekore starting when DIAGNOSTIC INDEX Refer to page 186 INSPECTION ACTION DESCRIPTION Describes each troubleshooting item E PAGE Shows the reference Starter does not Emm page or section Pee TROUBLESHOOTING GUIDE 9 ANY ENGINE TEMPERATURE CRANKS NORMALLY BUT HARD TO START WHEN ENGINE COLD AFTER WARM UP Starter cranks engine at normal speed but eng
3. 4L as 40 an ar 34 oH fao 90 far 2 2 2 20 28 5 1 0 F 63 F ON BOARD DIAGNOSIS FUNCTION is there poor connection in Lockup off signal circuit between PCME and PCMT 76 SLIP LOCKUP OFF SIGNAL Repair or replace connector Go to next step Go to next step Check for open circuit in wiring harness Is there continuity between PCME terminal 2G and PCMT terminal 2H Is PCMT terminal 2H voltage OK Go to next step Check for cause x page 156 Replace PCME i page 150 Is PCME terminal 2G voltage OK Check for short circuit in wiring harness PCMT PCME Circult Diagram fav Yaw Jau Jas 4o 40 as ae sc ac oe sc pa 21 25 2e ac 2 u s a o jaz fax av ar jan fan 41 4r fan jan aP aN au art ar 90 38 2 22 2 zr v T n P F 64 ON BOARD DIAGNOSIS FUNCTION F CODE No 77 TORQUE REDUCED SIGNAL sree 0 ACEON s there poor connection in torque reduced signal Yes Repair or replace connector circuit between PCME and PCMT Go to next step Yes Goto next step i Check for open circuit in wiring harness i PCMT PCME Go to next step Check for cause s page F 156 Yes Replace PCME page 150
4. a f t UT B Battery positive voltage Correct mem Ignition switch ON Self Diagnosis Buzzer sounded for 3 sec after ignition switch Below 2 5V e With Self checker OFF Diagnosis Check Data link er and System connector FEN Buzzermoteounded orafter3sec Selector e With System Se lector test switch at SELF TEST Buzzer not sounded 4 Malfunction oa illuminated for 3 sec Eo ignition switch 2 5V indicator lamp MIL Lampnotiluminatedafter3sec not illuminated after 3 sec Lamp illuminated Below 5V With system selector test switch at SELF TEST D Cum PIRE ERE o mee eem 7 LL PCME Electrical load ON Ignition switch ON Electrical load OFF 4 5 5 5V F 136 Denn aah a aa SCSEMEONT TNT rA Te T DOUBLE THROTTLE CONTROL SYSTEM F DOUBLE THROTTLE CONTROL SYSTEM DESCRIPTION The response delay of the manifold absolute pressure sensor followed mounted by rapid acceleration tem porarily causes a lean fuel mixture The double throttle control system prevents hesitation caused by this lean fuel mixture by slightly delaying the opening of the double throttle valve after the secondary throttle valve The double throttle valve is controlled by the PCME through the solenoid valve M gt lt ql A PCME E Ge E CHAMBER DOUBLE THROTTLE CONTROL
5. page F 78 6 Throttle body Inspection Adjustment page F 79 7 Double throttle valve Inspection age F 79 8 Actuator Double throttle control Inspection page F 139 F 2 9 Intake manifold Inspection eee 10 Extension manifold Installation 11 Accelerator cable Inspection Adjustment 12 Actuator Turbo control Inspection 13 Actuator Charge control Inspection 14 Change relief valve Inspection 15 Turbocharger Inspection wives Removal Installation 16 Actuator Turbo precontrol Inspection wade 17 Actuator Wastegate control Inspection sare s m m 9 amp 9 b 9 9 9 m 9 v 9 page 88 89 91 89 90 INDEX e F Fuel System and Evapolative Emission Control System 1 Fuel tank Removal Inspection Instaliation 2 Fuel pump Inspection Removal installation Disassembly Assembly 3 Fuel filter High pressure Replacement 4 Pressure regulator Inspection Removal Installation 5 Injector Inspection On vehicle Removal Installation Inspection 6 Pulsation damper Removal 7 Check valve two way Inspection 8 Check v
6. Is air leakage felt or heard at intake air system com ponents at idle Repair or replace Go to next step Go to next step Is fast idle cam OK w page 79 sz page F 79 Connect data link connector terminals F P and GND with a jumper wire is fuel line pressure correct with ignition switch ON ES Low pressure Fuel line pressure RIEF S dei pressure while pinching fuel 250 280 kPa 2 Sedo pet f pressure quickly increases check pressure regulator e page 104 9 f pressure gradually increases check for clogging between fuel pump and pres sure regulator If hose not clogged check fuel pump maximum pressure sz page 101 F 194 ES TROUBLESHOOTING GUIDE F ACTION Yes Goto next step Piug outlet of pressure regulator is fuel line pressure held after ignition Is fuel line pressure held after ignition switch is turned OFF page F 97 Fuel pressure More than 150 kPa 1 5 kgf cm 21 psi PRESSURE switch is turned OFF F 100 If yes replace pressure regulator s page 104 if no check fuel pump hold pressure x page F 101 If fuel pump OK check injectors for fuel leakage s page 106 INSALL CLAMP Are spark plugs OK z Section G Go to next step Repair replace Yes Go to next step Is EGR control system OK
7. 1 NIVN 193 SERVICE POINTS Laza sinus POEET LEN a79 7 n 0 ES a 43 H0SN3S 843 YOSNIS 3univi3dW3l 3 BOSN3S N39AX0 29 18 805836 3B8h SdHd W3 H0SN3S 3gnivH3dW3L 7 W3 SANA 010 3705 BATIYA 01083105 3317034 39HVHO 18 01083708 7081002 311104Hl 319700 66 18 010837105 1081 02 39UVHJ 26 18 W3 01043305 91 II WL WL Ol 3NI9N3 331000W 10H1N02 NIVHINSAOd 10 18 94 8 NOILO3S 07H N011238 91 8 011236 s PED NOISSIWSNVH1 i r 3 SDSN3S04H3H1 300100 30H1N02 Wa 1303 A US NIVULHAAOd 9 8 9 88 A 1 Wa Wa i QU LEM 7 asas T T Tr 8 U8 1 9 8 W3 8 YOSN3S 805 26 N39AXO 320N3 43 3 8 8 432 8 H98 43 8 48 W3 H HB t L 0b 18 bb i8 i b 18 N3 H3 PRE 8 8 8 88 710 warren 806836 ONTUSLIW 1 NOILISOd Ayr 2b i8 1 18 3 10NHi 2 806838 05 18 69 18 i 3ani v 3unLlvu3dN3l ai 18 UIN ANUANI LNY7003 JBIA 9 T 3N19N3 eo quae 9 1 3 5728 amp 18 lb 18 43 H3 Wa WI 3 wa 8 4 M 3 pom pan E W3 A748
8. Shortereu Poorground 3C Oxygen sensor Code No 15 output Code No 15 output NA No symptom symptom mm Manifold absolute pressure sensor Opessruk Shetcreut Poor ground Code No 13 output Code No 13 output PCME 10 Manifoid absolute pres sure sensor Poor acceleration Poor acceleration PCME 3l Manifold absolute pressure 0409 idle Rough idle sensor PCME 4D Manifold absolute pres No symptom sure sensor Steering pressure sensor Condition ee 1N Steering pressure sensor No symptom Idle speed slightly high Mo O O Reduced torque signal slip lock up signal AT eee ee ee Te 1Q PCMT 2P Shift shock slightly increased wa Solenoid valve Shift A AT mes PCME 2K PCMT 1D Shift shock slightly increased PNA Solenoid valve Shift B AT EET EE PCME 21 1B Shift shock slightly increased Stoplight signal Stoplight switch ee LE 15 Stoplight switch STOP fuse 20A burns out SNA Throttle position sensor range Full range Po Condition 025252500000 ae eee PCME 3F Throttle position sensor Code No 18 output Code No 18 output Narrow range Rough idle Rough idle Strong shift shock Strong shift shock AT PCME 3G Throttle position sensor Code No 12 o
9. ACTUATOR KS TURBO PRECONTROL v 1 1 zs ACTUATOR E EXT SECONDARY TURBO CONTROL SOLENOID Ke VALVE WASTEGATE TURBO WASTEGATE CONTROL CONTROL CONTROL VALVE TuRBO VALVE ACTUATOR PRIMARY PRECONTROL WASTEGATE TURBOCHARGER vai ve CONTROL Operation Engine speed Low speed High speed Devices light load Heavy load Boost pressure Turbocharger e contro ON Charge conte Tuo conte d Solenoid valve F 84 PREPARATION SST 49 F088 740 Pressure tester SEQUENTIAL TWIN TURBOCHARGER SYSTEM inspection of turbocharger 49 F018 902 Adapter harness Fo inspection of solenoid valve F 85 SEQUENTIAL TWIN TURBOCHARGER SYSTEM 22 2 TURBO CONTROL TCNT EIL ystem Operation 1 Connect the SST Engine signal Monitor Adaptor Har ness to the PCME as shown 2 Start the engine and verify that the actuator rod is moved once 3 Run it idle 4 Short the PCME terminal 4R and verify that the actuator rod is pulled into the actuator 5 If the actuator rod is not moved check the following condi tion below Vaccum tube Inspect vaccum line fitting connections and components for leaks Refer to page F 10 Vaccum and pressure chamber Visually check for clogging damage or crack Sol
10. 7 If notas specified replace the manifold absolute pressure sensor 8 Cancel the memory of malfunctions by disconnecting the negative baitery cable for at least 20 seconds and de press brake pedal 9 Reconnect the negative battery cable F 167 F CONTROL SYSTEM THROTTLE POSITION SENSOR Inspection 1 Warm up the engine to normal operating temperature and run it at idle 2 Verify the first idle cam separates 3 Stop the engine 4 Connect the SSTs Engine Signal Monitor and Adaptor Harness to PCME CONNECTOR 5 Turn the ignition switch to ON ii 6 Rotate the throttle link by hand verify that the voltage is within specification 49 9200 162 Specification Throttle valve condition PCME Termina Closed throttle Wide open pros position EET throttle Narrow range 0 75 125V 1 0 5 0V 4 8 5 0V THROTTLE lt POSITION S amp SENSOR 7 If not as specified adjust or replace the throttle position sensor Adjustment 1 Warm up the engine to normal operating temperature and run it idle 2 Verify that the first idle cam separates 3 Stop the engine 4 Connect the SSTs Engine Signal Monitor and Adaptor Harness to PCME 5 Turn the ignition switch to ON 6 Loosen the screws and rotate the throttle position sensor to set the correct closed position voltage Refer to Specification above 7 Checkthe correct open position vol
11. Solenoid valve continuity Solenoid valve Charge relief Solenoid valve connector Wiring from solenoid valve to PCME Solenoid valve continuity Solenoid valve Double throttie control Fuel pump relay connector Wiring from relay to PCME Relay continuity Fuel pump relay speed Air pump relay connector Wiring from relay to Relay continuity Air pump relay OFF 24 ON BOARD DIAGNOSIS FUNCTION Injector connector Injector e Wi iring from injector to n second Injector resistance Open circuit Injector connector Injector e Wi E iring from injector to eed second Injector resistance PCMT connector Slip lock up off Wiring from PCMT to PCME signal PCMT Open or Short circuit PCMT connector Torque reduced Wiring from PCMT to PCME signal PCMT Note f more than one failure is present the code numbers will be indicated in numerical order After repairs cancel the code numbers by performing the After repair procedure Refer to page F 66 F 25 F ON BOARD DIAGNOSIS FUNCTION Troubleshooting If a trouble code number is shown on the SST check for the cause by referring to the related chart 02 CRANKSHAFT POSITION SENSOR NE SENSOR CODE No e a
12. B Solenoid vaive Charge control Ignition switch ON Reference value Idle 596 Solenoid valve Turbo control before operates 9596 Solenoid valve Wastegate control Oscilloscope Initial acceleration m 50 13 0V Ignition switch ON idie B Reference value idie 5 Solenoid valve Turbo control after operates 5 Solenoid valve Turbo precontrol Oscilloscope 4 0 10 0V Reference Initial acceleration Engine speed above 3 000 rpm CONTROL SYSTEM F B Battery positive voltage Incorrect voltage Always above 1 0V Refer to Code No 02 Troubleshooting Refer to page F 26 Always 0V or B Refer to Code No 26 Troubleshooting Refer to page F 42 Always below 1 0V or B Refer to Code No 25 Troubleshooting Refer to page 41 Refer to Code No 32 Troubleshooting Refer to page F 47 Always below 1 0V or B Always below 1 0V or B4 Refer to Code No 28 Troubleshooting Refer to page 44 Always below 1 0V or B Refer to Code No 38 Troubleshooting Refer to page F 51 Always below 1 0V or B Refer to Code No 34 Troubleshooting Refer to page F 49 Always below 1 0V or B Refer to Code No 44 Troubleshooting Refer to page F 56 Always below 1 0V or B Refer t
13. F 91 F SEQUENTIAL TWIN TURBOCHARGER SYSTEM 1 Negative battery cable 16 Air hose 2 Under cover 17 Air pipe 3 Braket 18 Charge control valve assembly 4 Three way catalyst assembly Inspection page F 87 5 Insulator 19 Air intake pipe Secondary 6 Oxygen sensor 20 Air intake pipe Primary 7 Warm up three way catalyst 21 Water hose 8 Fresh air duct 22 Oil return pipes 9 Air hoses 23 Oil pipe 10 Air cleaner housing 24 Water hose 11 Accelerater cable 25 Turbocharger Removal installation page 80 Inspection yo eo isch es eee cece cede below Inspection Adjustment page F 80 26 Actuator Turbo control 12 Pressure chamber 5 2254220 0455155 page 86 13 Air pipe 14 Drive belt 15 Air pump ACTUATOR d Installation Note CC 1 Verify that the paint mark on the actuator rod is aligned with actuator braket end 2 If the mark is not aligned adjust the actuator rod length LOCKNUT BRACKET END 3 Check the stud bolt tighting torque before installing turbo charger Tighting torque 16 24 N m 1 6 2 4 kgf m 12 17 ft Ibf 8 12 N m 0 8 1 2 kgf m 5 8 8 7 ft Ibf Inspection 1 Be sure the engine is cool 2 Remove the turbocharger 3 Check that the compressor wheel assembly turns smoot ly 4 If there is excessive drag or noise replace the turbochar ger F 92 Musis OPCBAE OR ar s DY SEQ
14. page F 126 Check as follows Solenoid valve EGR for sticking Condition of solenoid valve connector fe male terminal s Try known good PCME does condition improve ss page 150 F 195 F TROUBLESHOOTING GUIDE IDLE AT ANY ENGINE TEMP DURING FAST IDLE ENGINE STALLS IDLE AFTER WARM UP DESCRIP Engine stops unexpectedly at idle and or during fast idle operation TION TROUBLESHOOTING HINTS Injector EGR control valve Fuel leakage from injector s EGR control valve stuck Injector s clogged idle air control valve Fuel pump Poor connection of connector Poor connection of connector Crankshaft position sensor Fuel pump relay Poor connection of connector Poor connection of connector Spark plug 9 Poor connection of connector Dirty or worn spark plug s Igniter Manifold absolute pressure sensor Poor connection of connector Poor connection of manifold absolute pressure sensor connec Metering oil pump tor Malfunction of oil pump 00 displayed f symptom occurs at idle at any engine temp go to next step f symptom occurs during fast idle opera tion go to next step f symptom occurs at idle after warm up go to Step 6 Is 00 displayed on SST with ignition switch ON page 20 Trouble Code No displayed Check for cause Refer
15. 00 displayed on SST with ignition switch ON page F 20 Go to next step 49 8019 9 Trouble Code No displayed Check for cause Refer to specified check sequence er page F 22 Check idle air control valve and replace it if necessary er page F 83 if OK go to ENGINE STALLS IDLE WHEN SHIFTED FROM or P TO OTHER RANGES in Section of this manual No Try known good PCME and check if condi tion improves t page F 150 Is terminal voltage at POME correct at idle page F 150 4Q terminal Approx 5 11V at idle F 198 TROUBLESHOOTING GUIDE F 1 swawesmus C b0RVEAWN DESCRIP Engine stops unexpectedly upon driveaway TION Idle condition normal TROUBLESHOOTING HINTS Injector Fuel filter Engine coolant temperature sensor Fuel leakage from injector s Fuel filter clogged Poor connection of connector 9 injector s clogged Metering oil pump Crankshaft position sensor Q Pressure regulator Poor connection of connector Malfunction of sensor 9 diaphragm damaged smp ts 00 displayed on SST with ignition switch ON 00 displayed page 20 Go to next step 49 8019 SAD Trouble Code No displayed Check for cause Refer to specified check sequence t page 22 Using Engine Signal Monitor do voitage reading and Y
16. LL 28 Idle fluctuates idle hunts 29 Hesitates Stumbles on acceleration fo ol fol fol 111 fof fof 30 Surges while cruising _ 31 Lackot power LT TT To lo Jol TTT TT lel 1 32 Poorfueleconomy 33 ACdoesnotwork TT TTT TTT ETE TT 34 Knocking Pinging TE TT fof TTT TTT TTT TTT o 35 Fuelodor EET 36 Exhaustsuttursmel TEE TTT To PTET TTT EE TT ET TT fof T 87 Highoitconsumption TTT TTT TTT TTT ET TT EE ETT ETE TT 38 Sett Diagnosis Checker flashes88 TT TTT 1711 39 SeltDiagnosis Checker will notwork T TT TTT TITEL TTT TT iti titi ti 180 TROUBLESHOOTING GUIDE F Possible parts and reference page CONTROL SYSTEM INPUT SIGNAL OTHERS we 169 170 168 172 J E LF 175 F i34 FF i78 2172 LF 173 143 Oxygen sensor B 5 o 5 5 2g E SIEIS Qo ol x 2 8 sists Iv LZ X eL H LHeststes Stumbles on acceleration 20 a SE Lack of power 1 Poor fuel economy 32 A C does not work 33 ps Burgos white cruising 3 EJ Knocking Pinging 3 3 35 Exhaust sulfursmell LELISLLISLLELLISLLLLLLLLLLLLL Llo Hion oitconsumption 97 PPE TTT TT TTT oof Setbiagness Checkerfishes
17. f the solenoid valve or circuit has an open or short Trouble Code No 34 is output f the circuit is open the valve will always closed throttle position causing rough idle and hard starting If the circuit is shorted the valve will always wide open throttle causing high idle speed After warm up engine hunts at approx 1500 rpm igniter if a trailing igniter or circuit has an open or short idle speed will be slightly decreased and poor accelera tion will be cased f the leading igniter or circuit has an open or short hard starting and rough idle will be caused MEN Terminal Data Link Connector f the circuit is open the monitor lamp will not illuminate f the circuit is shorted the monitor lamp will stay on Metering oil pump f the pump or circuit has an open or short Trouble Code No 26 27 are output Inthe above conditions PCME fixes ignition timing and fuel injection amount causing engine poor accel eration PCMT AT Refer to section K 221 F SERVICE POINTS Secondary air bypass valve f the solenoid valve or circuit has an open or short Trouble Code No 31 is output If the circuit is open no symptom will be noticed If the circuit is shorted solenoid valve will be always open and CO and HC will be increased Secondary air switching valve if the solenoid valve or circuit has an open or short Trouble Code No 32 is output If the circuit
18. s ae ec aa Jaw E B Tex T fax av fa ja v c fo foe F 52 ON BOARD DIAGNOSIS FUNCTION F 40 SOLENOID VALVE PURGE CONTROL PURGEJ Does solenoid valve circuit have a poor connection Repair connector and or wiring harness Go to next step Go to next step Check for open or short circuit in wiring harness Solenoid valve B terminal Main relay D terminal Is connector B terminal voltage OK with solenoid valve connector disconnected Condition Voltage Ignition switch ON Battery positive voltage Is there continuity between solenoid valve A terminal and PCME terminal 3H Check for short circuit in wiring harness Solenoid valve A terminal PCME terminai 3H x If OK go to next step If not OK repair wiring harness Repair wiring harness Replace PCME sz page 150 Replace solenoid valve page F 131 Is solenoid valve OK SOLENOID VALVE PURGE CONTROL PURGE EG MAIN RELAY av su as 40 Jav ax ac ae po po o ao Sc aa ox 2 ao 2e ac u s o o M KT e E 6 42 ax av 47 jap jan 4L 4J 4r j4D aP an jat 3 3H aF aD fat 22 2 Jar 20 28 vi rjiR P NjUL J H F F 53 F ON BOARD DIAGNOSIS FUNCTION
19. ESTED PE 2 SS 222222222222722 LULA j Snn eu DRAIN PLUG page F 77 11 Throttle body Inspection isd sive page F 79 12 Extension manifold Inspection EBEN eu page F 79 13 Fuel hose 14 Connector page F 16 15 Vacuum hose 16 Intake manifold Inspection F 79 17 idle air control valve inspection page F 83 18 Solenoid valve AWS Inspection page F 83 19 Charge air cooler Removal Inspection Installation page F 78 Removal Note 1 Loosen the drain plug and radiator cap and drain the cool ant from radiator A 2 Remove the water hose from the throtlle body 3 After installation of the throttle body refill the radiator Re fer to section E Installation Note Install the air intake hose clamp and hose same place as shown in the figure AIR BYPASS VALVE Inspection 1 Remove the air bypass valve 2 Connect a vaccum pump to the air bypass valve port A 3 Check the operation of the air bypass valve Fully open Apply approx 14 22 kPa 70 100 170 mmHg 3 9 6 7 inHg Apply approx 31 3 kPa 235 mmHg 9 2 inHg F 77 Fo INTAKE AIR SYSTEM CHARGE AIR COOLER Removal Inspection Installation 1 Remove in the order shown in the figure 2 inspect the charge air cooler visually and repair or replace if necessary 3 Install in the rev
20. Engine speed 3 000 rpm 1 8 2 2V Initial acceleration Slip iock up OFF signal Engine speed hold 3 000 rpm after 8 se Below 10V Initial acceleration conds Ignition switch ON Barometric abso lute pressure sig nal Approx 5V Powertrain control module Transmission AT Powertrain control module Transmission AT Powertrain control module Transmission AT Idle signal Powertrain control module Transmission AT Ignition switch ON Below 2 0V Idle Temp Below 100 C 212 F Idle Temp Above 100 C 212 F Below 1 0V Below 1 0V Engine speed Idle Below 3 250 rpm CONTROL SYSTEM F 2 B Battery positive voitage Always B Clutch switch malfunction Refer to page F 173 Open circuit in wiring from clutch switch to terminal 10 Always below 1 0V Clutch switch malfunction Refer to page F 173 Short circuit in wiring from clutch switch to terminal 10 Always B4 Open circuit in wiring from PCME terminal 1Q to PCMT terminal 2P Always below 1 0V Short circuit in wiring from PCME terminal 10 to PCMT terminal 2P Always below 1 0V Neutral switch malfunction Refer to page F 172 Short circuit in wiring from neutral switch to PCME terminal 1R Always Neutral switch malfunction Refer to page
21. F CODE 25 SOLENOID VALVE PRESSURE REGULATOR CONTROL PRC ACTION Does solenoid valve circuit have a poor connection Repair connector and or wiring harness od Go to next step Go to next step Check for open or short circuit in wiring harness Solenoid vaive A terminal Main relay D terminal Is connector A terminal voltage OK with solenoid valve connector disconnected Condition Vola Ignition switch ON Battery positive voltage Is there continuity between solenoid valve B terminal and PCME terminal 4M Check for short circuit in wiring harness Solenoid valve B terminal PCME terminal 4M gt If OK go to next step c If not OK repair wiring harness Repair wiring harness Replace PCME page 150 Replace solenoid valve Is solenoid valve OK page 176 Circuit Diagram SOLENOID VALVE PRESSURE REGULATOR CONTROL PRC EGI MAIN RELAY F FUEL TEMP SENSOR EM a Tas AE p Bo La 4j a ar je so 5N 3 fag 3c px 21 26 2E jac 2 u sj ajo M Kk 3 jar ap joe fat 2 12 2 20 v TjR lH FiO Ss 41 ON BOARD DIAGNOSIS FUNCTION 26 METERING OIL PUMP STEPPING MOTOR SrEP INSPECTION 2 Are there any poor connections at metering oil pump Yes Repair or replace connector and PCME connector
22. Go to next step 5 Replace MOP Yes Repair wiring harness MOP Main relay C SMA C SME DMB O ae D SMF Is continuity between MOP stepping motor and PCME terminals OK ae oc d ERES GG 4L Repair wiring harness MOP PCME terminals 4 Sur 4 Disconnect negative battery cable for at least 20 seconds Connect battery cable and recheck for trouble code Is trouble code displayed Yes Replace PCME Circuit Diagram MAIN RELAY POSITION SENSOR METERING OIL PUMP EGI MAIN RELAY F au s Jao Jam ai aE 4c fao fam fak az fax av jan an at 4u 40 48 F 42 TOR ON BOARD DIAGNOSIS FUNCTION F B Battery positive voltage 27 METERING PUMP Repair or replace connector ps Go to next step Is PCME terminal voltage OK Go to step 4 Condition Voltage o d f 1 0 4 2 Are there any poor connections at metering oil pump and PCME connector Is resistance of MOP position sensor OK Yes Gotonext step Resistance J H 0 4 12 pun Replace MOP J 10 2 Go to step 7 H I 0 4 12 kQ li Go to next step Yes Goto next step Replace Repair wiring harness MOP Main relay 15 PCME terminals voltage OK Specification Idie
23. Goto next step x page 134 Adjust is intake manifold vacuum correct at idie Yes Go to next step Check as follows Intake air system components for proper installation Vacuum hoses for disconnection and damage Engine compression ss Section Are injectors OK Yes Goto next step 106 lbs Go to next step Check for cause sr Section Vacuum More then 60 0 kPa 450 mmHg 17 7 inHg Is engine compression er Section Compression 690 kPa 7 0 kgf cm 100 psi 250 rpm Differential limit of chambers 150 kPa 1 5 kgf cm 21 psi 250 rpm atit TROUBLESHOOTING GUIDE F aa a E E LE ee DRIVEAWAY 2626 POOR ACCELERATION ON ACCELERATION one Engine speed increases normally but vehicle speed slowly increases during driveaway or acceleration N TROUBLESHOOTING HINTS Injector Crankshaft position sensor Fuel leakage from injector s Poor connection of connector injector nozzle clogged Metering oil pump Pressure regulator Malfunction of oil pump Pressure regulator malfunction Fuel injection amount and ignition timing fixed Fuel filter Solenoid valve Turbo control Charge control Filter clogged Malfunction of solenoid valve amp Spark plug Fuel injection amount and ignition timing fixed Misfire EGR control system Igniter FOR control valve stuck open Poo
24. Re fer to page F 152 F 143 F ELECTRICAL COOLANT FAN CONTROL SYSTEM ELECTRICAL COOLANT FAN CONTROL SYSTEM DESCRIPTION To improve idle smoothness and engine reliability the electrical coolant fan control system controls the electrical fan speed by PCME This system consist of the coolant fan fan relays PCME and input devices ENGINE COOLANT TEMPERATURE SENSOR IGNITION SWITCH IGNITION SWITCH FAN RELAY NO 1 TO DATA LINK CONNECTOR TFA TERMINAL 5 lt WATER THERMOSWITCH Operation electrical load operation No 1 No 2 No 3 No 4 operation or ow on ow moe Coolant temperature above 108 C 226 F Water thermoswitch ON F 144 ELECTRICAL COOLANT FAN CONTROL SYSTEM PREPARATION SST 49 F018 902 For inspection Adaptor ae of solenoid harness valve 145 F 146 ELECTRICAL COOLANT FAN CONTROL SYSTEM ELECTRICAL COOLANT FAN SYSTEM OPERATION n E 1 Connect the data link connector terminals TFA and GND with a jumper wire 2 Turn ignition switch ON 3 Verify that electrical coolant fans operate Inspection 1 Connect the SST Engine Signal Monitor Adaptor Har ness to the PCME 2 Turn ignition switch ON 3 Short the PCME terminals and verify that the coolant fan operate as following condition below Fan reay _ 4 If not as specified check the harness and relays
25. c if continuity repair or replace wiring If no continuity go to next step Ed Repair wiring harness Try known good knock sensor is same code No Replace PCME sz page F 166 present 1 Replace knock sensor page F 171 Circult Diagram SHIELD SENSOR fav Jaw at 4S ex a ae Jac nA 50 poa 5 31 e Bc sn Be e oA v Ta TOTMTKT T T8 TETE TA az fax av er jan fav c Jar juo jo fo oe 53 poe ae joo c 2o an a stall S 28 ON BOARD DIAGNOSIS FUNCTION F 06 VEHICLE SPEED SENSOR Yes Goto next step Go to step 5 Check for PCMT trouble code Yes Gotostep5 Is code No 07 also present Go to next step Does vehicle speed sensor circuit have a poor con Yes Repair connector and or wiring harness nection Go to next step _ Is there vehicle speed sensor terminal 1M voltage Yes Check for open or short circuit wiring har OK ness Vehicle speed sensor terminal SE PCME terminal 1M Condition Vota woan Remove vehicle speed sensor is resistance felt when turning sensor driven gear by hand gt If OK go to step 8 If not OK repair wiring harness Go to next step Yes Goto next step Replace vehicle speed sensor Disconnect vehicle speed sensor connector and con Yes Goto next step nect circuit tester Does pointer of circuit fester
26. is resistance of MOP stepping motor OK Terminal Resistance es Is continuity between MOP stepping motor and PCME terminals OK c 988 US Disconnect negative battery cable for at least 20 seconds Connect battery cable and recheck for trouble code Is trouble code displayed Repair wiring harness MOP PCME terminals Intermittent poor connection check for cause Circuit Diagram Refer to page 42 F 43 F ON BOARD DIAGNOSIS FUNCTION 28 SOLENOID VALVE EGR Yi Repair connector and or wiring harness Go to next step Go to next step Condition Voltage Check for open or short circuit in wiring harness Solenoid valve B terminal Main Does solenoid valve circuit have a poor connection Is connector B terminal voltage OK with solenoid valve connector disconnected Ignition switch ON Battery positive voltage relay D terminal is there Continuity between solenoid valve A termi nal and PCME terminal 4O Check for short circuit in wiring harness Solenoid valve A terminal PCME terminal 40 c if OK go to next step c If not OK repair wiring harness Repair wiring harness Replace PCME page F 150 Replace solenoid valve Is solenoid valve OK i page 176 Circuit Diagram SOLENOID VALVE EGR EGI MAIN RELAY F SOLENOIO VALVE E G RHEN a faa ae
27. page F 150 2 Crankshaft position sensor Removal Installation page 166 Manifold absolute pressure sensor _ Inspection page F 167 4 Throttle position senso Inspection Adjustment page 168 Removal Installation page F 169 5 Engine coolant temperature sensor Removal installation Inspection page 169 6 Intake air temperature sensor Removal installation T Inspection page F 169 7 Fuel thermosensor 3 Removal Installation Inspection page F 170 8 Oxygen sensor Inspection page F 170 Removal Installation page 113 9 Knock sensor Inspection On vehicle Removal Installation page F 171 10 Steering pressure sensor Inspection On vehicle Removal Installation 11 Stoplight switch Inspection Removal Installation 12 Neutral switch MT Inspection Removal installation 13 Clutch switch MT Inspection Removal Installation 14 1 2 switch MT Inspection Removal Installation 15 EGR Function Sensor Inspection Removal Installation 16 Mileage switch 17 Heat hazard sensor Inspection Removal installation 18 E L unit Inspection Removal Installation page 172 eus page F 172 page F 172 page F 173 page F 173 dena e page F 173 page F 127
28. 0 0 0 4 Coolant fan Electrical coolant fan does not relay operating During electrical coolant fan Below 1 0V operating TFA terminal of data link connector is Below 1 0V Ignition switch ON grounded Engine coolant Engine coolant temperature 20 C 68 F Approx 2 5v ignition switch ON temperature Throttle posi Accelerator pedal released 0 75 1 25 tion sensor Narrow range Accelerator pedal fully depressed 4 8 5 0 Throttle posi Accelerator pedal released 0 1 0 7 tion sensor Full range Accelerator hea fully depressed 4 2 4 6 After warm up Engine speed 1 500 3 300 rpm 9 ignition switch ON After warm up ignition switch ON Solenoid valve purge control 158 Tw CONTROL SYSTEM F B Battery positive voltage Incorrect voltage Possible cause Always below 1 0V 9 Short circuit in wiring from 1 2 switch to PCME terminal 2K 9 1 2 switch malfunction Refer to page F 173 Always B Open circuit in wiring from 1 2 switch to PCME terminal 2K 1 2 switch malfunction Refer to page F 173 Always below 1 0V Short circuit in wiring from PCMT terminal 1D to PCME terminal 2K Always B Open circuit in wiring from PCMT terminal 1D to terminal 2K Always below 1 0V 9 Short circuit in wiring from 1 2 switch to PCME terminal 2L 1 2 switch malfunction Refer to page 173 Always B Open circuit in wiring from 1 2 switch to PCME t
29. 45 output Lack of power Poor acceleration NA EGI INJ fuse 30A burns out when ignition switch ON Solenoid valve Charge relief Lack of power 4S Solenoid valve Poor acceleration Opecrui Shotcrut Peorground Code No 46 output Code No 46 output Momentarily Intake air noise on acceleration Solenoid valve Main relay INJ fuse 30A burns out MAE when ignition switch ON Solenoid valve Double throttle control Poor acceleration Short creut Poor ground PCME 30 Solenoid valve Code No 50 output Code No 50 output Poor acceleration Hesitation when engine cold Solenoid valve Main relay EGI INJ fuse 30A burns out when ignition switch ON Solenoid valve EGR ANE NENNT PCME 40 Solenoid valve Code No 28 output Code No 28 output Engine stall j Hard starting NA Solenoid valve Main relay INJ fuse 30A burns out when ignition switch No symptom NA Not applicable Code No 32 output No symptom FKTIWEBENDOCE SLOT ART SIS EE PM E TAO mmm a F 234 gt SERVICE POINTS F Code No 40 output No symptom Solenoid valve Port air bypass PCME SN Solenoid valve Code No 33 ou
30. CODE No m 42 SOLENOID VALVE TURBO PRECONTROL Smp meon _ A Does solenoid valve circuit have a poor connection Repair connector and or wiring harness pes Go to next step Go to next step Check for open or short circuit in wiring harness Solenoid valve B terminal Main relay D terminal Is connector B terminal voltage OK with solenoid valve connector disconnected Condition Ignition switch ON Battery positive voltage Is there continuity between solenoid valve A terminal and PCME terminal 4V Check for short circuit in wiring harness Solenoid valve terminal PCME terminal 4V if OK go to next step c If not OK repair wiring harness Repair wiring harness Replace PCME page 150 Replace solenoid valve Is solenoid valve OK s page F 93 Circuit Diagram SOLENOID VALVE TURBO PRECONTROL MAIN RELAY F SOLENOID VALVE F 54 ON BOARD DIAGNOSIS FUNCTION F CODE No 5 43 SOLENOID VALVE WASTEGATE CONTROL Repair connector and or wiring harness pe Go to next step Go to next step Check for open or short circuit in wiring harness Solenoid valve B terminal Main relay D terminal is connector B terminal voltage OK with solenoid valve connector disconnected Ignition switch ON Battery positive voltage Is there continuity between solenoid valve A terminat a
31. Check for short circuit in wiring harness Is there continuity between PCME terminal 2D and PCMT terminal 2C is PCMT terminal 2C voltage OK Is PCME terminal 2D voltage OK Circuit Diagram E fa au aS ec Jaa E c n x a e pe n v Ta ow STE T6 42 av at 40 48 j3P fon 3t Jau aH aF ap at 2 2 jr 20 28 v Tj R Pj Nj UL 0 F 65 ON BOARD DIAGNOSIS FUNCTION After repair Procedure Cancel the memory of trouble code number by disconnect ing the negative battery cable for 20 sec and depress the brake pedal Reconnect the negative battery cable Self Diagnosis Checker 1 Connect the SST System Selector to the data link con nector 2 Set system select to position 1 3 Set the test switch to SELF TEST 4 Connect the SST Self Diagnosis Checker to the System Selector and a ground 5 Set the select switch of the Self Diagnosis Checker to position A 6 Turn the ignition switch ON 7 Verify that no trouble code numbers are displayed 66 ON BOARD DIAGNOSIS FUNCTION SWITCH MONITOR FUNCTION Individual switches can be inspected by the SST Self Diagnosis Checker Preparation The TEN terminal of the data link connector must be grounded and the ignition switch turned
32. MT 17 Power steering operation 17 Steering pressure sensor 18 Braking signal 18 Stoplight switch 19 Starter signal 19 Ignition switch 20 Electrical Load E L condition 20 unit 21 EGR condition 21 EGR function sensor Control operation of the following 1 Fuel injection system 2 Ignition control system 3 Idle speed control system 4 Pressure negulaton control system 5 Secondary air injection Injector Igniter Solenoid valve Idle air control Solenoid vaive Pressure Regulator control Solenoid valve Split air bypass SAB Solenoid valve Port air bypass PAB Secondary air switching valve Solenoid valve Relief No 2 RELIEF2 Secondary air bypass valve Solenoid valve AWS Solenoid valve Turbo contro No 1 TCNT1 Solenoid valve Turbo control No 2 TCNT2 Solenoid valve Wastegate control WGONT Solenoid valve Turbo precontrol TPCNT Solenoid valve Change control CCNT Solenoid valve Change relief CRF 6 Accelerated warm up System 7 Sequential twin turbocharger control system 8 Exhaust Gas Recirculation control system Solenoid valve EGR 9 Double throttle control system Solenoid valve DTCNT 10 A C control system relay 11 Electric coolant fan contro system Fan relay 12 Lock up control system PCMT 13 Slip control system PCMT 14 On board diagnosis function Self diagnosis checker
33. PRESSURE REGURATOR F 104 ENGINE COOLANT TEMPERATURE 2 e 223545 565 665 sU uus EE REF eeu F 105 SENSOR ccce nere oorr rro F 169 FUEL PUMP CONTROL SYSTEM F 108 INTAKE AIR TEMPERATURE SENSOR F 169 FUEL PUMP RESISTOR 109 FUEL THERMOSENSOR 170 FUEL PUMP RELAY SPEED F 110 OXYGEN SENSOR F 170 PRESSURE REGULATOR CONTROL PRC KNOCK SENSOR F 171 SYSTEM 25452555056 111 STEERING PRESSURE SENSOR sates qaa 172 SYSTEM OPERATION entice cx nr Ex ede R EA F 112 STOPLIGHT SWITCH F 172 EXHAUST SYSTEM PI F 113 NEUTRAL SWITCH MT F 172 COMPONENT PARTS exu Er Rx EEEREK EA F 113 CLUTCH SWITCH MT F 173 OUTLINE OF EMISSION SYSTEM F 114 1 2 SWITCH MT ae wis F 173 OS TRUCTUAL TP F 114 MAIN RELAY EGI RELAY 174 SECONDARY AIR INJECTION F 115 FUEL PUMP RELAY 174 AIR CONTROL VALVE ACV F 117 HEAT HAZARD SENSOR F 175 SOLENOID VALVE PORT AIR BYPASS F 719 MILEAGE SWITCH F 175 SOLENOID VALVE SPLIT AIR BYPASS ore F 120 SOLENOID VALVES F 176 CHECK VALVE PORT AIR
34. Remove the 1 2 switch 3 Install in the reverse order of removal Tightening torque 25 34 N m 2 5 3 5 kgf m 18 25 ft Ibf F 173 F CONTROL SYSTEM MAIN RELAY EGI RELAY Inspection On vehicle Check that a clicking sound is heard at the main relay when turning the ignition switch OFF and ON inspection 1 Disconnect the main relay 2 Apply battery positive voltage and ground to terminals A and B of the main relay 3 Check continuity of the relay B Battery positive voltage FUEL PUMP RELAY inspection On vehicle Check that a clicking sound is heard at the fuel pump relay when turning the ignition switch OFF and ON Inspection 1 Disconnect the fuel pump relay 2 Apply battery positive voltage and ground to terminals and B of the fuel pump relay 3 Check continuity of the relay B Battery positive voltage em Continuity 1 Not applied F 174 CONTROL SYSTEM F HEAT HAZARD SENSOR HEAT HAZARD inspection Warning system WARNING LIGHT 1 Turn the ignition switch to ON and verify that the heat haz ard warning light illuminates 2 Start the engine and verify thatthe warning lamp goes out 3 Disconnect the heat hazard sensor connector 4 Check that the heat hazard warning light illuminates on when a jumper wire is connected to the terminals of the sensor connector harness side Removal 1 Remove the right front seat 2 Lift up the floor mat 3
35. Yes 00 displayed Go to next step Trouble Code No displayed Check for cause Refer to specified check sequence Is 00 displayed on SST with ignition switch ON zr page 20 49 B019 SAO page F 22 Check spark plug s If OK go to next step If not OK clean or replace spark plug s Check ignition system Is strong blue spark visible at each disconnected high tension lead at idle Section G HIGH TENSION LEAD Is fuel line pressure correct at idle s page 104 Low pressure Check fuel line pressure while pinching fuel return hose 9 If pressure quickly increases check pressure regulator page 104 f pressure gradually increases check for clogging between fuel pump and pres sure regulator If hose not clogged check fuel pump maximum pressure ex page 101 Fuel line pressure 190 220 kPa 1 9 2 3 kgf cm 2 28 32 psi PRESSURE INSALL CLAMP F 212 the a ET ARERR SITE TRU IUE I ret TROUBLESHOOTING GUIDE F Go to next step Check pressure regulator Go to next step Repair or replace Try known good PCME does condition improved s page 150 Does fuel pressure increase when throttle valve opened engine running 104 Are following terminal voltage at PCME correct Go to next step s page F 154 10
36. ac pa ax 21 as 26 2c 2 u at 34 aF 30 21 22 2 2F j20 28 v F 44 ON BOARD DIAGNOSIS FUNCTION F 30 SOLENOID VALVE SPLIT AIR BYPASS ACTION Repair connector and or wiring harness Go to next step Does solenoid valve circuit have a poor connection valve connector disconnected Voltage Check for open or short circuit in wiring harness Solenoid valve A terminal Main Ignition switch ON Battery positive voltage relay D terminal Is there continuity between solenoid valve B terminai Yes Check for short circuit in wiring harness and PCME terminal 4F Solenoid valve terminal PCME terminal 4F If OK go to next step If not OK repair wiring harness Is connector A terminal voltage OK with solenoid Go to next step Repair wiring harness Yes Replace PCME esr page F 150 Is solenoid valve OK page F 120 Replace solenoid valve Circuit Diagram SOLENOID VALVE SPLIT AIR BYPASS EGI MAIN RELAY SPLIT AIR BYPASE av ax a Joa 50 m 5e n o foe oc fea ar joe v 2a jon ar oo F 45 F ON BOARD DIAGNOSIS FUNCTION action Repair connector and or wiring harness Go to next step Go to next step Check for open or short circuit in wiring harness Solenoid valve B terminal Main relay D terminal Does solen
37. fakes page 175 ore eS page F 175 Uum page F 136 Seis teks page F 150 F 5 F Control System Output Devices INDEX PRESSURE REGULATOR NTROL CONTRO GE RELIEF Q ECONDARY AIR BYPASS VALVE RN ECONDARY AIR SWITCHING VALVE TURBO CONTROL E CONTROL CONTROL 4 IGNITER SERVICE SECTION G 1 Main relay 10 Solenoid valve Relief 2 Inspection page F 174 Removal Installation page F 119 2 Fuel pump relay Inspection 119 inspection page F 174 11 Solenoid valve Split air bypass 3 Solenoid valves Removal installation page F 119 Removal Installation page F 176 Inspection page F 120 Inspection page F 177 12 A C relay 4 idle air control valve page F 142 Removal Installation page F 83 13 Fan relay Inspection NET page F 83 Inspection 2 page F 146 5 Solenoid valve AWS 14 Fuel pump relay speed Removal Installation page F 83 Inspection page 110 Inspection page F 83 15 Fuel pump resistor 6 Solenoid valve Turbo precontrol Removal Installation page F 109 Removal installation page 93 Inspection page 109 Inspection eee nnn page F 93 16 relay 7 Solenoid valve Wastegate control Ins
38. sg Outpt hc e LL a TEN terminal of data link connector is grounded F 11 F OUTLINE COMPONENT DESCRIPTIONS Component Function 7 Remak t2swich Detects gear postion ist 2nd MT Actuator charge control Controls charge control valve oom Actuator Double throttle contrat Controls double trots vave inssledonexensonmantod Air Bypass Valve Reduces sound of intake air entering air clean er housing from turbocharger deceleration Air Cleaner Element Filters air entering throttle chamber Oil permeated type Air Control Valve Directs air to one of three locations exhaust Consists of two valves port three way catalyst or relief air silencer Secondary air bypass valve Secondary air switching valve Airpump Supplies secondary air to air control valve With electromagnetic clutch Barometric Absolute Pressure Detects atmospheric pressure sends signal to Built in Sensor PCME Charcoal Canister Stores fuel tank fumes when engine is stopped Vented to atmosphere through charcoal and air filter Detects clutch condition engaged disen MT only gaged Crankshaft position Sensor Detects eccentric shaft angle at 30 intervals and front rotor position sends signal to PCME Dashpot Prevents sudden throttle valve closing during deceleration Data link connector Service connector ter
39. ss page F 171 35 FUEL ODOR DESCRIP Gasoline smell or visible leaks TION TROUBLESHOOTING HINTS 9 Solenoid valve purge control 9 Open harness Code No 26 output Charcoal canister Canister full of fuel and leaking 36 EXHAUST SULFUR SMELL DESCRIP Rotten egg smell sulfur from exhaust TION TROUBLESHOOTING HINTS High sulfer content fue used HIGH OIL CONSUMPTION DESCRIP Oil consumption excessive TION TROUBLESHOOTING HINTS D Metering oil pump Malfunction of metering oil pump Open or short in wiring harness valve PCV valve stuck open F 216 page 131 STR Section D ss page 124 TROUBLESHOOTING GUIDE F DESCRIP TION SELF DIAGNOSIS CHECKER FLASHES 88 Checker flashes 88 with test connector TEN grounded TROUBLESHOOTING HINTS Short circuit in wiring between data link connector terminal FEN and PCME terminal 1F PCME malfunction DESCRIP TION Self Diagnosis Checker indicates Trouble Code No of input device but MIL never ON TROUBLESHOOTING HINTS X Bulb burnt Electrical load unit 1K terminal circuit open page 135 217 RR a PE STAT I OL TEIN A F SERVICE POINTS SERVICE POINTS OUTLINE Power and Ground Main relay Battery power If the circuit is shorted the INJ fuse 30A will burn out PCME ground Injector An open circuit will not
40. 0 140 41 4G fae fac An Fan ar Jau aF 40 4A eo sk 3 foa pA 36 za ae av a au jn ar joo joa at 2 24 ON BOARD DIAGNOSIS FUNCTION F CODE No 94 SOLENOID VALVE IDLE AIR CONTROL Does solenoid valve circuit have a poor connection Repair connector and or wiring harness Go to next step Go to next step Check for open or short circuit in wiring harness Solenoid valve B terminal Main relay D terminal 15 connector B terminal voltage OK with solenoid valve connector disconnected Condition ignition switch ON Battery positive voltage Is there continuity between solenoid valve A terminal and PCME terminal 4Q Check for short circuit in wiring harness Solenoid valve A terminal PCME terminal 4Q If OK go to next step gt If not OK repair wiring harness Repair wiring harness Replace PCME v page 150 ba Replace solenoid valve Is solenoid valve OK page 83 SOLENOID VALVE IDLE AIR CONTROL ISC EGI MAIN RELAY F ee oa xo Te ATCT Aag EJ Eg plaz 4x av Jn ap Jat au 4r 40 48 aP an fat fan ar 30 38 2 2u jan 2F 49 ON BOARD DIAGNOSIS FUNCTION CODE No 37 METERING OIL PUMP srp 1 INSPECTION O O o Specification 12 14 at idle Re
41. 126 F 204 TROUBLESHOOTING GUIDE F ae IDLE WITH A C P S AND OR ON mm ENGINE ROUGH IDLE WHEN SHIFTED FROM OR P TO OTHER RANGES Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at idle when A C P S and or E L ON Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at idle when shifted from P or N to other range TROUBLESHOOTING HINTS Idle speed Idle air control valve Idle speed too low Solenoid valve stuck Q Monitor switch function SST Air conditioning sensor Headlight switch Rear window defroster switch 9 Blower switch DESCRIP TION Yes Goto next step Is idle speed correct sr page F 16 page F 16 Is 00 displayed on SST with ignition switch ON 00 displayed s page F 20 Go to next step 58 39 8012 9A0 Trouble Code No displayed Check for cause Refer to specified check sequence c page 22 Are following terminal voltage at PCME correct Go to next step s page 1 1E Air conditioning sensor 1N Steering pressure sensor 1R AT Electrical load unit 3D Electrical coolant fan Check for cause f symptom occurs at idle with A C ON check A C system in section U of this ma
42. 15 Monitor function Self diagnosis checker 16 Back up function Pressure regulator Adjusts fuel pressure supply to injectors S Secondary air bypass vaive Controls relief valve Installed below extension manifold Secondary air switching valve Controls switching valve of air control valve Installed below extension manifold Puisation dumper Absorbs fuel pulsations Solenoid valve TCNT2 Controls turbo contro valve Installed below extension manifold vacuum i applied Solenoid valve IAC Supplies bypass air into intake manifold Controlled by duty signal from PCME olenoid valve SAB Controls split air volume e Installed in ACV Solenoid valve PRC Controls vacuum to pressure regulator Installed below extension manifold F 13 F OUTLINE Component Remark Solenoid valve WGCNT Controlled by duty signal from PCME Solenoid vaive TPCNT Controlled by duty signal from PCME Soienoid valve CCNT Installed below extension manifold Solenoid valve CRF Installed below extension manifold Solenoid valve EGR Installed below extension manifold Solenoid valve DTCNT Controls double throttle valve 9 installed below extension manifold Solenoid valve PURGE Controls evapolative fumes from chacoal can Controlied by duty signal from PCME ister to intake manifold Steering pressure sensor Detects P S operation Steering pressure sensor when steering wheel turned Sto
43. 9 8 9 aso 10 18 zzz zzzzzzzzzzz 10 18 6 0 QU 09 89 EY 0 ANTON 19 9 D 99 31000N 1091902 av NIVULYIAGd 5v WI H3 43 43 W374 1 8 93 8 0 8 3 3 W3 4W3 wa Qa RU 4 9 1 88 9 1 d WS 847 05 18 2 E 6 18 9 18 eis ge 18 66 18 b 18 202 zeig 18 184 0 18 3AWA AWA 01083108 e 1 TION IUS 108 01093708 010N3308 EONS 108 7031909 01002105 331738 1001905 7091002 2 1081402 7041802 38d SAY aiy 3001 311108Hl 319315 ad ades 2 EN 1 110 05 18 18 86 18 rit 96 187 St 18 18 Va 28 18 be 18 06 16 SNIN3L3M N3 W3 83 43 43 3 43 3 N3 91 8 011238 A S 8 8 ns 8 A a A a an A a 8 8 8 dis asa 8 isi Avia pe 4 4 LU 4 203 4 j 031 4 WD 4 L3 O3 p A a A a M8 n a n a A G n a na WALSAS 70 1 02 3NION3 F 226 SERVICE POINTS 9 HOSN3S NOIlISOd LJVHSXNYBO 85 18 1 N011238 NOISSIMSNYH1133n00M J30HINOO NIVHLIHJADd M Y 4 3 4 4 n Wat WI W3 W3 4 M A 2 3 A 9 OD 9 3 d 4 4 8 91 8 0 9 4 1 3 011238 91 3 NOI1235 HOLI
44. Applying more than 98 kPa 1 0 kgf cm 14 psi of compressed can damage the actuator 3 Replace turbocharger if necessary Refer to page F 91 F 89 F SEQUENTIAL TWIN TURBOCHARGER SYSTEM Actuator wastegate control 49 F018 902 System Operation 1 Connect the SST Engine Signal Monitor Adaptor Har ness to the PCME 2 Turn ignition switch to ON 3 Short the PCME terminal 4U and verify that the operating sound is heard 4 If no sound is heard check the solenoid valve Refer to page F 93 Inspection 1 Disconnect the air hoses and attached one to the SST and plug the other pipe as shown 2 Verify that the actuator rod is moved when applying pressed air pressure to 69 98 kPa 0 7 1 0 kgf cm 10 14 psi Caution Applying more than 98 kPa 1 0 kgf cm 14 psi of compressed can damage the actuator ACTUATOR WASTEGATE CONTROL 3 Replace turbocharger if necessary Refer to page F 91 CHECK VALVE Inspection 1 Remove the check velve 2 Blow through A and verify that air flows from B 3 Blow through B and verify that air does not flow from A F 90 SEQUENTIAL TWIN TURBOCHARGER SYSTEM F Removal Installation Turbocharger handling procedures Holding the actuator the rod or the actuator hose when removing and carrying the turbocharger can cause damage Set the turbine down with the shaft horizontal Replace damaged studs and nuts Use only the specified studs and
45. CLAMP fuel line 1 Start the engine 2 Remove the fuel pump relay 3 After the engine stalls turn the ignition switch to OFF NE 4 Install the fuel pump relay B Avoid leakage 1 When disconnecting a fuel line hose wrap a rag around it to protect against fuel leakage 2 Plug the hose after removal 2224 C Install hose clamps to secure the fuel pressure gauge connections FUEL SYSTEM F PREPARATION SST 48 013 102 491018 901 AS 2 For For SS inspection Hose inspection E F 95 F FUELSYSTEM 7 2 Priming Fuel System After releasing the fuel pressure for repairs or inspection Me s the system must be primed to avoid excessive cranking when first starting the engine Follow the steps below 1 Connect the data link connector terminals F P and GND with a jumper wire 2 Turn the ignition switch ON for Approximately 10 se conds and check for fuel leaks 3 Turn the ignition switch OFF and remove the jumper wire SYSTEM OPERATION Fuel Pressure Hold Inspection Warning e Fuel line spills and leaks are dangerous Fuel can ignite and cause serious injuries or death and dam age Fuel can also irritate skin and eyes To prevent this always complete the Fuel Line Safety Proce dures on page F 95 1 Disconnect the negative battery terminal 2 Install a fuel pressure gauge as shown 3 Connect the negative battery terminal S NN T Dir 4 Connect the data link connector
46. Disconnect the heat hazard sensor connector and re move the sensor Installation Install in the reverse order of removal inspection 1 Wrap the sensor and a thermometer in aluminum foil and place them in a container of oil 2 Connecta test lamp and battery positive voltage to the ter minals of the sensor connector 3 Gradually heat the oil 4 Verify that the test lamp comes when the temperature in the aluminum foil reaches 95 105 C 203 221 F 5 Replace the sensor if necessary MILEAGE SWITCH Inspection 1 Connect the SST Engine Signal Monitor to the PCME 2 Turn the ignition switch to 3 Measure the voltage at PCME terminal 1N within the first two seconds after the ignition switch is turned to ON B Battery positive voltage S ECTOR Under 20 000 miles B 1 49 9200 162 Over 20 000 miles Below 1 5 49 F018 902 CONNECTOR B F 175 F CONTROL SYSTEM SOLENOID VALVES Removal Installation 1 Remove in the order shown in the figure 2 Install in the reverse order of removal 19 25 1 9 2 6 14 19 7 8 11 80 110 kgf cm 69 95 10 1 Battery cable 2 Pressure chamber 3 Accelerator cable removal installation page F 80 Inspection adjustment page F 80 4 Water hose 5 Vacuum hoses F 176 SECONDARY AIR BYPASS VALVE SECONDARY AIR Q EGR SWITCHING VALUE TURBO CONTROL CHARGE CONTROL DOUBLE
47. FAN RELAY Inspection 1 Disconnect coolant fan relay 2 Apply battery positive voltage and ground to terminal A and B of fan relay 3 Check continuity of the relay B Battery positive voltage B applied B Not applied CONTROL SYSTEM F CONTROL SYSTEM PREPARATION SST 49 9200 162 For 49 F018 902 For inspection inspection Engine Signal of PCME Adaptor of PCME Monitor terminal voltage harness terminal voltage 49 F018 903 For 49 H018 9A1 For inspection inspection of Sheet of PCME Self Diagnosis oxygen sensor terminal voltage Checker and knock sensor For inspection of oxygen sensor and knock sensor 49 B019 9A0 System Selector F 147 CONTROL SYSTEM STRUCTUAL VIEW F 148 CONTROL SYSTEM 1 Powertrain control module engine PCME Removal Installation 2 page F 150 Inspection page 150 2 Main relay Inspection 2 25 174 3 Fuel pump relay Inspection On vehicle page F 175 Inspection page 175 4 Crankshaft position sensor Removal Installation page F 166 Inspection page F 166 5 Manifold absolute pressure sensor Inspection F 167 6 Throttle position sensor Inspection page F 168 Adjustment p
48. Low pressure Check fuel line pressure while pinching fuel return hose if pressure quickly increases check pressure regulator f pressure gradually increases check for clogging between fuel pump and pres sure regulator If hose not clogged check fuel pump maximum pressure ce page 104 cz page 101 Yes Go to next step Repair or replace 203 F TROUBLESHOOTING GUIDE to next step er page F 83 Repair or replace Go to next step zr page 79 lig oerte Yes Goto next step er page F 83 EN Repair or replace Yes Goto next step Is idle air control valve OK Is fast idle cam OK Is accelerated warm up system OK Is engine compression correct Section Compression 690 kPa 7 0 kgf cm 100 psi 250 rpm Differential limit of chambers 150 kPa 1 5 kgf cm 21psi 250 rpm e Section Check for cause Are following PCME terminal voltages correct Yes Goto next step sz page F 152 10 Manifold absolute pressure sensor 3E Engine coolant temperature sensor 3L intake air temperature sensor 41 4J 4K 4L Metering oil pump e 4 Rear primary injector 4W Front primary injector Check for cause Try known good PCME does condition im prove r page 150 Repair or replace Is EGR control system i page
49. Manifold absolute pressure sensor Throttle position sensor Full range 3G Throttle position sensor Narrow range 3K Solenoid valve Relief 2 30 Solenoid valve Double throttle 3P Secondary air bypass valve 4E Crankshaft position sensor NE 41 4J 4K 4L Metering oil pump 40 Solenoid valve EGR 4R Solenoid valve Turbo control 4S Solenoid valve Charge relief 4T Solenoid valve Charge control 4V Solenoid valve Turbo precontrol 4W 4X 4Y 4Z Fuel injector Check for cause s page 155 Are injectors OK r page F 106 15 EGR control system OK sz page F 126 STEP F 213 F TROUBLESHOOTING GUIDE SURGES WHILE CRUISING _ DESCRIP Momentary minor irregularity in engine power at steady vehicle speed TION TROUBLESHOOTING HINTS Injector Igniter Poor connection of connector Poor connection of connector Spark plug 9 ignition Dirty or worn spark plug s Malfunction of ignition coil G Manifold absolute pressure sensor Throttie position sensor Poor connection of connector Is 00 displayed on SST with ignition switch ON 00 displayed ix page 20 Go to next step Trouble Code No displayed Check for cause Refer to specified check sequence mal 49 5019 9AO page F 22 Check spark plug s for damage If OK go to next step if not OK replac
50. PCME terminal 3F Is there continuity between throttle position sensor and PCME Throttle position sensor terminal PCME Is there continuity between terminals A and B with throttle valve closed to fully opened OK c If OK go to next step c If not OK repair wiring harness Repair wiring harness Ye Replace PCME s page F 150 Replace throttle position sensor page 168 Circuit Diagram PCME TVOA E TVOG VREF THROTTLE POSITION SENSOR THROTTLE POSITION SENSOR 2 us oTo TM t a e e ESEJ 2 I 2 H F 018 48 42 Jax av jan at 43 48 F 38 ON BOARD DIAGNOSIS FUNCTION CODE 20 METERING OIL PUMP POSITION SENSOR Are there any poor connections at metering pump Yes Repair or replace connector and PCME connectors Go to next step Is PCME terminal voltage OK Yes Goto step 4 Condition O de Go io next step 11 4 2 15 resistance of MOP position sensor Yes Repair wiring harness Mop position sensor PCME terminal Resistance J H 0 4 12 J 1 0 2kQ H I 9 4 12 Replace Replace PCME intermittent poor connection check for cause Disconnect negative battery cable for at least 20 se
51. Spark plug Air cleaner housing Dirty or worn spark plug s Clogged element Throttle position sensor Full range Three way catalyst Malfunction of throttle position sensor Clogged three way catalyst Fuel filter Fuel Filter clogged Low octane fuel used Pressure regulator Metering pump Malfunction of pressure regulator Poor connection of connector POOR FUEL ECONOMY DESCRIP Fuel economy unsatisfactory TION 2E TROUBLESHOOTING HINTS DEngine compression Compression low Spark plug s Dirty or worn spark plug s G Ignition coil Malfunction of ignition coil Pressure regulator Malfunction of pressure regulator intake air leakage Air hose damaged or disconnected 77738 AIC DOES NOT WORK ER DESCRIP A C compressor magnetic clutch does not engage when Air conditioning sensor ON TION TROUBLESHOOTING HINTS D A C relay Poor connection of connector 9 Relay malfunction ex Section U Q Air conditioning sensor 4 9 Does not send signal to PCME terminal 1 Fr page 152 c page 154 PCME 1L terminal circuit open F 215 F TROUBLESHOOTING GUIDE DESCRIP Sound produced when air fuel mixture is ignited by something other than spark plug i e hot spot in combustion cham TION ber TROUBLESHOOTING HINTS Knock sensor Open or short in harness Code No 05 output
52. THROTTLE PRESSURE SENSOR CONTROL FILTER SOLENOID VALVE PURGE CONTROL PRESSURE CHAMBER CHECK VALVE HARGE RELIEF VALVE ACTUATOR TO FUEL FILTER CHACOAL CHARGE CANISTER CONTROL SOLENOID VALVE SECONDARY AIR SWITCHING VALVE SOLENOID VALVE EGR SOLENOID VALVE TURBO CONTROL SOLENOID VALVE CHARGE CONTROL SOLENOID VALVE DOUBLE THROTTLE CONTROL SOLENOID VALVE CHARGE RELIEF SOLENOID VALVE WASTEGATE CONTROL SOLENOID VALVE TURBO PRECONTROL OUTLINE F SPECIFICATIONS Rm LLL Speieaon Ignition timing 2 Element type NE Type Primary maig ATTA Secondary mm in Throat diameter ae ET sa pareve ve Operation full open cen 55 65 131 149 or more Charge air cooler Core xh xt 2 in Turbocharger System ype Boost control aca Boost control method Fuerer S o o oA Minen Pressure regu ator Type er Regulated pressure kPa pal Type 2 Impeiler In tank Output pressure kPa kgf cm psi 490 740 50 7 5 71 1 106 7 Type Side feeding ue Primary cc fl oz min 550 550 16 5 Injection volume Secondary floz min 850 850 25 5 Three way catalyst w p i _ Three way catalyst Capsciy ae
53. TO FROM FROM CHARGE AIR AIR CLEANER FROM AIR CLEANER COOLER HOUSING AIR CLEANER HOUSING lt 4 HOUSING INTAKE MANIFOLD PCV VALVE Inspection 1 Warm up the engine to the normal operating temperature and run it at idle 2 Disconnect the PCV valve with the ventilation hose 3 Block the PCV valve opening 4 Verify that vacuum is felt 5 Remove the PCV valve 6 Blow through the valve from port A and verify that air comes out of port B 7 Blow through the valve from port B and verify that no air comes out of port A 8 Replace the PCV valve if necessary EXHAUST GAS RECIRCULATION EGR mE EXHAUST GAS RECIRCULATION EGR DESCRIPTION This system recirculates a small amount of exhaust gas into the intake manifold to reduce the combustion temperature and reduce NOx emissions This system consists of the EGR valve EGR function sensor solenoid valve PCME and input devices SOLENOID VALVE EGR T och CRANKSHAFT INTAKE mb LE POSITION MANIFOLD tas LE WA SENSOR ENGINE COOLANT TEMPERATURE SENSOR MANIFOLD ABSOLUTE PRESSURE SENSOR A THROTTLE E POSITION SENSOR NEUTRAL CLUTCH SWITCH MT EXHAUST MANIFOLD Operation Cold engine Engine coolant temperature below 70 C 158 F EGR operation is stopped to improve drivabilty when the engine is cold Warm engine The PCME controls the solenoid valve to supply EGR gases as described below Operating condition E
54. VALVE gt F 139 IDLE AIR CONTROL VALVE F 83 A C CUT OFF SYSTEM 140 SOLENOID VALVE AWS F 83 SYSTEM OPERATION 141 SEQUENTIAL TWIN TURBOCHARGER SYSTEM 84 AIC RELAY F 142 ACTUATOR TURBO CONTROL F 86 DECHOKE CONTROL SYSTEM F 143 ACTUATOR CHARGE CONTROL F 87 SYSTEM OPERATION e rene F 143 CHARGE RELIEF VALVE F 88 ELECTRICAL COOLANT FAN CONTROL TURBOCHARGER P glad F 89 SYSTEM 25 52 a ah F 144 CHECK VALVE ere ee F 90 SYSTEM OPERATION 146 SOLENOID VALVE TURBO PRECONTROL FAN RELAY F 146 WASTEGASTE CONTROL F 93 CONTROL SYSTEM F 147 FUEL SYSTEM sires sexo EkR Ee ERa A FREE T EEER E F 94 STRUCTUAL VIEW 24 4 F 148 PRECAUTION F 95 POWERTRAIN CONTROL MODULE ENGINE SYSTEM OPERATION F 96 PCME eee eee eet nnno F FUEL Tere e edu F 98 CRANKSHAFT POSITION SENSOR F 166 FUEL PUMP aM F 100 MANIFOLD ABSOLUTE PRESSURE SENSOR F 167 FUEL FILTER TERMI RS ES E F 103 THROTTLE POSITION SENSOR F 168
55. a o oe u 5 o o JM i G au jar a0 ae 31 so at 25 fan 2 T N c v n FD F 61 F ON BOARD DIAGNOSIS FUNCTION 71 INJECTOR FRONT SECONDARY Does injector circuit have a poor connection Repair connector and or wiring harness Go to next step Go to next step Check for open or short circuit in wiring harness injector terminai Main relay D is connector A terminal voltage OK with injector con nector disconnected Condition Voltage Ignition switch ON Battery positive voltage M Is injector resistance OK Go to next step terminal Resistance 13 5 20 C 68 F LI Forks inier Check for short circuit in wiring harness ls there continuity between injector terminal and Injector PCME PCME terminal Injector terminai gt If OK go to next step gt f not OK repair wiring harness Disconnect negative battery cable for at least 20 seconds Connect battery cable and recheck for trouble code is trouble code displayed INJECTOR INJECTOR INJECTOR INJECTOR ER 566 BEAR S PRIMARY SECONDARY PRIMARY SECONDAR MAIN RELAY INJECTOR S F EM Jaw aus Tas 40 ae 4A 20 ox a ac sc pa a o foe e s o o M k
56. below 4 Crankshaft position sensor plate 8 Crankshaft position sensor G signal 5 Bracket Inspection below Inspection 1 Remove the crankshaft position sensor 2 Measure the resistance of the sensor Resistance 0 95 1 25 20 C 68 F OHMMETER 3 If not as specified replace the crankshaft position sensor CRANKSHAFT POSITION SENSOR Installation Note Measure the crankshaft position sensor to crankshaft position sensor plate clearance by using feeler gauge Clearance 1 0 2 0 mm 0 039 0 078 in PULLEY F 166 mmm PRESSURE MANIFOLD ABSOLUTE PRESSURE CONTROL SYSTEM MANIFOLD ABSOLUTE VOLTMETER OLTMETER MANIFOLD ABSOLUTE PRESSURE SENSOR Inspection 1 Warm up the engine to normal operating temperature and run it at idle 2 Turn all electrical load off 3 Connect a voltmeter between the manifold absolute pres sure sensor terminal A and B and verify that the voltage is within specification Voltage 1 3 1 6V 4 Disconnect vacuum tube and plug the vacuum tube and verify that the voltage is within specification Voltage 2 38 2 78V 5 Connect a vacuum pump to the manifold absolute pres sure sensor 6 Apply vacuum and measure the voltage of the manifold absolute pressure sensor Voltage 7 66 kPa 500 mniHg 19 7 inHg Vacuum 1 25 1 55V 0 kPa 0 mmHg 0 inHg 2 38 2 78 98 7 kPa 740 mmHg 29 1 inHg Pressure 4 35 4 65V
57. catalyst is cut off and the first and second stages are used the ternary catalyst Seedsqe THREE WAY CATALYST WARM UP THREE WAY CATALYST AND THREE WAY CATALYST Inspection 1 Check the three way catalyst for deterioration or clog ging 2 Check the insulation covers welded onto the three way catalyst for damage 3 Excessive heat will occur at the floor if the insulation cover is touching the three way catalyst 128 PL FUEL EVAPORATIVE SYSTEM FUEL EVAPORATIVE SYSTEM DESCRIPTION CHECK VALVE FUEL VAPOR VALVE SEPARATOR SOLENOID VALVE CHECK VALVE TWO WAY FUEL TANK CHACOAL CANISTER INTAKE MANIFOLD CHECK VALVE ONE WAY Y CATCHTANK S55 SOLENOID VALVE PURGE CONTROL FUEL FILLER CHACOAL 22 CANISTER FUEL VAPOR VALVE The fuel evaporative system temporarily stores in the canister the evaporative fumes generated in the fuel tank The stored gas is then passed into the air intake system for combustion when the engine is running This operation prevents evaporative fumes from flowing out to the atmosphere Sending a large volume of evaporative fumes at one time into the air intake system deteriorates the air fuel ratio thus the PCME uses the solenoid valve purge control to regulate this volume Operation With engine sto
58. during fast idle but returns to normal after warm up Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at idle after warm TROUBLESHOOTING HINTS Injector Fuel leakage from injector s 9 njector s clogged Q Air pump Malfunction of air pump Fuel pump relay Poor connection of connector Spark plug Misfire Engine Compression low 15 00 displayed on SST with ignition switch ON s page F 20 Connect data link connector terminals F P and GND with a jumper wire is fuel line pressure correct with ignition switch ON s page 98 PRESSURE INSALL CLAMP Is air pump OK ry page 121 6 Fast idle cam Malfunction of fast idle cam Manifold absolute pressure sensor Malfunction of manifold absolute pressure sensor 8 Engine coolant temperature sensor Poor connection of connector EGR control valve EGR control valve stuck Idle air control valve Poor connection of connector Fuel thermosensor 00 displayed Go to next step Trouble Code No displayed Check for cause Refer to specified check sequence page 22 Go to next step Clean or replace Go to next step Check ignition system Section G f symptom occurs at idle at any engine temperature go to next step 9 f symptom occurs during fast idle opera tion go to Step 6 9 if symptom occurs at idle after warm up go to Step 10
59. engine CHECK VALVE SOLENOID VALVE PORT AIR BYPASS SECONDARY AIR BYPASS VALVE EN aoe SWITCHING VALVE SOLENOID VALVE SPLIT AIR BYPASS SOLENOID VALV RELIEF 2 AIR PUMP CHECK VALVE SPLIT AIR AIR PUMP RELAY SECONDARY AIR BYPASS VALVE SOLENOID VALVE RELIEF 2 AIR CLEANER RELIEF HOUSING SECONDARY AIR SWITCHING VALVE SWITCHING CHECK VALV VALVE PORT AIR SOLENOID VALVE SPLIT AIR BYPASS CHECK VALVE SPLIT AIR THREE WAY CATALYST F 115 SECONDARY AIR INJECTION PREPARATION SST 49 2113 0118 49 F018 902 For Air pump gauge inspection Adapter set ofairpump harness F 116 For inspection of solenoid valve SECONDARY AIR INJECTION F 3 ME t d 0 CAUISE SWITCHING VALVE AIR CONTROL VALVE ACV Switching Valve System operation 1 Connect the SST Engine Signal Monitor Adapter Har ness to the PCME as shown 2 Start the engine and run it idle 3 Short the PCME terminal 4N and verify that the engine condition change idle roughing 4 If the engine condition does not change check the follow ing below Vacuum tube Inspect the vacuum line fitting connections and com ponents for leaks Refer to page F 10 Secondary air switching valve Inspection Refer to page F 176 Air r
60. gi I Gi e T 5 5 5 o ajc 5 u amp gr J eg t 1 Melts main or other fuse tojo 2 Will not crank or cranks slowly No combustion but wil when engine cold not start Partial combustion after warm up Granis namely aa ae PHHH EHEH T but hard tostat Afterwamup TT TT TT TT TT ETT fol PTET T iesu o LE ee Ho HeH H HH d HHH AHHH HH Idle after warm up after warm up Idle with A C P S and or E L ON Pa Idle when shifted from N or P to other De e Driveaway _ CECH EE White cruising JTT fof Ondeceleration SAITTA LLLI deatanyengnetemp Jojo lof Joe Jolelele MER AeH HR HR Idle after warm up after warm up Engine Idle with A C P S rough and or E L ON Idle when shifted from N or P to other ranges 24 Poor ac E mum 26 LI RERRRR RNNN 27 High idle speedatterwarmup lololol TT ETT lolol TTT TTT TTL TT TT ELLE 178 TROUBLESHOOTING GUIDE F Possible parts and reference page Throttle position i o T o 2 c 10 pen ce C Melts main or other fuse Will not crank or cranks slowly No combustion Cranks P
61. his file is available for free download at htto www iluvmyrx com This file was not scanned to deprive Mazda of any money it was scanned due to the rareness of the original manuals and the overwhelming need of the RX 7 owner to have this information so that they can accurately troubleshoot problems Perhaps if Mazda s dealerships could support the Rotary Engine it wouldn t be so necessary for the owners to do so Many thanks to Lenny Terris for scanning this Before beginning any service procedure refer to the 1994 RX 7 Body Elec trical Troubleshooting Manual see section S for air bag system service warnings and section J1 for audio antitheft system alarm conditions FUEL AND EMISSION CONTROL SYSTEMS INDEX us su esa F dera wo wis Wie Risen E eh Ae F 126 OUTLINE since ra ERAT UMP RE RE F EGR F 127 SYSTEM F 7 EGR FUNCTION SENSOR F 127 WIRING DIAGRAM F 8 SOLENOID VALVE EGR F 127 VACCUM HOSE ROUTING DIAGRAM F 10 THREE WAY CATALYST SYSTEM 128 SPECIFICATIONS RE ra F 11 THREE WAY CATALYST F 128 COMPONENT DESCRIPTIONS F 12 FUEL EVAPORATIVE SYSTEM F 129 ENGINE TUNE UP F 15 SYSTEM OPERATION F 130 BASIC
62. injector installation 1 Use new O rings 2 Apply asmall amount of clean engine oil to the O rings be fore installing them 3 Install the injector squarely into fuel distributor and gradu ally twist it 4 Verify that the deposit is notto the holder inside of fuel dis tributor 5 If there is clean the holder inside by used to gasoline Fuel leakage test 1 Install the fuel hose 2 Connect the data link connector terminals F P and GND with a jumper wire 3 Turn the ignition switch and check for fuel leaks from the fuel distributor 4 If fuel leaks check the injector O ring and fuel distributor Air bleed socket installation INTERMEDIATE HOUSING Align the tab of the air bleed socket with the notches in the intermediate housing F 106 TO FUEL TANK 2 LA 7 et I 2 M p 491018 901 FUEL SYSTEM F Inspection Injector resistance 1 Disconnect injector connector as shown in figure 2 Measure the resistance of the injection with ohmmeter Resistance Approx 13 8 Q 20 C 68 F 3 If not as specified replace the injector Fuel leakage test Warning Fuel vapor is hazardous It can very easily ignite causing serious injury and damage Always keep sparks and flames away from fuel 1 Remove the injector together with fuel distributor 2 Connect the SST as shown in figure 3 Connect the data link connector terminals F P and GND with a jumper wir
63. is open no symptom will be noticed If the circuit is shorted rough idle will result Solenoid valve Accelerated warm up system if the solenoid valve or circuit has an open or short Trouble Code No 38 is output f the circuit is open the fast idle speed just after engine starting will not exceed 2 000 rpm if the circuit is shorted the idle speed will be increased and then hunted at the specified speed approx 1500 rpm after warm up Solenoid valve Charge control f the solenoid valve or circuit has an open or short Trouble Code No 45 is output inthe above conditions the PCME fixes the ignition timing and fuel injection amount causing poor accel eration and lack of power Solenoid valve Charge relief f the solenoid valve or circuit has an open or short Trouble Code No 46 is output if the circuit is open the charge relief valve will always open causing poor acceleration f the circuit is shorted the charge relief valve will always closed causing momentarily intake air noise on acceleration Solenoid valve Double throttle control if the solenoid valve or circuit has an open or short Trouble Code No 50 is output f the circuit is open the double throttle valve will always closed causing poor acceleration and lack of power f the circuit is shorted the double throttle valve will always open causing hesitation when the engine is cold Solenoid valve EG
64. nuts Using damaged or unspecified studs and nuts can cause gas leakage because of insufficient clamping Cover the turbocharger air port and exhaust port with tape to keep out foreign material Foreign material may damage the turbocharger s internal components 1 Disconnect the negative battery cable 2 Lift up the vehicle 3 Drain the engine coolant 4 Remove in the order shown in the figure 5 Install in the reverse order of removal reffering to Installation Note 8 11 22 29 2 3 3 0 16 22 69 95in bt 37 52138 5 3 27 38 4 y 1 N lt 8 11 N m 80 110 kgf cm 69 95 in Ibf A 4 9 6 9N m _ 50 70 kgf cm 8 11 43 58 80 110kgf em 14 4 5 9 32 43 80 110 kgf cm 9 95in Ibf SELF LOCK NUT REPLACE 69 95in Ibf mtema GASKET x 8 11N m 80 110kgf cm 69 95 in Ibt GASKET REPLACE 19 26 1 9 2 6 22 36 N S 3 NS 8 s L d 7 4 9 6 9N m 50 70 Kgf cm 43 62 in Ibf DRIVE BELT 2 ADJUSTMENT 122 64 89 6 5 9 1 47 66 GASKET REPLACE REPLACE 64 89 6 5 9 1 47 66 CLIP REPLACE yas y 52 fi X99 3 25 1 16 23 1 6 2 3 12 17 2 7 8 10 8 N m GASKET 80 110kgf cm gt REPLACE 69 95 in Ibf FASTENER N m kgf m ft Ibf
65. or misaligned pulleys Adjustment Refer to section C F 122 SECONDARY AIR INJECTION F AIR PUMP RELAY Inspection On vehicle Check that a clicking sound is heard at the Air pump relay when turning the ignition switch ON and OFF Inspection 1 Disconnect the air pump relay 2 Apply Battery positive voltage and ground to terminals B and D of the relay 3 Check continuity of the relay B Applied B Not applied B Battery positive voltage A C terminals SOLENOID VALVE RELIEF2 System Operation Engine Signal Monitor 1 Connect the SST Engine Signal Monitor Adaptor Har ness to the PCME 2 Turn ignition switch ON 3 Short the PCME terminal 3K and verify that the operation sound is heard Inspection 1 Disconnect the solenoid valve Refer to page F 119 2 Measure the solenoid valve resistance with an ohmmeter Resistance 27 32 Q 20 C 68 F 3 If not as specified replace solenoid valve Refer to page F 119 F 123 F POSITIVE CRANKCASE VENTILATION PCV SYSTEM POSITIVE CRANKCASE VENTILATION PCV SYSTEM DESCRIPTION The PCV valve is operated by the intake manifold vacuum When the engine is running at idle the PCV valve is opened slightly and a small amount of blow by gas is drawn into the dynamic chamber to be burned As the engine speed rises the PCV valve is opened further allowing a larger amount of blow by gas to be drawn into the intake manifold
66. page F 127 page F 175 page F 175 page F 175 page F 176 page F 177 F 149 5 PCME Inspection Engine Signal Monitor page F 151 6 Connector 7 E L unit Inspection page F 136 1 Battery cable 2 Scuff plate 3 Front side trim 4 Connectors 150 CONTROL SYSTEM POWERTRAIN CONTROL MODULE ENGINE Removal installation 1 Remove in the order shown in the figure 2 Install in the reverse order of removal 7 8 10 8 80 110 601 69 95 1 1 OT y 7 8 10 8 N m 80 110 E kgf cm 3s R Ew qe CONTROL SYSTEM F Inspection 49 9200 162 Engine signal Monitor Connect the SSTs to the PCME as shown Use connector A of the adapter to measure voltage at ter minals 1A through 1V and 3A through 3P and use con nector B to measure voltage at the terminals 2A through 2L and 4A through 42 2 Place the SST Sheet 76 pin type on the SST Engine Signal Monitor 3 Measure the voltage at each terminal LR gt 4 F 4 Ld Li LA r r 4 Ie ta J a ET a gt m E 4277 or output device and related wiring If they are normal re place the PCME LLLLDUGLITIE adau py Pj 351113 538 Caution Applying voltage to SST terminals A or will dam age the SST E aat a5 SES a4 F 151 4 If any PCME
67. page F 99 9 Separator 3 Evapolative hoses Inspect for cracks and corrosion Installation Note page F 99 10 Fuel vapor valve 4 Under cover Inspection page F 132 5 Fuel filler pipe 11 Fuel pump 6 Fuel tank strap Inspection page F 101 7 Fuel tank Removal Installation page F 98 Inspect for cracks and corrosion Assembly Disassembly page F 102 12 Nonreturn valve Installation Note 1 Push the ends of the main fuel hose fuel return hose and evaporative hoses onto the fuel tank fittings at least 25 mm 1 0 in 2 Push the fuel filter hose onto the fuel tank pipe and filter pipe at least 35 mm 1 4 in 3 Push the evaporative hoses onto the fuel vapor valve at least 20 mm 0 8 in 4 Push the evaporative hoses onto the check valve at least 17 mm 0 7 in 5 Connect the fuel filler hose and breather hose onto the fuel tank as shown in the figure Nonreturn Valve Verify that the nonreturn valve operates under its own weight as shown in the figure 99 z N INSTALL FUEL SYSTEM FUEL PUMP Inspection Fuel pump operation 1 Connect the data link connector terminals F P and GND with a jumper wire 2 Remove the fuel filler cap 3 Turn the ignition switch ON 4 Listen for operational sound of the fuel pump at the filler inlet 5 Install the fuel filler cap 6 If no sound was heard measure the voltage the fuel
68. specified replace the solenoid valve CHARCOAL CANISTER Inspection Visually check for damage and replace the charcoal can ister if necessary F 131 ELEM ICT LF LTE CET TET ET TET LO F FUEL EVAPORATIVE SYSTEM CHECK VALVE TWO WAY Inspection 1 Remove the check valve 2 Checkthe operation of the check valve by using a vacuum pump Apply approx 5 kPa 37 mmHg 1 46 inHg At Apply approx 6 kPa 44 mmHg 1 73 inHg vacuum at port B CHECK VALVE ONE WAY Inspection 1 Remove the check valve 2 Blow through the check valve from port A and check that the air flows from port B 3 Blow through the check valve from port B and check there is no flow SEPARATOR Inspection Visually check for damage and replace the separator if necessary FUEL VAPOR VALVE Inspection 1 Remove the valve 2 Blow through the valve and verify that air flows in the direction shown 3 Turn the valve over and blow through the valve Verify that no air flows 4 Replace the valve if necessary F 132 DECELERATION CONTROL SYSTEM F DECELERATION CONTROL SYSTEM DESCRIPTION Dashpot To prevent the throttle valves from closing suddenly idle air control valve To prevent afterburn air is supplied to intake manifold during deceleration Fuel cut contro To improve the fuel economy and to prevent engine bucking during decelera tion Air bypass valve Bypasses compre
69. to specified check sequence Go to next step page F 79 c page F 79 Go to next step Is strong blue spark visible at each disconnected high tension lead while cranking engine Check ignition system s Section G HIGH TENSION LEAD F 196 TROUBLESHOOTING GUIDE F Go to next step Check for cause 153 Go to next step Are following PCME terminal voltages OK page 152 1B PCME power 9 1G 1H 1J Igniter 10 Manifold absolute pressure sensor 9 iT Fuel pump relay 3E Engine coolant temperature sensor Throttle position sensor narrow range 9 4E 4G Crankshaft position sensor 40 Solenoid valve EGR Solenoid valve AWS 40 Idle air control vaive 9 4W 4Y Primary fuel injector Connect data link connector terminals F P and GND with a jumper wire is fuel line pressure correct with ignition switch ON page F 98 Low pressure Check fuel line pressure while pinching fuel Fuel line pressure ig quickly increases check 250 260 kPa 2 5 2 7 kgf cm 36 38 psi pressure regulator page F 104 If pressure gradually increases check for clogging between fue pump and pres sure regulator if hose not clogged check fuel pump maximum pressure PRESSURE sr page F 101 INSALL CLAMP Is
70. 1 Fuel pump connector 5 O ring 2 Bracket 6 Seal rubber 3 Mounting rubber 7 Fuel filter Low pressure side 4 Fuel pump Assembly Note After installing the fuel pump to the braket pull the pump down so that it is tight against the braket F 102 FUEL SYSTEM F FUEL FILTER Replacement Warning Fuel vapor is hazardous It can very easily ignite causing serious injury and damage Always keep sparks and flames away from fuel High pressure side The fuel filter must be replaced at the intervals outlined in the maintenance schedule 1 Before removing the fuel filter release the fuel pressure from the fuel system 2 Remove in the order shown in the figure 3 Install in the reverse order of removal 4 Verify that the fuel hoses are pushed fully onto the fuel filter nipple 80 110 kgf cm 69 75in Ibf 7 8 10 8N m 80 110 kgf cm 69 95 Ibf 1 Under cover 2 Fuel filter High pressure side F 103 Eoo FUEL SYSTEM PRESSURE REGULATOR Inspection Fuel line pressure Warning e Fuel line spills and leaks can be dangerous Fuel can ignite and cause serious injuries or death and can damage the vehicle Fuel can aiso irritate skin and eyes To prevent this from happening release the fuel pressure according to Fuel Line Safety Procedures on page F 95 1 Disconnect the negative battery terminal E 2 Connect a fuel pressure gauge between the fuel filter and the fuel main hose Insta
71. 1 Remove any corrosion on the clamps or batiery posts and coat them with grease uu 2 Verify that the battery top is clean If necessary clean with baking soda and water ux s v 8 Verify that cables are not frayed or corroded Repair or re place if necessary 4 Verify that cable clamps are tight 5 Verify that the rubber protector completely covers the positive terminal and clamp Electrolyte level and specific gravity 1 Verify that the electrolyte level is between the Upper and Lower level marks 0 2 Add distilled water if necessary Do not over fill 3 Check the specific gravity with a hydrometer Specific Gravity 1 27 1 29 at 20 C 68 F F 15 ENGINE TUNE UP Air Cleaner Element Inspection 1 Check the air cleaner element for excessive dirt and for oll and damage Caution Cleaning the element with compressed air will re duce the element s ability to filter the air Don t use compressed air to clean the element 2 Replace the element if necessary ADJUSTMENT Preparation 1 Warm up the engine to normal operating temperature 2 Turn all electric loads OFF 3 Connect the SST to the data link connector 4 Connect a tachometer to the data link connector IG ter minal as shown Ignition Timing The ignition timing is set at the factory and must not be ad justed Any adjustment will negatively effect the engine per formance 1 Perform preparation refer
72. 14 Troubleshooting Refer to page F 34 Open or short circuit in wiring from PCMT terminal 2C to terminal 2D Short circuit in wiring from heat hazard sensor to PCME terminal 21 Heat hazard sensor malfunction Refer to page F 175 Open circuit in wiring from heat hazard sensor to PCME terminal 21 Heat hazard sensor malfunction Refer to page F 175 Refer to Code No 54 Troubleshooting Refer to page F 61 Always below 1 0V Always B Always below 1 or B 157 F CONTROL SYSTEM B Battery positive voltage Terminal input Output Connected to Test condition Correct voltage 1 2 switch 1st and 2nd position B ignition switch ON MT PCMT 2nd or 3rd position Below 1 0V While running eT Du 2nd position Below 1 0V Ignition switch ON Barre POMT 3rd or O D position 1 0V While running 1 0 4 2V Voltage increase Approx 1 1V when accelerating Accelerator 2V Metering oil pump position sensor Below 4 0V unit Blower motor position ili IV N Lr ReardefrosterswitthON defroster switch ON froster Sitch are OFF Oxygen Driving Cold engine Approx 0V sensor After warm up 0 1 kt Oscilloscope HEe xn 0 5 s div Acceleration after warm 0 5 1 0V Deceleration after warm up
73. 395 AX 1338 dWhd 1313 0 18 3 80151538 dW d 13212 G0 91 3N19N3 3 1n 004 IGHLNDD NIVYLYSA0d i8 4 40 LOSNNOI 381A Q131HS 91 Y3SN30N09 8 1 44 8 011236 91 1 1103 qu 580193251 AN g n Lut ecco 91119 61 18 d S 98 E ound TANA i 1 8 51 I g 21 31 di E Ra SEM JHIA jl L LI n 1 L oinnes E HA 478 1 L 1 T IIS ion i S t o 91 OM 50 7 4 9173 w91 A a 8 01 Lez x 31 a 0 8 1 nou E ced ua 0 WA og i og 21 71102 a nod AR OE QE NO 1LINDi 3 AW k a U co ig 0 1g 8 1 8 1 20 19 ando E MUT 7 S 4 100181838 og alin 9178 8 u h 8 1 3 49 143919 DAI 0231H8 1 1102 NIVW 1 60 18 n 19 170 NOILINDI 7304 193 9311991 OVE 3 51 8 Li X 20 18 it Lh a5 10 18 3 78 0 18 if aj 0 18 3NISN3 223 4 ta 1091402 3 03346 AV 73a 91 8 DA NIVULUAMOd did 713 4 3 3 53 44 3 A 8 H 1 49 57 8 41 8 012935 a 1180 OHINO2 6 4 0 01 1 91419373 8 91 8 31 8 WALSA
74. 7 inHg Caution Applying vacuum greater than 66 7 kPa 500 mmHg 19 7 inHg can damage the air control valve 4 If not as specified replace air control valve F 118 SECONDARY AIR INJECTION F Removal installation 1 Remove the extension manifold Refer to page F 76 2 Remove in the order shown in the figure 3 Install in the reverse order of removal _ 20 25 2 0 2 5 14 18 Jt f 20 25 2 0 2 5 14 18 7 8 11N m 80 110 kgf cm 69 95in ibf 1 Solenoid valve Turbo control 5 Solenoid valve Port air bypass Inspection F 176 Inspection nm below 2 Air control valve 6 Solenoid valve Split air bypass 3 Gasket Inspection page F 120 4 Check valve Port air 7 Solenoid valve Relief2 Inspection page F 120 Inspection page F 123 SOLENOID VALVE PORT AIR BYPASS P 49 F018 902 System Operation 1 Connect the SST Engine Signal Monitor Adaptor Har ness to the M 2 Turn ignition switch ON a Jj 3 Short the PCME terminal 3N and verify that the operation 7 al sound is heard inspection 1 Disconnect the solenoid valve Port air bypass connec tor 2 Measure the solenoid valve resistance with an ohmmeter Resistance 26 6 32 6 20 C 68 F 3 If not as specified replace solenoid valve Above F 119 120 SECONDARY AIR INJEC
75. 8 E 6 42 Jax Jav aT jap at Jau an aF an op ac Jar sp 2 22 2 20 28 v rj n P N 62 ON BOARD DIAGNOSIS FUNCTION F 73 INJECTOR REAR SECONDARY ACTION Does injector circuit have a poor connection Repair connector and or wiring harness Go to next step Is connector A terminal voltage OK with injector con Go to next step nector disconnected Condition Voltage Check for open or short circuit in wiring j inal Main relay D Ignition switch ON Battery positive voltage pales MUT he ues Resistance 13 8 20 C 68 F Replace injector Is there continuity between injector terminal and Yes Check for short circuit in wiring harness terminal Injector PCME terminal e If OK go to next step c If not OK repair wiring harness shia p wiring harness ree rnt Replace PCME page F 150 Intermittent poor connection Check for cause Disconnect negative battery cable for at least 20 seconds Connect battery cable and recheck for trouble code Is trouble code displayed INJECTOR INJECTOR INJECTOR SONT SECONDARY Pan MARY 8 EGON DARY INJECTOR S F EM INJECTOR S R EM 4t 4G fac 120 fam 3 3G ae sc foa ok 21 20 oe fac 2 u S Too wk
76. AS 431679 1H9I Id018 LNSWNYLSNE ItO 011238 LINA 1081802 asinug 09 8 25 18 HOLIAS 21179 26 1 020 1 0 9 1 0207 3 x 90 1 99 8011236 AvI38 3 HOLIAS 2 1 83398 3 9 C3 BZA 99 N011233 HOLEAS JYNSs3ud 1NYU39IUJ38 HILIAS WHlf3N F 227 me CANO LW H3 3N 4OSNaS HOLIAS IvHin3N 06 8 NOTLISOd ldVHSXNYHO 6b i8 INISN3 310004 30H1NO2 NIVUIUJADd 10 18 H0SN3S 9 4OSN3S NOILISOd NOILFSOd lJVHSXNYu2 LJVHSNNYU 3HIM 813 P 8131 5 V VNYO t2 V NOIL938 HOLIAS fe 1 T 4 av wona HOLIAS WOOTUBINI 8319916 W31SAS 10H1N02 3 19 3 s F SERVICE POINTS ELECTRICAL DIAGNOSIS SUPPORT Power and Ground Main relay Battery power ore rere te PCME 1B Main relay Engine hard starting EGI INJ fuse 30A burns out NA when ignition switch ON Room fuse Memory power ee 77 PCME 1A Room fuse No symptom ROOM fuse 15A burns out PCME ground Output device Injector System Analogue eee Sets Poor ground PCME 4A Ground Output device One side open circuit One side poor ground i No symptom 4B Ground injector Both sides open circuit Engine wilt not start 4C Ground System No sympiom NA PCME 4D Ground Analogue Code Nos 09 11 12 13 20 and 23 Engin
77. ATONLY fT AUS 2E CHECK VALVE N S SECONDARY mn t Ww PRIMARY OPERATION When the engine coolant temperature below 80 C 176 F the PCME turns the solenoid valve ON applies vacuum to the actuator double throttle control and closes the double throttle valve F 137 F 138 DOUBLE THROTTLE CONTROL SYSTEM SYSTEM OPERATION 1 Start the engine and verify that the actuator Double throttle control rod is pulled into actuator while engine is cold 2 If the actuator rod is not pulled check the following condi tion below Vacuum tube Inspect vacuum line fitting connections and compo nents for leaks Refer to page F 10 Vacuum chamber Visually check for dogging damage or crack Actuator Inspection Refer to below Solenoid valve Double throttle control DOUBLE THROTTLE Inspection Refer to page F 176 CONTROL Engine coolant temperature sensor Inspection Refer to page F 169 3 Verify that the actuator rod is returned when warm up the engine to normal operating temperature 4 If the actuator rod is not return check the following condi tion below Solenoid vaive Double throttle control Inspection Refer to page F 176 Engine coolant temperature sensor Inspection Refer to page F 169 ACTUATOR DOUBLE THROTTLE CONTROL PULL DOUBLE THROTTLE CONTROL SYSTEM F VACUUM PUMP ACTUATOR DOUBLE THROTTL
78. Below 1 0V After warm up pas While running Crankshaft Ignition switch ON Below 1 0V Oscilloscope EL LIA E m 20 msec div Voltmeter 0 1 0 4V Reference position sensor Crankshaft Ignition switch ON Below 1 0V G signal F 160 P CONTROL SYSTEM m F B Battery positive voltage 9 Short circuit in wiring from main relay to PCME terminal 3I Main relay malfunction Refer to page 174 EGR function sensor malfunction Refer to page F 127 9 Open or short circuit in wiring from EGR function sensor to PCME terminal 3J ncorrectvoltage Always 0V Always OV or B Always below 1 0 or B Aiways OV or approx 5V Refer to Code No 11 Troubeshooting Refer to page 31 Always 0V Refer to Code No 05 Troubleshooting Refer to page F 28 Always beiow 1 0V or B Refer to Code No 33 Troubleshooting Refer to page F 48 Refer to Code No 39 Troubleshooting Refer to page 52 Refer to Code No 50 Troubleshooting Refer to page F 59 Always below 1 0V or B Always below 1 0V or B Refer to Code No 31 Troubleshooting Refer to page 46 Above 0 0 Poor connection at ground terminal Open circuit in wiring from PCME Always approx OV or approx 5V Refer to Code No 03 Troubleshooting Refer to page F 27 Refer to Code No 30 Troubleshooting Refer to page F 45 Always below 1 0V or B Always approx OV
79. E CONTROL Inspection 1 Disconnect vacuum hose 2 Connect a vacuum pump and verify that actuator rod is pulled into actuator when apply the vacuum more than 22 0 28 7 kPa 165 215 mmHg 6 5 8 5 inHg 3 If not as specified replace the actuator Removal Installation Refer to page F 76 CHECK VALVE Inspection 1 Remove the check valve 2 Blow through A and check that air flows from B 3 Blow through B and check that air does not flow from A F 139 F CUT OFF SYSTEM A C CUT OFF SYSTEM DESCRIPTION An A C cut off system used to improve idle smoothness immediately after starting the engine and to improve acceleration performance AN SI THROTTLE POSITION SENSOR STEERING PRESSURE SENSOR AIR CONDITIONING DETERMINATION SENSOR OF CUT OFF K ENGINE COOLANT TEMPERATURE SENSOR 9 IGNITION SWITCH START A C RELAY PARK NEUTRAL IGNITION SWITCH SIGNAL PCMT AT NEUTRAL SWITCH MT MAGNETIC CLUTCH 517 BATTERY 7 CLUTCH SWITCH MT Operation Throtile valve wide open throttle Improved drivabitity Approx 7 sec Prevent engine from over heating F 140 6 x 1000i min AIC CUT OFF SYSTEM o EF SYSTEM OPERATION 1 Start the engine and let it idle 2 Turn the A C sensor and blower switch ON and verify that no engine speed decrease 3 Turn the blower switch OFF and verify that no engine spe
80. F 3 CRANK NORMALLY BUT WILL NOT START NO COMBUSTION DESCRIP 9 Starter cranks engine at normal speed but engine shows no indication of firing TION TROUBLESHOOTING HINTS Crankshaft position sensor 9 Poor connection of connector Main relay Poor connection of connector 9 Malfunction of relay Fuel pump No fuel in tank 9 Poor connection of fuel pump connector 9 Poor connection of connector Especially 1H 10 1T 31 4D 4E 4G 4H Igniter Poor connection of connector Injector Poor connection of connector 224 CRANKSNORMALLY BUT WILL NOT START PARTIAL COMBUSTION WHEN ENGINE COLD Starter cranks engine at normal speed and engine shows indication of firing but will not run when engine is cold at ini tial starting Engine wil not continue running when cold when ignition switch is returned from STA to IG position Refer to ENGINE STALLS if this symptom initially appears after engine stalls Fuel in tank Battery in normal condition TROUBLESHOOTING HINTS DESCRIP TION D tgniter Engine coolant temperature sensor 9 Poor connection of connector Poor connection of connector Q Ignition coil Engine compression 9 Poor connection of connector PCME Spark plug Poor connection of connector 9 Dirty or worn spark plug s Especially 1B 1G 1H 1J 1 10 17 4E 4G 4H G Injector primary Sol
81. F 172 Open circuit in wiring from neutral switch to PCME terminal 1R Always below 1 0V Always B Always below 1 0V Stoplight OK Open circuit in wiring from stoplight switch to PCME terminal 1S Always below 1 0V or B Open or short circuit in wiring from fuel pump relay to POME terminal 1T Fuel relay malfunction Refer to page F 174 Always Approx or approx 5V Refer to Code No 23 Troubleshooting Refer to page 40 9 Open circuit in wiring from data link connector IG terminal to PCME terminal 2B Crankshatt position sensor malfunction Refer to page F 166 PCME malfunction Always B Open circuit in wiring from PCMT terminal 2G to PCME terminal 2C Park neutral switch malfunction Refer to section Short circuit in wiring from PCMT terminal 1C to PCME terminal 1R Park neutral switch malfunction Refer to section K Open circuit in wiring from PCMT terminal 1C to PCME terminal 1R Always Always below 1 0V Short circuit in wiring from PCMT terminal 2G to PCME terminal 2C Always OV or 4V Always below 1 0V Short circuit in wiring from PCMT terminal 2M to PCME terminal 2E Always B Open circuit in wiring from PCMT terminal 2M to PCME terminal 2E Short circuit in wiring from PCMT terminal 2P to PCME termina 2G Always below 1 0V Open circuit in wiring from PCMT terminal 2P to POME terminal 2G Always B Refer to Code No
82. FL fol fo fo ofofolofol fol fol fol 111111 lolol lo Fsmeueswrn BPE NEUTRAL swiTcH wy lol lololol Jololojojololojololofololol lolol lei Jo lololo leloje elojo jele o e ele o l lolol fo Preswircnam 1 1T T T LET loll Pear runcrionsenson T T T Epp BEES Meet cee oe I et SOLENOID SHIFT A ler lel Jolo E fel lel VALVE SIGNAL AT SHIFT B T LE eT PARKI NEUTRAL SIGNAL O DATA LINK CONNECTOR TEN TERMINAL BAROMETRIC ABSOLUTE PRESSURE SENSOR IN PCME 182 lt gt lt 2 TROUBLESHOOTING GUIDE Output devices and Engine condition ENGINE CONDITION CRAN FUEL INJECTION Rich Normal SU AMOUNT INJECTOR Not Oper Not operate FUEL PUMP RELAY FUEL PUMP REAY OFF ON OFF SPEED Low speed High speed Low speed Fixed at BTDC 5 ACELERATED WARM UP AWS mE IDLE AIR ON ON ON CONTROL IAC Feedback duty Fixed duty Feedback duty DOUBLE THROTTLE ON OFF a OFF CONTROL Closed Open Open TURB gt OFF Closed Depends on engine condition Closed WASTEGATE OFF Depends on OFF CONTROL Closed engine condition Closed
83. FUEL TANK Removal Inspection Installation Warning Fuel vapor is hazardous It can very easily ignite causing serious injury and damage Always keep sparks and flames away from fuel ae Fuel line spills and leaks are dangerous Fuel can ignite and cause serious injuries or death and damage Fuel can also irritate skin and eyes To prevent this always complete the Fuel Line Safety Procedures on page F 95 Repairing a fuel tank that has not been properly steam cleaned can be dangerous Explosion or fire may cause death or serious injury Always properly steam clean a fuel tank before repair ing it 1 Drain the fuel from the fuel tank 2 Remove in the order shown in the figure 3 Inspect the fuel tank components visually and repair or replace if necessary 4 Install in the reverse order of removal referring to Installation Note 4 4 1 7 N m 11 17kgf cm 9 5 15in Ibf 7 8 10 8N m 80 110 kgf cm 69 95 in Ibf FASTNER 7 8 10 8N m dil 80 110 kgf cm gt 2 i mi 69 95in C IE 1 1 1 7 N m 11 17kgf cm 9 5 15in Ibf 180 110 kg 69 95in Ibf SEAL RUBBER REPLACE 7 8 10 8N m 80 110 kgf cm 69 95in Ibf 2 5 2 9 N m 25 30 kgf cm 22 26in Ibf N m kgf m ft Ibfj 98 FUEL SYSTEM F 1 Battery cable 8 Check valve 2 Fuel hoses Inspection page F 132 Installation Note
84. GR operation St High engine speed Above 3850 rpm Heavy load ee eg n o O MT 5th gear AT OD position F 125 F PREPARATION SST 49 F018 902 Adapter harness F 126 EXHAUST GAS RECIRCULATION EGR For inspection of solenoid valve SYSTEM OPERATION 1 Connect the SST Engine Signal Monitor Adaptor Har ness to the PCME as shown 2 Start the engine 3 Accelerates the engine and verify that PCME terminal 40 voltage B while the engine is still cold 4 Warm up the engine to normal operating temperature and run it at idle 5 Short the PCME terminal 4 and verify that the engine runs roughly or stalls at idle EXHAUST GAS RECIRCULATION EGR F EGR VALVE Removal Installation 1 Remove the intake air system component parts Refer to page F 76 2 Remove in the order shown in the figure 3 Install in the reverse order of removal MEE D NR GASKET REPLACE 7 8 10 8N m 80 110 kgf cm 69 95in Ibf 2 5 3 5 25 35 kgf cm 22 30in Ibf 3 EGR valve 1 Insulator Inspection cere am vk ER RR below 2 Connector Inspection 1 Connect vacuum pump as shown and apply vacuum 2 Verify that the EGR valve moves at more than the speci fied vacuum EGR VALVE Specification 0 11 15 3 kPa 85 115 mmHg 3 3 4 5 inHg 3 If not as specified replace EGR valve EGR FUNCTION SENSOR
85. INSPECTION sss suere F 15 SOLENOID VALVE PURGE CONTROL F 131 ADJUSTMENT gt suas uviwien sale F 16 CHACOAL CANISTER F 131 ON BOARD DIAGNOSIS FUNCTION F 18 CHECK VALVE TWO WAY F 132 DIAGNOSTIC TROUBLE CODE NUMBER F 20 CHECK VALVE ONE WAY F 132 SWITCH MONITOR FUNCTION F 67 SEPARATOR ce ee eeeeeenarn sanno F 132 OXYGEN SENSOR MONITOR FUNCTION F 75 FUEL VAPOR VALVE 4 F 132 KNOCK SENSOR MON ITOR FUNCTION F 75 DECELERATION CONTROL SYSTEM F 133 INTAKE AIR SYSTEM F 76 DASHPOT F 134 AIR BYPASS VALVE F 77 ANT AFTERBURN CONTROL F 134 CHARGE AIR COOLER F 78 ELECTRICAL LOAD E L CONTROL THROTTLE BODY F 79 SYSTEM F 135 EXTENSION MANIFOLD F 79 SYSTEM OPERATION F 136 INTAKE MANIFOLD esee F 79 DOUBLE THROTTLE CONTROL SYSTEM F 137 ACCELERATOR PEDAL F 80 SYSTEM OPERATION F 138 ACCELERATOR CABLE STT F 80 ACTUATOR IDLE SPEED CONTROL SYSTEM F 81 DOUBLE THROTTLE CONTOS V asus wan ES F 139 SYSTEM OPERATION F 82 CHECK
86. If not as specified replace the actuator Refer to page F 91 F 87 F SEQUENTIAL TWIN TURBOCHARGER SYSTEM CHARGE RELIEF VALVE Removal Installation 1 Remove in the order shown in figure 2 Install in the reverse order of removal System operation 1 Connect the SST Engine Signal Monitor Adaptor Har ness to the PCME as shown 2 Turn ignition switch to ON 3 Short the PCME terminal 4S and verify that the operating sound is heard when the solenoid valve ON 4 If no sound is heard check the solenoid valve Refer to page F 176 Inspection 1 Remove the charge relief valve 2 ConnectavacuumpumptoportA 3 Apply approx 26 7 kPa 200 mmHg 7 87 inHg to port and verify that air flows between and C 4 Replace if necessary F 88 SEQUENTIAL TWIN TURBOCHARGER SYSTEM __ F 49 F018 902 ACTUATOR TURBO PRECONTROL TURBOCHARGER Actuator Turbo precontrol System operation 1 Connect the SST Engine Signal Monitor Adaptor ness to the PCME 2 Turn ignition switch to ON 3 Short the PCME terminal 4V and verify that the operating sound is heard 4 If no sound is heard check the solenoid valve Refer to page 93 Inspection 1 Disconnect the air hoses and attached one to the SST and plug the other pipe as shown 2 Verify that the actuator rod is moved when applying com pressed air pressure to 69 98 kPa 0 7 1 0 kgf cm 10 14 psi Caution
87. Inspection 1 Remove the EGR valve Refer to above 2 Connect a ohmmeter between the terminals 3 Connect a vacuum pump as shown and apply vacuum 4 Verify that the EGR function sensor ON continue at more than the specified vacuum Specification 11 15 3 kPa 85 115 mmHg 3 3 4 5 inHg 5 If not as specified replace EGR valve SOLENOID VALVE EGR Inspection Refer to page F 176 F 127 F THREE WAY CATALYST SYSTEM THREE WAY CATALYST SYSTEM DESCRIPTION Two bets three way catalysts are used to reduce CO HC and NOx emissions For efficient operation the warm up three way catalyst is placed close to the exhaust manifold so that it will heat up quickly and purify exhaust gas efficiently when engine runs at idle WARM UP THREE WAY CATALYST oo THREE WAY CATALYST INJECTION PIPE The three way catalysts reduce CO and HC emissions through oxidization and NOx emissions by chemi cal reaction Three way catalyst Warm up three way catalyst Three way catalyst Operation 1 Before the engine is warmed up when large amounts of CO and HC are ceated the three way catalyst is supplied port air and uses both the first and second stages as the oxidization catalyst 2 In the normal driving range the three way catalyst is supplied split air and uses the first stage as the ternary catalyst and second stage as the oxidization catalyst 3 During high speed driving an additional air to the three way
88. MANIFOLD ABSOLUTE PRESSURE SENSOR MANIFOLD ABSOLUTE PRESSURE SENSOR AY su Jas 40 40 fam ak Jac ac 20 Eo ao ac pa ax 21 28 zc o S To o M TK 1 e E ea 142 Jax Jav ar Jan ap fan at jan ar 40 ae aP fan at au 3H sr 3o at 22 a 2F 20 28 V T JR P N C 2 H F 018 F 33 ON BOARD DIAGNOSIS FUNCTION cope No 7 BAROMETRIC ABSOLUTE PRESSURE SENSORINPOME Replace PCME page F 150 CODE No 15 OXYGEN SENSOR INACTIVATION If Code No 15 and 17 are both present first perform the checking procedure for Code No 17 Repair connector and or wiring harness Go to next step Does oxygen sensor circuit have a poor connection Go to next step Replace oxygen sensor c page F 113 Is oxygen sensor output voltage OK Check for short circuit in wiring c page F 150 Is there continuity between oxygen sensor and PCME terminal 3C e If OK replace PCME c f not OK repair wire harness Repair wiring harness Circuit Diagram OXYGEN SENSOR Ba ae ha po a pa fae ac sA a 22 8 42 fax av an ap an at Jar ar 39 SH fan 24 0 8 F 34 ON BOARD DIAGNOSIS FUNCTION F CODE No E 16 EGR FUNCTION SENSOR STEP IN
89. N SENSOR ENGINE COOLANT INTAKE AIR TEMPERATURE SENSORS THROTTLE VALVE PRIMARY EACUNI FROM CHARGE AIR COOLER AIR CONDITIONING STEERING IGNITION SENSOR PRESSURE SWITCH SENSOR F 82 IDLE SPEED CONTROL SYSTEM SYSTEM OPERATION 1 Warm up the engine and let it idle 2 Verify that the fast idle cam separates 3 Turn all electrical loads OFF 4 ON a tachometer to the data link connector terminal 5 With the coolant fan off verify that the idle speed is within specification idle speed Neutral or P range 700 750 720 35 rpm 6 Verify that the idle speed is within specification under the condition below IDLE SPEED CONTROL SYSTEM F REPLACE SOLENOID VALVE 7 8 10 8N m 80 110kgf cm 69 95in Ibf SOLENOID VALVE AWS IDLE AIR CONTROL VALVE Removal Installation 1 Disconnect negative battery cable 2 Remove the extension manifold Refer to page 76 3 Disconnect the solenoid valve connector 4 Remove the idle air control valve as shown in figure 5 Install in the reverse order of removal Inspection 1 Remove the solenoid valve Refer to above 2 Measure the solenoid valve resistance with an ohmmeter Resistance 10 7 12 3 Q 20 C 68 F 3 If not as specified replace solenoid valve SOLENOID VALVE ACCELERATED WARM UP SYSTEM AWS Removal Installation 1 Disconnect negative battery cable 2 Remove the extension m
90. No 44 output Poor acceleration NA Not applicable F SERVICE POINTS Solenoid valve Turbo precontrol PCME 4V Solenoid valve Open circuit Shotcicut _ Poorgrond Code No 42 output Code No 42 output Hesitation Poor acceleration NA Solenoid valve Main relay INJ fuse 30A burns out when ignition switch ON 0 Solenoid valve Wastegate control Hesitation Poor acceleration ee ee 4U Solenoid valve Code No 43 output Code No 43 output No symptom NA Solenoid valve Main relay EGI INJ fuse 30 burns out when ignition switch ON Lack of power NA Not applicable Poor acceleration F 236
91. Not apply 1 110 PRESSURE REGULATOR CONTROL PRC SYSTEM PRESSURE REGULATOR CONTROL PRC SYSTEM DESCRIPTION This system cancels the vacuum applied to the pressure regulator and increases the fuel pressure during hot engine start up and for a period immediately following engine start up This improves hot stanting as well as providing smooth idle L SOLENOID IGNITION SWITCH 3 STARTER SIGNAL CONTROL FUEL THERMOSENSOR FUEL TEMPERATURE dme ENGINE COOLANT _ TEMPERATURE SENSOR d PCMT ME PARK NEUTRAL SIGNAL NEUTRAL CLUTCH SW NEU MD THROTTLE POSITION a SENSOR THROTTLE OPENING OPENING ANGLE 30 APPROXIMATELY 90 SECONDS DURING AND AFTER ENGINE START UP Operation To prevent vapor lock during hot restart idle vacuum to the pressure reg ulator is momentarily cut and fuel injection pressure is increased F 111 F PRESSURE REGULATOR CONTROL PRC SYSTEM INSTALL CLAMP 112 SYSTEM OPERATION Warning Fuel line spills and leaks can be dangerous Fuel can ignite and cause serious injuries or death and can damage the vehicle Fuel can also irritate skin and eyes To prevent this from happening release the fuel pressure according to Fuel Line Safety Procedures on page F 95 1 Remove the fuel pump relay 2 Connect a fuel pressure gauge to the main hose 3 Connect the fuel pump relay 4 Start the engine an
92. OL 2 FURBO CONTROL 1 EGI MAIN RELAY F SOLENOID VALVE Pepa a Jo a as Tas 6 Jav x a as ae ec aa Se Be a Ex es EE E A LTS Tao TuT T TTG TET az jx ov a in eps c n erar ops v o b rojo f i pnr ote v e a e Lo 6 F 56 ON BOARD DIAGNOSIS FUNCTION F VALVE CHARGE CONTROL Repair connector and or wiring harness i Go to next step Go to next step Check for open or short circuit in wiring harness Solenoid valve B terminal Main relay D terminal A 45 SOLENOID is connector B termina voltage OK with solenoid valve connector disconnected Condition Voltage Ignition switch ON Battery positive voltage Is there continuity between solenoid valve A terminal and PCME terminal 4T Check for short circuit in wiring harness Solenoid valve A terminal PCME terminal 4T c If OK go to next step If not OK repair wiring harness Repair wiring harness Yes page 150 Replace solenoid vaive sr page 176 Is solenoid valve OK Circuit Diagram SOLENOID VALVE CHARGE CONTROL os JJ oon Tae Sea eas teva hoe Ta 57 F ON BOARD DIAGNOSIS FUNCTION 46 SOLENOID VALVE CHARGE RELIEF Repair connector and or wiring harness Go to next step Go to next step Check for open or
93. ON a PA RUNS ROUGH ON PRECAUTION 22 Fuel Pressure Release and Servicing Fuel System a Fuel in the fuel system remains under high pressure when the engine is not running Before disconnecting any fuel line release the fuel pres sure from the fuel system as described to reduce the pos sibility of injury or fire 1 Start the engine 2 Remove the fuel pump relay 3 After the engine stalls turn OFF the Ignition switch 4 install the fuel pump relay b Use a rag as protection from fuel spray when disconnect ing the hoses Plug the hoses after removal c When inspecting the fuel system use a suitable fuel pres sure gauge Install hose clamps to secure the fuel pressure gauge to prevent fuel leakage u taf INSALL CLAMP F 189 F TROUBLESHOOTING GUIDE SYMPTOM TROUBLESHOOTING weiss MAN on OTHER FUSE TROUBLESHOOTING HINTS Check the condition of the fuse Shorted harness or unit ag Ri Replace fuse Repair as necessary Damaged Fuse Related Wiring Harness MAIN 120A Main fuse Alternator BTN 60A BTN fuse ROOM fuse ROOM 10A ROOM fuse PCME terminal 1A INJ 30 Main relay Injectors PCME terminal 1B Oxygen sensor Solenoid valves E L unit Air pump relay METER 15A METER fuse Data link connector terminal B FUEL PUMP 20A FUEL PUMP fuse Fuel pump relay Fuel pump relay Fuel pump F 190 TROUBLESHOOTING GUIDE
94. OR FUNCTION With the System selector set to Engine Signal Monitor SELF TEST the knock sensor is monitored by the Self Diagnosis Checker as described below Item monitored ats Knock sensor output Tap the engine hanger E signal lightly with hammer SELF TEST Monitor lamp Flashes F 75 F INTAKE AIR SYSTEM INTAKE AIR SYSTEM COMPONENT PARTS Removal Inspection Installation 1 Remove in the order shown in the figure reffering to Removal Note Refer to page 77 2 Inspect all parts and repair or replace as necessary 3 Install in the reverse order of removal reffering to Installation Note Refer to page 77 7 8 10 8N m 80 110 kgf cm 69 95in ibf 10 o GASKET REPLACE S l m 5 80 110 kgf cm 69 95in Ibf e S i S oe EA Ng 78 108N m 80 110 kgf cm 69 95in Ibf SEN PA QUE SS eS De C 52 ff SS a v SEN 49 6 9N m ery 50 110 kgf cm 43 95in Ibf 2 O N m kgf m ft Ibf F 76 INTAKE AIR SYSTEM F 1 Fresh air duct Inspect for damage and cracks 2 Accelerator cable 3 Air intake hose Inspect for damage 4 Air cleaner housing Inspection 5 Air bypass valve Inspection 6 Pressure chamber 7 Air intake pipe Inspect for damage and cracks 8 Water hose 9 Connector 10 Vacuum hose A4 5
95. PCME and controls fuel pump operation voltage via the fuel pump resistor Fuel pump resister Tho fuel pump resister controis fuel pump operation voltage During low speed engine operation fuel pump voltage is supplied via the fuel pump resistor Operation TE 1 In low speed range 1K terminal of PCME is battery positive voltage The fuel pump is driven by voltage from the fuel pump resister 2 In high speed range 1K terminal of is OV The fuel pump is driven by battery positive voltage Operating conditions The system operates when either of the following conditions is met During engine start up Solenoid valve pressure regulator control operating High speed and heavy load F 108 FUEL SYSTEM F RESISTER CONNECTOR FUEL PUMP RESISTOR Removal Installation 1 Remove in the order shown in the figure 2 Install in the reverse order of removal Inspection 1 Disconnect fuel pump resistor connector 2 Measure resistance of the fuel pump resistor with an ohm meter Resistance 0 57 0 70 Q at 20 C 68 F 3 Replace the fuel pump resistor if necessary F FUEL SYSTEM FUEL PUMP RELAY SPEED Inspection Operation check Listen for operational sound of the fuel pump relay speed when ignition switch ON FUEL PUMP RELAY SPEED Continuity inspection Check continuity between the terminals with ohmmeter B Battery positive voltage Terminal A B Terminal C D Apply B Yes
96. R f the solenoid valve or circuit has an open or short Trouble Code No 28 is output f the circuit is open no symptom will be noticed 9 f the circuit is shorted the EGR valve will always open causing engine stalling and hard starting Solenoid valve Port air bypass f the solenoid valve or circuit has an open or short Trouble Code No 33 is output 9 n the above conditions no symptom will be noticed Solenoid valve Pressure regulator control f the solenoid valve or circuit has an open or short Trouble Code No 25 is output If the circuit is open hard starting may result when the engine is hot if the circuit is shorted fuel pressure will always be approx 280 kPa 2 9 kgf cm 41 psi and no symptom will be noticed F 222 SERVICE POINTS F Solenoid valve Purge control If the solenoid valve or circuit has an open or short Trouble Code 40 is output f the circuit is open no symptom will be noticed e If the circuit is shorted the engine stalls at low speed Solenoid valve Relief 2 If the solenoid valve or circuit has an open or short Trouble Code No 39 is output If the circuit is open no symptom will be noticed If the circuit is shorted secondary air noise will be heard while the air pump operates Solenoid valve Split air bypass 9 f the solenoid valve or circuit has an open or short Trouble Code No 30 is output in the above condition
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99. SPECTION ACTION Does EGR function sensor circuit have a poor con Yes Repair connector and or wiring harness nection e Go to next step Is connector A terminal voltage OK with EGR func Yes Goto next step tion sensor connector disconnected Check for open or short circuit in wiring harness EGR function sensor A terminail PCME terminal 3J Is there continuity between EGR function sensor B Yes Goto next step terminal and PCME terminal 4D Ed Repair wiring harness Replace PCME s page F 150 Ga Replace EGR valve Is EGR function sensor OK page 127 Circuit Diagram EGR FUNCTION SENSOR alutsialolMix iialetcyal i v r nje u rj u rjo e F 35 F ON BOARD DIAGNOSIS FUNCTION 17 OXYGEN SENSOR INVERSION Go to next step Check oxygen sensor circuit for a poor con nection STEP Is the same Code No present following after repair procedure sr page F 66 c If OK perform troubleshooting Code No 15 Does monitor lamp of Self Diagnosis Checker illumi Yes Goto next step nate at idle after the engine has been warmed up and run at 2500 3000 rpm for 3 min AJF mixture rich Go to Step 6 A F mixture is lean or misfire is occurring Is there air leakage in intake air system compo Yes Goto next step nents Repair or replace i page F 76 Is fuel line pressure correct at idle Yes j Goto next step s
100. T F 21 F ON BOARD DIAGNOSIS FUNCTION Diagnostic Trouble Code Numbers Diagnosed Crankshaft position sensor connector Wiring from crankshaft posi tion sensor to PCME Crankshaft position sensor Memo Yes F 26 Crankshaft posi tion sensor NE signal No NE signal 7 Crankshaft position sensor connector Wiring from crankshaft posi tion sensor to POME Crankshaft position sensor Crankshaft posi tion sensor G signal No G signal Knock sensor connector Wiring from knock sensor to PCME Knock sensor Open or shout Knock sensor circuit 9 Vehicle speed sensor connec tor Wiring from vehicle speed sen sor to PCME Engine coolant temperature sensor connector Wiring from engine coolant temperature sensor to PCME Engine coolant temperature sensor resistance Intake air temperature sensor connector Wiring from intake air temper ature sensor to PCME ntake air temperature sensor resistance No vehicle speed sensor signal Vehicle speed Sensor Engine coolant temprature sensor Intake air tem prature sensor Throttle position sensor con nector Wiring from throttle position sensor to PCME Manifold absolute pressure sensor connector Wiring from manifold absolute pressure sensor to PCME Manif
101. THROTTLE CONTROL N m kgf m ft lbf 6 Connector 7 Extension manifold 8 Solenoid valves Inspection ates page 177 CONTROL SYSTEM Inspection 1 Disconnect the connector 2 Connect a circuit tester to the solenoid valve 3 Check the continuity at the terminals 4 Verify that air flows between each ports as below 5 Connect battery positive voltage and a ground to the ter minals of the solenoid valve 6 Verify that air flows between each ports as below 7 Replace the solenoid valve if necessary F 177 F TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE QUICK DIAGNOSIS CHART This Quick Diagnosis Chart shows the relationship between troubleshooting items and inspection points i iti Turbo Secondary air Emis po Fuel system charger Injection sion y y system system system CKD IO 5 eco CO 69 COT Blane PEEN kk kikik LL LL LL 1L LL LL LC LL ILL 4 Possible parts and reference pag F 137 F 76 F 105 F 103 F 100 F 110 F 109 F 110 104 F Secion 3 8 218 enema 212 5 gt als 5 z olaaa Sis lo o 92 eit essersi 5852 g 9 lalalajal IS ole Eja E EIEE olo 3s als Glo falals S SIS Shai S56 ole os ajajalalz al8 Sje 15 8 815 5 5 8 2
102. TION 49 F018 902 SOLENOID VALVE SPLIT AIR BYPASS System Operation 1 Connect the SST Engine Signal Monitor Adaptor Har ness to the PCME 2 Turn ignition switch ON 3 Short the PCME terminal 4F and verify that the operation al sound is heard Inspection 1 Disconnect the solenoid valve 2 Measure the solenoid valve resistance with an ohmmeter Resistance 27 32 20 C 68 F 3 If not as specified replace solenoid valve Refer to page F 119 CHECK VALVE PORT AIR Inspection 1 Disconnect the air hose From air pump to air control valve at the air control valve 2 Start the engine and run it idle 3 Verify that the exhaust gas does not flow from air control valve 4 If the exhaust gas flows from air control valve replace the check valve port air Refer to page F 119 CHECK VALVE SPLIT AIR inspection 1 Disconnect the air hose From air control valve to air pipe atthe air pipe 2 Start the engine 3 Increase the engine speed to 2 000 rpm and verify that the exhaust gas does not flow from split air pipe 4 if not as specified replace the check valve Spilit air CHECK VALVE Inspection 1 Remove the check valve 2 Blow through A and verify that air flows from B 3 Blow through B and verify that air does not flow from A SECONDARY AIR INJECTION F MAGNETIC AIR PUMP System Operation 1 Start the engine 2 Increase the engine speed to above 3250 rpm and
103. TURBO OFF ON OFF CONTOROL Closed Open Closed ON OFF ON OHANA CONTROL Closed Open Ciosed CHARGE RELIEF OFF ON OFF CONTROL Open Closed Closed SECONDARY AIR OFF ON OFF BYPASS Closed Open Closed OFF ON OFF ON OFF PRESSURE OFF CONTROL PRC Ree 2 PURGE CONTROL p T ON SECONDARY AIR OFF ON OFF 2 SWITCHING Pot Split _ OFF ON OFF During hot start RECIRCULATION OFF ON OFF Engine speed EGR EGR Cut EGR EGR Cut 1 700 3 850 rpm OFF OFF cut cut COOLANT FAN RELAY Depends on engine coolant temperature METERING OIL PUMP meer for fm F TROUBLESHOOTING GUIDE USING THIS SECTION Introduction Most of the fuel and emission control systems are electronically controlled often making it difficult to diag nose problems especially intermittent problems Before undertaking actual checks take few minutes to talk with a customer who approaches with a drivabilitiy complaint The customer is often a good source of information on such problems especially the intermittent ones Through a talk with the customer you will usually find out what the symptoms are and under what conditions they occur Work flow CHECK LISTEN TO CUSTOMER COMPLAINTS REFER TO TROUBLESHOOTING PAGE THAT CORRESPONDS TO ACTUAL SYMPTOM CHECK FOR WHAT IS BAD IN SYSTEM CHECK FOR WHAT PART 1S BAD Umm
104. Tightening torque 20 24 N m 2 0 2 5 kgf m 15 18 ft Ibf Inspection 1 Place the fuel thermosensor in water with a thermometer and heat the water gradually 2 Measure the resistance of the sensor with an ohmmeter Water temperature 20 C 68 F 2 2 2 7 80 C 176 F 0 29 0 35 3 Replace the sensor if necessary OXYGEN SENSOR Inspection of Terminal Voltage 1 Warm up the engine to normal operating temperature and run it at idle 2 Disconnect the oxygen sensor connector 3 Connect a high internal resistance voltmeter more than 40 between the oxygen sensor terminal and ground 4 Measure the voltage while increasing and decreasing the engine speed suddenly several times Specification Engine condition Voltage While decelerating 0 0 0 4 While accelerating 22 2 0 5 1 0V EON Bes KNOCK SENSOR CONTROL SYSTEM F KNOCK SENSOR Inspection On vehicle 1 Connect a voltmeter Oterminal to the MEN terminal of the data link connector 2 Connect the data link connector terminals TEN and GND by using a jumper wire 3 Turn the ignition switch to ON 4 Lightly tap the engine hanger with a hammer 5 Verify that the voltmeter indicator moves 6 Turn the ignition switch to OFF Self Diagnosis Checker 1 Connect the SSTs System Selector and Self Diagnosis Checker to data link connector 2 Set switch A to position of Self Diagnosis Che
105. UENTIAL TWIN TURBOCHARGER SYSTEM F SOLENOID VALVE TURBO PRECONTROL WASTEGATE CONTROL Removal Installation 1 Remove in the order shown in the figure 2 Install in the reverse order of removal 8 11 N m 80 110 kgf cm 69 95 in Ibf 8 11N m 80 110 kgf cm 69 95in 1bf 80 110 kgf cm 69 95in Ibf TR 1 Pressure chamber 4 Solenoid valve Turbo precontrol 2 Connectors Inspection below 3 Vaccum hoses 5 Solenoid valve Wastegate contro z Inspection below Inspection 1 Remove the solenoid valve 2 Blow through the solenoid valve from hose A and check that air does not flow from B to A that air does flow the solenoid valve from A to B 4 If not as specified measure the resistance Resistance 29 33 20 C 68 F F 93 3 Apply battery positive voltage to solenoid valve and check F FUEL SYSTEM FUEL SYSTEM DESCRIPTION This system supplies the necessary fuel at constant pressure to the injectors Fuel is metered and injected into intake manifold and intake port according to the injection control signals from the PCME Powertrain Control Module Engine This system consists of fuel pump fuel filters pressure regulator pulsation dumper solenoid valve Pres sure regulator control and injectors SECONDARY INJECTOR OPERATING RANGE When the engine speed Is above 2750 RPM and the total fuel injection amount is above the pres
106. YM OW IHL 331799 WYO 15014 SATA GIONSIOS ONISNOH vil JAVA u3NV3TO LONG HS3ud JATA 1 39uvHo 10B81NO 3OH1NO2 SILLOYHL 318n0d 31LLOHHA 338000 HOLYNLOV 3KIVA GION310S 471009 3OHVHO Agy SATVA SSVdAG HIV GIONJIOS t A 3ATVA 323H9 SYSTEM DIAGRAM F OUTLINE WIRING DIAGRAM STEERINGPRESSURE SENSOR i RKA Fa an 3089 58584 TIN ee rt 8 OUTLINE F J INTAKE A SPLIT AIR BYPASS H jm SENSO a ACCELERATED WARM UP 2 H AWS PORT AIR BYPASS OFT E PAB SECONDARY AIR TH SWITCHING VALVE PRESSURE REGULATOR paa H CONTROL AIR PUMP SENSOR IPRC MAGNETIC e EXHAUST GAS CLUTCH RECIRCULATION i 317 TURBO CONTROL A LL 3 5 TURBO CONTROL NO 2 DE e B o vo CHARGE RELIEF EO A CHARGE CONTROL 122 8 1 WASTEGATE CONTROL WGCNT TURBO PRECONTROL NT IDLE AIR CONTROL a wee a L Bl pun o e E mue AIR BYPASS METERING OIL PUMP MOP EEEN BUNTIT i PRINARY an EO H 5 INJECTOR F OUTLINE VACCUM HOSE ROUTING DIAGRAM AIR CONTROL SOLENOID VALVE TURBO CONTROL ACTUATOR WASTEGATE CONTROL ACTUATOR TURBO PRECONTROL ACTUATOR TURBO CONTROL F 10 ACTUATOR MANIFOLD ABSOLUTE DOUBLE
107. age F 168 Removal Installation page F 168 7 Engine coolant temperature sensor Removal Installation page 169 inspection 8 intake air temperature sensor Removal Installation page F 169 Inspection page F 169 9 Fuel thermosensor Removal Installation page F 170 Inspection page F 170 10 Oxygen sensor m Inspection page F 170 Removal Installation page F 170 11 Knock sensor Inspection On vehicle Removal Installation 12 Steering pressure sensor Inspection On vehicle Removal Installation 13 Stoplight switch Inspection Removal Installation 14 Neutral switch MT Inspection Removal Installation 15 Clutch switch MT inspection Removal Installation 16 1 2 switch MT Inspection Removal Installation 17 EGR position sensor Inspection Removal Installation 18 Mileage switch Inspection 19 Heat hazard sensor Inspection Removal Installation 20 Solenoid valves Removal Installation Inspection page 171 page F 171 page F 172 page F 172 page 172 page F 172 page F 172 page F 172 page F 173 page F 173 page 173 page F 173 page F 127
108. alve one way Inspection 9 Separator Inspection 20 25 page F 99 100 ee page 99 page F 102 page 103 Eds page F 104 ic page F 105 TE page F 105 page 107 sia sua page F 105 T page F 132 page 132 sees page F 132 10 Fuel vapor valve Inspection page F 132 11 Solenoid valve Pressure regulator control Removal Installation page 176 inspection page F 177 12 Solenoid valve Purge control Removal Installation page F 131 Inspection page F 131 13 Catch tank 14 Chacoal canister inspection page F 131 F 3 INDEX Exhaust System 1 Main silencer 4 Exhaust manifold Removal inspection Removal Inspection Installation page F 113 Installation page 113 2 Three way catalyst 5 Secondary air pipe Removal inspection Removal inspection EINE Installation n page 113 installation eese page 113 3 Warm up three way catalyst 6 Check valve Split air 7 271 24 Removal Inspection Inspection sess page F 120 Installation page F 113 F 4 INDEX Control System Input Devices IGNITION TIMING SERVICE PAGE 16 1 Powertrain control module engine PCME Removal Installation Inspection
109. anifold Refer to page F 76 3 Disconnect the solenoid valve connector 4 Remove the solenoid valve AWS as shown in the figure 5 install in the reverse order of removal Inspection 1 Remove the solenoid valve Refer to page F 76 2 Measure the solenoid valve resistance with an ohmmeter Resistance 9 3 11 3 Q 20 C 68 F 3 If not as specified replace solenoid valve 83 F _ SEQUENTIAL TWIN TURBOCHARGER SYSTEM SEQUENTIAL TWIN TURBOCHARGER SYSTEM The sequential twin turbocharger system consists of two turbochargers primary and secondary fitted inline with each other In the low speed light load range turbocharging is done only by the primary turbo charger in the high speed heavy load range turbocharging is done by the primary and secondary turbo chargers in union To prevent a drop of boost pressure when the secondary turbocharger begins to operate the secondary turbocharger is made to spin prior to its operation The sequential twin turbocharger system consists of the primary and secondary turbochargers and the actuators and solenoid valves turbo precontrol turbo control wastegate control charge control charge relief CHARGE AIR COOLER ACTUATOR AIR CLEANER CHARGE HOUSING CONTROL CHARGE RELIEF VALVE B am ar CHAMBER SOLENOID VALVE SOLENOID CHARGE RELIEF VALVE TURBO PRECONTROL SOLENOID VALVE TURBO CONTROL
110. artial combustion normally when engine cold but will Partial combustion not start after warm up Any engine temp Cranks 7 _ Knock sensor Vehicle speed sensor o o c hen engine cold d After warm up tostat 9 dle at any engine temp 10 During fast idle FELEIEGSCHEE LEEEPEEEEEPCERLE dle after warm up i2 mare ON S and or E L ON Engine Idle when shifted f e aee Driveaway i On acceleration 16 While cruising On deceleration idle at any engine temp During fast idle 20 idle after warm up Idle with A C P S Engine and or E L ON rough Idle when shifted from 23 N or P to other ranges On deceleration Driveaway Poor ac On acceleration celeration High idle speed after warm up TROUBLESHOOTING GUIDE Possible parts and reference pag i Turbo Secondary air Deum j charger Injection system system F 128 131 Lo o 518 5 HE PES Qo a 2218 gt Sif sle 3 21 416 IS Ole 2 gt giz e mlolo Surio EH 5 2 2 E E18 o 13181 5 gt olaja SiS l gt 5 8 osi a EIE E amp 1212 5 amp Oo iel Bis GT Solos 510 2 212181015 l 5 lt 21
111. ay catalyst melted f the circuit is open the air pump will never operate causing rough idle Fan relay f the circuit is shorted the coolant fan will always operate while the ignition switch ON fthecircuitis open the coolant fan will not operate until the engine temperature exceeds 108 C 226 F FEN terminal Data link connector e if the circuit between the data link connector and unit is open the Self Diagnosis Checker buzzer will not sound during the trouble code check f the circuit between PCME 1F terminal and E L unit is open the Self Diagnosis Checker buzzer will constantly sound during the trouble code check e Ifthe circuit is shorted code 88 will keep flashing and the buzzer will continue sounding Self Diagnosis Checker preventing a trouble code check Fuel injector f a secondary injector or circuit has an open or short Trouble Code No 71 Front or 73 Rear is output causing poor acceleration and lack of engine power f a primary injector or circuit has an open engine will stall and will not start Fuel pump relay e f the circuit is open the engine will not start f the circuit is shorted the fuel pump will operate whenever the ignition switch is ON Fuel pump relay speed f the relay or circuit has open or short Trouble Code 51 is output f the circuit is open engine will hesitate or engine power will lack idle air control valve
112. cker 3 Set SYSTEM SELECT position 1and TEST SW to SELF TEST of System Selector _ 4 Turn the ignition switch to ON 5 Lightly tap the engine hanger with a hammer 6 Verify that the monitor lamp illuminates for approx 0 5 se conds 7 Turn the ignition switch to OFF Installation 1 Disconnect knock sensor connector 2 Remove the knock sensor 3 Install in the reverse order of removal Tightning Torque 20 34 N m 2 0 3 5 kgf m 14 25 ft Ibf F 171 F CONTROL SYSTEM STEERING PRESSURE SENSOR inspection On the vehicle 1 Disconnect the steering pressure sensor connector 2 Start the engine and check continuity of the switch Steering whee Yes Straight ahead a aa 3 Replace the steering pressure sensor if not as specified Removal Installation Refer to section N 7 W STOPLIGHT SWITCH Inspection 1 Disconnect the stoplight switch connector 2 Connect a circuit tester between the stoplight switch ter minals C and D 4 3 Check the continuity of the switch Yes Released PN Removal installation 1 Disconnect the stoplight switch connector 2 Remove the stoplight switch 3 Install the stoplight switch 4 Connect a circuit tester between the stoplight switch ter minals C and D and verify that the continuity when the brake pedal depressed and no continuity when the brake pedal released 5 Tighten the adjust nut Tig
113. conds Connect baitery cable and recheck for trouble code Is trouble code displayed Circuit Diagram MAIN RELAY POSITION SENSOR METERING OIL PUMP MAIN RELAY M O PUMP EM 1 Po oe 40 4E lac 30 Bv ox T 33 ac oa at a3 2e 2A fan far 34 fon 3D 38 2 22 24 25 20 28 F ON BOARD DIAGNOSIS FUNCTION 23 FUEL THERMOSENSOR srp Does the fuel thermosensor circuit have a poor con Yes Repair connector and or harness nection Go to next step Go to next step Check for short or open circuit in wiring _ Condition Voitage harness Fuel thermosensor B terminal Is fuel thermosensor B terminal voltage OK with fuel thermosensor connector disconnected PCME terminal 1U Ignition switch ON Approx 5 0V c If OK replace PCME lt gt If not OK repair wiring harness Is there continuity between fuel thermosensor A ter Go to next step minal and a ground Repair wiring harness Is resistance of fuel thermosensor OK Ye Replace PCME page 150 Replace fuel thermosensor sz page 170 77789017690 029 035 Circuit Diagram FUEL THERMOSENSOR fea oo sc A c v S ao M o E jon at sr ap at au a far 8 v r n P Nj HLF ON BOARD DIAGNOSIS FUNCTION
114. d run it idle 5 Verify the fuel pressure Fuel line pressure 190 220 kPa 1 9 2 3 kgt cm 28 32 psi 6 Short the PCME Terminal 4M and verify that fuel pres sure Fuel line pressure 250 260 kPa 2 5 2 7 kgf cm 36 38 psi 7 If notas specified check the pressure regulator and sole noid valve EXHAUST SYSTEM EXHAUST SYSTEM COMPONENT PARTS inspection On vehicle Start the engine and verify that there is no exhaust gas leakage from the exhaust system components Removal Inspection Installation 1 Remove in the order shown in the figure 2 Check all parts and repair or replace if necessary 3 Install in the reverse order of removal referring to Installation Note 7 8 10 8N m 80 110 kgf cm 69 95 in Ibf 19 7 8 10 8N m 80 110 kgf cm 69 95 in ibf GASKET REPLACE 7 8 10 8N m 80 110kgf cm 69 95in Ibf 7 8 10 8N m 80 110 Kot 9 95in Ibf 1 Braket 2 Secondary air pipe Inspect for deterioration and restriction 3 Three way catalyst Inspect for deterioration and restriction 4 Main silencer Inspect for deterioration and restriction 5 Insulator STUD BOLT 2 e 16 23 1 6 2 3 12 17 Ly 2 7 8 10 8N m 80 110kgf cm amp 5 69 95in Ibf 64 89 6 5 9 1 47 66 N m kgf m ft Ibf 6 Warm up three way catalyst T Inspect for deterioration and restriction 7 Turbocharger R moval 8 Insula
115. e 5 resistance of crankshaft position sensor NE SEN Go to next step SOR OK NE SENSOR Does crankshaft position sensor circuit have poor connection Is clearance of crankshaft position sensor NE sig Replace crankshaft position sensor ur page 166 Resistance 0 95 1 25 20 F 68 F me pes Go to next step nal OK Clearance 1 0 2 0 mm 0 039 0 078 in Adjust clearance r page 169 15 there continuity between ground and 4E or ground Check for short circuit in wiring Crankshaft and 4H terminal at harness side position sensor 4H or 4E terminal Ld bacs MM Replace PCME page F 150 Check for open circuit in wiring Crankshaft position sensor 4H or 4E terminal Disconnect connector from PCME is resistance be tween 4E and 4H terminals OK Resistance 0 95 1 25 20 C 68 F Circuit Diagram G SENSOR NE SENSOR CRANKSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR CRANKSHAFT POSITION SENSOR Jaw Jau 4s 40 pam 4G ae ac 30 T x 20 2 iac ujsaloTwIk i e e c a 42 Jax jan Jap JAN au ja 4r fan 48 3P TON far 21 12 jatar 20 2 lH 0 8 F 26 ON BOARD DIAGNOSIS FUNCTION F CODENo 03 CRANKSHAFT POSITION SENSOR G mecnm Is Code No 02 also present Go to step 5 Repair connector and or wiring harnes
116. e 4 Turn the ignition switch ON and check for fuel leaks from the injector Fuel leakage Less than 1 drop 5 min 5 If not as specified check the injector O ring and fuel dis tributor contact face 6 Install the injector 7 Turn the ignition switch ON and check for fuel leaks from injector 8 If not as specified replace the injector Volume Test 1 Remove the injectors together with the fuel distributor 2 Connect the SST as shown in figure Warning Fuel vapor is hazardous It can very easily ignite causing serious injury and damage Always keep sparks and flames away from fuel 3 Check the injection volume with a graduated container Injection volume Primary injector 128 147 ml 128 147 cc 3 84 4 41 fl oz 15 sec Secondary injector 198 227 198 227 cc 5 94 6 81 fl oz 15 sec 4 If not as specified replace the injector F 107 F FUEL SYSTEM FUEL PUMP CONTROL SYSTEM Description The PCME turns the fuel pump ON OFF via the fuel pump relay By controlling the fuel pump relay speed the PCME also controls fuel pump operation in two phases to improve fuel pump reliability and ensure the necessary fuel amount FUEL PUMP FUEL PUMP IGNITION RELAY SPEED RELAY 3 SWITCH Fuel pump relay JN The fuel pump relay is controlled by the PCME and turns the fuel pump ON OFF Fuel pump relay speed m The fuel pump relay speed is controlled by the
117. e air control Charging system MOP connector Wiring from MOP to PCME Low battery pos itive voltage Metering Oil Pump 23 F ON BOARD DIAGNOSIS FUNCTIO Diagnosed Memo Coen oa Pase Solenoid valve connector Wiring from solenoid valve to PCME Solenoid valve continuity Solenoid valve Accelerated warm up Sys tem Solenoid valve connector Wiring from solenoid valve to PCME Solenoid valve continuity Solenoid valve Relief 2 Solenoid valve connector Wiring from solenoid valve to PCME Solenoid valve continuity Solenoid valve Purge control Solenoid valve connector Wiring from solenoid valve to PCME Solenoid valve continuity Solenoid valve Turbo precon trol Solenoid valve connector Wiring from solenoid valve to PCME Solenoid valve continuity Solenoid valve Wastegate con trol Solenoid valve connector Wiring from solenoid valve to PCME Open or Short Circuit Solenoid valve Turbo control Solenoid valve continuity Solenoid valve connector Wiring from solenoid valve to PCME Solenoid valve continuity Solenoid valve Charge control Solenoid valve connector Wiring from solenoid valve to PCME
118. e hard starting No symptom Rough idie Both sides poor ground Engine will not start No symptom Code Nos 09 11 12 13 20 and 23 Engine hard starting Rough idle Input Device Air conditioning sensor 7 Shortereut_ Poorground PCME 1E A C amplifier i Air conditioner magnetic Air conditioner will constantly NA clutch will not operate operate with blower ON Clutch switch MT PCME 1Q Clutch switch No symptom 0 2 Crankshaft position sensor NE G signal 77 opmerut Poor ground Condition short Poor ground PCME 4E Crankshaft position sensor Code No 02 output Code No 02 output NE Engine will not start Engine will not start 4G Crankshaft position sensor Code No 03 output Code No 03 output G Engine will not start Engine will not start 4H Crankshaft position sensor Code Nos 02 and 03 output NA Engine will not start Ground NA Not applicable Engine wiil not start Engine suddenly stalls 228 SERVICE POINTS F E L unit Open circuit Short circuit Poorground 1F E L unit H MIL will never ON MIL will always ON Self Diagnosis Checker buzzer sounds constantly PCME 3B E L unit N Idle speed will be low when idle speed will be high E L ON Main relay E L unit A Idle speed wi
119. e idle speed drops when the A C P S or electrical load is ON Oxygen sensor if the sensor output voltage continues below 0 55V for 100 sec after the engine exceeds 1 500 rpm be cause of an open or short circuit Trouble Code No 15 is output f the sensor output voltage continues unchanged 50 Sec after the engine exceeds 1 500 rpm Trouble Code No 17 is output In the above conditions no fuel injection closed loop control will be present and no symptom will be not iced Park Neutral signal AT Refer to section K f the circuit is open or shorted the idle speed will be slightly low in R D S and L ranges F 219 F SERVICE POINTS Reduce torque signal AT Refer to section K WT f a malfunction occurs in the reduce torque signal the torque reduction control system is inhibited and line pressure will be high at shifting Shift shock may be slightly increased Slip lock up signal AT Refer to section K If a malfunction occurs in the slip lock up signal line pressure will be high at shifting and shift shock may be slightly increased Solenoid valve Shift A AT Refer to section K Solenoid valve Shift B AT Refer to section K Start signal A lack of engine cranking signal will cause hard starting when engine is cold Steering pressure sensor Refer to Mileage switch Stoplight switch The switch monitor function can confirm the presence of an open or sh
120. e sensor in water with a thermometer and heat the water gradually 2 Measure the resistance of the sensor with an ohmmeter 20 C 68 F 2 2 2 7 80 176 222 0 29 0 35 3 Replace the sensor if necessary INTAKE AIR TEMPERATURE SENSOR Removal Installation 1 Remove the extension manifold Refer to page F 76 2 Remove the intake air temperature sensor from extension manifold 3 Install the intake air temperature sensor Tightening torque NE 7 9 11 7 N m 80 120 kgf cm 70 104 Ibf Inspection 1 Remove the intake air temperature sensor and heat the sensor as shown in the figure 2 Measure the resistance of the sensor with an ohmmeter 20 C 68 F 2 2 2 7 80 C 176 F 0 29 0 35 3 Replace the sensor if necessary 169 F 170 CONTROL SYSTEM YSN FUEL JS LA on PUMP RELAY OXYGEN SENSOR CONNECTOR FUEL THERMOSENSOR Removal installation Warning Fuel line spills and leaks can be dangerous Fuel can ignite and cause serious injuries or death and can damage the vehicle Fuel can also irritate skin and eyes To prevent this from happening release the fuel pressure according to Fuel Line Safety Procedures on page F 95 1 Remove the intake air system component parts Refer to page F 76 2 Disconnect the fuel thermosensor connector 3 Remove the fuel thermosensor 4 Install in the reverse order of removal
121. e spark plug s Is strong blue spark visible at each disconnected high tension lead while cranking engine HIGH TENSION Check ignition system zr Section G Check condition of connector Does idle become rough when shaking connector of following devices 9 njector 9 Igniter Ignition coil Crankshaft position sensor Go to next step Are following terminal voltage at PCME correct Go to next step re page 158 Check for cause F 159 Try known good PCME does condition improved page 150 9 1G 1H 1J Igniter 3G Throttle position sensor Full range 9 40 Solenoid valve EGR 4R Solenoid valve Turbo control 45 Solenoid valve Charge relief 4V Solenoid valve Turbo precontrol 4W 4X 4 42 Injector 214 TROUBLESHOOTING GUIDE F LACK OF POWER DESCRIP Performance poor under load i e power down when climbing hills TION TROUBLESHOOTING HINTS Manifold absolute pressure sensor Double throttle control system Malfunction of manifold absolute pressure sensor Double throttle valve not open Secondary injector Sequential twin turbo control system Poor connection of connector Secondary port not open Nozzle clogged Malfunction of check valve s Q Air leakage EGR control system Turbo boost leakage EGR contro valve stuck open amp
122. ed increase 4 if not as specified check for cause Idle air control valve Inspection Refer to page F 82 A C signal PCME terminal 1E Inspection Refer to page F 152 F 141 142 A C CUT OFF SYSTEM Inspection Acceleration cut off 1 Turn ignition switch ON 2 Shift transmission into gear MT on shift into D range A 3 Turn the A C sensor and blower switch ON 4 Open the throttle vaive fully and verify that the magnetic clutch disengage click is heard then renganges after approx 5 seconds A C RELAY Continuity inspection Check continuity between the terminals with ohmmeter B Battery positive voltage Termina Terminal C D Apply B Yes Not Apply B 5 DECHOKE CONTROL SYSTEM F DECHOKE CONTROL SYSTEM DESCRIPTION To facilitate starting the engine if the spark plugs become fouled such as when the engine is flooded fuel injection is cut if the throttle valve is held wide open throttle while cranking the engine This allows the spark plugs to dry and purges excess fuel from the cylinders SYSTEM OPERATION 1 Verify that the engine will not start and no operational sound of primary injector with a screwdriver or a sound scope when cranked at normal speed with the throttle wide open throttle 2 If the engine starts and operational sound of primary in 2 CN jector is heard inspect the throttle position sensor Refer to page F 182 and the PCME terminal 1 C voltage
123. efer to page 152 11 Disconnect the SST 12 Verify that the ignition timing advances when the engine is above 1 500 RPM idle Speed Because the idle speed is controlled automatically by the PCME it is usually not necessary to check and adjust the idle speed control valve However if the engine is idling roughly use the following procedure to make adjustments 1 Perform Preparation Refer to page 16 2 Set SYSTEM SELECT to position 1 3 Set TEST SW to SELF TEST 4 With the coolant fan off verify that the idle speed is within specification s 30 POSITION 1 5 If not within the specification adjust the idle by turning the air adjusting screw AAS 6 Ifnot within the specification when air adjusting screw fully 222 closed loosen the locknut and turn the throttle adjusting THROTTLE screw to set the idle ADJUSTING 7 Tighten the locknut and put a paint mark on the nut and throttle body 8 Disconnect the SST F 17 F ON BOARD DIAGNOSIS FUNCTION ON BOARD DIAGNOSIS FUNCTION DESCRIPTION f When trouble occurs in the main input or output devices check for the cause by using the SST Failure of input and output devices is indicated and retrieved from the powertrain control module engine PCME as diagnostic trouble code numbers For input devices the PCME continuously checks for malfunctions For output devices it checks for mal functions only in a three second period after t
124. el A malfunction in the sensor causes engine roughness at high elevation Clutch switch MT Refer to Neutral clutch switches on page 173 Crankshaft position sensor NE G signal if the NE signal circuit has an open or short Trouble Code No 02 is output f the G signal circuit has an open or short Trouble Code No 03 is output if the NE or G signal circuit has an open or short the engine will not start No fuel injection and no ignition E L unit If the circuit has an open the switch monitor function can confirm that the blower fan headlight rear win dow defroster signals are not input to the PCME f the circuit is short the Idle speed will be increased slightly F 218 SERVICE POINTS F EGR function sensor e f the EGR function sensor or circuit has an open or short Trouble Code No 16 is output Engine coolant temperature sensor f tho thermosensor or circuit has an open or short Trouble Code No 09 is output and PCME uses a preprogrammed temperature value of 82 C 180 F e A malfunction in the engine coolant temperature sensor or its circuit will cause hard starting or engine stall when engine is cold In the above condition the electric coolant fan will constantly operate when the ignition switch is ON Fuel thermosensor f the thermosensor circuit has an open or short Trouble Code No 23 is output e n the above conditions the PCME will use a preprogrammed tem
125. elief valve Inspection Refer to page F 118 Air pump Inspection Refer to page F 121 Air pump relay Inspection Refer to page F 123 Inspection 1 Remove the air control valve Refer to page F 119 2 Connect a vacuum pump to port A 3 Verify that the switching valve opens at a vacuum 14 7 kPa 110 mmHg 4 3 inHg Caution Applying vacuum greater than 66 7 kPa 500 mmHg 19 7 inHg can damage the air control valve 4 If not as specified replace air control valve Refer to page F 119 F 117 F SECONDARY AIR INJECTION Air Relief Vaive System operation Engine Signal Monitor 1 Connect the SST Engine Signal Monitor Adaptor Har ness to the PCME as shown 2 Start the engine and run it idle 3 Verify that air does not flows from air relief Valve 4 Short the PCME terminal 3P and verify that the air flows from air relief valve 5 If the air does not flow check the following condition be low Vacuum tube Inspect the vacuum line fitting connections and com AIR RELIEF VALVE dc AIR HOSE ponents for leaks Refer to page F 10 Secondary air bypass valve Inspection Refer to page 176 Air pump Inspection Refer to page F 121 Air pump relay Inspection Refer to page F 123 inspection 1 Remove the air control valve Refer to page F 119 2 Connect a vacuum pump to port A 2210 VACUUM 3 Verify that the air relief valve opens at a vacuum 19 3 kPa 145 mmHg 5
126. engine compression correct zr Section C Compression 690 kPa 7 0 kgf cm 100 psi 250 rpm Differential limit of chambers 150 kPa 1 5 kgf cm 21 psi 250 rpm T T Try known good PCME does condition improved page F 150 Are spark plugs OK Section G F 197 F TROUBLESHOOTING GUIDE IDLE WITH A C P S and or ON ee IDLE WHEN SHIFTED FROM N OR P TO OTHER RANGES DESCRIP Engine stops unexpectedly when A C P S and or turned ON at idle TION Engine stops unexpectedly when shifted from or P to other ranges at idle Idle condition is normal when A C P S and are OFF and in N and P TROUBLESHOOTING HINTS D Monitor switch functions SST Idle air control valve Solenoid valve stuck 9 Air conditioning sensor Headlight switch Air control valve 9 Rear window defroster switch Malfunction of air control valve Blower switch Yes next step Yes Are switches correct when checked by using SST monitor switch function while ignition switch ON s page F 44 Blower switch 9 Headlight switch Rear window defroster switch 9 Electric coolant fan Electrical load unit Air conditioning sensor Lamp not ON OFF with specified switch Check for cause Refer to specified check sequence er page 45 00 displayed Is
127. enoid valve Purge control 9 Poor connection of connector 9 Short circuit Solenoid valve fully opened Fuel leakage from injector s Intake air system Air leakage Is 00 displayed SST with ignition switch ON 00 displayed page F 20 Go to next step Hi B19 Troubie Code No displayed Check for cause Refer to specified check sequence F 191 F TROUBLESHOOTING GUIDE Is strong blue spark visible at each disconnected high tension lead while cranking engine HIGH TENSION LEAD Connect jumper wire between F P and GND terminals of data link connector will engine start GND LU DATA LINK CONNECTOR Are PCME terminal voltages OK page F 152 Terminal 1B 1G 1H 1J 1 10 17 4E 4G 4H Connect data link connector terminals F P and GND with a jumper wire is fuel line pressure correct with ignition switch ON page 98 Fuel line pressure 250 260 kPa 2 5 2 7 kgf cm 2 36 38 psi DATA LINK CONNECTOR Yes Section G Go to next step Clean or replace Check as follows 1T terminal voltage at PCME Continuity between 1T terminal and fuel pump relay connector terminal Condition of PCME and fuel pump relay connector female terminals page 156 Check if fuel pump operating sound is heard f yes go to next step If no check fuel pump and wiring harness F 100 Go to next step
128. enoid valve Turbo control Inspection Refer to page F 176 9 Actuator Turbo control Inspection Refer to below N ACTUATOR TURBO CONTROL Inspection 1 Disconnect the air hose and attached it to the SST as shown 2 Adjust the compressioned air pressure to 49 kPa 0 5 kg f cm 7 1 psi 3 Verify that the actuator rod is move when appying and re leasing air pressure ACTUATOR os Caution TURBO CONTROL Applying more than 79 4 kPa 0 81 kgf cm 11 5 49 F088 740 psi of compressed can damage the actuator 4 If not as specified replace the actuator Refer to page 91 86 ACTUATOR CHARGE CONTROL ACTUATOR CHARGE CONTROL SEQUENTIAL TWIN TURBOCHARGER SYSTEM F ACTUATOR CHARGE CONTROL System Operation 1 Start the engine and verify that the actuator rod is pulled into the actuator 2 If the actuator rod is not pulled check the following condi tion below Vacuum tube Inspect vaccum line fitting connections and components for leak Refer to page F 10 Vacuum chamber inspect the damage or crack Solenoid valve Charge control Inspection Refer to page F 176 Actuator Charge control Inspection Refer to below e Shutter valve Inspection Refer to below Inspection 1 Disconnect the vacuum hose from the actuator 2 Connect a vacuum pump 3 Verify that the actuator rod is pulled when applying vacu um more than 6 7 kPa 50 mmHg 1 9 inHg 4
129. ent amount pre programmed in the ECU the secondary fuel injector operates The total fuel injection amount is determined by engine speed intake manifold pressure intake air temperature and atmospheric pressure For troubleshooting the secondary fuel injector please refer to the self diagnosis function service code No 71 73 PRESSURE REGULATOR FUEL VAPOR VALVE FUEL R FILTER SEPARATO HIGH PRESSURE PULSATION FUEL INJECTOR SECONDARY gt ERR Sy 45 VALVE f uc r aTi e AS A 2 CLP me 1 Cp A a gt en n n 2 Py 2 e Ta V c CANISTER TANK FUEL PUMP IN TANK SOLENOID VALVE PRESSURE REGULATOR CONTROL CATCH TANK SOLENOID VALVE PURGE CONTROL F 94 Injector checker S of injector injector checker of injector PRECAUTION Warning Fuel vapor is hazardous It can very easily ignite causing serlous injury and damage Always keep sparks and flames away from fuel Fuel in the fuel system is under high pressure when the engine is not running Warning Fuel line spills and leaks are dangerous Fuel can ignite and cause serious injuries or death and dam age Fuel can also irritate skin and eyes To prevent this always complete the following Fuel Line Safety Procedures Fuel Line Safety Procedures INSALL A Release the fuel pressure before disconnecting a
130. eration Engine speed increases normally but vehicle speed slowly in Section K creases during acceleration 27 High idle speed after warm up Idle speed continues at fast idle after warm up Engine returns F 209 slowly to idle after accelerator is released Idle fluctuates Idle hunts Engine speed hunts between specified idle speed and higher i F 211 speed Hesitates Stumbles on acceleration Momentary pause at beginning of acceleration or during accel F 212 eration Surges while cruising Momentary minor irregularity in engine power at steady vehicle F 214 speed Section K Lack of power Performance poor under load i e power down when climbing F 215 hills Section K Poor fuel economy Fuel economy unsatisfactory F 215 Section K A C does not work A C compressor magnetic clutch does not engage when Air F 215 conditioning sensor ON Knocking Pinging Sound produced as air fuel mixture is ignited by some thing F 216 e other than spark plug i e hot spot in combustion chamber 8 Gasoline fuel smell or visible leaks F 216 Exhaustsufursmel Rotten egg sulfur smell from exhaust F 216 High consumption Oil consumption excessive F 216 Self Diagnosis Checker flashes 88 Checker flashes 88 with test connector grounded F 217 2 MIL never ON Self Diagnosis Checker indicates Trouble Code No of input F 217 device but MIL never ON Vehicle does not move when accelerator pedal is depres
131. erburn FROUBLESHOOTING HINTS D Fuel pump Idle air control valve Poor connection of connector Solenoid valve stuck Q Idle speed amp EGR control valve speed too low Solenoid valve stuck open Crankshaft position sensor Poor connection of connector Poor connection of connector Manifold absolute pressure sensor Fuel cut control Malfunction of manifold absolute pressure sensor Is 00 displayed on SST with ignition switch ON s page F 20 Go to next step Trouble Code No displayed Check for cause Refer to specified check sequence Are following PCME terminal voltage correct MT When checking voltages tap move and wiggle the Check neutral switch and clutch switch e page F 173 harness and the connector AT 1B Main relay Go to ENGINE STALLS ON 9 1G 1H 1J Igniter DECELERATION in Section K of this manual 1T Fuel pump relay 4D Ground 4W 4Y Primary injector Check for cause 202 TROUBLESHOOTING GUIDE F 19 20 21 ENGINE ROUGH IDLE AT ANY ENGINE TEMP DURING FAST IDLE IDLE AFTER WARM UP Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake at any engine temperature DESCRIP idle speed too low and excessive engine shake at any engine temperature TION Fast idle speed too low and excessive engine shake
132. erminal 2L 1 2 switch malfunction Refer to page 173 Always below 1 0V 9 Short circuit in wiring from PCMT terminal 1B to PCME terminai 2L 9 Open circuit in wiring from PCMT tarminal 1B to PCME terminal 2L Always approx OV or approx 5V Refer to Code No 27 Troubleshooting Refer to page F 43 Short circuit in wiring from switches E L unit PCME terminal 3B Always below 1 0 Switches malfunction Refer to section T Always B OV after warm up Always approx 1V after warm up Open circuit in wiring from switches E L unit PCME terminal 3B Switches malfunction Refer to section T Refer to Code No 15 Troubleshooting Refer to page F 34 Refer to Code No 17 Troubleshooting Refer to page 36 Open or short circuit in wiring from coolant fan relay to PCME terminals 3D Fan relay malfunction Refer to page 146 9 PCME malfunction Always approx or approx 5V Refer to Code No 09 Troubleshooting Refer to page F 30 Always approx 0V Referto Code No 2 Troubleshooting Refer to page F 32 Always below 1 0V or Always B Always approx 5V Always approx 0 Refer to Code No 18 Troubleshooting Refer to page F 38 Always approx 5V Always OV or B Refer to Code No 40 Troubleshooting Refer to page F 53 F 159 CONTROL SYSTEM Tl B Battery positive voltage rminal Input Tes
133. erse order of removal reffering to Instaliation Note 7 8 11 80 110 69 95 FASTNER 7 8 11 80 110 69 95 N m kgf cm in Ibf 1 Fresh air duct 4 Airhose 2 Charge air cooler braket 5 Charge air cooler 3 Air separation tank Installation Note Install the air intake hose and hose clamp same place as shown in the figure F 78 ADJUST INTAKE AIR SYSTEM F SCREW THROTTLE BODY Inspection Fast idle cam 1 Verify that the indicated mark on the fast idle cam is aligned with the center of the cam 2 Warm up the engine to operating temperature and verify that the waxrod extends outuard fully and the idle cam separates from the roller at 55 65 C 131 149 F 3 Adjust the adjust screws if necessary Adjustment 1 To adjust the first idle cam separates point D turn adjust screw B 2 To adjust the first idle cam opening temperature turn ad just screw A Temperature 20 C 4 F 60 140 F Double throttle valve Inspection 1 Verify that the No 2 secondary throttle valve and linkage move smoothly when primary throttle valve is fully opened 2 Replace throttle body if necessary EXTENSION MANIFOLD Inspection 1 Visually check for cracks or damage and replace it if nec essary 2 Check for distortion of extension manifold and replace if necessary INTAKE MANIFOLD 1 Visually check for cracks or damage and replace if neces Say 2 2 C
134. es Go to next step lamp operation change as follows upon driveaway 10 Voltage gradually increase Check as follows Condition of female terminals in related 4E 4G Voltage not suddenly change connector AW 4Y Flashing of green and red lamps Continuity between injector connector becomes quicker and PCME 4W or 4Y terminal Connect data link connector terminals F P and GND Yes Go to next step with a jumper wire is fuel line pressure correct with ignition switch ON Low pressure page 98 Check fuel line pressure while pinching fuel return hose Fuel line pressure pressure quickly increases check 250 260 kPa 2 5 2 7 kgf cm 36 38 psi regulator x page F 104 If pressure gradually increases check for clogging between fuel pump and pres PRESSURE sure regulator If hose not clogged check fuel pump maximum pressure zr page F 101 INSALL CLAMP Yes Go to next step pus Replace injector cr page 105 Are injectors OK 9 No fuel leakage s page 106 njectors not clogged Perform volume test page F 67 F 199 TROUBLESHOOTING GUIDE Go to next step Is engine compression OK sz Section G Compression 690 kPa 7 0 kgf cm 100 psi 250 rpm Differential limit of chambers 150 kPa 1 5 kgf cm 21 psi 250 rpm Check for cause Go to next s
135. etween intake air temperature Go to next step sensor A terminal and a ground Repair wiring harness Is resistance of intake air temperature sensor OK Replace PCME i page F 150 Resistance kO 20 C 68 F 22 27 Replace intake air temperature sensor s page F 169 85 C 185 02905 INTAKE AIR TEMPERATURE SENSOR sv Ja x a p e pc Joa Joo a c eS v Te Te 6 42 fax av aT jan j4P fan Ja as jan jar 40 48 SP jat au ar 30 36 Jat 2s far 20 28 o H F D B F 31 F ON BOARD DIAGNOSIS FUNCTION Does throttle position sensor circuit have a poor con nection Is throttle position sensor A terminal voltage OK with throttle position sensor disconnected Condition Votage Ignition switch ON Approx 5 0V Check for open or short circuit in wiring harness Throttle position sensor A terminal PCME terminal 3l c If OK replace PCME c If not OK repair wiring harness Check for short circuit in wiring harness Throttle position sensor D terminal PCME terminal 3G Is there continuity between throttle position sensor and PCME c if OK go to next step c If not OK repair wiring harness Repair wiring harness Replace PCME r page F 150 pen Replace throttle position sensor page 168 Is there continuity between ter
136. go to next step lt gt f not OK repair wiring harness dud Repair wiring harness pee Replace PCME page F 150 Replace fuel pump relay speed Is fuel pump relay speed OK x page F 110 Circuit Diagram FUEL PUMP RELAY SPEED FUEL PUMP RESISTER Sms oS Se SOLS ole eae STS SP aN Jat faH ar fan o8 jar 22 2 zr vir n je N F 60 ON BOARD DIAGNOSIS FUNCTION F CODENo 54 AIR PUMP RELAY sup SECTION Does air pump relay circuit have a poor connection Repair connector and or wiring harness Go to next step Check for open or short circuit in wiring harness Air pump relay terminal Main relay D terminal 15 connector terminal voltage OK with air pump relay connector disconnected Condition Votage Ignition switch ON Battery positive voltage Js there continuity between air pump relay C terminal and PCME terminal 2J Check for short circuit in wiring harness Air pump relay C terminal PCME terminal 2J c if OK go to next step gt If not OK repair wiring harness Repair wiring harness Replace PCME er page F 150 Replace air pump relay Is air pump relay OK page 123 AIR PUMP MAGNETIC CLUTCH AIR PUMP MAGNETIC AIR PUMP RELAY F CLUTCH A P EM ax 4 pa po aa ex
137. he ignition switch is turned to ON or the TEN terminal of the data link connector is grounded OUTPUT ANALOG DEVICES INPUT tc mn 2 2 Q tc 3 mi x gt 2 T Q z lt tr ul CAE T c D pany SWITCH INPUT FEN TERMINAL DIGITAL BUFFER DIGITAL INPUT TEN TERMINAL DIGITAL BUFFER DIGITAL F 18 49 H018 9A1 49 B019 9A0 J ea For For diagnosis Self Diagnosis diagnosis System Selector N Checker ON BOARD DIAGNOSIS FUNCTION F PREPARATION SST ON BOARD DIAGNOSIS FUNCTION DIAGNOSTIC TROUBLE CODE NUMBER 49 019 9 0 019 9 0 Inspection Procedure 1 Connect the SST to the Self Diagnosis Checker to the data link connector 40 B019 2 Set system select to position 1 3 Set the test switch to SELF TEST 4 Connect the SST to the System Selector and a ground 5 Set the select switch to position A 6 Turn the ignition switch ON 7 Verify the 88 flashes on the digital display and the buzzer sounds for 3 sec after turning the ignition switch ON 8 If 88 does not flash check the main relay refer to page F 174 power supply circuit and data link connector wir ing 9 If 88 flashes and the buzzer sounds continuously for more than 20 sec check for a short circuit between the PCME terminal 1 F and the data link connector Replace the PCME if neces
138. heck for distortion of the intake manifold and replace it if necessary F 79 F INTAKE AIR SYSTEM ACCELERATOR PEDAL Removal Inspection Installation 1 Remove in the order shown in the figure 2 Visually check the accelerator pedal and retainer for cracks or damage 3 Install in the reverse order of removal 1 Accelerator cable Inspection Adjustment 2 Retainer 3 Clip ACCELERATOR REPLACE 4 4 Shaft below 5 Return spring 6 Accelerator pedal ACCELERATOR CABLE Inspection Adjustment 1 Warm up the engine at normal SEO temperature 2 Depress the accelerator pedal to the floor and check that the throttle valve is fully opened 3 Inspect the play of the accelerator cable Play 1 3 mm 0 04 0 12 in 4 Loosen nuts A to adjust the play if necessary E RE EES OEN Ed IDLE SPEED CONTROL SYSTEM F IDLE SPEED CONTROL SYSTEM DESCRIPTION Idle speed control system controls the bypass air amount that passes through the throttle valve the idle speed control system performs closed loop control so that engine idle smoothly and atthe target speed The system also performs the function of the AAV anti afterburns valve there by eliminating the AAV and sim plifying deceleration control system EXTENSION NEUTRAL MANIFOLD CLUTCH SWITCH CRANKSHAFT POSITION IDLE AIR CONTROL SENSOR MANIFOLD ABSOLUTE PRESSURE SENSOR ow THROTTLE 2 POSITIO
139. htening Torque 14 18 N m 1 4 1 8 kgf m 10 13 ft Ibf NEUTRAL SWITCH MT Inspection 1 Disconnect the neutral switch connector 2 Connect a circuit tester to the switch 3 Check the continuity Yes 3 In other ranges PN F 172 CONTROL SYSTEM F Removal Installation 1 Remove the power plant frame Refer to section J MT Refer to section K AT 2 Disconnect the neutral switch connector 3 Remove the neutral switch 4 Install in the reverse order of removal Tightening Torque 25 34 N m 2 5 3 5 kgf m 18 25 lbf CLUTCH SWITCH MT Inspection 1 Disconnect the clutch switch connector 2 Connect a circuit tester to the switch 3 Check the continuity xu Removal Installation 1 Remove the power plant frame Refer to section J MT Refer to section K AT 2 Remove the clutch switch 3 Install the clutch switch 4 Connect a circuit tester to the switch and verify that the continuity when the clutch pedal depressed and no conti nuity when the clutch pedal released 5 Tighten the adjust nut Tightening torque 14 18 N m 1 4 1 8kgf m 10 13 ft Ibf 1 2 SWITCH MT Inspection 1 Disconnect 1 2 switch 2 Connect a circuit tester to the switch 3 Check the continuity m in ist and 2nd range in other range In other range Removal installation 1 Remove the extension housing Refer to section J 2
140. i Check for cause page 153 Go to next step Low pressure TIR Check fuel line pressure while pinching fuel return hose f pressure quickly increases check pressure regulator f pressure gradually increases check for clogging between fuel pump and pres sure regulator If hose not clogged check fuel pump maximum pressure or page 104 e page 101 TROUBLESHOOTING GUIDE 21 Replace injector s Page F 105 Go to next step Check for cause e Section C Try known good PCME does condition improve amp page 150 PARTIAL COMBUSTION AFTER WARM UP Starter cranks engine at normal speed and engine shows indication of firing but wili not run when engine is warm 9 Engine will not continue running when ignition switch is returned from STA to IG position Are injectors OK i Page 107 9 Fuel leakage 9 Primary injector s clogged Is engine compression OK Section C Compression 690 kPa 7 0 kgf cm 100 psi 250 rpm Differential limit of chambers 150 kPa 1 5 kgf cm 21psi 250 rpm 8 CRANKS NORMALLY BUT WILL NOT START DESCRIP TION TROUBLESHOOTING HINTS D Solenoid valve PRC Evaporative emission control 9 Poor connection of solenoid valve connector or PCME 4M ter Malfunction of check valve two way minal Fuel pump Fuel Malfunction of fuel pump relay High RVP winter fuel
141. icle speed sensor Ignition switch ON after 2 seconds Manifold abso lute pressure sensor 81 URS v 540 Pad mmHo PRESSUR CONTROL SYSTEM F a a B Battery positive voltage incorrect condition Possible cause Always below 1 0V Short circuit in wiring from data link connector terminal TEN to PCME terminal 11 Always B Open circuit in wiring from data link connector terminal TEN to PCME terminal 11 Open circuit in wiring from data link connector terminal GND to ground Always 0 Refer to page 16 Ignition timing adjustment Always below 1 0V Refer to Code No 51 Troubleshooting Refer to page F 60 Always B Poor connection at PCME connector Fuel pump relay speed malfunction Refer to page F 110 9 PCME malfunction Always B Always below 1 0V Always relay malfunction Refer to page F 142 Open circuit in wiring from ignition switch to A C relay Open circuit in wiring from A C relay to PCME terminal 11 Short circuit in wiring from A C relay to PCME terminai 1L A C relay malfunction Refer to page 142 Open or short circuit in wiring from vehicle speed sensor to PCME terminal 1M Vehicle speed sensor malfunction Refer to section Steering pressure sensor malfunction Refer to page F 172 Short circuit in wiring from steering pressure sensor t
142. ifold pressure sends signal sensor to PCME Neutral Clutch switches MT Detects in gear condition sends signal to Switch is ON in neutral PCME Detects oxygen concentration sends signalto 9 Zirconic and platinum coat PCME Igniter F 12 OUTLINE Component lt Park neutral switch Detects load condition sends signal to PCME ee C CENE PCV valve Controls blowby gas introduced into engine RENE Powertrain control module Detects the following engine PCME 1 Engine speed 1 Crankshaft position sensor 2 Knocking signal 2 Knock sensor 3 Vehicle speed 3 Vehicle speed sensor 4 Engine coolant temperature 4 Engine coolant temperature sensor 5 Intake air temperature 5 Intake air temperature sensor 6 Throttle valve opening angle fuil range 6 Throttle position sensor full range 7 intake manifold pressure 7 Manifold absolute pressure sensor 8 Atmospheric pressure 8 Barometric absolute pressure sensor 9 Oxygen concentration 9 Oxygen sensor 10 Air Fuel ratio s 10 Oxygen sensor 11 Throttle valve opening angle narrow 11 Throttle position sensor narrow range range 12 Metering pump MOP position signal 12 MOP position sensor 13 Fuel temperature 13 Fuel thermosensor 14 Gear position 14 1 2 switch MT 15 Clutch condition 15 Clutch switch MT 16 In gear condition 16 Neutral switch
143. ill not continue running when warm when IGN switch is returned from STA to IG position Will start in other than P and ranges Engine starts in P N and other ranges hard to start ture cessive cranking time before starting at any engine tempera ture Engine starts after stalling a few times at any engine tempera ture when engine cold cessive cranking time before starting when engine is cold En gine starts after stalling a few times when engine is cold After warm up Starter cranks engine at normal speed but engine requires ex cessive cranking time before starting after warm up Engine stalls Idle at any engine Engine stops unexpectedly at any engine temperature temperature idle after warm up Engine stops unexpectedly at idle after warm up Idle with A C 5 Engine stops unexpectedly when A C P S and or is and or E L ON turned ON at idle Idle when shifted from Engine stops unexpectedly when shifted from N or P to other N or P to other ranges ranges at idle Engine stops unexpectedly upon driveaway Foie While cruising Engine stops unexpectedly while cruising On deceleration Engine stops unexpectedly at beginning of deceleration or re F 202 ae e covery from deceleration Exhaust afterburn Section K Idle at any engine Engine speed fluctuates between specifiedidiespeedandlow temperature er speed and excessive engine shake at any engine tempera Idle speed too slow and excessive engine shake atany engine temperature Du
144. illuminated Clutch switch malfunction er page 173 Open circuit in related wire harness PCME terminal 1Q voltage incorrect s page 150 PCME malfunction Clutch switch OK Release clutch pedal 70 ON BOARD DIAGNOSIS FUNCTION F Air conditioning sensor Turn blower switch to 1st position Turn Air conditioning sensor ON Is monitor lamp illuminated Air conditioning sensor OK PC Air conditioning Open circuit in wire harness oe Air conditioning sensor Blower switch PCME terminal 3B voltage incorrect page 150 PCME malfunction 1994 RX 7 Body electrical sensor malfunction troubleshooting manual F 71 F ON BOARD DIAGNOSIS FUNCTION Rear window defroster switch Turn rear window defroster switch ON 16 monitor lamp illuminated Rear window defroster switch OK Turn rear window defroster switch OFF PC 9 Rear window 1994 RX 7 Body electrical defroster switch troubleshooting manual malfunction 9 Open circuit in wire harness Rear window defroster switch PCME PCME terminal 3B voltage incorrect page F 150 PCME malfunction unit malfunction F 72 ON BOARD DIAGNOSIS FUNCTION F Park neutral switch AT Shift transmission into L S R or D range iun PC 9 Park neutral switch Section is monitor tamp illum
145. inated malfunction Open or short circuit in related wire harness PCME terminal 1R voltage incorrect c page 150 Park neutral switch OK E MT malfunction Shift P or N range PE malfunction F 73 F ON BOARD DIAGNOSIS FUNCTION Blower switch PC 9 Blower switch 1994 RX 7 Body electrical Turn blower switch to 3rd or 4th position Is monitor lamp illuminated malfunction troubleshooting manual Open circuit in wire harness et lower switch PCME CME terminal 3B voltage incorrect tr page 150 PCME malfunction unit malfunction Blower switch OK Stoplight switch Brake pedal depressed Stoplight switch 1994 RX 7 Body electrical is monitor lamp illuminated malfunction troubleshooting manual Circuit wire arness NS toplight switch PCME CME terminal 1S voltage incorrect s page 150 PCME malfunction Stoplight switch OK Release brake pedal F 74 ON BOARD DIAGNOSIS FUNCTION F OXYGEN SENSOR MONITOR FUNCTION Engine Signal Monitor With the SST see to Oo Monitor the oxygen sensor is monitored by the Self Diagnosis Checker as de scribed Engine Systemselectorswitch Oxygen sensor output Vehicle running monitor Oxygen sensor output signal more than 0 45 V Monitor lamp Flashes KNOCK SENSOR MONIT
146. ine requires excessive cranking time before starting Engine staris after stalling a few times Battery in normal condilion Engine runs normally at idle if idle condition not OK refer to Engine rough Nos 19 20 21 22 or 23 Troubleshooting chart DESCRIP TION TROUBLESHOOTING HINTS DInjector Intake air system Fuel leakage from injector s Air leakage Fuel pump Engine coolant temperature sensor Poor connection of pump connector Poor connection of engine coolant temperature sensor Poor connection of fuel pump relay connactor Malfunction of engine coolant tamperature sensor QD Pressure regulator D Solenoid valve Purge control Malfunction of pressure regulator air leakage Fast idle cam 9 Metaring pump Malfunction of fast idle cam when engine cold Malfunction of pump Spark plug Crankshaft position sensor Dirty or worm spark plug s Ground circuit open Is 00 displayed on SST with ignition switch ON page 20 Trouble Code No displayed Check for cause Refer to specified check sequence eee is air leakage feit or heard at intake air system components at idle DESCRIPTION Further describes the system Confirm that the chart addresses the actual symptom before beginning troubleshooting TROUBLESHOOTING HINTS This describes the possible point of malfunction STEP This shows the order
147. inuity between solenoid valve A terminal and PCME terminal 3O Is connector B terminal voltage OK with solenoid valve connector disconnected Check for short circuit in wiring harness Solenoid valve A terminal PCME terminal if OK go to next step 30 gt If not OK repair wiring harness Yes Ed Repair wiring harness 15 solenoid valve Yes Replace PCME zz page 150 Replace solenoid valve Circuit Diagram SOLENOID VALVE DOUBLE THROTTLE CONTROL fax 2 25 2e oper jas se ec os Fo pe 5 6 6 se fa asf oro e foo Su Jae pe 2 2r os 71 F 59 _ ON BOARD DIAGNOSIS FUNCTION 51 FUEL PUMP RELAY SPEED ACTION Repair connector and or wiring harness Go to next step Go to next step Check for open or short circuit in wiring harness Fuel pump relay A terminal Main relay D terminal Does fuel pump relay speed circuit have a poor connection Is connector A terminal voltage OK with fuel pump relay speed connector disconnected Condition Votege Ignition switch ON Battery positive voltage Is there Continuity between fuel pump relay speed B terminal and PCME terminal 1K Check for short circuit in wiring harness Fuel pump relay speed B terminal PCME terminal 1K c If OK
148. ir control valve OK Yes zr page F 83 Is fuel line pressure correct at idle Yes t page 98 Fuel line pressure 190 220 kPa 1 9 2 3 kgf cm 2 28 32 psi idle air control valve Solenoid valve stuck Intake air system Air leakage 00 displayed Go to next step Trouble Code No displayed Check for cause Refer to specified check sequence Check spark plug s If OK go to next step If not OK clean or replace spark plug s Check as follows 9 Ignition coils Igniter High tension leads PCME 1G 1H 14 terminal voltage Go to next step cz page F 22 e Section G Yes Repair or replace Replace PCV valve Go to next step Go to next step Replace Go to next step Low pressure Check as follows Fuel fiiterfor clogging Operation of pressure regulator F 211 F TROUBLESHOOTING GUIDE HESITATES STUMBLES ON ACCELERATION DESCRIP Momentary pause at beginning of acceleration or during acceleration TION TROUBLESHOOTING HINTS njector control valve Fuel leakage from injector s EGR control valve stuck Pressure regulator Double throttle contro 9 Pressure regulator stuck Double throttle valve stuck Q High tension lead 9 Lead damaged amp Spark plug Dirty or worn spark plug s Manifold absolute pressure sensor Malfunction of manifold absolute pressure sensor ACTION
149. it in wiring from ignition switch to data link connector terminal B 88 displayed and Open or short circuit in wiring from data link connector terminal FEN to PCME terminal buzzer sounds 1F continuously Always B Poor connection at PCME connector PCME malfunction Always 0V Refer to page 16 Ignition timing adjustment Always 0V Refer to page 16 Ignition timing adjustment F 153 F CONTROL SYSTEM B Battery positive voltage Terminal Input Output Connected to Test condition Correct voltage Data link con System Selector test switch at Oo B With System Se nector MONITOR tector TEN terminal System Selector test switch at SELF TEST 9 Ignition switch ON Ignition switch ON 0 2 0 5V Reference Igniter Trailing Rear rotor Oscilloscope Engine speed above 2500 rpm 0 5 0 8V Reference Initial acceleration Ignition switch ON Below 1 0V While cranking Below 1 0V Fuel pump relay Speed Solenoid valve PRC does not B operate Solenoid vaive PRC operates Below 1 0V iL A C relay While cranking Air conditioning sensor During acceleration Running Ignition switch ON OV or 4 0 5 0V Driving 0 2 Steering pres P S OFF at idle B sure sensor P S ON at idle Below 1 0V Mileage switch Over 20 000 miles 34 000 km Below 1 5V Under 20 000 miles 34 000 km MEE Ignition switch ON Approx 2 6V Veh
150. k if the Monitor Lamp illuminates when each switch is made to function as described Caution if either switch remains activated the monitor lamp will be illuminated Do not start the engine F 68 ON BOARD DIAGNOSIS FUNCTION F Procedure Set conditions to deactivate each switch 9 All accessories OFF Transmission in neutral All pedals released Is monitor lamp illuminated Check each switch and related wire harness Clutch switch oF page F 173 9 Neutral switch s page F 172 Headlight switch 1994 RX 7 Body electrical troubleshooting manual Rear window defroster 1994 RX 7 Body electrical switch troubleshooting manual 9 Blower switch 1994 RX 7 Body electrical troubleshooting manual Air conditioning sensor 1994 RX 7 Body electrical troubleshooting manual Position switch zz 1994 RX 7 Body electrical troubleshooting manual Check each switch as described 69 F ON BOARD DIAGNOSIS FUNCTION Neutral switch MT Shift transmission into in gear Clutch pedal released is monitor lamp illuminated YES PC 9 Neutral switch malfunction sz page 172 9 Open circuit in related wire harness PCME terminal 1R voltage incorrect 150 PCME malfunction Neutral switch OK 222 Return transmission to neutral Clutch switch MT Clutch pedal depressed In neutral Is monitor lamp
151. ll be low when EGI INJ fuse 30A burns out when ignition switch ON Headlight switch E L unit B Idie speed be low when Parking lights will always NA headlight switch ON Rear window defroster switch E L unit Idle speed may be low when Rear window defroster al D defroster switch ON ways ON when ignition switch ON Heater control unit E L unit E Idle speed may be low when High idle speed when blower blower fan operate high fan not operate speed MIL E L unit K MIL will never ON MIL will always ON Ground E L unit M idle speed drops when Idle speed hunts or drops ON when MIL will never ON MIL will never ON 1 ON Headlight switch ON rear window defroster switch ON or blower switch at 3rd or 4th position EGR function sensor 3J EGR function sensor PCME 4D EGR function sensor Shorteireut Poor ground Code No 16 output Code No 16 output No symptom NA No symptom Fuel thermosensor No symptom Open circuit Short circuit _ Poorgroud POME 1U Fuel thermosensor Code No 23 output Nosymptom Code No 23 output PCME 4D Fuel thermosensor No symptom Heat hazard sensor open crout Shorteirout Poorground _ PCME 21 symptom Heat hazard warning light il luminates NA Rough idle Ground Heat hazard sensor No s
152. ll clamps as shown 3 Connect the negative battery terminal 4 Start the engine and run it at idle 5 Measure the fuel line pressure Fuel line pressure 190 220 kPa 1 9 2 3 kgf cm 28 32 psi X INSALL CLAMP Removal Installation Refer to page F 105 F 104 FUEL SYSTEM INJECTOR Inspection On vehicle 1 Warm up the engine and run it idle 2 Listen for the operational sound of primary injector with a screwdriver or a sound scope Removal Installation Warning TE Fuel line spills and leaks are dangerous Fuel can ignite and cause serious injurles or death and damage Fuel can also irritate skin and eyes To prevent this always complete the Fuel Line Safety Procedures on page 95 4 Remove in the order shown in the figure 2 Install in the reverse order of removal referring to Installation Note O RING REPLACE kgf cm 22 30 in Ibf 25 35kgf cm 22 30in Ibf N m kgf m ft Ibf 1 Negative battery cable 8 Injector Primary 2 Extension manifold Refer to page F 76 Inspection page F 107 3 Connector 9 Injector Secondary 4 Fuel hoses INSMOCUON page F 107 5 Fuel distributor assembly Primary 10 Pulsation damper 6 Fuel distributor assembly Secondary 11 Pressure regulator 7 Cover Inspection page F 104 12 Insulator 13 Air bleed socket 105 F FUEL SYSTEM Installation Note
153. minal voltage at PCME correct ss page 152 1E Air conditioning sensor 10 Manifold absolute pressure sensor 38 Electric load unit 3E Engine coolant temperature sensor 3F Throttle position sensor Narrow range 3L Intake air temperature sensor Solenoid valve AWS 40 Idle air control valve Is throttle valve closed throttle position Yes Goto next step Check following devices Accelerator cable linkage Throttle lever Accelerator pedal Fast idle cam F 209 TROUBLESHOOTING GUIDE m is solenoid valve AWS OK Yes Go to next step page F 83 ld ico eset 7 Tty known good PCME does condition improved page 150 i 15 engine coolant temperature sensor OK s page F 183 210 TROUBLESHOOTING GUIDE IDLE FLUCTUATES IDLE HUNTS PN M Engine speed changes back and forth between specified idle speed and higher speed ON TROUBLESHOOTING HINTS DPCV valve e PCV valve stuck Spark plug Dirty or worn spark plug s Throttle position sensor Incorrect adjustment is 00 displayed on SST with ignition switch ON zr page 20 wy 49 B019 19 ls strong blue spark visible at each disconnected high tension lead while cranking engine is air leakage felt or heard at intake air system com ponents Yes Is PCV valve stuck s page 124 Is idle a
154. minals 25 pin located near fuse box 1 CIS self diagnosis 1 FEN terminal 2 PCMT on board diagnosis AT 2 TAT and FAT terminal 3 initial set 3 TEN terminal 4 Fuel pump check 4 F P terminai 5 Engine speed output 5 IG terminal 6 Switch and oxygen sensor monitor 6 MEN terminal 7 Supply battery positive voltage 7 B terminal 8 Ground 8 GND terminal 9 A C self diagnosis 9 TAC and FAC terminal 10 Cruise control self diagnosis 10 TSC and FSC terminal 11 Electrical coolant fan self diagnosis _ 11 TFA terminal Engine coolant temperature sen Detect coolant temperature send signals to installed in engine sor PCME _Fuel fitter Filters particles from fuel E ee eee Provides fuel to injectors Operates while engine running In fuel tank Mo Fuel pump relay Voltage for fuel pump while engine running gt Nike ee ERE Receives spark signal from and gener ates high voitage in ignition coil Z ignition switch START position Sends engine cranking signal to POME injects fuel into intake port Controlled by signal from PCME side feed type Intake air temperature sensor Detects intake air temperature sends signal to installed in extension manifold Knock sensor Detects engine knocking sends signal to _ Supplies current to output devices and PCME Manifold absolute pressure Detects intake man
155. minals A and D with throttle valve closed throttle position to fully opened OK Circuit Diagram PCME TVOG VREF THROTTLE POSITION SENSOR 3e sc sa 2k a as 2e Jac Tu Sj a o M sc 3j 3H ae Jat 22 2 far 20 jo s ER 142 ax av aT ap fan a aJ 40 an F 32 ON BOARD DIAGNOSIS FUNCTION F _ 13 MANIFOLD ABSOLUTE PRESSURE SENSOR Repair connector and or wiring harness Go to next step Go to next step Check for open or short circuit in wiring Does manifold absolute pressure sensor circuit have a poor connection Is connector C terminal voltage OK with manifold _ absolute pressure sensor connector disconnected Condition Vetage m harness manifold absolute pressure sensor ignition swich OR Approx C terminal PCME terminal Is there continuity between manifold absolute pres Yes Go to next step sure sensor terminal and PCME terminal 4D Repair wiring harness Replace PCME s page F 150 is output A termina voltage of manifold absolute pressure sensor OK Voltage Pressure or Vaccum 66 kPa 500 mmHg 19 7 inHg y 1 3 1 6V 0 kPa 0 mmHg 0 inHg 98 7 kPa 740 mmHg 29 1 inHg Pressure 4 3 4 6V Replace manifold absolute pressure sensor F 167
156. move slightly when driv en gear is slowly turned Replace vehicle speed sensor Check wiring and connectors from vehicle speed sensor to speedometer Yes Disconnect vehicle speed sensor connector Is resistance of sensor OK Resistance Approx 290 20 C 68 reference c If OK go to next step gt It not OK repair wiring and or connector Replace vehicle speed sensor Disconnect negative battery cable for at least 20 Yes Replace PCME er page F 150 seconds Connect battery cable and recheck for trouble code Is trouble Gade daplayed Intermittent poor connection Check for cause COMBINATION METER TO PCMT jas t ae ac foo 31 136 jac 2k 2t 26 an 42 4r fan 48 fon Jat as jar fao 38 24 2u fah 4 F ON BOARD DIAGNOSIS FUNCTION 09 ENGINE COOLANT TEMPERATURE SENSOR stee O O meen 00 Does the engine coolant temperature sensor circuit Repair connector and or wiring harness have a poor connection EE Go to next step Is engine coolant temperature sensor B terminal volt Yes Goto next step OK with engine coolant temperature sensor con 2 hector Ceconnected Check for short or open circuit in wiring har ness Engine coolant temperature sensor B Voltage terminal PCME terminal Ignition switch ON Approx 5 0V c IF OK replace PCME Is there contin
157. n any of the following switches are ON Rear window defroster switch Headlight switch Blower switch 3rd or 4th position a HEADLIGHT gt To PCME 9 REAR WINDOW 37 DEFROSTER _ EH BLOWER MOTOR CE DATA LINK CONNECTOR PREPARATION SST 49 B019 9A0 3 49 H018 9A1 diagnosis diagnosis System Selector Self Diagnosis EN Checker F 135 ELECTRICAL LOAD E L CONTROL SYSTEM SYSTEM OPERATION 1 Connect the SST System selector to the data link con 2 Set switch A to position 1 and TEST SW to SELF TEST 3 Connect the SST Self Diagnosis Checker to the System Selector and a ground 4 Set the select switch to position A 5 Turn ignition switch ON 6 Check if the monitor lamp illuminates when E L unit rela tive switch is made to function Refer to page F 67 inspection 1 Remove the E L unit Refer to page F 150 2 Connect the E L unit connector 3 Measure the voltage at each terminal by using a voltme ter 4 If any E Lunitterminal voltage is incorrect check the input or output device and related wiring harness If they are normal replace the E L unit Terminal voltage Freins ouput Conneciedto Test condition Pinay ron On Position light OFF a Ss See eee eee Rear window EX Rear window defroster ON Below 1 0V Ee Blower motor relay Below 1 0V E ECTS E TT T gt
158. n relay Coolant fan will not operate Coolant fan always operate until coolant temperature ex when ignition switch ON ceeds 108 C 226 F Fuel injector Short cirout Poorground PCME 4X 4Z Secondary injector Code No 71 or 73 output Code No 71 or 73 output Lack of power Engine will not start NA PCME 4W 4X Primary injector Engine stall Engine stalls Engine will not start Engine will not start NA Not applicable F 232 MURUS SRC TEETH Yt mm SERVICE POINTS F Fuel pump relay speed Openciruit CIC ME REMOVE PCME 1K Fuel pump relay speed Code No 51 output Code No 51 output Hesitation No symptom Lack of power FEN terminal Data link connector _ E eos ee mm aT PCME 1F Data link connector Self Diagnosis Checker Code 88 will keep flashing buzzer will not sound during and buzzer will continue trouble code check sounding during trouble code check idie air control valve eC ce a a Code No 34 output Code No 34 output Idle Rough idle speed stays or fluctuates at Hard start approx 1 500 rpm after warm up INJ fuse 30A burns out when ignition switch ON open crout 1G Igniter Trailing Front Eod ia l acceleration PCME 1J Igniter Trailing Rear Hard Eod when engine cold PCME 1H Igniter Leading Rough idle Poor accele
159. nal wire c If there is replace injector page F 105 c f there is not check for a short or open circuit in wire harness Replace injector at dead rotor from step 6 inspection Try known good oxygen sensor page 105 c if itis OK replace oxygen sensor x If itis not OK replace PCME Is the same Code No present following afterrepair procedure System Circuit Diagram OXYGEN SENSOR v Jaw Jau 40 Jak t ac Jae ac o0 pm Joe Sa Jax 2t 28 2 4 v 5 a o M K i 42 Jax av 4 ap an fat au an ar 40 oe an jat au anjar 20 ae ja 22729 2 20 28 v r JR P N C 2 M F 0 8 F 37 ET TT AIRTEL PE RR F ON BOARD DIAGNOSIS FUNCTION CODE No 18 THROTTLE POSITION SENSOR NARROW STEP __ INSPECTION Does throttle position sensor circuit have poor con Y Repair connector and or wiring harness nection Go to next step Go to next step Check for open or short circuit in wiring har ness Throttle position sensor A terminal PCME terminal x If OK replace PCME c If not OK repair wiring harness Is throttle position sensor A terminal voltage OK with throttle position sensor disconnected Condition vonage Ignition switch ON Approx 5 0V Check for short circuit in wiring harness Throttle position sensor B terminal
160. nce Oscilloscope Engine speed above 2 500 rpm 0 8 1 2V Reference Initial acceleration F 152 CONTROL SYSTEM B Battery positive voltage Possible cause ROOM 10A fuse burnt Open circuit in wiring from ROOM 10A fuse to POME terminal 1A Incorrect voltage Always 0V Always 0 Main relay malfunction Refer to page F 174 Open or short circuit in wiring from main relay to PCME terminal 1B Always OV starter turns Open or short circuit in wiring from ignition switch to PCME terminal 1C 9 ignition switch malfunction Refer to section T Always 0 Main relay FUEL INJ relay malfunction Refer to page 174 Open circuit in wiring from ignition switch to data link connector terminal B Open or short circuit in wiring from data link connector terminal MEN to PCME terminal 1D Always B Poor connection at PCME connector PCME malfunction Always approx 5V PCME malfunction Always below 1 0V Short circuit in wiring from air conditioning sensor to PCME terminal 1E Air conditioning sensor malfunction Refer to section T Always B4 Open circuit in wiring from air conditioning sensor to PCME terminal 1E Air conditioning sensor malfunction Refer to section T Always below No display on Self Main relay FUEL INJ relay malfunction Refer to page F 174 2 5V Diagnosis Checker Open circu
161. nd PCME terminal 4U Check for short circuit in wiring harness Solenoid valve A terminal PCME terminat 4U If OK go to next step If not OK repair wiring harness Repair wiring harness Yes Replace PCME sz page F 150 Replace solenoid valve 15 solenoid valve OK sr page F 93 Circuit Diagram SOLENOID VALVE WASTE GATE CONTROL er an ae fav a as ar Jo F 55 F ON BOARD DIAGNOSIS FUNCTION 44 SOLENOID VALVE TURBO CONTROL Repair connector and or wiring harness TA Go to next step Go to next step Check for open or short circuit in wiring harness Solenoid valves B terminal Main relay D terminal Does solenoid valves circuit have a poor connec tion 15 connector B terminal voltage OK with solenoid valve connector disconnected Condition voltage F Ignition switch ON Battery positive voltage Is there continuity between solenoid valves A termi nal and PCME terminal 4R Check for short circuit in wiring harness Solenoid valves A terminal PCME terminal 4R gt If OK go to next step c If not OK repair wiring harness Repair wiring harness Replace PCME sr page 150 Replace solenoid vaive Is solenoid valve OK page F 93 Circuit Diagram SOLENOID VALVE SOLENOID VALVE TURBO CONTR
162. ngine speed flares up on acceleration When upshifting and or Engine flares up when accelerator pedal depressed before up downshifting shifting Engine flares up suddenly when accelerator pedal depressed before downshifting Excessive shift shock P Nto and or NtoD Strong shift shock felt at id e when shifting from N to D or R range When upshitting Excessive shift shock felt when accelerating at upshitting and or downshifting Engine speed drops to idle but vehicle does not slow when ac celerator pedal released when L range at low vehicle speed Excessive shift shock felt when accelerator pedal depressed at No mode change Mode does not change to from normal mode in D range Hold mode not engaged or not cancelled Section K Section K No engine braking speed downshifting during cruising Engine speed drops to idle but vehicle does not slow when ac celerator pedal released during cruising at medium to high Transmission noise Danemese noisy in all eal when vehicle is idling IN T pr T mE 58 Transmission overheats E 188 TROUBLESHOOTING GUIDE Description of Drivability Problems STUMBLE Mild jerking during acceleration HESITATION Flat spot occurring just after the accelerator pedal is depressed SURGE Continuous soft jerking while cruising ENGINE SPEED SURGE p 4 v HESITATI
163. nual if symptom occurs at idle with ON check E L unit cr page 135 if symptom occurs at idle with P S ON check P S pump in section N of this manual f symptom occurs at idle when shifted from N or P to other range go to EN GINE ROUGH IDLE WHEN SHIFTED FROM N OR P TO OTHER RANGE in Section K of this manual AT Check fast idle cam cr page 79 Warm up engine Does idle speed decrease when idle air contro valve connector disconnected F 205 TROUBLESHOOTING GUIDE DECELERATION e ER shakes at beginning of deceleration or recovery from deceleration TION Exhaust afterburn TROUBLESHOOTING HINTS D Fuel pump Throttle position sensor Poor connection of connector Poor connection of connector Q Injector Secondary air injection Fuel leakage from injector s idle air contro valve Dashpot Solenoid valve stuck Dashpot misadjusted Is 00 displayed on SST with ignition switch ON page 20 Go to next step wit 39 6019 900 Trouble Code No displayed Check for cause Refer to specified check sequence page 22 Check spark plugs If OK go to next step if not OK clean or replace spark plug ls strong blue spark visible at each disconnected high tension lead 2 HIGH TENSION LEAD Check ignition system zs Section G is dashpot OK Yes
164. o Code No 46 Troubleshooting Refer to page F 58 Always below 1 0V or B Refer to Code No 45 Troubleshooting Refer to page F 57 Always below 1 0V or B Refer to Code No 43 Troubleshooting Refer to page F 55 Refer to Code No 42 Troubleshooting Refer to page F 54 Aiways below 1 0V or B F 163 _ BRR at LE ut YR SP Pet F CONTROL SYSTEM B Battery positive voltage Terminal Input Output Connected to Test condition Correct voltage Injector Ignition switch ON Secondary injec Front primary tor not working at no load condi Injector tion Front secondary Engine Signal Monitor Green 4Y injector 4Z Injector Rear secondary lamp flash PCME Connector PCME Side Oscilloscope HHHH 10 msec div F 164 CONTROL SYSTEM F Incorrect voltage Possible cause Always 0 Open or short circuit in wiring from injector to PCME terminal 4W 4X 4Y or 47 Main relay malfunction Refer to page F 174 Refer to Code No 71 73 Refer to page F 62 63 troubleshooting F 165 F CONTROL SYSTEM CRANKSHAFT POSITION SENSOR Removal Installation 1 Remove in the order shown in the figure 2 Install in the reverse order of removal referring to Installation Note uy 7 8 11N m 80 110kgf cm 69 95in Ibf 1 Battery cable 6 Connectors 2 Drive belt 7 Crankshaft position sensor NE signal 3 Eccentric shaft pulley Inspection
165. o POME terminal 1N PCME malfunction Steering pressure sensor malfunction Refer to page F 172 Open circuit in wiring from steering pressure sensor to POME terminal 1N Open circuit in wiring from steering pressure sensor to ground Mileage switch malfunction Refer to page F 175 PCME malfunction Always below 1 0V Always B Always B under 20 000 miles Mileage switch malfunction Refer to page F 175 Always below 1 5V over 20 000 miles PCME malfunction Refer to Code No 13 Troubleshooting Refer to page F 33 Always OV or 5V F 155 F CONTROL SYSTEM B Battery positive voltage aia Toi Connected to Test condition Correct voltage Clutch switch Clutch pedal released ignition switch ON MT Clutch pedal depressed Below 1 0V Reduce torque Powertrain signal shifting from 1st to 2nd or from 2nd Below 1 0V AT to 3rd with the throttle opening above 1 5 8 dde Slip lock up signal When slip lockup with the throttle opening Below 1 0V below 0 5 8 Powertrain Por N range Below 1 0V control module Neutral switch MT 9 Park Neutral sig nal ignition switch ON Stoplight Brake pedal released ignition switch ON oT Brake pedal depressed Bee Ponton swich ON Fuel pump Ignition switch ON LE S br T LAU TIL c RR RR RC thermosensor Data link Ignition switch ON connector
166. of troubleshooting Proceed with troubleshooting as indicated INSPECTION This describes an inspection to quickly determine the malfunction of parts If a detailed procedure is nec essary to perform the INSPECTION refer to the page specified by the mark ACTION This recommends the appropriate action to take as a result Yes No of the INSPECTION How to per form the actions is described on the reference page specified by the mark F 185 F TROUBLESHOOTING GUIDE DIAGNOSTIC INDEX TROUBLESHOOTING ITEM DESCRIPTION No TROUBLE B 1 Metts main or other tuse Will not crank or cranks slowly Starter does not work Section G Starter cranks engine at slow speed Cranks normally but No combustion Starter cranks engine at normal speed but engine shows no in F 191 dication of firing will not start Partial combustion Starter cranks engine at normal speed and engine shows in when engine cold dication of firing but will not run when engine is cold or at initia starting Engine will not continue running when cold when ignition switch is returned from STA to iG position Starter cranks engine at normal speed and engine shows in dication of firing but will not run when engine is warm 191 Partial combustion when warm up Section K F 198 Section K Engine rough Engine w
167. ogging Operation of pressure regulator MT Go to next step AT Go to POOR ACCELERATION DRIVEAWAY ON ACCELE RATION in section K of this manual Try known good PCME does condition improved page F 150 TROUBLESHOOTING GUIDE F HIGH IDLE SPEED AFTER WARM UP DESCRIP idie sped continues at fast idle after warm up TION Engine returns slowly to idle after accelerator is released TROUBLESHOOTING HINTS Fast idie cam Idle air control valve Malfunction of fast idle cam idie air control valve stuck open Accelerated warm up system A C P S or signal always ON Solenoid vaive AWS open Throttle valve amp Engine coolant temperature sensor Vaive not closed throttle position Malfunction of engine coolant temperature sensor Dashpot is 00 displayed on SST with ignition switch ON 00 displayed sr page F 20 Go to next step 49 8019 SAO Trouble Code No displayed Check for cause Refer to specified check sequence 22 ir page 152 Check following terminal voltage at PCME 1E Air conditioning sensor 1N Steering pressure sensor 3B Electrical load unit Connect data link connector terminals TEN and GND with a jumper wire does idle speed decrease Go to next step Yes Goto next step Check for cause s page 153 Are following ter
168. oid valve circuit have a poor connection is connector B terminal voltage OK with solenoid valve connector disconnected Condition Voltage ignition switch ON Battery positive voltage is there continuity between solenoid valve A terminal and PCME terminal Check for short circuit in wiring harness Solenoid valve A terminal PCME terminal c If OK go to next step c If not OK repair wiring harness Repair wiring harness 5 solenoid valve OK page 123 Replace PCME rz page 150 Replace solenoid valve SECONDARY AIR BYPASS VALVE CIS MAIN RELAY F SECONDARY AIR BYPASS VALVE RELIEF 1 EM NOOO OOO c HA D eT n P oo OD Te Tu x Ta Te TE T ERR REA SIS ac F 46 ON BOARD DIAGNOSIS FUNCTION F 32 SECONDARY AIR SWITCHING VALVE Repair connector and or wiring harness es Go to next step Go to next step Check for open or short circuit in wiring har ness Solenoid valve terminal Main relay D terminal Is connector B terminal voltage OK with solenoid valve connector disconnected Condition Voltage Ignition switch ON Battery positive voltage is there continuity between solenoid valve A terminal and PCME terminal 4N Check for short circuit in wiring harness Solenoid valve A terminal PCME terminai 4N c If OK go to next step c If no
169. old absolute pressure sensor resistance Throttle position sensor Full range Open or short circuit Manifold abso lute pressure sensor Barometric absolute pressure sensor Sensor output Oxygen sensor connector continues less Wiring from oxygen sensor to 8 than 0 55V 25 PCME sec in closed Oxygen sensor loop zone EGR function sensor connec tor Wiring from EGR function sensor to PCME EGR function sensor EGR function sensor Open or short circuit Fuel pressure Sensor output Iniecfi Oxygen sensor notchanged 120 0 Inversion sec in closed Ar loop zone e 9 PCME Throttle position sensor con nector Wiring from throttle position sensor to PCME Throttle position sensor Narrow range Open or short circuit rat ON BOARD DIAGNOSIS FUNCTION F Indicator flashing pattern Diagnosed Page circuit rized MOP connector Wiring from MOP position peel dm sensor to PCME sensor MOP position sensor continu ity 9 Fuel thermosensor connector e Wiring from Fuel thermosen sor to PCME Fuel thermosensor resistance Fuel O thermosensor O Ol Open or Short ci
170. or approx 5V Refer to Code No 02 Troubleshooting Refer to page F 26 F 161 CONTROL SYSTEM B Battery positive voltage Connected to Test condition Correct voltage Remark Crankshaft Constant Below 1 0V position sensor Stepping Ignition switch ON B moor 3 terminals Meteri il 4 terminals B Other terminal 5 9V Pressure Idle after hot start Below 1 0V approx 90 seconds regulator ignition switch ON Idle Engine speed above 3 200 rpm Below 1 0 Initial acceleration After warm up Solenoid valve p EGR position MT OD AT Below 1 0V While running Solenoid valve Before warm up approx 40 C 104 F Below 1 0V AWS Ignition switch 8 0 11 0V Reference value Cranking 99 9 Idle 32 65 9 nitial set 38 control Secondary air switching valve Idle air contro valve ISC Oscilloscope Solenoid valve Turbo control Engine speed above 5 500 rpm MT Below 1 0V Initial acceleration Engine speed above 5 250 rpm AT Below 1 0V Initial acceleration Solenoid valve Charge relief Engine speed 4 000 5 500 rpm MT for 4 8 sec 3 500 5 000 AT for 4 8 Engine speed above 5 500 rpm MT above 5 250 rpm AT Beowtov Engine speed above 5 500 rpm MT Initial acceleration Engine speed above 5 250 rpm _
171. ort circuit An open or short circuit will produce no symptom Ashort circuit will cause the STOP fuse 20A burn out TEN terminal Data link connector f the circuit is open the Self Diagnosis Checker can not perform trouble code checks If the circuit is shorted the opening amount of the idle air control valve will not change causing hard start ing and rough idle The Self Diagnosis Checker cannot perform sensor monitoring checks a Throttle position sensor Narrow range If the sensor or circuit has an open or short Trouble Code No 18 is output n the above condition rough idle and engine stail on deceleration will be caused Throttle position sensor Full range f the sensor or circuit has an open or short Trouble Code No 12 is output in the above condition poor acceleration will be caused Vehicle speed sensor If the vehicle speed signal circuit has an open or short Trouble Code No 06 is output If the circuit has open or short hold mode will not operate 220 SERVICE POINTS F Output Device A C relay f the circuit is open the air conditioner Magnetic clutch will not operate e f thecircuit is shorted the air conditioner will constantly operate when blower is ON causing rough idle Air pump relay f the relay or circuit has an open or short Trouble Code No 54 is output f the circuit is short air pump will always operate causing three w
172. page F 104 Fuel line pressure High pressure page F 104 190 220 kPa 1 9 2 3 kgf cm 2 28 32 psi Check if fuel return hose is clogged or restricted e if OK replace pressure regulator Replace injector sy page F 105 Check engine coolant temperature sensor page F 169 ts there fuel leakage at injector F 107 x If it is OK replace oxygen sensor x If itis not OK replace it Go to next step Go to Step 8 Go to next step Low pressure Check fuel line pressure while pinching fuel return hose Disconnect each high tension lead at idle does en gine speed decrease equally at each rotor is fuel line pressure correct at idle rr page 97 Fuel line pressure 190 220 kPa 1 9 2 3 kgf cm 28 32 psi c If it quickly increases check pressure regulator zr page F 104 If it gradually increases check for clog ging between fuel pump and pressure regulator gt If hose is not clogged check fuel pump maximum pressure s page 101 Yes Repair or replace ignition system compo nent s Ed Go to next step Is there a misfire of a dead rotor from step 6 inspec tion F 36 ON BOARD DIAGNOSIS FUNCTION F B Battery positive voltage ACTION Is there an injector operating sound at idle of dead Yes Goto next step rotor from step 6 inspection Check for approx B at injector termi
173. pair charging system and or Battery Yes Replace PCME page 150 Intermittent poor connection Check for cause Disconnect negative battery cable for at least 20 seconds Connect battery cable and recheck for trouble code Is trouble code displayed Circuit Diagram MAIN RELAY POSITION SENSOR METERING OIL PUMP EGI MAIN RELAY F M O PUMP EM Jaw Jau To 40 ac 4 ac paa 20 v x Toa se c pa fer a Jas ac Tu 8 o oM 1e E C 42 ax av an jap an ac 4r jab 4 av 2 sr aD pe 21 212 2 20 28 F 50 ON BOARD DIAGNOSIS FUNCTION F 38 SOLENOID VALVE ACCELERATED WARM UP SYSTEM AWS STEP INSPECTION 1 Does solenoid valve circuit have a poor connection Repair connector and or wiring harness Go to next step 15 connector terminal voltage OK with solenoid Go to next step valve connector disconnected Condition ignition switch ON Battery positive voltage Is there continuity between solenoid valve A terminal and PCME terminal 4P Check for open or short circuit in wiring harness Solenoid valve terminal Main relay D terminal Check for short circuit in wiring harness Solenoid valve A terminal PCME terminal c If OK go to next step c If not OK re
174. pair wiring harness Repair wiring harness Replace PCME page F 150 Is solenoid valve OK sr page 83 Replace solenoid valve Circuit Diagram SOLENOID VALVE ACCELERATED WARM UP SYSTEM AWS EGI MAIN RELAY F CREER Lo fe jaw jau as 40 jao 4 4E 90 42 Jax jav an 40 aP aN far 51 ON BOARD DIAGNOSIS FUNCTION CODE No 39 SOLENOID VALVE RELIEF 2 Does solenoid valve circuit have a poor connection Repair connector and or wiring harness Go to next step Go to next step Check for open or short circuit in wiring harness Solenoid valve A terminal Main relay D terminal Repair wiring harness Replace PCME page F 150 Ed Replace solenoid valve Is connector A terminal voltage OK with solenoid valve connector disconnected Voltage Ignition switch ON Battery positive voltage Is there continuity between solenoid valve B terminal and PCME terminal 3K Check for short circuit in wiring harness Solenoid valve B terminal PCME terminal 3K c If OK go to next step c If not OK repair wiring harness Is solenoid valve OK F page 123 SOLENOID VALVE RELIEF 2 EGI MAIN RELAY F SOLENOID VALVE RELIEF 2 EM 21 aa 2 Jac 20 28 v Jaw Jeu
175. pection page F 123 Removal Installation page F 93 17 Data link connector Inspection F 93 18 Airpump 8 Solenoid valve Turbo control Inspection Removal Installation page F 93 Removal Installation page F 121 Inspection page F 93 19 Check valve Port air 9 Solenoid valve Port air bypass Inspection page 120 Removal Installation page F 119 INSDOCHON recor page F 119 F 6 OUTLINE OUTLINE laval Nod JAVA JOYLNOOSAYd QION3IOS JAYA GION3110S dana dol HOHLNOO uaisiSau Tan OHu1NOO 3ATVA ANDAI iach NOLLYS1Nd uv GION331OS JAVA n3 ae Ya9YVHOOSYNL HAOUVHOOBHNL Co LINO 5 SATA mcs HO1Vnl oV ASATVIVO AVM SSYHL u3oNanis E NIVIN ASATV1VO AVNc338HL dN WHYM eu JAWA SSVd g HIY _ p iam ae HOLY INDY 39055999 A HOSN3S 5 ead HOIVO Sa 5550 3lnlosasv JATAL UU HOSN3S aww Oo3Ho EF ox L E NO GWA GIONSOS NS 1NOO OUND HOSN3 A ens JAVA GION310S NOILISOd P E YSEWYHOD noui 42 H 553 LOdHSVG X
176. perature value of 50 C 122 F and no symptom will be noticed Heat hazard sensor if the circuit has open no sympotm will be noticed e f the sensor or circuit has a short the heat hazard warning light will illuminate and the air pump will not operate causing rough idle Intake air temperature sensor e if tho thermosensor or circuit has an open or short Trouble Code 11 is output n the above conditions no symptom will be noticed Knock sensor if the knock sensor or circuit has an open or short Trouble Code No 05 is output in the above conditions ignition timing is retarded Manifold absolute pressure sensor f the sensor or circuit has an open or short Trouble Code No 13 is output n the above condition the PCME uses a preprogrammed fuel injection amount causing rough idle and poor acceleration with afterburn Metering oil pump position sensor e f tho sensor or circuit has an open or short Trouble Code 20 is output n In the above conditions the fuel injection amount is fixed causing poor acceleration and hesitation Mileage switch Steering pressure sensor f the sensor circuit has an open circuit no particular symptom will be noticed f the sensor circuit has a short circuit idle speed will be increased Neutral switches MT e The switch monitor function of the Self Diagnosis Checker can confirm the presence of an open or short circuit f the circuit is open th
177. plight switch Three Way Catalyst Throttle body Throttle position sensor Installed on throttle body Vehicle speed sensor Detects vehicle speed sends signal to PCME nstalled in instrument cluster F 14 ENGINE TUNE UP F ENGINE TUNE UP PREPARATION SST 498 019940 For 49 H018 9A1 inspection of i For ignition timing Self Diagnosis s diagnosis System Selector and idle speed Checker and diagnosis BASIC INSPECTION Engine Oil 1 Remove the dipstick and check the engine oil level and condition 2 Add or change oil as necessary Coolant engine cold Warning Removing the radiator cap or the coolant filler cap while the engine is running or when the engine and radiator are hot is dangerous Scalding coolant and steam may shoot out and cause serious injury _ may also damage the engine and cooling system Turn off the engine and wait until it is cool Even then be very careful when removing the cap Wrap a thick cloth around it and slowly turn it counter clockwise to the first stop Step back while the pressure escapes e When you re sure all the pressure is gone press down on the cap still using a cloth turn it and re move it 1 Remove the coolant level gauge from the coolant recervir 2 Verify that the coolant level is between the and marks of the gauge 3 Add coolant if necessary Battery Terminalandcable
178. pped and no load applied The evaporative fumes from the fuel tank are absorbed by the charcoal canister With engine running and load applied The evaporative fumes absorbed by the charcoal canister are drawn into the engine via the solenoid valve purge control The volume of fumes drawn depends on engine conditions F 129 F FUEL EVAPORATIVE SYSTEM SYSTEM OPERATION 1 Warm upthe engine to normal operating temperature and run it at idle SOLENOID VALVE 2 Disconnect the vacuum hose from the solenoid valve PURGE CONTROL purge control as shown in the figure and verify that no vacuum is felt at the solenoid valve 3 If not as specified check the solenoid valve 80 110kgf cm 69 95in Ibf 6 130 FUEL EVAPORATIVE SYSTEM F SOLENOID VALVE PURGE CONTROL Removal Installation 1 Disconnect the vacuum hoses and connector from sole SOLENOID VALVE noid valve PAURGE CONTROL 2 Remove the mounting nuts and solenoid valve 3 Install in the reverse order of removal 7 8 10 8R m 80 110 kgf cm 69 95in Ibf Inspection 1 Disconnectthe vacuum hoses and connector from the so lenoid valve 2 Blow into the valve and verify that no air flows through it 3 Apply battery positive voltage as shown in the figure 4 Blow into the valve and verify that air flows through it 5 If not as specified measure the solenoid valve resistance with an ohmmeter Resistance 30 34 20 C 68 F 6 If not as
179. produce any symptom If the PCME ground Output devices circuit also has an open the engine will not start PCME ground Output devices An open circuit will not produce any symptom if PCME ground Injector circuit also has an open the engine will not start PCME ground System 9 An open circuit will not produce any symptom PCME ground Analogue if the circuit has an open engine hard starting and rough idle will be caused and Trouble Code Nos 09 11 12 13 20 and 23 will be output Room fuse PCME memory power i If the circuit is open the PCME memory function will not operate and trouble codes for intermittent mal functions will not be indicated Aiso the learning control will be canceled but will not produce any particu lar symptom f the circuit is shorted the ROOM fuse 15A will burn out Input Device 1 2 switch MT if the circuit has an open or short no symptom will be noticed Air conditioning sensor Tho switch monitor function can confirm the presence of an open or short circuit f the circuit is open the air conditioner the magnetic clutch will not operate If the circuit is shorted the air conditioner will constantly operate when the blower is ON Barometric absolute pressure sensor The sensor is contained in the PCME ifthe sensor has an open or short circuit Trouble Code No 14 is output and the PCME will use a prepro grammed pressure of sea lev
180. pump connector wire W R Voltage Battery positive voltage 7 If not correct check the fuel pump relay and its circuits Refer to page F 110 8 If the voltage is normal check for continuity between fuel pump connector A and B 9 If there is no continuity replace the fuel pump Hold pressure Perform the inspection if the fuel pressure hold inspection is not as specified Warning Oo Fuel line spills and leaks are dangerous Fuel ignite and cause serious injuries or death and dam age Fuel can also irritate skin and eyes To prevent this always complete the Fuel Line Safety Proce dures on page F 95 Disconnect the negative battery terminal 2 Connect a fuel pressure gauge to the fuel main pipe and plug the outlet of the fuel pressure gauge as shown Install clamps as shown 3 Connect the negative battery terminal 4 Connect data link connector terminals F P and GND with a jumper wire 5 Turn the ignition switch ON and measure the fuel pres Sure Fuel pressure 490 740 kPa 5 0 7 5 kgf cm 71 106 psi 6 Turn the ignition switch OFF and disconnect the jumper wire 7 If not as specified replace the fuel pump FUEL SYSTEM PRESSURE Fuel pump maximum pressure Warning Fuel line spills and leaks are dangerous Fuel can ignite and cause serious injuries or death and dam age Fuel can also irritate skin and eyes To prevent this always complete the Fuel Line Safe
181. r connection of connector Engine coolant temperature sensor Air leakage in intake air system Malfunction of thermosensor Manifold absolute pressure sensor Double throttle control system Manifold absolute pressure sensor filter or hose clogged Check valve Turbo control Charge control Charge relief Poor connection of connector 15 00 displayed on SST with ignition switch ON Yes 00 displayed page F 20 Go to next step Trouble Code No displayed Check for cause Refer to specified check sequence er page 22 Check spark plugs If OK go to next step If not OK clean or replace spark plug Is a strong blue spark visible at each disconnected high tension lead while cranking engine Check ignition system amp Section G Is intake manifold vacuum correct at idle Go to next step Check as follows Intake air system components and installation Vacuum hoses for disconnection and damage Engine compression Section Vacuum More than 60 0 kPa 450 mmHg 17 7 inHg Repair or replace Go to next step Is air leakage felt heard at intake air system com ponents F 207 208 TROUBLESHOOTING GUIDE mE Is fuel line pressure correct at idle Yes Go to next step page 98 Fuel line pressure 190 220 kPa 1 9 2 3 kgf cm 28 32 psi Low pressure Check as follows Fuel filter for cl
182. ration Hard starting when engine cold Metering oil pump Condition esae ee a ee POME 41 4J 4K 4L Metering oil Code No 26 and 27 output NA pump Poor acceleration MEN terminal Data link connector C 1D MEN terminal Monitor lamp will not Monitor lamp stays on NA illuminate air bypass valve PCME 4Q Solenoid valve Solenoid valve Main relay Igniter Condition Shorteireut Poor ground PCME 3P Solenoid valve Code No 31 output Code No 31 output No symptom CO and HC increased Solenoid valve Main relay EGI INJ fuse 30A burns out when ignition switch ON NA Not applicable F 233 F SERVICE POINTS Secondary air switchig valve oe deam PCME 4N Solenoid valve Code No 32 output Rough idle Solenoid valve Main relay EGI INJ fuse 30A burns out when ignition switch ON Solenoid vaive Accelerated warm up system eee ee a PCME 4P Solenoid valve Code No 38 output Code No 38 output Idle speed stays stays or fluctu ates at approx 1 500 rpm af NA ter warm up Solenoid valve Main relay INJ fuse 30A burns out when ignition switch ON Fast idle speed just after en Solenoid valve Charge control gine starting will not exceed et ee PCME 4T Solenoid valve 2 000 rpm Opencrut Shorteircuit Peorgrud Solenoid vaive Main relay Code No 45 output Code No
183. rcuit Solenoid valve connector Wiring from solenoid valve to PCME Solenoid valve continuity Solenoid valve pressure regu lator contro MOP connector Wiring from MOP to Metering oil N F N stepping moter MOP continuity Open or short MOP connector Metering oil circuit or Stick Wiring from MOP to PCME F pump ing of MOP sen Mop continuity sor Solenoid valve connector Wiring from solenoid valve to PCME Solenoid valve continuity Solenoid valve EGR O O z UM Solenoid valve connector Wiring from solenoid valve to PCME 9 Solenoid valve continuity Solenoid valve Split air bypass F OF O Solenoid valve connector Wiring from solenoid valve to PCME Solenoid valve continuity Secondary air bypass valve Open or short circuit Solenoid valve connector Wiring from solenoid valve to PCME Solenoid valve continuity Secondary air switching valve FF ON OFF Solenoid valve connector Wiring from solenoid valve to PCME Solenoid valve continuity ON OFF Solenoid valve Port air bypass Solenoid valve connector Wiring from solenoid valve to PCME Solenoid valve continuity Solenoid valve Idl
184. ring fast idle Fast idle speed too slow and excessive engine shake aum fast idle but returns to normal after warm up idie after warm up Engine speed fluctuates between specified idle speed and low er speed and excessive engine shake at idle after warm up Cranks normaily but Any engine tempera Starter cranks engine at normal speed but engine requires ex Starter cranks engine at normal speed but engine requires ex During fast idle Engine stops unexpectedly during fast idle operation On acceleration Engine stops unexpectedly at beginning of acceleration or dur ing acceleration F 201 ture Refer to section F before referring to section F 203 186 TROUBLESHOOTING GUIDE F TROUBLESHOOTING ITEM DESCRIPTION TROUBLE Engine rough Idle with A C P S Engine speed fluctuates between specified idle speed and low and or E L ON er speed and excessive engine shake at idle when A C P S and or E L ON 20 Idle when shifted from Engine speed fluctuates between specified idle speed and low N or P to other range er speed and excessive engine shake at idle when shifted from N to other range On deceleration Engine shakes at beginning of deceleration during decelera F 206 tion or recovery from deceleration Section K Exhaust afterburn Poor acceleration Driveaway Engine speed increases normally but vehicle speed slowly in creases during driveaway 207 accel
185. s Go to next step Yes Goto next step Does crankshaft position sensor circuit have poor connection Is resistance of crankshaft position sensor G SEN SOR OK Resistance 0 95 1 25 20 F 68 F Replace crankshaft position sensor page F 166 G SENSOR Is clearance of crankshaft position sensor signal Yes Goto step OK Clearance 1 0 2 0 mm 0 039 0 0178 in Adjust clearance e page 166 Check for short circuit in wiring Crankshaft position sensor 4H or 4G terminal Go to next step Yes Replace PCME m page 150 Is there continuity between ground and 4G or groun and 4H terminal at harness side lt lt Disconnect connector from PCME is resistance be tween 4G and 4H terminals OK Resistance 0 95 1 25 20 C 68 F check for open circuit in wiring Crankshaft position sensor 4G or 4H terminal SHIELD WIRE I G SENSOR NE SENSOR SENSOR N CRANKSHAFT POSITION SENSOR 2 x jols ja 31 ac faa 2k 21 25 2t ae jan 2 22 29 12 F 27 F ON BOARD DIAGNOSIS FUNCTION 05 KNOCK SENSOR Repair connector and or wiring harness Go to next step 15 there continuity between knock sensor and PCME Check continuity between PCME terminal terminal 3M 3M and ground
186. s no symptom will be produced Solenoid valve Turbo control 1 Turbo control 2 If the solenoid valve or circuit has an open or short Trouble Code No 44 is output If the circuit is open the turbo control valve will not open causing poor acceleration and lack of power If the circuit is shorted turbo control valve will open earlier on acceleration causing poor acceleration Solenold valve Turbo precontrol If the solenoid valve or circuit has an open or short Trouble Code No 42 is output If the circuit is open the precontrol valve will open earlier causing slightly hesitation and poor accelera tion If the circuit is short precontrol valve will never open causing hesitation and poor acceleration Solenoid valve Wastegate control If the solenoid valve or circuit has an open or short Trouble Code No 43 is output If the circuit is open wastegate valve will open earlier causing poor acceleration and lack of power If the circuit is shorted wastegate valve will not open easily and no symptom will be noticed To prevent engine damage the overboost fuel cut will be operated F 223 SERVICE POINTS WIRING DIAGRAM 31 1102 NOTLINDI M1 d YaSN30N09 91 L 7109 NOILINSI 3 d V H21nn2 OI13NDVW 40 18 1 19 01 18 3 AVIAN dWM d HIV 80 19 d3 dWna 1303 Angi e 9 1 18 0 18 3 03
187. sary perform Steps 3 and 7 again 10 Note any code numbers and check for the causes by re ferring to the check sequences shown on pages F 26 through 65 Repair as necessary 11 After repairs cancel the code numbers by performing the After repair procedure Refer to page 66 F 20 ON BOARD DIAGNOSIS FUNCTION Principle Code Cycle Trouble codes are determined as shown below 1 Code cycle break The time between trouble code cycles is 4 0 seconds the time the buzzer is off SELF DIAGNOSIS CHECKER DIGTAL CODE CHECKER WITH SIGNAL ADAPTER 1cycLE TROUBLE CODE CYCLE TROUBLE CODE BREAK CYCLE BREAK 1 CYCLE 2 Second digit of trouble code ones position mE The digit in the ones position of the trouble code represents the number of times the buzzer sounds 0 4 second during one cycle SELF DIAGNOSIS CHECKER DIGITAL CODE CHECKER WITH SIGNAL ADAPTER severe TROUBLE CODE TROUBLE lr BREAK t CODE 03 ON TROUBLE CODE TROUBLE al evoe BREAK CODE 03 TROUBLE SEC SEC TROUBLE CODE CODE 08 ON 3 First digit of trouble code tens position The digit in the tens position of the trouble code represents the number of times the buzzer is on 1 2 se conds during one cycle The buzzer is off for 1 6 seconds between the long and short pulses 1 CYCLE TROUBLE CODE TROUBLE CODE 22 SEC FIRST DIGIT SECOND DIGI
188. se 36 PCE TTT EEE ET 6 Sett diagnosis checker wit not work 39 181 F TROUBLESHOOTING GUIDE RELATIONSHIP CHART SOLENOID VALVE INJECTOR UEL PUMP RELAY SPEED METERING OIL PUMP LE AIR CONTROL URGE CONTROL IR PUMP RELAY ROUBLE CODE MONITOR LAMP UEL PUMP RELAY POWERTRAIN CONTROL MODULE TRANSMISSION PRESSURE REGULATOR CONTROL TURBO PRECONTROL DOUBLE THROTTLE CONTROL SECONDARY AIR SWITCHING SPLIT AIR BYPASS PORT AIR BYPASS 2 gt 5 2 3 SECONDARY AIR BYPASS WASTEGATE CONTROL TURBO CONTROL lt a lt uj d 9 lt CHARGE CONTROL nesena sso ese fol o mur POSITION RANGE EE PL Je TEMPERATURE SENSOR Eon eem EEE EET et SENSOR oj 5650 e fol Jele PRESSURE SENSOR owewsewon tet TTT ole KNOCK SENSOR I EIE DIE cele vemaeseeeoseonR o 8 Ee wor rosmonsensor 1ttittiiftti ttt tort lol ET fool PT e AncoomowsesoR fol f TTT TTT TT TTT TTT STEERING PRESSURE SENSOR O tT Tt tT ttt tt tT L LI
189. sed SectionK after shifted to D S L and or R ranges Vehicle moves in N range Vehicle creeps in N ranges Section K Vehicle moves with accelerator pedal not depressed Vehicle moves P range Vehicle rolls in P range Excessive creep Vehicle moves quickly in D S Land R range with accelerator pedal not depressed Excessive N to R range and N to D range Vehicle does not move in D S L and or R ranges No creep at all SectionK shift shock felt Refer to section F before referring to section K F 187 TROUBLESHOOTING GUIDE TROUBLESHOOTING ITEM TROUBLE DESCRIPTION Single range shift 1st gt 2nd 2nd 3rd or 3rd O D only Sometimes shifts correctly Section K Gear position held in hold mode Abnormal shift Shifts incorrectly incorrect shift pattern ex Vehicle shifts 1st O D Section K directly when accelerating with accelerator pedal de pressed slightly Frequent shifting Downshift occurs when accelerated slightly in D S and section K ranges except hold mode Shift point high or low Shift points do not match shift diagram Shift delayed when accelerating Shift occur too fast when accelerating and engine speed does not increase No lockup No lockup when vehicle speed reaches lockup range No kickdown Does not downshift when accelerator peda depressed more than 7 8 within kickdown range Engine speed f ares up When accelerating E
190. short circuit in wiring harness Solenoid valve terminal Main relay D terminal Is connector B terminal voltage OK with solenoid valve connector disconnected Condion Voltage Ignition switch ON Battery positive voltage Is there continuity between solenoid valve A terminal and PCME terminai 4S Check for short circuit In wiring harness Solenoid valve A terminal PCME terminai 4S gt If OK go to next step e if not OK repair wiring harness Repair wiring harness Replace PCME page F 150 Replace solenoid valve page F 176 Is solenoid valve OK Circuit Diagram SOLENOID VALVE CHARGE RELIEF EG MAIN RELAY F SOLENOID VALVE CHARGE RELIEF EM a Jaw aS ao Jav e jac pa oo a T i fo se BA Ex A Tu T5 Ta To a TR TT TG TE Te bz av or fa Ja ja a Jo oe ov Jat 37 n ar foo fa as afar pos v 118 e N t s 8 Fo 8 F 58 ON BOARD DIAGNOSIS FUNCTION F 50 SOLENOID VALVE DOUBLE THROTTLE CONTROL INSPECTION O Does solenoid valve circuit have a poor connection Repair connector and or wiring harness ld br Go to next step il Check for open or short circuit in wiring _ ignition switch ON Battery positive voltage harness Solenoid valve B terminal Main relay D terminal Is there cont
191. ssed air from after the turbocharger to air cleaner housing during deceleration to prevent noise IDLE AIR CONTROL VALVE NEUTRAL SWITCH CLUTCH SWITCH IGNITER CRANKSHAFT POSITION SENSOR F 133 IDLE AIR CONTROL VALVE CONNECTOR F 134 DECELERATION CONTROL SYSTEM THROTTLE DASHPOT Inspection 1 Open the throttle valve fully then push the dashpot rod with a finger and verify that the rod goes in slowly 2 Release the rod and verify that it comes out quickly 3 Replace it if necessary Adjustment 1 Warm up the engine to the normal operating temperature and run it idle 2 Verify that the fast idle cam separates 3 Turn all electrical loads OFF 2 Connect a tachometer to the data link connector terminal IG 5 Open the throttle valve until the dashpot rod separates from the lever 6 Checkthe engine speed when the dashpot rod touches to the lever Engine speed 2600 3000 2800 200 rpm 7 Loosen the locknut and adjust by turning the dashpot if necessary ANTI AFTERBURN CONTROL System operation 1 Start the engine and run it at idle 2 Disconnect the idle air control valve connector 3 Increase the engine speed to over 4 000 rpm then de crease the engine speed rapidly 4 Verify that the engine speed decrease roughly at 1500 1000 rpm ELECTRICAL LOAD E L CONTROL SYSTEM F ELECTRICAL LOAD E L CONTROL SYSTEM DESCRIPTION The engine speed increases whe
192. t OK repair wiring harness een Replace PCME page F 150 Replace solenoid valve Is solenoid valve OK page F 176 Circuit Diagram SECONDARY AIR SWITCHING VALVE EGI MAIN RELAY F SECONDARY AIR SWITCHING VALVE EM ac 80 fo t fan a 4J 40 48 aP fan at 32 SH aF F 47 F ON BOARD DIAGNOSIS FUNCTION CON BOARD DIAGNOSIS TONS IY CODE No 33 SOLENOID VALVE PORT AIR BYPASS STEP o ACON 0 Does solenoid valve circuit have a poor connection Repair connector and or wiring harness Go to next step Go to next step Is connector A terminal voltage OK with solenoid valve connector disconnected Check for open or short circuit in wiring harness Solenoid valve A terminal Main relay D terminal Ignition switch ON Battery positive voltage Is there continuity between solenoid valve B terminal and PCME terminal 3N Check for short circuit in wiring harness Solenoid valve B terminal PCME terminal 3N c If OK go to next step c If not OK repair wiring harness Repair wiring harness is solenoid valve OK page 119 Replace PCME s page F 150 al Replace solenoid valve Circuit Diagram SOLENOID VALVE PORT AIR BYPASS EG MAIN RELAY F SOLENOID VALVE PORT AIR BYPASS EM
193. t condition Correct voltage Throttle position Constant Approx 5 0V Ignition switch ON sensor EGR valve does not operate Below 1 0V el EGR function EGR valve operates B ee Solenoid Ignition switch ON Reliel2 Before warm up approx Below 1 0V 40 C 104 F Intake air Ambient air temperature 20 C 68 F Approx 2 5V Ignition switch ON temperature sensor After warm up Approx 0 6V ignition switch ON Approx 25V Knocking occur Ignition switch ON Tap the engine hanger with hammer Measure the ter minal voltage by using the digital pe voltmeter Ignition switch ON MEE See eee After warm up Below 1 0 While running Engine speed 1 500 3 000 rpm Engine coolant temperature below Below 1 0V Ignition switch ON 80 C 176 F ater warmup aS el Secondary air After warm up bypass valve Engine speed 3 250 3 750 rpm for 0 5 sec Below 1 0V 2 6 2 8 Reference Solenoid valve Double throttle A a Ground Output Consta 0 V V Ground CPU V 0 0 oma E Engine signal position sensor monitor Red lamp flash NE signal 20 msec div Oscilloscope Voltmeter 0 1 0 4V Reference Solenoid valve Sth position MT OD
194. tage and close to open voltage Refer to Specification above 9 Tighten the screws Tightening Torque 1 6 2 4N m 16 24 kgf cm 140 210 in ibf 10 Cancel the memory of malfunctions by disconnecting the negative battery cable for at least 20 seconds and de press the brake pedal 11 Reconnect the negative battery cable 168 SHAS ENGINE COOLANT TEMPERATURE INTAKE AIR TEMPERATURE ENSOR THERMOMETER INTAKE AIR TEMPERATURE SENSOR CONTROL SYSTEM F Removal Installation 1 Turn ignition switch to OFF 2 Disconnect the throttle position sensor connector 3 Remove the throttle position sensor 4 install the throttle position sensor 5 Adjust the throttle position sensor Refer to page F 168 ENGINE COOLANT TEMPERATURE SENSOR Removal Installation Warning e Removing the engine coolant temperature sensor while the engine hot is dangerous Scalding cool ant and steam may shoot out and cause serious in jury Turn off the engine and wait until it is cool Even then be very careful when removing the en gine coolant temperature sensor 1 Remove the extension manifold Refer to page F 76 2 Disconnect engine coolant temperature sensor connector 3 Remove the engine coolant temperature sensor 4 Install a new gasket and install in the reverse order of re moval Tightening torque 20 24 N m 2 0 2 5 kgf m 15 18 ft Ibf Inspection M 1 Place the engine coolant temperatur
195. tep u Clean or replace 7 Try known good PCME does condition improved er page 150 Are spark plugs OK Section G F200 TROUBLESHOOTING GUIDE F DESCRIP Engine stops unexpectedly at beginning of acceleration or during acceleration TION Engine stops unexpectedly while cruising TROUBLESHOOTING HINTS Fuel pump Manifold absolute pressure sensor Poor connection Poor connection of connector Q Pressure regulator Spark plug Diaphragm damaged Misfire Crankshaft position sensor Main relay Poor connection of connector Poor connection of connector 00 displayed Is 00 displayed on SST with ignition switch ON page 20 Ground terminal F P of data link connector within ignition switch ON does condition improve 2d DATA LINK Aal Go to next step Trouble Code No displayed Check for cause Refer to specified check sequence Check as follows Poor connection of fuel pump relay Yes Poor connection of PCME 1T terminal Go to next step Go to next step ll Replace 4 Try known good PCME does condition improved rx page 150 Is pressure regulator OK sr page 104 F 201 TROUBLESHOOTING GUIDE 48 ENGINE STALLS 9 ON DECELERATION _ DESCRIP 9 Engine stops unexpectedly at beginning of deceleration or recovery from deceleration TION Exhaust aft
196. terminal voltage is incorrect check the input F CONTROL SYSTEM Terminal voltage 1 the engine signal monitor B Battery positive voltage input Output Connected to Test condition Correct voltage 0 FUEL INJ cy s START switch While cranking START Ignition switch ON 5 1 0V Self Test switch at SELF TEST 4 5 5 5V With Self Diagnosis Lamp illuminated for 3 sec after ignition Diagnosis checker Switch OFF checker and System Selector monitor lamp Lamp not illuminated after 3 sec Lampnotilluminatedafter3sec Br Test switch at Oo MONITOR Lamp illumi 4 5 5 5V nated Test switch at O2 MONITOR Lamp not illu minated Air conditioning sensor ON T 3 0V Air conditioning sensor OFF with Blower SW Air conditioning sensor Self Buzzer sounded for 3 sec after ignition Below 2 5V Diagnosis switch OFF ON checker ON ignition switch ON 9 With Self Diagnosis checker and pode UR Buzzer not sounded for after 3 sec e inside Selector test Below 2 5V Switch at SELF Buzzer not sounded osi Ignition switch ON 0 2 0 5V Reference igniter Trailing Front rotor Oscilloscope Engine speed above 2 500 rpm Igniter Ignition switch ON Leading 0 5 0 8V Reference Initial acceleration 0 2 0 5V Refere
197. terminals F P and GND with a jumper wire 5 Turn the ignition switch ON for 10 seconds to operate the fuel pump 6 Turn the ignition switch OFF and disconnect the jumper wire 7 Observe the fuel pressure 5 minutes Fuel pressure More than 150 kPa 1 5 kgf cm 21 psi 8 If not as specified perform the following inspections Fuel pump hold pressure Refer to page F 100 e Pressure regulator fuel line pressure Refer to page F 104 Injector fuel leakage Refer to page F 107 F 96 PRESSURE GAUGE INSALL FUEL SYSTEM F Fuel Line Pressure Inspection Warning Fuel line spills and leaks are dangerous Fuel can ignite and cause serious injuries or death and dam age Fuel can also irritate skin and eyes To prevent this always complete the Fuel Line Safety Proce dures on page 95 1 Disconnect the negative battery cable 2 install a fuel pressure gauge as shown in the figure 3 Connect the negative battery cable 4 Connect data link connector terminals F P and GND with a jumper wire 5 Turn the ignition switch ON 6 Measure the fuel line pressure Fuel line pressure ANN 250 260 kPa 2 5 2 7 kg cm 36 38 psi Pressure low Measure fuel pump maximum pressure Refer to page F 101 If as specified the fuel line or fuel filter might be clogged or re stricted Pressure high Replace the pressure regulator Refer to page 105 F 97 F FUEL SYSTEM
198. to ON engine off If any switch remains activated the monitor lamp will be illuminated NEUTRAL SWITCH CLUTCH SWITCH M SHR DIAGNOSIS DATALINK SYSTEM CHECKER CONNECTOR SELECTOR MONITOR LAMP dla TEST SWITCH Self Diagnosis Checker Monitor lamp Lamp ON Lamp OFF oom O Clutch switch MT Pedal depressed Pedal released 0 00000 Neutral switch Ciutch pedal released Park neutral switch eee L S Dor R range NorPrange Headlight switch switch ON O o OSOS Headlight switch or il position At 3rd or 4th o a gt lt NN Rearwindowdefrosterswitch 04 Blower switch at ist or 2nd Stoplight switch Pedal depressed Pedal released he eee PARK NEUTRAL SWITCH AIR CONDITIONING SENSOR KNOCK SENSOR STOPLIGHT SWITCH HEADLIGHT SWITCH BLOWER SWITCH ee REAR WINDOW DEEROSTER TEST MODE SWITCH 9206 90 F 67 ON BOARD DIAGNOSIS FUNCTION Inspection Procedure Self Diagnosis Checker 1 Connect the SST System Selector to the data link con nector 2 Set system select to position 1 3 Set TEST SW to SELF TEST SYSTEM SELECTOR 40 B019 9A0 4 Connect the SST Self Diagnosis Checker to the System Selector and a ground 5 Set the select switch of the Self Diagnosis Checker to position A 6 Turn the ignition switch ON 7 Chec
199. to above gt gt 2 Verify that the electric coolant fan does not operate io 3 Remove the fuel filler cap m 4 Set SYSTEM SELECT to position 1 5 Set TEST SW to SELF TEST 6 If the SST is not used connect a jumper wire between the TEN terminal and the GND terminal of the data link connector 7 Make sure the idle speed is within specification if not ad CONNECTOR just the idle speed 8 Connect a timing light to the high tension lead of the front trailing side Note Some timing lights will not illuminate even if the ignition is working properly CRANKSHAFT 9 Verify that the timing mark white on the crankshaft posi POSITION 4 tion sensor plate is aligned with the indicator pin lgnition timing Trailing side 20 ATDC 20 BTDC Leading side 5 ATDC 5 BTDC Idle speed Neutral or P range 550 950 rpm INDICATOR anm F 16 ENGINE TUNE UP F 10 If the timing is incorrect check the following procedure Verify that no trouble code number is present If trouble code number present check for cause by referring to the specified check sequence Refer to page F 20 05 knock sensor e 13 Manifold absolute pressure sensor Input devices E L P S A C Coolant fan Crankshaft position sensor NE signal Manifold absolute pressure sensor e Throttle position sensor Neutral SW Clutch SW MT Park Neutral signal AT Others PCME terminal 31 R
200. tor 9 Exhaust manifold Inspect for deterioration and restriction 10 insulatior Installation Note Check the stud bolt tighting torque before installing ex haust manifold Refer to page 89 Tighting torque 30 35 N m 3 0 3 6 kgf m 22 26 ft Ibf F 113 F OUTLINE OF EMISSION SYSTEM OUTLINE OF EMISSION SYSTEM STRUCTURAL VIEW The following systems are employed to reduce CO HC and NOx emissions 1 Secondary air injection 2 Positive crankcase ventilation system 3 Fuel evaporative system 4 Three way catalyst 5 Deceleration control system 6 Exhaust gas recirculation FUEL VAPOR VALVE CHECK VALVE PORT AIR THREE WAY AIRCONTROLVALVE CATALYST d Y lt lt 7 gt amp isi we 6 SPLIT AIR PIPE A p drm ESSEN d 5 5 a gt 5 CHACOAL CANISTER CHECK VALVE CATCH TANK PCV irm SOLENOID VALVE PURGE CONTROL F 114 SECONDARY AIR INJECTION __ F SECONDARY AIR INJECTION DESCRIPTION The secondary air injection helps to clean the exhaust gas by introducing fresh air into the exhaust port or three way catalyst in relation to the during condition The controls secondary air by actuating the solenoid valves secondary air switching secondary air bypass relief 2 port air bypass split air bypass and the air pump relay This system consist of an air control valve ACV three way solenoid valves air pump relay and powertrain control module
201. tput Code No 33 output No symptom No symptom NA Solenoid valve Main relay INJ fuse 30A burns out when ignition switch ON Solenoid valve Pressure regulator control PCME 4M Solenoid valve Code No 25 output Code No 25 output starting when engine No symptom NA INJ fuse 30A burns out when ignition switch ON m Solenoid valve Purge control Code No 40 output Hard starting Engine stalls at low speed NA Solenoid valve Main relay EGI INJ fuse 30A burns out when ignition switch ON Solenoid vaive Relief 2 ee e ee ee n No symptom Secondary air noise heard while air pump operates NA Solenoid valve Main relay Solenoid vaive Split air bypass Opencireuit PCME 4F Solenoid valve No symptom Solenoid valve Main relay ee eee ee c Red 4R Solenoid valve s ee ee O Shortcircuit_ Poorground Solenoid valve Main relay Opencrut Shoterut Poorground PCME 3H Solenoid valve PCME 3K Solenoid valve Code No 39 output Code No 39 output INJ fuse 30A burns out when ignition switch ON Code No 30 output Code No 30 output No symptom INJ fuse 30A burns out when ignition switch ON Solenoid valve Turbo control 1 Turbo control 2 Code No 44 output Poor acceleration N Solenoid valve s Main relay INJ fuse 30A burns out when ignition switch ON Code
202. ty Proce dures on page F 95 1 Disconnect the negative battery terminal 2 Connect a fuel pressure gauge to the fuel main pipe and plug the outlet of the gauge as shown Install clamps as shown 3 Connect the negative battery terminal 4 Connect data link connector terminals F P and GND with a jumper wire EM 5 Turn the ignition switch ON to operate the fuel pump 6 Measure the pump maximum pressure Fuel pump maximum pressure 490 740 kPa 5 0 7 5 kgt cm 71 107 psi 7 Turn the ignition switch OFF and disconnect the jumper wire 8 If not as specified replace the fuel pump Continuity Inspection 1 Remove the luggage room carpet 2 Remove the acoustic wave guide assembly if equipped 3 Disconnect the fue pump connector 4 Check for continuity between the fuel pump connector A and B 5 If there is none replace the fuel pump Refer to page F 98 101 F FUEL SYSTEM Disassembly Assembly Warning When replacing the fuel system parts keep sparks cigarettes and open flames away from the fuel Fuel line spills and leaks are dangerous Fuel can ignite and cause serious injuries or death and damage Fuel can also irritate skin and eyes To prevent this always complete the Fuel Line Safety Procedures on page F 95 1 Disassemble in the order shown in the figure 2 Assemble in the reverse order of disassembly referring to Assembly Note SEAL RUBBER REPLACE o
203. uity between engine coolant tempera Yes Goto next step ture sensor A terminal and a ground Replace PCME page F 150 Is resistance of engine coolant temperature sensor OK 929 935 rz page F 169 Replace engine coolant temperature sensor If not OK repair wiring harness Repair wiring harness Circuit Diagram ENGINE COOLANT TEMPERATURE SENSOR ENGINE COOLANT TEMPERATURE SENSOR ESER Jaw su Jas 40 av Jac Jac 4 50 SK fae sc 5A Jax 21 faa 2E Tac 25 v s o oM e E T6 142 4x jav fan aL 4J 40 48 jap Jot au jar 2 24 o N L v jH F F 30 ON BOARD DIAGNOSIS FUNCTION F 11 INTAKE AIR TEMPERATURE SENSOR srEp INSPECRON ACTION Does the engine coolant temperature sensor circuit Yes Repair connector and or wiring harness have a poor connection pes Go to next step Is Intake air temperature sensor B terminal voitage Yes Goto next step OK with intake air temperature sensor connector isco cme Check for short or open circuit in wiring harness Intake air temperature sensor B Condition Voltage terminal PCME terminal 3L Ignition switch ON Approx 5 0V c If OK replace PCME c If not OK repair wiring harness is there continuity b
204. used in warm weather Engine coolant temperature sensor Malfunction of engine coolant temperature sensor 193 ANY ENGINE TEMPERATURE F TROUBLESHOOTING GUIDE WHEN ENGINE COLD 7 8 9 CRANKS NORMALLY BUT HARD TO START 9 AFTER WARM UP Starter cranks engine at normal speed but engine requires excessive cranking time before starting DESCRIP TION Engine starts after stalling a few times Battery in normal condition Engine runs normally at idle if idle condition not OK refer to Engine rough Nos 19 20 21 22 or 23 TROUBLESHOOTING HINTS Injector Intake air system Fuel leakage from injector s Air leakage Q Fuel pump Engine coolant temperature sensor Poor connection of pump connector Poor connection of engine coolant temperature sensor Poor connection of fuel pump relay connector Malfunction of engine coolant temperature sensor Pressure regulator Solenoid valve Purge control Malfunction of pressure regulator Air leakage Fast idle cam Metering oil pump Malfunction of fast idle cam when engine cold Malfunction of pump Spark plug Crankshaft position sensor Dirty or worn spark plug s Ground circuit open Is 00 displayed on SST with ignition switch ON 00 displayed c page 20 Go to next step Trouble Code No displayed Check for cause Refer to specified check sequence
205. utput Code No 12 output Full range Poor acceleration Poor acceleration Strong shift shock AT Strong shift shock AT PCME Si Throttle position sensor Code Nos 12 18 output Code Nos 12 and 18 output Rough idle Rough idle Code No 12 output POME 4D Throttle position sensor Rough idle No sympton NA Not applicable F 231 SERVICE POINTS TEN terminal Data link connector om ee ee 11 Data link connector Cannot perform trouble code Hard starting checks and switch monitor Rough idle checks Engine coolant temperature sensor 8 eee ee re PCME coolant tempera Code No 09 output Code No 09 output ture sensor Rough idle and hard starting when engine cold No symptom Vehicle speed sensor Rough idle and hard starting PCME 4D Engine coolant tempera S eg when engine cold ture sensor Shotcicut Poor ground PCME 1M Vehicle speed sensor Code No 06 output NA Hold mode will not operate Output Device A C relay o meam Regu 11 relay A C will not operate A C constantly operate when blower ON Rough idie Air pump relay Opendrut Shotcrun Poorground PCME 2J Air pump relay Code No 54 output Code No 54 output Rough idle Three way catalyst melted Fan relay Opedrut Shotcwut Poorground PCME 3D fa
206. verify that the air pump magnetic clutch OFF inspection Magnetic clutch 1 Connect the SST Engine Signal Monitor Adaptor Har ness to the PCME 2 Turn ignition switch ON 3 Short the PCME terminal 2 and verify that the magnetic clutch OFF 4 If the magnetic clutch does not OFF check the air pump relay Refer to page F 123 5 If the relay is OK disconnect the air pump connector and check the continuity 6 If not as specified replace the air pump Continuity 1 Disconnect the air pump connector 2 Check for continuity between terminals 3 If no continuity replace the air pump Pressure 1 Disconnect air hose from air control valve to air pump at the air control valve 2 Connect the SST to the air hose 3 Start the engine and run it idle 4 Measure the pressure Pressure More than 4 9 kPa 0 05 kgf cm 0 7 psi 5 If not as specified replace the air pump F 121 F SECONDARY AIR INJECTION Removal Installation 1 Remove in the order shown in the figure 2 Install in the reverse order of removal 19 25 1 9 2 6 14 19 Nm kgf m ft Ibf 1 Air hoses 4 Braket 2 Connector 5 Air pump 3 Drive belt Inspection page F 121 below AIR PUMP DRIVE BELT Inspection 1 Check the drive belt for cracks deterioration or oil contam ination 2 Replace if necessary 3 If the belt is noisy check for loose
207. ymptom No symptom Not applicable F 229 F SERVICE POINTS Park Neutral signal AT ert raus PCME 1R PCMT 1C Idle speed drops when shifted to L S R range OON Intake air temperature sensor asses stort et Poor PCME 3L Thermosensor Code No 11 output Code No 11 output No symptom NA No symptom PCME 4D Thermosensor 5 __ circuit Shoncicut Poor ground Knock sensor PCME 3M Knock sensor Code No 05 output Code No 05 output Lack of power Lack of power NA Knocking i Metering oil pump position sensor Knocking Shon circuit Poorgrund 3A Metering oil pump J Code No 20 output Poor acceleration Hesitation PCME 4D Metering oil pump H No symptom NA Code No 20 output Poor acceleration Hesitation PCME 3I Metering pump 1 Mileage switch Condition Poor ground PCME 1N Mileage switch No symptom idle speed slightly high PNA Code No 20 output Poor acceleration Hesitatiori Neutral switch MT o 99 ee P S ON DN 1 2 switch MT opon crout Shorcircut No symptom No symptom BEEN Ground 1 2 switch Nosympom NA Not applicable F 230 SERVICE POINTS Oxygen sensor

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