Engine Control PDF

ENGINE CONTROL
SECTION EC
CONTENTS
PRECAUTIONS ................................................... EC-2 COMPONENT PARTS INSPECTION ................EC-45
On Board Diagnostic (OBD) System Crankshaft Position Sensor (POS) ................EC-45
of Engine......................................................... EC-2 Camshaft Position Sensor (PHASE)..............EC-45
Precaution....................................................... EC-2 Mass Air Flow Sensor ....................................EC-45
PREPARATION ................................................... EC-5 Engine Coolant Temperature Sensor ............EC-45
Special Service Tools ..................................... EC-5
DESCRIPTION .................................................... EC-6
Throttle Position Sensor 1, 2
(Electric throttle control actuator assembly)....EC46
EC
Description ...................................................... EC-6 Accelerator Pedal Position Sensors 1, 2
TROUBLE DIAGNOSIS .................................... EC-11 (Accelerator work unit) ...................................EC-46
Component Parts Location ........................... EC-11 Intake Air Temperature Sensor
ECM Component .......................................... EC-12 (Joined with mass air flow sensor).................EC-47
Circuit Diagram ............................................. EC-14 Stop Lamp Switch..........................................EC-47
ECM Terminal ............................................... EC-15 Spark Plug .....................................................EC-47
How to Proceed with Trouble Diagnosis ....... EC-22 Ignition Coil ....................................................EC-48
Diagnosis Chart by Symptom ....................... EC-25 Injector ...........................................................EC-48
Description .................................................... EC-31 Fuel Pump .....................................................EC-49
Fail-Safe Function......................................... EC-31 Electric Throttle Control Motor (Electric
Table of DTC................................................. EC-32 throttle control actuator assembly).................EC-49
Service Tool .................................................. EC-36 Heated Oxygen Sensor .................................EC-49
Self-Diagnosis Function Map Sensor (Atmosphere Pressure
(Without Service tool).................................... EC-39 Sensor) ..........................................................EC-49
ECM Input/Output Monitor ............................ EC-40 LPG Injector...................................................EC-50
ECM Active Test ........................................... EC-40 LPG Assistance Injector ................................EC-50
BASIC INSPECTION ......................................... EC-41 PTC Heater (Integrated with vaporizer) .........EC-50
Inspection of Idle Speed and PCV GAS RECIRCULATION DEVICE...............EC-51
Ignition Timing............................................... EC-41 System Diagram ............................................EC-51
Throttle Valve Closed Position Learning Component Parts Inspection .........................EC-51
and Idle Air Volume Learning........................ EC-42 ECM COMPONENTS .........................................EC-52
Accelerator Pedal Released Removal and Installation ...............................EC-52
Position Learning .......................................... EC-43
Fuel Pressure Inspection .............................. EC-43
Fuel Pressure Release ................................. EC-44
109
PRECAUTIONS
PRECAUTIONS On Board Diagnostic (OBD) System of

Engine
The ECM has an on board diagnostic system. It will light up the
malfunction indicator lamp (MIL) to warn the driver of a malfunction
causing emission deterioration.
CAUTION:
• Be sure to turn the ignition switch OFF and disconnect the
negative battery cable before any repair or inspection
work. The open/short circuit of related switches, sensors,
solenoid valves, etc. will cause the MIL to light up.
• Be sure to connect and lock the connectors securely after
work. A loose (unlocked) connector will cause the MIL to
light up due to the open circuit. (Be sure the connector is
free from water, grease, dirt, bent terminals, etc.)
• Certain systems and components, especially those related
to OBD, may use a new style slide-locking type harness
connector.
• Be sure to route and secure the harnesses properly after
work. The interference of the harness with a bracket, etc.
may cause the MIL to light up due to the short circuit.
• Be sure to connect rubber tubes properly after work. A
misconnected or disconnected rubber tube may cause the
MIL to light up due to the malfunction of fuel injection
system, etc.
• Be sure to erase the unnecessary malfunction information
(repairs completed) from the ECM before returning the
vehicle to the customer.
Precaution
• Always use a 12 volt battery as power source.
• Do not attempt to disconnect battery cables while engine is
running.
• Before connecting or disconnecting the ECM harness
connector, turn ignition switch OFF and disconnect battery
ground cable. Failure to do so may damage the ECM
because battery voltage is applied to ECM even if ignition
switch is turned OFF.
• Before removing parts, turn ignition switch OFF and then
disconnect battery ground cable.
SEF0289H
• Do not disassemble ECM.

• If a battery cable is disconnected, the memory will return to
the ECM value. The ECM will now start to self-control at its
initial value. Engine operation can vary slightly when the
terminal is disconnected. However, this is not an indication
of a malfunction. Do not replace parts because of a slight
variation.
• If the battery is disconnected, the following emission-
related diagnostic information will be lost within 24 hours.
– Diagnostic trouble codes
– 1st trip diagnostic trouble codes
110 EC-2
PRECAUTIONS
PREPARATION Precaution (Cont’d)

• When connecting ECM harness connector, fasten it
securely with levers as far as they will go as shown in the
figure.
• When connecting or disconnecting pin connectors into or

from ECM, take care not to damage pin terminals (bend or
break).
Make sure that there are not any bends or breaks on ECM
pin terminal, when connecting pin connectors.
• Securely connect ECM harness connectors. A poor
connection can cause an extremely high (surge) voltage to
develop in coil and condenser, thus resulting in damage to
ICs.
• Keep engine control system harness at least 10 cm (4 in)
away from adjacent harness, to prevent engine control
system malfunctions due to receiving external noise,
degraded operation of ICs, etc.
• Keep engine control system parts and harness dry.
• Before replacing ECM, perform ECM Terminals and
Reference Value inspection and make sure ECM functions
properly.
• Handle mass air flow sensor carefully to avoid damage.
• Do not disassemble mass air flow sensor.
• Do not clean mass air flow sensor with any type of
detergent.
• Do not disassemble electric throttle control actuator.
• Even a slight leak in the air intake system can cause
serious incidents.
MEF040D • Do not shock or jar the camshaft position sensor (PHASE),
crankshaft position sensor (POS).
• After performing each TROUBLE DIAGNOSIS, perform DTC
Confirmation Procedure or Overall Function Check.
The DTC should not be displayed in the DTC Confirmation
Procedure if the repair is completed. The Overall Function
Check should be a good result if the repair is completed.
EC-3 111
PRECAUTIONS
Precaution (Cont’d)
• When measuring ECM signals with a circuit tester, never
allow the two tester probes to contact. Accidental contact
of probes will cause a short circuit and damage the ECM
power transistor.
• Do not use ECM ground terminals when measuring input/
output voltage. Doing so may result in damage to the
ECM’s transistor. Use a ground other than ECM terminals,
such as the ground.
SEF348N
• Do not operate fuel pump when there is no fuel in lines.

• Tighten fuel hose clamps to the specified torque.
• Do not depress accelerator pedal when starting.

• Immediately after starting, do not rev up engine
unnecessarily.
• Do not rev up engine just prior to shutdown.
SEF709Y
112 EC-4
PREPARATION
PREPARATION Special Service Tools

Description Application
EGI fuel pressure indicator For measuring fuel pressure gauge

91H20-09010
ECM0013
Heated oxygen sensor wrench Removing and installing heated oxygen sensor
91H20-09020
ECM0014
GSE kit For system inspection and diagnosis

16A68-11500
ECM0015
Check adapter V For control unit input/output signal inspection

91H20-09030 (for SMJ 150-pin
connector)
ECM0016
Harness adapter
91H20-09040
(150-pin to 121-pin conversion adapter)
ECM0017
EC-5 113
DESCRIPTION
DESCRIPTION Description
• Adopts Engine Control Module (ECM). Fuel injection control,
ignition timing control, idle speed control, and electronically
controlled governor control etc. are all performed by a single
control unit.
• Adopts electric throttle control actuator system to control
electronically controlled governor.
• Adopts Hall IC type crankshaft position sensor (POS) and
camshaft position sensor (PHASE).
Items Description
Electric throttle control actuator • Adopts electronic throttle control actuator with integrated throttle control motor to adjust
throttle valve opening optimally according to driving conditions or to improve safety and
operability by electronically controlled governor.
Fuel injection control • With fuel injection control, air-fuel ratio is optimized to improve exhaust performance and
response.
• Using feedback control through learning of air-fuel ratio compensation, the system corrects
the ratio during transitional conditions, such as sudden sharp changes in the ratio, in order
to improve drivability.
Ignition timing control • Uses Hall IC crankshaft position sensor (POS) and camshaft position sensor (PHASE) to
perform controls so that optimum ignition timing is obtained for every operating condition.
Optimum ignition timing setup according to each fuel is also enabled at the time of a
combined use formula.
• Adopts electronic distribution system (NDIS) in which each cylinder is equipped with an
ignition coil incorporating a power transistor for better ignition performance.
Idle speed control • Adopts electronic throttle control actuator that continuously regulates intake air amount
required for idling.
Governor speed control • Performs maximum regulation of engine speed for oil pressure pump protection by engine
speed signal.
Maximum speed regulation control • Performs maximum speed regulation by vehicle speed sensor signal. Also, performs
variable control of maximum speed by changeover switch.
Idling area torque up control • Performs torque up control in idling area by engine speed signal in order to also enable
cargo work at idling.
Overheat prevention control • Reduces engine heat generation by reducing maximum engine speed and regulating
maximum throttle opening when engine coolant temperature reaches approximately 110°C
(230°F).
• Prevents resulting in engine breakage by overheat by performing fuel cut at 1,000 rpm or
more when engine coolant temperature reaches approximately 135°C (275°F).
Power/soft mode control • Changes throttle opening characteristic of throttle position by power/soft mode control
switch, and then minute operation of engine speed is enabled. (Option setting)
Fuel pump control (gasoline) • Turns fuel pump relay ON/OFF depending on engine speed signal.
LPG interception valve control • Turns interception valve relay ON/OFF depending on engine speed signal and fuel
pressure sensor signal.
Fail-safe function • Ensures vehicle’s safe operation and enables vehicle to be driven in an emergency when
any of the major system components (mass air flow sensor, engine coolant temperature
sensor, etc.) have malfunctioned.
Diagnostic system • Adopts self-diagnosis system for easier trouble diagnosis.
114 EC-6
DESCRIPTION
Description (Cont’d)
K-ENGINE ELECTRONIC CONTROLLED SYSTEM DIAGRAM (GASOLINE)
EC-7 115
DESCRIPTION
K-ENGINE ELECTRONIC CONTROLLED SYSTEM DIAGRAM (LPG)
116 EC-8
DESCRIPTION
K-ENGINE ELECTRONIC CONTROLLED SYSTEM DIAGRAM
(COMBINED USE)
EC-9 117
DESCRIPTION
SENSORS AND ACTUATORS CONTROL ITEMS
Main sensors and actuators related to the ECM are listed below.
Combined
Gasoline std std std std std std std std opt std std
Fuel
Fuel changing (Gasoline and LPG) Combined

LPG std std std — std std std std opt std std
Control Item Fuel injection

control
Maximum vehicle speed control

Maximum engine speed control
Power ECO mode control

Ignition timing control
A/F feedback control
Fuel injection control
Fuel pump control
Idle speed control
Self-diagnosis
Fuel cut off
Fail-safe
: Significant impact to control
: Impact to control
Crankshaft position sensor (POS, PHASE)         
Mass air flow sensor      
Intake air temperature sensor  
Engine coolant temperature sensor      
Heated oxygen sensor   
Vehicle speed sensor      
Throttle position sensor          
Accelerator pedal position sensor          
Sensors
Ignition switch        
P/N POSI SW     
Stop lamp switch 
Headlamp (electrical load) switch 
Power ECO mode switch (opt) 
Battery voltage     
LPG fuel pressure sensor   
Fuel changing switch     
Map sensor   
Gasoline injector   
Power transistor  
Ignition system
Ignition coil 
Throttle control motor relay   
Throttle control motor    
Gasoline fuel pump relay  
Actuators
Gasoline fuel pump  

Ignition relay 
ECM relay          
LPG injector    
LPG assistance injector    
LPG interception valve relay   
LPG interception valve  
118 EC-10
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS Component Parts Location
Specifications
Main component part Type Location
Gasoline LPG Combined
Actuators Gasoline injector High resistance Intake manifold  

LPG injector Gas injection Integrated in injector  
holder (on intake
manifold)
Fuel pump Electric motor/turbine Integrated in fuel tank  
Fuel pressure regulator Diaphragm  
Throttle control motor Electric DC motor (DC Integrated in electronic   
motor) throttle control actuator
Ignition coil Mold (built-in power Cylinder head (On each   
transistor) spark plug)
EC-11 119
TROUBLE DIAGNOSIS
Component Parts Location (Cont’d)

Specifications
Main component part Type Location
Gasoline LPG Combined
Sensors Crankshaft Crankshaft Hall IC (element) Front cover   

position position sensor
sensor (POS)
Camshaft position Chain housing   
sensor (PHASE)
Mass air flow sensor Hot wire Air horn   
Accelerator pedal position Variable resistance Integrated in accelerator   
sensors 1 and 2 work unit (accelerator
pedal assembly)
Throttle position sensors 1 and 2 Integrated in electronic   
throttle control actuator
Engine coolant temperature Thermistor Water outlet   
sensor
Intake air temperature sensor With air flow meter   
Heated oxygen sensor Zirconia (with heater) Exhaust manifold   
ECM 121-pin digital control Vehicle side   
EGI & IGN coil relay Compact general relay Vehicle side   
(1M X 2)
ECM Component
Specifications NOTE
Component Location
Gasoline LPG Combined Actuator Sensor Other
Gasoline injector Intake manifold   
LPG injector Integrated in injector holder (on   
intake manifold)
Throttle control motor Integrated in electronic throttle    
control actuator
Throttle position sensors 1 and 2    
Ignition coil Cylinder head (on each spark plug)    
Crankshaft position sensor (POS) Front cover    
Camshaft position sensor (PHASE) Front housing    
Mass air flow sensor Air horn    
Intake air temperature sensor With air flow meter    
Engine coolant temperature sensor Water outlet    
Accelerator pedal position sensors Integrated in accelerator work unit    
1 and 2 (accelerator pedal assembly)
Fuel pump Integrated in fuel tank   
Fuel pressure regulator   
Heated oxygen sensor (Vehicle side)    
Vehicle speed sensor (Vehicle side)    
ECM (Vehicle side)    
EGI & IGN coil relay (Vehicle side)    
Stop lamp switch (Vehicle side)    
Throttle control motor relay (Vehicle side)    
Fuel pump relay (Vehicle side)  
Vaporizer (Vehicle side)   
LPG interception valve (Vehicle side)   
120 EC-12
TROUBLE DIAGNOSIS
ECM Component (Cont’d)
EC-13 121
TROUBLE DIAGNOSIS
Circuit Diagram
K-ENGINE ELECTRONIC CONTROLLED ECM CIRCUIT DIA-
GRAM (COMBINED GASOLINE AND LPG)
122 EC-14
TROUBLE DIAGNOSIS
ECM Terminal
REFERENCE VALUE LIST

Voltage is measured with a circuit tester, and the sample waveforms
obtained with an oscilloscope are shown below for each ECM
terminal. Measurement data varies depending on variation in parts
as well as many other factors. Such factors include vehicle history,
driving conditions, environmental conditions, maintenance status,
measuring instrument/method, etc. Data shown below are reference
values.
Terminal
Description Measurement condition Measured value
signal
1 ECM ground Always Approx. 0V
2
115
116
66 Sensor ground (Throttle position sensor) At idle after warming up Approx. 0V
At approx. 2,000 rpm
67 Mass air flow sensor ground Always Approx. 0V
78 Heated oxygen sensor ground Always Approx. 0V
82 Accelerator pedal position sensor 1 Always Approx. 0V
ground
83 Accelerator pedal position sensor 2 Always Approx. 0V
ground
32 Fuel changing switch 2 (Gasoline) Changing switch ON (At gasoline side) Approx. 5V
Changing switch ON (At LPG side) Approx. 0V
56 Governor control switch At normal speed setting Approx. 0V
At low speed setting Battery voltage
70 Fuel changing switch 1 (LPG) Changing switch ON (At LPG side) Approx. 5V
Changing switch ON (At GAS side) Approx. 0V
84 Headlamp switch Lighting switch OFF Approx. 0V
Lighting switch ON Battery voltage
101 Brake switch Brake pedal released Approx. 0V
Brake pedal depressed Battery voltage
102 Neutral switch N position Approx. 0V
Other than above Battery voltage
109 (IGN) Ignition switch Ignition switch OFF Approx. 0V
Ignition switch ON Battery voltage
EC-15 123
TROUBLE DIAGNOSIS
ECM Terminal (Cont’d)

Terminal
signal
13 Crankshaft position sensor (POS) At cranking Approx. 2.6V
ECM0052
At idle after warming up Approx. 3V
ECM0053
At approx. 2,000 rpm Approx. 3V
ECM0054
14 Camshaft position sensor (PHASE) At cranking Approx. 0.15V
ECM0055
At idle after warming up Fluctuates between approx. 1.5 - 2V.
ECM0056
At approx. 2,000 rpm Approx. 2V
ECM0057
24 Heated oxygen sensor heater At idle after warming up Approx. 0.3V

31 LPG fuel pressure sensor At idle after warming up Approx. 0.78V
124 EC-16
TROUBLE DIAGNOSIS
Terminal
signal
35 Heated oxygen sensor At idle after warming up Changes between approx. 0.1 -
0.4V;approx. 0.6 - 0.9V
ECM0058
At approx. 2,000 rpm Changes between approx. 1 -

0.4V;approx. 0.6 - 0.9V
ECM0059
50 Throttle position sensor 1 At idle after warming up Approx. 0.6V

Ignition switch ON with engine stopped Approx. 0.5V
Accelerator pedal is fully depressed
Accelerator pedal is released
At approx. 2,000 rpm Approx. 0.7V
51 Mass air flow sensor Ignition switch ON Approx. 1V
At cranking Approx. 1.5V
At idle after warming up Approx. 1.3V
69 Throttle position sensor 2 At idle after warming up Approx. 4.5V
EC-17 125
TROUBLE DIAGNOSIS

Terminal
signal
98 Accelerator pedal position sensor 2 At Idle Approx. 0.335 - 0.435V
Ignition switch ON with engine stopped Approx. 0.335 - 0.435V
106 Accelerator pedal position sensor 1 At Idle Approx. 0.67 - 0.87V
27 PTC heater relay At idle after warming up Approx. 0V
(Except North America) Ignition switch ON when the engine Battery voltage
coolant temperature is 30°C (86°F) or
less (except for cranking)
104 Throttle control motor relay Ignition switch ON, engine running Approx. 1V
112 LPG interception valve relay Engine running Battery voltage
Ignition switch OFF Approx. 0V
113 Gasoline F/P relay For approximately 1 second after ignition Approx. 1V
switch ON
After that Battery voltage
At cranking, engine running Approx. 1V
3 Throttle control motor relay power supply Always Battery voltage
48 Sensor power supply Ignition switch ON, engine running Approx. 5V
49 Fuel changing switch power supply Changing switch ON Approx. 5V
Changing switch ON (At neutral) Approx. 0V
90 Accelerator pedal position sensor 1 Ignition switch ON, engine running Approx. 5V
power supply
91 Accelerator pedal position sensor 2 Ignition switch ON, engine running Approx. 2.5V
power supply
110 Power supply for ECM (backup) Always Battery voltage
118 Power supply for ECM Ignition switch ON, engine running Battery voltage
121
4 Throttle control motor (Close) At idle after warming up Approx. 2 - 2.5V
5 Throttle control motor (Open) At idle after warming up Approx. 0.1 - 0.15V
11 LPG assistance injector At idle after warming up Battery voltage
126 EC-18
TROUBLE DIAGNOSIS
Terminal
signal
22 Injector drive signal At cranking Approx. 10.5V
23
41
42
ECM0060
At idle after warming up Battery voltage
ECM0061
At approx. 2,000 rpm Relatively lower than battery voltage
ECM0062
34 Intake air temperature sensor signal Intake air temperature is approx. 20°C Approx.
(68°F). 3.5V
Intake air temperature is approx. 80°C Approx.

(176°F). 1.2V
ECM0499
47 Electric throttle control actuator open Ignition switch ON, engine running Approx. 5V
EC-19 127
TROUBLE DIAGNOSIS

Terminal
signal
61 Ignition signal (power transistor drive At cranking Approx. 0.2V
62 signal)
80
81
ECM0047
At idle after warming up Approx. 0.1V
ECM0048
ECM0049
73 Engine coolant temperature sensor Engine coolant temperature is approx. Approx.

signal 20°C (68°F). 3.5V
Engine coolant temperature is approx. Approx.

80°C (176°F). 1.2V
ECM0500
85 (K LINE) Signal line for service When connected to Service tool Approx. 6.6 - Battery voltage
When not connected to Service tool Approx. 6V
86 CAN communication line L Always Approx. 2.2V (Varies depending on
communication status.)
ECM0051
128 EC-20
TROUBLE DIAGNOSIS
Terminal
signal
94 CAN communication line H Always Approx. 2.4V (Varies depending on
communication status.)
ECM0050
111 Self shut-off For approximately 10 seconds with Approx. 1V

ignition switch ON and after ignition
switch OFF
Approximately 10 seconds on more after Battery voltage
ignition switch OFF
119 LPG injector drive (H) Battery voltage
Time axis may change according to
setting data and driving condition.
120 LPG injector drive (L) Battery voltage

Time axis may change according to
setting data and driving condition.
NOTE:
Numerical values are obtained using an analog circuit tester.
EC-21 129
TROUBLE DIAGNOSIS
TROUBLE DIAGNOSIS How to Proceed with Trouble Diagnosis

1. The most important point in performing trouble diagnosis of
malfunctions is to thoroughly understand the vehicle systems
(both control and mechanical).
An ECM-based engine controls actuators such as injectors and
the ignition coil according to information from sensors. Then
through actuator operation, the engine (mechanical system)
runs. Sensors transmit information on the running condition,
which changes constantly, to ECM. It is important to under-
stand these cycles.
ECM0031
2. It is also important to clarify customer concerns before starting

the inspection.
First of all, reproduce the symptom, and understand it fully.
Ask the customer about his/her concerns carefully. In some
cases, it will be necessary to check the symptoms by driving
the vehicle with the customer.
CAUTION:
Customers are not professionals. Do not assume “maybe the
customer means ...” or “maybe the customer mentioned this
ECM0032
symptom”.
3. It is essential to confirm symptoms right from the beginning in
order to ensure all malfunctions are completely repaired.
For an intermittent malfunction, it is important to reproduce the
symptom based on an interview with the customer and past
examples. Do not perform an inspection on an ad hoc basis.
Most intermittent malfunctions are caused by poor contacts. In
this case, it will be effective to shake the suspected harness or
connector by hand. When repairs are performed without any
symptom check, no one can judge if the malfunction has actu-
ally been eliminated.
ECM0033
4. The next important thing is to find which system among the
following is causing the malfunction: ECM control signal
system, or a mechanical system (such as the engine main body
and auxiliary component). It is important to inspect the system
using Service tool or by checking the ECM input/output signals.
When checking the ECM input/output signals, connect a check
adapter (Service tool) to ECM in order to prevent misdiagnosis.
Special Service Tools (Service tool):
Check adapter V (91H20-09030) (for SMJ 150-pin
connector)
Harness adapter (91H20-09040) (150-pin  121-pin
conversion adapter)
5. Use the reference value of input/output data (guideline) in this
manual in order to judge the ECM input/output signals. Measure
the data of another vehicle of the same model under the same
conditions when it is difficult to judge, and compare the data. It
is advisable to collect sufficient data of a normally operating
vehicle.
ECM0034
130 EC-22
TROUBLE DIAGNOSIS
How to Proceed with Trouble Diagnosis

(Cont’d)
TROUBLE DIAGNOSIS FLOW CHART
There are many different malfunction symptoms. So there is no
perfect trouble diagnosis technique applicable to all malfunctions.
Experience is also important to achieving an accurate trouble
diagnosis.
Nonetheless, an accurate trouble diagnosis can be performed by
applying similar procedures, regardless of the malfunction symptom.
Perform trouble diagnosis following the flow chart shown below.
ECM0035
DIAGNOSTIC WORK SHEET

Description
• In order to clarify the malfunction symptom, it is important to ask
the customer and collect information about their concerns.
• Ask the customer about what symptoms are present under what
conditions. Use the information to clarify the symptom.
• Use the trouble diagnosis sheet to be certain not to miss any
vital information.
ECM0036
EC-23 131
TROUBLE DIAGNOSIS
How to Proceed with Trouble Diagnosis

(Cont’d)
ECM0037
132 EC-24
TROUBLE DIAGNOSIS
Diagnosis Chart by Symptom

RELATIONSHIP BETWEEN MALFUNCTIONING SYMPTOMS
AND THE SENSOR CIRCUIT
The table below shows the possible symptoms caused by the
malfunction of each sensor circuit.
Poor starting
Check that symptoms are detected with self-diagnosis.

Impossible
to start
Engine
Other
Symptoms Poor idle Poor driving control
Check that symptoms are in fail-safe condition.

stall
During surge and constant speed driving

Engine rpm does not increase smoothly.
Inconsistent idle when engine is cold.
Engine over temperature (Overheat)

Inconsistent idle when warming up
Poor fuel consumption efficiency

During surge and acceleration
When engine is warming up
Description/notable
Fast idle is not effective

No initial combustion
characteristics of the
When engine is cold
During a heavy load

During deceleration
Poor power output
Poor acceleration
Initial combustion
symptom
High idle rpm
Low idle rpm
After-burn
Knocking
Backfire
Driving
At Idle
Sensor malfunction
: Highly possible
: Possible
Crankshaft position sensor OPEN       • An open circuit in either REF or

(POS, PHASE) POS signal makes it impossible
for the vehicle to start.
• Control signals for fuel system
and ignition system are not
output.
Momentarily              • The symptom depends on the

open duration of momentarily open
circuit and the operating
conditions. Slight shocks and
surges may be sensed during
driving, while engine stall may
be caused during idle.
Mass air flow Signal OPEN             • It will be in fail-safe condition,

sensor and vehicle runs at an engine
speed from 800 rpm to 1,600
rpm.
High output                • The air-fuel ratio becomes rich.

Black smoke may accompany.
Poor connection of grounding
may be a possible cause.
Low output                  • The air-fuel ratio becomes lean.

Contaminated hot wire or
suction of air may be suspected.
Ground OPEN       • It will be over-rich.
Power OPEN             • It will be in fail-safe condition,

supply and vehicle runs at an engine
speed from 800 rpm to 1,600
rpm.
Intake air temperature OPEN/ 

sensor SHORT
Engine coolant temperature OPEN/               • It will be in fail-safe condition,

sensor SHORT and then Engine Warning lamp
turns ON. This malfunction
tends to occur when engine is
cold or when the engine coolant
temperature is high.
Resistance                  • The engine coolant temperature

is large. is judged as low. This
malfunction tends to occur after
warming up.
Resistance                     • The engine coolant temperature

is small. is judged as high. This
malfunction tends to occur when
engine is cold.
Heated oxygen sensor OPEN/          • It will be base air-fuel ratio.

SHORT
EC-25 133
TROUBLE DIAGNOSIS
Diagnosis Chart by Symptom (Cont’d)
Poor starting

Impossible
to start
Engine
Other
Symptoms Poor idle Poor driving control

stall



Description/notable

When engine is cold characteristics of the
During a heavy load

During deceleration
Poor power output
Poor acceleration
Initial combustion
symptom
High idle rpm

Low idle rpm
After-burn
Knocking
Backfire
Driving
At Idle
Sensor malfunction
: Possible
Vehicle speed sensor OPEN/     • Duration of fuel cut becomes

SHORT shorter or fuel may not be cut.
Throttle position sensor OPEN/                 • Idle will be base rpm. No

SHORT addition for acceleration.
Output           • Possible interruption by

fluctuation unnecessary fuel injection. Poor
ground or control unit
connection may be the cause.
Poor   • Idling is judged as OFF during

adjustment idle. Turning ignition switch
repeatedly to ON and OFF will
set the system to normal.
Accelerator pedal position OPEN/        

sensor SHORT
Output       
fluctuation
Ignition switch IGN OPEN      • Impossible to start without

outputs for fuel and ignition
systems.
Neutral SW OPEN        • Neutral switch is judged as OFF,

and the target cold engine
speed in N/P position is
lowered.
SHORT • Neutral switch is judged as ON,

and fast idle is effective for cold
engine in positions other than N/
P position, making the creep
larger.
Stop lamp switch OPEN/

SHORT
Headlamp (electrical load) OPEN/  

switch SHORT
CAN communication line OPEN/ 

SHORT
Power supply for ECM OPEN       • Impossible to start without

outputs for fuel and ignition
systems.
Sensor ground (coolant OPEN/                 • The same as the open circuit in

temperature sensor, throttle SHORT the applicable sensor.
position sensor)
Control unit and connector Poor                        • A slightly raised connector often
connection, results in poor connection. Entry
water entry? of water causes engine stall,
and afterwards it is momentarily
impossible to restart engine. In
some cases, restarting is
possible after a short wait.
LPG fuel pressure sensor OPEN/  

SHORT
Fuel changing switch OPEN  • Fuel changing cannot be done.
LPG fuel pressure sensor OPEN        • LPG interception valve OFF.
134 EC-26
TROUBLE DIAGNOSIS

RELATIONSHIPS BETWEEN MALFUNCTIONING SYMPTOMS
AND ACTUATOR CIRCUITS
malfunction of each actuator circuit.
Poor starting

Impossible
to start
Engine
Other
Symptoms Poor idle Poor driving

stall



Description/notable

characteristics of the
When engine is cold
During a heavy load

During deceleration
Poor power output
Poor acceleration
Initial combustion
symptom
High idle rpm

Low idle rpm
After-burn
Knocking
Backfire
Driving
At Idle
Actuator malfunction
: Possible
Gasoline injector Power OPEN               • No fuel injection to cylinder with

supply open circuit, resulting in LEAN
circuit Momentarily     output of heated oxygen
open sensors.
• Starting engine is impossible
Coil OPEN               when the circuits for all the
cylinders are open.
Momentarily    
open
Drive OPEN                 
circuit
(ECM Momentarily 
side) open
SHORT                • Continuous fuel injection to

cylinder with short circuit,
resulting in OVER-RICH and
misfiring.
• Starting engine is impossible
when the circuits for all the
cylinders are open.
Nozzle Foreign               • The cylinder with foreign

hole material material will keep injecting.
intrusion
Clogging                  • The symptom depends on

clogging status. The correction
factor of air-fuel ratio becomes
larger.
Ground OPEN      • Shocks may be sensed and

circuit engine stall may be occur
(ECM) depending on the duration of the
operation conditions.
Momentarily         
open
Ignition signal circuit OPEN                  • Slight shocks and surges may

be sensed depending on the
Momentarily    duration of momentarily open
open circuit and the operating
conditions.
Ignition coil Power OPEN              
supply
circuit Momentarily    • Engine stall may occur if
open duration of momentarily open
circuit is too long.
Coil OPEN               • Shocks may be sensed and

engine stall may be occur
depending on the duration of the
operation conditions.
Ground OPEN               • Injects fuel toward spark plug on

circuit the cylinder with open circuit.
Momentarily   
open
EC-27 135
TROUBLE DIAGNOSIS
Poor starting

Impossible
to start
Engine
Other

stall



Description/notable

When engine is cold characteristics of the
During a heavy load

During deceleration
Poor power output
Poor acceleration
Initial combustion
symptom
High idle rpm

Low idle rpm
After-burn
Knocking
Backfire
Driving
At Idle
Actuator malfunction
: Possible
EGI relay circuit OPEN      

Throttle control motor circuit OPEN/      
SHORT
Throttle motor relay circuit OPEN              • The same malfunction may

occur as power supply open of
throttle control motor and
throttle position sensor.
Heated oxygen sensor OPEN

heater circuit
• Fuel pump relay circuit OPEN      • Impossible to start

• Fuel pump circuit
• Ignition relay circuit Momentarily      • Impossible to start
open
Fuel pump OPEN/    
Pressure regulator SHORT
LPG injector HI side OPEN        • LPG interception valve OFF

circuit
SHORT        • LPG interception valve OFF
Coil OPEN        • LPG interception valve OFF
LO side OPEN        • LPG interception valve OFF

circuit
SHORT        • LPG interception valve OFF
LPG assistance injector OPEN   

Control unit      
side short
LPG interception valve relay OPEN     
Control unit
side short
LPG interception valve OPEN     

Malfunction indicator lamp OPEN
Improper TAS learning OPEN       
136 EC-28
TROUBLE DIAGNOSIS

RELATIONSHIP BETWEEN MALFUNCTIONING SYMPTOM AND
THE ENGINE MAIN BODY/AUXILIARY COMPONENT
malfunction of engine main body system. It will be helpful in
malfunction trouble diagnosis. (The table lists general symptoms
and some may not be applicable.)
Poor starting
Impossible
to start
Engine
Other
stall



Fast idle is not effective Description/notable
When engine is cold
During a heavy load

During deceleration
Poor power output
Poor acceleration
characteristics of the symptom
Initial combustion
High idle rpm

Low idle rpm
After-burn
Knocking
Backfire
Driving
At Idle
: Possible
: Not very possible
Air sucked from oil level gauge        • Air-fuel ratio becomes LEAN.
• High air-fuel correction factor.
Air sucked from oil filler cap        • Low suction power (vacuum pressure) of
intake manifold.
Air sucked from PCV hose                * Check the suction using a pressure
(downstream of PCV) gauge.
* Generally applicable to air suction in air
Air sucked from intake manifold and                intake system
gasket
PCV kept open         • Noise (high hissing tone)
Clogged fuel strainer               • Symptom depends on clogging status.

This tends to happen during high-speed
Clogged air cleaner element       or high load operation.
Malfunctioning gasoline pressure                • Symptom varies depending on

regulator combustion pressure.
Fuel mixture
Poor quality gasoline                  • Symptom varies depending on oil quality.
Improper LPG fuel (cold area and                  • Starting ability in cold area is changed
propane ratio) depending on propane ratio.
• Use LPG with proper propane ratio.
Malfunctioning LPG vaporizer                • If the pressure is low, it is caused by poor

pressure adjusting valve output during high-speed or high load
operation.
• If the pressure is excessively high, relief
valve operates and engine stalls at rich.
Clogged LPG vaporizer hot water              • Symptom depends on fuel temperature.

circuit This tends to happen during engine stall
and is impossible to restart during engine
warming up.
Clogged LPG interception valve             • Symptom depends on clogging status.

filter This tends to happen during high-speed
or high load operation.
Valve deposit                 • Air-fuel ratio becomes LEAN. High air-

fuel correction factor.
Improper connection of wire                   • Check that wiring route is proper.

connector
Poor connection of wire connector                  • Check that connector is slightly raised.

Poor starting if slightly raised connectors
are in all cylinders.
Sparking
Improper ignition timing adjustment                  —
Malfunctioning spark plug             • Check that the gap is proper. Check

spark plug for electric wear, soil (fuel
injection, smoking), and damaged
insulator.
Leakage from high-pressure parts                 • Symptom varies depending on the level

of leakage.
EC-29 137
TROUBLE DIAGNOSIS
Poor starting
Impossible
to start
Engine
Other
stall



Description/notable
When engine is cold
During a heavy load

During deceleration
Poor power output
Poor acceleration
characteristics of the symptom
Initial combustion
High idle rpm

Low idle rpm
After-burn
Knocking
Backfire
Driving
At Idle
: Possible
: Not very possible
Improper bulb contact                 • Symptom varies depending on contact
Compression
condition and the number of cylinders.

pressure
Worn piston ring                • Symptom varies depending on degree of

wear and the number of cylinders.
Clogged three-way catalytic                • In some cases, after engine stall,

converter /exhaust system restarting is possible.
Low idle base speed         • Engine stall may occur by power steering
load and cargo load during deceleration
or at idling.
Dragging of brakes     • Tires/wheels are hot.
Belt tension too high (excessive      —

tension)
High A/T load      • Insufficient ATF amount, improper oil
Other
specification (This symptom may

especially occur in the cold.)
High HYD PUMP load (PS, Cargo)          • Malfunctioning oil pressure relief valve,
improper oil specification (This symptom
may especially occur in the cold.)
Foreign material in fuel tank (such                • With low fuel, this may easily occur.
as dust)
Damaged fan, malfunctioning water  • Noise
pump
Clogged/restricted radiator/  —
condenser
Also check the following items other than the above:

• Check harness tension.
• Check each connector connection.
• Check ground wire for looseness.
• Check battery connection for looseness or corrosion.
• Check water and oil condition.
• Check fan belts for looseness.
138 EC-30
TROUBLE DIAGNOSIS
Description
• “When” a malfunction occurs that is caused by the sensors of
engine or the air-fuel ratio control, “{ }” of the meter panel
illuminates. Then, Diagnostic Trouble Code (DTC) is displayed
on the meter. At this time, the possible cause is displayed by
operating the button.
• For DTC, refer to Table of DTC (EC-32).
• When a malfunction has occurred, check the symptom and
perform the trouble diagnosis using “Diagnosis history”, “ECM
input/output monitor” and “Active test” in the meter.
NOTE:
• For “Diagnosis history”, refer to EC-32.
• For “ECM Active Test”, refer to EC-40.
Fail-Safe Function
When any of the critical sensors or systems sends a malfunction
message, the fail-safe function estimates the driving conditions with
other input signals and selects safer conditions for engine (vehicle)
control, based on data previously stored in ECM.
Engine
Related sensors Malfunction condition Fail-safe Warning
lamp
Mass air flow sensor Same as self-diagnosis • Selects fuel injection pulse width depending on engine speed and ON
malfunction detection throttle position so the vehicle can be driven. However, fuel injection
conditions. will be inhibited (fuel cut off) when engine speed exceeds
approximately 800 - 1,600 rpm.
• Idle speed is 800 rpm.
Engine coolant • Uses the estimated engine coolant temperature (varies with elapsed ON
temperature sensor time after start) to perform controls so the vehicle can be driven.
Accelerator pedal position • Fuel injection will be inhibited when 1 circuit is opened. Release ON
sensor valve mechanically until it can drive at low speed when disconnecting
connector.
Throttle position sensor • Fixes output to a preset value so the vehicle can be driven. However, ON
fuel injection will be inhibited (fuel cut off) when engine speed
exceeds approximately 2,500 rpm.
EC-31 139
TROUBLE DIAGNOSIS
Table of DTC
SELF-DIAGNOSIS RESULTS
When a malfunction occurs in ECM input/output signal circuit, the
malfunctioning circuit is recorded and displayed. Also, the
malfunction item that is occurred is displayed.
Display sample [Example: When there is a malfunction in mass air
flow sensor] Display DTC and the malfunction item in the alarm
monitor screen.
Engine
DTC for
DTC Name warning Malfunction return condition Diagnosis outline Trip
GST
lamp
— NO DTC — — — — —
E-03 VCM U1001 • Malfunction occurs in CAN communication — 2
communication transmit/receive data or in VCM, and data
signal circuit — transmission/reception cannot be confirmed.
malfunction • CAN communication data is transmitted/
received for predetermined period.
E-04 ECM U1001 • Malfunction occurs in CAN communication — 2
communication transmit/receive data or in ECM, and data
E-05 DCM U1001 • Malfunction occurs in CAN communication — 2
communication transmit/receive data or in DCM, and data
E-07 MP U1001 • Malfunction occurs in CAN communication — 2
communication transmit/receive data or in MP, and data
Mass air flow P0102 When the engine is running and the mass air Detect disconnection and 1
sensor signal flow sensor output voltage has been 0.5V or short circuit and make MIL
circuit less (open or shorted) for a predetermined go on.
malfunction period.
E-21 ON
P0103 When the engine is stopped (ignition switch
ON) and the mass air flow sensor output
voltage has been approx. 4.9V or more (open
or shorted) for a predetermined period.
Engine coolant P0117 Engine coolant temp. sensor output voltage Detect disconnection and 1
temperature has been less than 0.06V (open or shorted) for short circuit and make MIL
signal circuit a predetermined period. go on.
malfunction
E-22 ON
P0118 Engine coolant temp. sensor output voltage
has been approx. 4.8V or more (open or
shorted) for a predetermined period.
140 EC-32
TROUBLE DIAGNOSIS
Table of DTC (Cont’d)

Engine
DTC for
GST
lamp
Throttle position P0122 Throttle position sensor 2 output voltage has Detect disconnection 1
sensor signal circuit been approx. 0.3V or less (open) for a and short circuit and
malfunction predetermined period. make MIL go on.
P0123 Throttle position sensor 2 output voltage has
been approx. 4.8V or more (shorted) for a
predetermined period.
P0222 Throttle position sensor 1 output voltage has
been approx. 0.3V or less (open) for a
E-23 ON* P0223 Throttle position sensor 1 output voltage has
been approx. 4.8V or more (shorted) for a
P1225 When the throttle valve closed position Compare inconsistency
learning value is excessively low. between two separate
P1226 When the throttle valve closed position circuits which are
learning cannot be performed. installed for redundancy
P2135 A malfunction occurs in the relation between and judges abnormal
condition and make MIL
throttle position sensors 1 and 2.
go on.
Accelerator pedal P2122 Accelerator pedal position sensor 1 output Detect disconnection 1
position sensor voltage has been approx. 0.15V or less and short circuit and
signal circuit (open) for a predetermined period. make MIL go on.
malfunction P2123 Accelerator pedal position sensor 1 output
voltage has been approx. 5V or more
(shorted) for a predetermined period.
P2127 Accelerator pedal position sensor 2 output
voltage has been approx. 0.15V or less
(open) for a predetermined period.
E-24 — P2128 Accelerator pedal position sensor 2 output
voltage has been approx. 5V or more
(shorted) for a predetermined period.
P2138 A malfunction occurs in the relation between Compare inconsistency
accelerator pedal position sensors 1 and 2. between two separate
circuits which are
installed for redundancy
and judges abnormal
condition and make MIL
go on.
Heated oxygen — P0132 Heated oxygen sensor output voltage is Detect disconnection 2
E-25 sensor signal circuit higher than normal (1.4V or more). and short circuit and
malfunction P0134 Heated oxygen sensor signal circuit is open. make MIL go on.
Heated oxygen — P0031 Heated oxygen sensor heater control voltage Detect disconnection 2
sensor heater has been approx. less than 0.12V (open or and short circuit of an
signal malfunction shorted) for a predetermined period. oxygen sensor heater
E-26
P0032 Heated oxygen sensor heater control voltage circuit and make MIL go
has been approx. 4.7V or more (shorted) for on.
a predetermined period.
EC-33 141
TROUBLE DIAGNOSIS

Engine
DTC for
GST
lamp
Crankshaft P0335 • The crankshaft position sensor (POS) signal is Detect abnormal crank angle 2
position not detected for a predetermined time at engine sensor signal and make MIL
sensor signal start or during engine running (during camshaft go on.
circuit position sensor (PHASE) signal input).
E-27 malfunction ON • A crankshaft position sensor (POS) signal
irregular waveform is detected for a
predetermined time during engine running
(during camshaft position sensor (PHASE) signal
input).
Camshaft P0340 • At start-up, no camshaft position sensor Detect abnormal cam angle 2
position (PHASE) signal has been detected for more than sensor signal and make MIL
sensor a predetermined period. go on.
(PHASE) • The camshaft position sensor (PHASE) signal
signal circuit is not detected for a predetermined time during
malfunction engine running (during crankshaft position
E-28 ON
sensor (POS) signal input).
• A camshaft position sensor (PHASE) signal
irregular waveform is detected for a
predetermined time during engine running
(during crankshaft position sensor (POS) signal
input).
Self shut off P0605 Self shut off of ECM doesn’t operate normally. — 1
E-29 malfunction —
ECM circuit P0605 CPU system or circuits in ECM have a Detect abnormal condition in 1 or 2
malfunction malfunction. CPU or an engine control (Note)
module circuit and make MIL
go on.
P1065 Power is not supplied to ECM for some time. Detect insufficient power
E-30 ON*
supply for ECM and make
MIL go on.
P1229 Sensor power supply voltage has been 5.6V or Detect improper voltage
more or less than 4.6V for a predetermined output for sensors and make
period. MIL go on.
Electric P1124 Electric throttle control motor power supply Detect disconnection and 1
throttle control circuit is shorted. short circuit of a motor
actuator P1126 Electric throttle control motor power supply driving circuit and make MIL
control signal circuit is open. go on.
circuit
P1128 Electric throttle control motor signal circuit is
malfunction
shorted.
P0605 When an abnormal occurs for the target of Compare the difference Locked
throttle position. between target throttle ON: 1
E-31 — P1121 Because of mechanical malfunction of the position and actual throttle Locked
electric throttle control actuator, the electric position, judge abnormal OFF: 2
throttle control actuator does not operate condition and make MIL go
normally. on.
P1122 • When a malfunction occurred due to the
correlation between the target throttle position
and the actual throttle position.
• Over current flows into throttle motor control
circuit.
Overheat P1218 Engine coolant temp. sensor output voltage has — 1
E-32 signal — been approx. 0.35V or less for a predetermined
(STEP1) period (with the coolant temp. sensor normal)
Overheat P1217 Engine coolant temp. sensor output voltage has Detect overheat condition by 1
E-33 signal ON* been approx. 0.35V or less for a predetermined water temperature sensor
(STEP2) period (with the coolant temp. sensor normal) and make MIL go on.
Ignition signal P0350 Ignition signal has not been continuously Detect electric current in an 1
circuit generated while the engine is running. ignition coil circuit, judge
E-34 —
malfunction abnormal ignition interval
and make MIL go on.
142 EC-34
TROUBLE DIAGNOSIS

Engine
DTC for
GST
lamp
Map sensor P0107 The map sensor low input The map sensor output voltage 2
malfunction diagnosis has been approx. 0.08V or less
(open) for a predetermined
period.
E-44 ON
P0108 The map sensor high input The map sensor output voltage 2
diagnosis has been approx. 4.82V or more
(shorted) for a predetermined
period.
LPG fuel injection P1240 Over current flows into LPG Detect abnormal electric current 1
open circuit injector 1 (injection area). in an LPG injector driving circuit
E-35 malfunction — and make MIL go on.
P1241 Over current flows into LPG
injector 1 (no injection area).
LPG vaporizer P1249 • LPG fuel pressure sensor circuit Detect abnormally higher fuel 1
malfunction is open. pressure by LPG fuel pressure
• LPG fuel pressure in fuel piping sensor and make MIL go on.
E-38 —
from LPG Vapo to injector has
been excessively increased for a
Stop lamp switch P1805 Brake switch signal circuit is open — 1
E-41 malfunction — or shorted.
GAS air-fuel ratio P1814 After engine warmed with gasoline Air-fuel ratio does not cross 1
malfunction fuel, when oxygen sensor signal is stoichiometry for a long time
sticked and does not reverse at a during intended closed-loop
condition of A/F ratio is operation. (written in 40CFR
excessively lean or rich. Parts 1048.110.)
E-42 ON*
P1148 After engine is started with
gasoline fuel, when closed-loop
control does not start within a
LPG air-fuel ratio P1815 After engine warmed with LPG Air-fuel ratio does not cross 1
malfunction fuel, when oxygen sensor signal is stoichiometry for a long time
sticked and does not reverse at a during intended closed-loop
condition of A/F ratio is operation. (written in 40CFR
E-43 ON* excessively lean or rich. Parts 1048.110.)
P1817 After engine is started with LPG
fuel, when closed-loop control
does not start within a
LPG fuel pressure P1245 LPG fuel pressure sensor circuit is Detect disconnection and short 1
E-36 sensor malfunction ON* shorted. circuit and make MIL go on.
EC-35 143
TROUBLE DIAGNOSIS
Service Tool
Trip 1: If a malfunction is detected by self-diagnosis between the
time ignition switch is turned ON (engine is running) and then turned
OFF (this is defined as “trip”), Engine Warning lamp is lit. The
corresponding DTC is recorded immediately after detection.
Trip 2: When a malfunction is detected by self-diagnosis for the first
time in the first trip, a tentative DTC is recorded. If the same
malfunction is detected again by self-diagnosis in the next trip
(second trip), Engine Warning lamp is lit and the corresponding final
DTC is recorded.
Self-diagnostic results timing

• For items of trip 1, timing “0” is displayed immediately after
detection of a malfunction.
• For items of trip 2, when a malfunction is detected for the first
time (trip 1), timing “1t” is displayed. When a malfunction is
detected again in the next trip (trip 2), it is displayed as “0”.
Accumulative counting is performed at the end of warming-up
operation.
Conditions to turn off Engine Warning lamp

• The Engine Warning lamp, marked with *, is turned off when
ignition switch is turned ON (engine starts) again after normal
state is resumed.
• For other self-diagnostic items, self-diagnostic results shall be
erased by turning ignition switch to OFF after normal operation
is resumed.
144 EC-36
TROUBLE DIAGNOSIS
Service Tool (Cont’d)

OBD SYSTEM COUNTER (FOR TRIP 2 DETECTION DIAGNOSIS
WHEN MIL TURNS ON)
Relation of MIL, first trip DTC, DTC and possible detection
items
• When the malfunction is detected for the first time, ECM records
first trip DTC.
• When the same malfunction is detected twice continuously,
ECM records DTC and MIL turns ON.
• MIL turns OFF after driving the vehicle by 3 trips without the
malfunction. If the same malfunction occurs while counting, the
counter is reset.
• DTC is displayed until the vehicle is driven by 40 trips while the
same malfunction is not reproduced.
• If the self-diagnosis result is OK at the second trip, the first trip
DTC is not displayed.
Table of counter systems

Unit: Trip
Items Trips Driving conditions

MIL (OFF) 3 B
DTC (CLEAR) 40 A
First trip DTC (CLEAR) 1 B
Driving conditions
• Driving condition A
Driving condition A is the condition that the engine can be warmed
up.
Specifically, count up the counter if all of the following conditions are
satisfied.
• The engine speed becomes 400 rpm or more.
• The engine coolant temperature rises 20C (68F) or more after
the engine is started.
• The engine coolant temperature becomes 70C (158F) or
more.
• The ignition switch turns OFF from ON.
NOTE:
• When the same malfunction is detected regardless of the driv-
ing condition, the A counter is reset.
• Count up the A counter when the above conditions are satisfied
while the same malfunction not detected.
• When the A counter reaches 40, DTC is not displayed.
• When the A counter counts once while the same malfunction is
not detected after ECM records first trip DTC, first trip DTC is
cleared.
EC-37 145
TROUBLE DIAGNOSIS
Service Tool (Cont’d)

• Driving condition B
Driving condition B is the condition that all diagnosis can be
performed just once.
Specifically, count up the counter if all of the following conditions are
satisfied.
• The engine speed becomes 400 rpm or more.
• The engine coolant temperature becomes 70C (158F) or
more.
• The vehicle speed of 6 - 40 km/h (4 - 25 MPH) continues for 3
seconds or more at closed loop control.
• The vehicle speed of 4 km/h (2 MPH) or less and the idle
determination ON continue for 5 seconds or more at closed loop
control.
• Allow 6 minutes or more to pass after starting the engine.
NOTE:
• When the same malfunction is detected regardless of the driv-
ing condition, the B counter is reset.
• Count up the B counter when the above conditions are satisfied
while the same malfunction is not detected.
When the B counter reaches 3 without the malfunctions, MIL
turns OFF.
146 EC-38
TROUBLE DIAGNOSIS
Self-Diagnosis Function
(Without Service tool)
DIAGNOSTIC TEST MODE II - SELF-DIAGNOSTIC RESULTS

• In this mode, the MIL blinks (indicating the DTC) to identify the
system that returned a malfunction.
• If no DTC is detected, DTC “0000” is displayed.
EC-39 147
TROUBLE DIAGNOSIS
ECM Input/Output Monitor

Heated oxygen sensor output At idle: Changes between approx. 0.1 - 0.4V0.6 - 0.9V
voltage Maintain at approx. 2,000 rpm: Changes between approx.
0.1 - 0.4V0.6 - 0.9V
Intake air temperature sensor Values according to intake air temperature
LPG fuel pressure sensor Ignition switch ON: Approx. 29 kPa (0.3 kg/cm2) [4 psi]
ECM Active Test

ECM active test has the following items.
• Idle Air Volume (Normal)
• Air-fuel ratio adjustment
• Air-fuel ratio clear
• Ignition timing adjustment
• Fuel pressure clear
• Power balance
• Self-diagnosis clear
(1) Idle Air Volume Learning

If the idle speed or the ignition timing is outside the standard (engine
status is malfunctioning) or if the electronic throttle control actuator
or ECM is replaced, perform Idle Air Volume Learning.
Standard
Idle speed: 70050 rpm
Ignition timing: 02/700 (BTDC/rpm)
(2) Air-fuel ratio adjustment

If the values of “Air-fuel ratio” in ECM input/output monitor are
outside the standard, adjust the air-fuel ratio.
Proper value: 100%

Adjustment range: 75 - 125%
(3) Ignition timing adjustment

If the values of “Ignition timing” in ECM input/output monitor are
outside the standard, adjust the ignition timing.
Proper value: 0
Adjustment range: 0 - 10
(4) Fuel pressure clear

Relieve fuel pressure before removing fuel piping to secure safety.
For relieving procedure of fuel pressure, refer to “Fuel pressure
clear”.
(5) Power balance

When the engine does not run smoothly or the misfires occur in
some cylinders, forcibly stop each cylinder in “Power balance”, and
then check which cylinder has the malfunction.
148 EC-40
BASIC INSPECTION
BASIC INSPECTION Inspection of Idle Speed and Ignition Timing

SERVICE DATA AND SPECIFICATIONS (SDS)
Fuel pressure kPa (kg/cm2) [psi] 353 (3.6) [51]
Idle speed (rpm) A/T model (at N position) 700±50

Ignition timing (°BTDC/rpm) A/T model (at N position) 0±2/700
Firing order 1-3-4-2
Spark plug Manufacturer/type/gap mm (in) NGK/FR2A-D/0.8 - 0.9 (0.0031 - 0.035)
Ignition advance device Electrically controlled ignition advance
Density of CO at idle speed (%)/Density of HC at idle speed (ppm) 0.1/50 or less
• Turn ignition switch ON, and then make sure that no

malfunction is detected by self-diagnosis.
• Make sure that engine is free of oil pressure pump loads and
any electrical loads. Perform the inspection with the shift lever in
the neutral or N position.
• Warm up engine and transmission to the normal operating
temperature.
EC-41 149
BASIC INSPECTION
Throttle Valve Closed Position Learning and

Idle Air Volume Learning
DESCRIPTION
When electric throttle control actuator or ECM connector is removed,
it is necessary for ECM to learn throttle valve closed position (throttle
position sensor output with throttle valve fully closed) after
reinstallation. Thus, throttle valve closed position learning is
performed.
When electric throttle control actuator or ECM is replaced, the
minimum required idle air volume needs to be learned. Thus, throttle
valve closed position learning and idle air volume learning are
performed.
Idle air volume learning is necessary even when idle speed or
ignition timing is outside the standard. Note that idle air volume
learning is equivalent to the base idle speed adjustment by
conventional throttle adjusting screw of carburetor or LPG mixer.
OPERATION PROCEDURE FOR THROTTLE VALVE CLOSED

POSITION LEARNING
1. Turn ignition switch ONOFF. (And hold it for approximately 5
seconds after turning it OFF.)
2. Make sure that throttle valve operates. (Check for operating
sound.)
3. Upon completion of the above, learning is complete.
CAUTION:
Throttle valve closed position learning cannot be performed
with Service tool.
OPERATION PROCEDURE FOR IDLE AIR VOLUME LEARNING

1. Perform throttle valve closed position learning.
2. Fully warm up engine, transmission, and lubricant. [Engine
coolant temperature: 70 to 90°C (158 to 194°F)]
3. Set the selector lever to neutral or N position. Make sure that
the engine is free of electrical loads, such as air conditioner, oil
pressure pump, and other electrical components.
4. Perform “Idle Air Volume Learning” of “ECM Active Test”.
CAUTION:
“IDLE AIR VOL LEARN (PLANT)” is the original setting on the
vehicle. Do not use it.
150 EC-42
BASIC INSPECTION
Throttle Valve Closed Position Learning and

Idle Air Volume Learning (Cont’d)
CAUTION:
It will take approximately 20 seconds to complete the idle air
volume learning. Do not turn OFF the ignition switch until
completion.
• Complete “Idle Air Volume Learning”, then make sure that idle
speed and ignition timing are within the standard.
• Perform “Idle Air Volume Learning” again if values are outside
the standard.
Accelerator Pedal Released Position

Learning
DESCRIPTION
When the accelerator pedal assembly has been replaced or the
accelerator pedal position sensor connector has been disconnected,
the accelerator pedal released position needs to be learned after
being repaired, so learn accelerator pedal in fully-released position.
OPERATION PROCEDURE
1. Turn ignition switch ON and wait at least 2 seconds.
2. Turn ignition switch OFF and wait at least 10 seconds.
3. Then turn ignition switch ON again and wait at least 2 seconds
(learning completed).
Fuel Pressure Inspection

QUICK INSPECTION
With Active Test
1. Perform “Fuel pressure clear” of ECM Active Test.
2. Pinch the fuel feed hose with the fingers. Hose should not feel
hard.
Without Active Test
• When the fuel feed hose is squeezed while fuel pump is
operating (for 1 second after the ignition switch is turned ON or
while cranking), the hose should be swelling with pressure or
pulsating.
FUEL PRESSURE INSPECTION
CAUTION:
• Safely and securely remove and install fuel hose.
• Use the fuel pressure gauge for fuel pressure inspection.
• Do not inspect fuel pressure while other systems are
operating. Malfunctions may occur in fuel pressure value.
1. Release the fuel pressure.
2. Install fuel pressure gauge using fuel hose for fuel pressure
inspection.
3. Remove fuel hose, and then install fuel hose for fuel pressure
inspection.
CAUTION:
Usable period of fuel hose for fuel pressure inspection is 30
times or less. (Fuel hoses that are damaged and allow fuel
leakage are not contained above.)
EC-43 151
BASIC INSPECTION
Fuel Pressure Inspection (Cont’d)

4. Turn ignition switch ON, and then make sure that there is no
fuel leakage.
5. Start engine, and check for fuel leakage.
6. Make sure that fuel pressure is within the standard.
At idle: 353 kPa (3.6 kg/cm2) [51 psi]
• If the vehicle shows poor starting, check fuel pressure with fuel
pump operating for approximately 1 second after ignition switch
is turned ON, and during cranking.
For 1 second after ignition switch is turned ON and
during cranking: 353 kPa (3.6 kg/cm2) [51 psi]
• Check the following items if a malfunction is detected.
CAUTION:
Also check fuel pressure at increased engine speed.
• Malfunctioning pressure regulator (integrated with fuel pump)
• Clogged fuel piping
• Clogged fuel filter (with fuel pump)
• Poor fuel pump discharge
Fuel Pressure Release

CAUTION:
Relieve fuel pressure before removing fuel piping to secure
safety.
With Active Test
1. Perform “Fuel pressure clear” of ECM Active Test.
2. Crank engine 2 or 3 times to consume the fuel in the fuel line
after it stalls.
3. Turn ignition switch OFF.
Without Active Test

1. Disconnect fuel pump fuse.
2. Start engine.
3. Crank engine 2 or 3 times to consume the fuel in the fuel line
after it stalls.
4. Turn OFF the ignition switch, and install the fuel pump fuse.
152 EC-44
COMPONENT PARTS INSPECTIONIS
COMPONENT PARTS INSPECTION Crankshaft Position Sensor (POS)

Check resistance between terminals using an analog circuit tester.
At room temperature
(+) - (-) Resistance
3-1 : Not 0  nor  
2-1 : Not 0  nor  
3-2 : Not 0  nor 
CAUTION:
Measurement values will vary depending on the measurement
range of circuit tester. Note that the higher the range is, the
ECM0086 larger the resistance is.
Camshaft Position Sensor (PHASE)

Check resistance between terminals using an analog circuit tester.
At room temperature
(+) - (-) Resistance
3-1 : Not 0  nor  
2-1 : Not 0  nor  
3-2 : Not 0  nor  
CAUTION:
ECM0091 range of circuit tester. Note that the higher the range is, the
larger the resistance is.
Mass Air Flow Sensor

1. Remove mass air flow sensor.
2. Turn ignition switch to ON. While blowing air into the mass air
flow sensor from the air cleaner case side, check output voltage
between terminal 3 and ground.
No air blowing: Approx. 1V
With air blowing: Approx. 1.3V
(The more the air is blown, the higher the voltage is.)
CAUTION:
If air is blown from the air duct side, the voltage becomes lower.
Engine Coolant Temperature Sensor

Check resistance between terminals 1 and 2 on the engine coolant
temperature sensor.
Resistance
Coolant temperature at approx. 20°C (68°F): Approx.
2.5 k 
Coolant temperature at approx. 80°C (176°F): Approx.
0.3 k 
EC-45 153
COMPONENT PARTS INSPECTION
Engine Coolant Temperature Sensor (Cont’d)

(k )
20
10
Resistance
2.5
1
0.3
0.1
20 (68) 80 (176) C ( F)
Coolant temperature
ECM0383
Throttle Position Sensor 1, 2 (Electric

throttle control actuator assembly)
Check voltage between ECM terminal 50, 69 and ground.
Terminal At idle after At approx.
Signal name
signal warming up 2,000 rpm
50 - (-) Throttle position sensor 1 Approx. 0.6V Approx. 0.7V

69 - (-) Throttle position sensor 2 Approx. 4.5V Approx. 4.4V
CAUTION:
• Make sure that there is no moisture around connector
when removing and installing throttle position sensor
ECM0101
connector. If there are any water drops, completely wipe
them off.
• Do not apply voltage to throttle position sensor terminal.
• Perform “Throttle Valve Closed Position Learning” if
disconnecting connector. Perform “Throttle Valve Closed
Position Learning and Idle Air Volume Learning” if
replacing electric throttle control actuator. (Refer to EC-42,
“Throttle Valve Closed Position Learning and Idle Air
Volume Learning”.)
COMPONENT PARTS INSPECTION Accelerator Pedal Position Sensors 1, 2
(Accelerator work unit)
Check voltage between ECM terminal 106, 98 and ground.
At approx.
Terminal Signal name At Idle
2,000 rpm
106 Accelerator pedal position sensor 1 Approx. 0.67 - Approx. 0.65V

0.87V
98 Accelerator pedal position sensor 2 Approx. 0.335 Approx. 0.35V
- 0.435V
CAUTION:
ECM0103 • Do not apply voltage to accelerator pedal position sensor
terminal.
• Do not disassemble accelerator work unit.
154 EC-46
Intake Air Temperature Sensor (Joined with

mass air flow sensor)
Check resistance between intake air temperature sensor (mass air
flow sensor connector) terminals 3 and 5.
Resistance
Intake air temperature at approx. 20C (68F): Approx. 2.5
k
Intake air temperature at approx. 80C (176F): Approx. 0.3
k
(k )
20
10
Resistance
2.5
1
0.3
0.1
20 (68) 80 (176) C ( F)
Intake air temperature
ECM0384
Stop Lamp Switch

Check continuity between stop lamp switch terminals 1 and 2.
Brake pedal released: Continuity should not exist.
Brake pedal depressed: Continuity should exist.
ECM0108
Spark Plug
1. Check electrode for dirt, damage, and wear and insulator for
damage.
2. Replace spark plug if necessary.
CAUTION:
• Check terminals for looseness.
• Check insulator for cracks or damage.
• Check for contamination by oil, water, and dust.
• Make sure that the spark plug gap is normal, using a feeler
gauge.
ECM0117 Spark plug gap: 0.8 - 0.9 mm (0.031 - 0.035 in)
EC-47 155
Ignition Coil
Check the resistance between terminals of the power transistor by
applying and exchanging (+ and -) the inspection rods of an analog
circuit tester.
(+) - (-) Resistance (at room temperature)
1-2 : Not 0  nor  
2-1 : Not 0  nor  
3-1 : Except 0 
1-3 : Except 0 
3-2 : Except 0 
2-3 : Except 0 
ECM0118
CAUTION:
Do not use a digital circuit tester because the standard is
different.
Injector
Check resistance between each cylinder injector terminals 1 and 2.
Standard resistance (all cylinders): Approx. 14.5 
(at room temperature)
ECM0123
WITH ECM INPUT/OUTPUT MONITOR

1. Check “INJ PULSE GAS” (gasoline) or “INJ PULSE LPG” (LPG)
in Input/Output monitor, and increase the engine speed to
approximately 2,500 rpm after warming up engine.
2. Make sure that “INJ PULSE GAS” (gasoline) or “INJ PULSE
LPG” (LPG) instantly drops when accelerator pedal is released.
WITHOUT SERVICE TOOL
1. Warm up the engine sufficiently.
2. Disconnect harness connector of the injector and connect a test
lamp.
3. Release the accelerator pedal at the engine speed of
approximately 2,500 rpm or more, and confirm test lamp goes
off for a moment.
ECM0147
156 EC-48
Fuel Pump
Check resistance between terminals 3 and 6.
Resistance: Approx. 1  (at room temperature)
Electric Throttle Control Motor (Electric

throttle control actuator assembly)
Check resistance between electric throttle control motor (throttle
position sensor connector) terminals 3 and 6.
Resistance: Approx. 1 -15  [at 25°C (77°F)]
CAUTION:
• Make sure that there is no moisture around connector
when removing and installing throttle position sensor
connector. Completely wipe off water drops if there are any.
• Do not apply voltage to electric throttle control motor
terminal.
• Perform “Throttle Valve Closed Position Learning” if
disconnecting connector. Perform “Throttle Valve Closed
Position Learning and Idle Air Volume Learning” if
replacing electric throttle control actuator. (Refer to EC-42,
“Throttle Valve Closed Position Learning and Idle Air
Volume Learning”.)
Heated Oxygen Sensor

Check resistance between heated oxygen sensor terminals 2 and 3.
Resistance: Approx. 3.3 - 3.5 
Map Sensor (Atmosphere Pressure Sensor)

1. Check resistance between terminals using an analog circuit
tester.
Resistance
1 - 3: Not 0 nor  
2 - 3: Not 0 nor  
CAUTION:
range of circuit tester. Note that the higher the range is, the
larger the resistance is.
EC-49 157
Map Sensor (Atmosphere Pressure Sensor)

(Cont’d)
2. Turn ignition switch to ON. Check output voltage between
terminal 2 and ground.
Output voltage: Approx. 0.08 - 4.82V
CAUTION:
Perform measurement in the environment of between altitudes
from 0 to 2,438 m (8,000 ft) or without pressurized and
depressurized.
LPG Injector
1. Check resistance between terminals 1 and 2.
Resistance: Approx. 1 (at room temperature)
2. Remove fuse cover, and then check fuse for open.
CAUTION:
Do not apply voltage to LPG injector.
LPG Assistance Injector

Check resistance between terminals 1 and 2.
Resistance: Approx. 27 (at room temperature)
Apply battery voltage directly to terminals 1 and 2, and
then check solenoid operation.
• Apply battery voltage directly between terminals 1 and
2: Continuity should exist.
• No voltage: Continuity should not exist.
PTC Heater (Integrated with vaporizer)

Check the resistance between PTC heater terminal and ground.
Resistance:
1.5 - 2.0 (Engine coolant temperature 25C (77F))
158 EC-50
PCV GAS RECIRCULATION DEVICE
PCV GAS RECIRCULATION DEVI System Diagram
Component Parts Inspection

PCV valve
1. At idle, remove PCV valve together with hoses from rocker
cover.
2. Check if hissing sound is heard from the air passage when PCV
valve is operating normally.
ECM0144
3. Check air flow through the PCV valve and sucking air to/from
the INT end.
Blowing air: No air flow
Sucking air: Air flow exists
ECM0145
EC-51 159
ECM COMPONENTS
ECM COMPONENTS Removal and Installation

ECM
CAUTION:
Disconnect the negative battery cable from the battery.
1. Disconnect ECM connector.
2. Remove ECM together with ECM bracket.
3. Remove ECM bracket.
4. Install in the reverse order of removal.
CAUTION:
Perform “Throttle Valve Closed Position Learning and Idle Air
Volume Learning” after installation if replacing ECM. (Refer to
EC-42, “Throttle Valve Closed Position Learning and Idle Air
Volume Learning.”)
CRANKSHAFT POSITION SENSOR (POS)

5.4 - 7.4 N m
(0.55 - 0.75 kg-m, 1. Remove fan.
Crankshaft position 48 - 65 in-lb)
sensor (POS)
2. Remove harness connector.
3. Remove crankshaft position sensor (POS).
NOTE:
O-ring
• Make sure that there is no foreign material on sensor flange, O-
rings, and cylinder block.
• Keep away from magnetized objects.
: Engine oil
Front cover • Make sure that the sensor is inserted securely into front cover
: Not reusable
ECM0385 before tightening bolts.
Chain housing
CAMSHAFT POSITION SENSOR (PHASE)
1. Remove fan.
5.4 - 7.4 N m 2. Remove harness connector.
(0.55 - 0.75 kg-m,
48 - 65 in-lb) 3. Remove camshaft position sensor (PHASE).
NOTE:
O-ring • Make sure that there is no foreign material on sensor flange, O-
rings, and chain housing.
Camshaft position
• Keep away from magnetized objects.
: Engine oil
sensor (PHASE)
• Make sure that the sensor is inserted securely into cylinder
: Not reusable
ECM0386 head front cover before tightening bolts.
MASS AIR FLOW SENSOR

1. Remove harness connector.
2. Remove mass air flow sensor assembly from air horn.
160 EC-52
ECM COMPONENTS
Removal and Installation (Cont’d)

ENGINE COOLANT TEMPERATURE SENSOR
Engine coolant
temperature sensor 1. Disconnect radiator drain plug, and drain coolant.
12 - 16 N m
(1.2 - 1.6 kg-m, CAUTION:
9 - 12 ft-lb)
Make sure to drain when the coolant temperature is cold.
Copper washer 2. Remove harness connector.

3. Remove coolant temperature sensor using a socket specially
designed for removing and installing coolant temperature
: Liquid gasket sensors [commercially available: Thermosensor Socket
: Not reusable manufactured by KTC (part No.: B20T-19)] and similar parts.
ECM0387
HEATED OXYGEN SENSOR (WITH HEATED OXYGEN SENSOR

HEATER)
1. Remove harness connector from heated oxygen sensor.
2. Remove heated oxygen sensor using a socket designed for
heated oxygen sensor removal and installation (Service tool).
CAUTION:
Handle it carefully and avoid impacts.
MAP SENSOR (ATMOSPHERE PRESSURE SENSOR)

1. Remove harness connector from map sensor.
2. Remove map sensor.
EC-53 161

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ENGINE CONTROL

PRECAUTIONS On Board Diagnostic (OBD) System of

• Do not disassemble ECM.

PREPARATION Precaution (Cont’d)

• When connecting or disconnecting pin connectors into or

• Do not operate fuel pump when there is no fuel in lines.

• Do not depress accelerator pedal when starting.

PREPARATION Special Service Tools

EGI fuel pressure indicator For measuring fuel pressure gauge

GSE kit For system inspection and diagnosis

Check adapter V For control unit input/output signal inspection

Fuel changing (Gasoline and LPG) Combined

Control Item Fuel injection

Maximum vehicle speed control

Power ECO mode control

Fuel pump control

Idle speed control

Gasoline fuel pump  

TROUBLE DIAGNOSIS Component Parts Location

Actuators Gasoline injector High resistance Intake manifold  

Component Parts Location (Cont’d)

Sensors Crankshaft Crankshaft Hall IC (element) Front cover   

ECM Component (Cont’d)

REFERENCE VALUE LIST

ECM Terminal (Cont’d)

At idle after warming up Approx. 3V

At approx. 2,000 rpm Approx. 3V

14 Camshaft position sensor (PHASE) At cranking Approx. 0.15V

At idle after warming up Fluctuates between approx. 1.5 - 2V.

At approx. 2,000 rpm Approx. 2V

24 Heated oxygen sensor heater At idle after warming up Approx. 0.3V

ECM Terminal (Cont’d)

At approx. 2,000 rpm Changes between approx. 1 -

50 Throttle position sensor 1 At idle after warming up Approx. 0.6V

ECM Terminal (Cont’d)

ECM Terminal (Cont’d)

At idle after warming up Battery voltage

At approx. 2,000 rpm Relatively lower than battery voltage

Intake air temperature is approx. 80°C Approx.

ECM Terminal (Cont’d)

At idle after warming up Approx. 0.1V

At approx. 2,000 rpm Approx. 0.1V

73 Engine coolant temperature sensor Engine coolant temperature is approx. Approx.

Engine coolant temperature is approx. Approx.

ECM Terminal (Cont’d)

111 Self shut-off For approximately 10 seconds with Approx. 1V

120 LPG injector drive (L) Battery voltage

TROUBLE DIAGNOSIS How to Proceed with Trouble Diagnosis

2. It is also important to clarify customer concerns before starting

How to Proceed with Trouble Diagnosis

DIAGNOSTIC WORK SHEET

How to Proceed with Trouble Diagnosis

Diagnosis Chart by Symptom

Check that symptoms are detected with self-diagnosis.

Check that symptoms are in fail-safe condition.

During surge and constant speed driving

Engine over temperature (Overheat)

Poor fuel consumption efficiency

Fast idle is not effective

During a heavy load

Crankshaft position sensor OPEN       • An open circuit in either REF or

Momentarily              • The symptom depends on the

Mass air flow Signal OPEN             • It will be in fail-safe condition,