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Rm617e PDF
Rm617e PDF
Body Ground 9 14 V ‘Aways HINT: If your display shows "UNABLE TO CONNECT TO VEHICLE” when you have connected the cable of the hand-held tester to DLC, turned the ignition switch ON and operated the hand held tester, there is a problem on the vehicle side or tool side. (1) tf communication is normal when the tool is con- nected to another vehicle, inspect DLC3 on the orig- inal vehicle. (2) If communication is still not possible when the tool is connected to another vehicle, the problem is probably in the tool itself, so consult the Service De- partment listed in the tool's instruction manual.Dé DIAGNOSTICS _— ENGINE OFF OFF OFF 0.25 sec. 2. _ INSPECT DIAGNOSIS (Normal Mode) (a) Check the check engine warning light. (1) The check engine warning light comes on when the ignition switch is tuned ON and the engine is not running HINT: If the check engine warning light does not light up, troubleshoot the combination meter. (2) when the engine is started, the check engine wan- ing light should go off. If the lamp remains on, the jiagnosis system has detected a malfunction or ab- normality in the system. (b) Check the DTC using hand-held tester. NOTICE: When the diagnosis system is switched from normal mode to check test mode, it erases all DTCs and freezed frame data recorded in normal mode. So before switching modes, always check the DTCs and freezed frame data, and note them down. (1) Prepare the hand-held tester. (2) Connect the hand-held tester to the DLC3. (3) Turn the ignition switch ON and switch the hand held tester main switch ON. (4) Use the hand-held tester to check the DTCs and freezed frame data, note them down. (for operating instructions, see the hand-held tester’s instruction book.) (5) Confirm the details of the DTCs. (c) Check the DTC not using hand-held tester. (1) Turn the ignition switch ON. (2) Using SST, connect between terminals 13 (TC) and 4 (CG) of DLC3. ‘SST 09843-18040 (3) Read the diagnostic trouble code from check en- gine warning light. HINT: If a diagnostic trouble code is not output, check the diagnostic connector (DLCS) circuit (See page DI~100).DLT DIAGNOSTICS_— ENGINE One Cycle Start | Flashing ON OFF 0.18 Seconds ‘As an example, the blinking pattems for codes; normal, 12 and 31 are as shown on the illustration. (1) Check the details of the maifunction using the diag- nostic trouble code chart on page DI-14, (2) After completing the check, disconnect terminals 13 (TC) and 4 (CG) and turn off the display. HINT: In the event of 2 or more malfunction codes, indication will begin from the smaller numbered code and continue in order to the larger. NOTICE: When simulating symptoms without a hand-held tester to check the DTCs, use normal mode. For code on the DTCs chart subject to "2 trip detection logic”, turn the ignition switch OFF after the symptom Is simulated the first time. Then repeat the simulation process again. When the prob- Jem has been simulated twice, the check engine warning light lights up and the DTCs are recorded in the engine ECU. 3. _ INSPECT DIAGNOSIS (Check (Test) Mode) HAND-HELD TESTER only: Compared to the normal mode, the check mode has an in- creased sensitivity to detect malfunctions. Furthermore, the same diagnostic items which are detected in the normal mode can also be detected in the check (test) mode. (a) Check the DTC. (1) Initial conditions. + Battery positive voltage 11 V or more + Throttle valve fully closed. + Transmission in neutral position + Airconditioning switched OFF. (2) Turn the ignition switch OFF. (3) Prepare the hand-held tester. (4) Connect the hand-held tester to the DLC3. (5) Turn the ignition switch ON and push the hand-held tester main switch ON. (6) Switch the hand-held tester normal mode to check (test) mode. (Check that the check engine warning light flashes. (7) Start the engine. (The check engine warning light goes out after the engine start). (8) Simulate the conditions of the malfunction de- soribed by the customer. NOTICE: Leave the ignition switch ON until you have checked the DTCs, etc.DLs DIAGNOSTICS — ENGINE Interface Box Vehicle Hamess (9) After simulating the malfunction conditions, use the hand-held tester diagnosis selector to check the DTCs and freezed frame data, etc. HINT: ‘Take care not to turn the ignition switch OFF. Turing the ignition switch OFF switches the diagnosis system from check (test) mode to normal mode, so all diagnostic codes, etc. are erased. (10) After checking the DTCs, inspect the applicable cir- cuit. (b) Clear the DTC. The following actions will erase the DTCs and freezed frame data. (1) Operating the hand-held tester to erase the codes. (See the hand-held tester's instruction book for op- erating instructions.) (2) Disconnecting the battery terminals or ECD fuse. NOTICE: If the hand-held tester switches the engine ECU from nor- mal mode to check (test) mode or vice-versa, or if the igni- tion switch is turned from ON to ACC or OFF during check (test) mode, the DTCs and freezed frame data will be erased. () Measure the engine ECU terminal values using break- out box and hand-held tester. (1) Hook up the break-out-box and hand-held tester to the vehicle. (2) Read the engine ECU input/output values by follow- ing the prompts on the tester screen. HINT: Hand-held tester has a "Snapshot" function. This records the measured values and is effective in the. diagno- sis of intermittent problems. Please refer to the hand-held tester/break-out-box operator's manual for further details.DIAGNosTics — ENGINE 4. FAIL-SAFE CHART if any of the following codes is recorded, the engine ECU enters fail-safe mode. DTONo. Fall Sate Operation Fail Sate Deactivation Conditions 2.of more TOC signals are detected or 4 engine revolution 2 TOV duty is fixed at 90.0 % Fuel cut 13 TCV uy is fixed at 1.0 % 2 of more NE signals are detected for 0.5 sec. Close diesel that valve ‘Accelerator pedal Gosed position SW ON ‘Accelerator pedal positon i xed a 0% 1901) | acoelerator pedal closed positon SW OFF ‘Accelerator pedal postion is xed at 8 % aaa ba min SON oO ‘Accelerator pedal postion i fixed a0 % +BOFF 4BOFF 19(2) | Accelerator pedal closed poston SW OFF ‘Accelerator pedal positions fed at 8% Accelerator pedal poston below 10% BORE ‘When tho ilo SW is faulty ‘Accelerator pedal closed postion SW ON: ‘Accelerator pedal postions fixed at 0% | +8 OFF ‘Accolrator pedal closed postion SW OFF: ‘Accelerator pedal positon is fhked at 8% 19(9) When the ile SW is okay. lle SW ON ‘Accelerator pedal poston i fixed at 0% | 48 OFF ide SWOFF ‘Accelerator peda poston below 10 % 19(4) [Accelerator pedal postion below 10% +B OFF, 2 Engine coolant temp. is fixed at 100°C (212°F) Fetum to normal condition 2 Tetake ai temp. fixed at 20°C (68°F) Return to normal condition 3 Intake air pressure is fixed at 101.3 KPa (760 mm, 30 n-Hg) | Return to normal conation % Fuel tmp. fixed at 60°C (140°F) Return to normal conetion 2 Vehicle sped fixed at Okra (0 mph) Vehicle speed > 0 kv (0 mph 5. CHECK FOR INTERMITTENT PROBLEMS HAND-HELD TESTER only: By putting the vehicle's engine ECU in check (test) mode, 1 trip detection logic is possible instead of 2 trip detection logic and sensitivity to detect open circuits is increased. This makes it easier to detect intermittent problems. (a) Clear the DTC (See page DI-4). (b) Set the check (lest) mode (See page DI-4), (©) Perform a simulation test (See page IN-8).. (d) Check the connector and terminal (See page IN-19). (e) Handle the connector (See page IN—19).DH10 DIAGNOSTICS — ENGINE 6. BASIC INSPECTION ‘When the malfunction code is not confirmed in the DTC check, troubleshooting should be carried out in the order for all possible circuits to be considered as the cases of the problems. In many cases, by carrying out the basic engine check shown in the following flow char, the location causing the problem can be found quickly and efficiently. Therefore, use of this check is essential in engine trouble- shootin. 1 |Is battery positive voltage 11 V or more when engine is stopped ? v0) Charge or replace battery. YES nN 2 |Isengine cranked ? No \\| Proceed to problem symptoms table on page DE-19. — _ YES Nn 3. | Check air filter (See page EM-1). [J 4 | Check fuel quality. NG_)| Repair or replace. CHECI + Check that use only diesel fuel + Check that the fuel does not contain any impurity. ne) Replace fuel. OKDEM DIAGNOSTICS_—_ENGINE 5 | Check engine oil (See page LU-1). ne) Repair or replace. OK 6 | Check coolant (See page CO-1). 7 | Check injection timing (See page EM-14). [*] NG | Replace coolant. NG _ | Adjusting injection timing. 8 | Check idle speed and maximum speed (See page EM-17). > Repair or replace injection pump. OK — 9 | Check diagnostic connector (DLC3) circuit (See page DI-100). NG_ | Repair or replace. oKDH12 DIAGNOSTICS _—_ENGINE 10 | Check vacuum pump (See page EC-3). > Repair or replace, oK Proceed to problem symptoms table on page DI-19. 7. _ REFERENCE VALUE OF ENGINE ECU DATA NOTICE: The values given below for "Normal Condition” are repre- sentative values, so a vehicle may still be normal even if its values from those listed here. So do not decide whether a partis faulty or not solely according to the "Normal Condi- tion” here. HINT: Engine engine ECU data can be monitored by hand-held tes- DLCs ie (a) Connect the hand-held tester to the DLC3. (b) Monitor engine ECU data by following the prompts on the tester screen. Please refer to the hand-held tester operator's manual for further detailD3 DIAGNOSTICS _~_ENGINE (©) _ Reference Value item Inspection Condon Reference Value Engine ating “1 412mm? INJECTION VOLUME [Engine racing at 2000 pm 48mm Engin racing at 3,000 rpm “1 5-9 mm i Engine ating “1 17.0-19.0°CA INJECTION TIMING [Engine racing at 2,000 pm" W7—15.7°CA. Engine racing at 8,000 rpm “1 17.0=230°CA, ENGINE SPO) RPM kept stable (Comparison with tachometer No great changes = 11 KPa Ege ating (20-50 mg. 250-3280) ted Engine racing at 2,000 rpm “1 97-117 KPa Engine racing at 3,00 rpm “1 110 190KPa (COOLANT TEMP Engine at normal operating temo. 75~95°0 (167 —209°F)-2 INTAKE AIR Engine at normal operating temp. ‘Ambionttemp.— 140°C FUEL TEMP: Engine anormal operating temp. ‘Ambient temp. —65°C ‘Accelerator pedal tly Gosed 0-20% ACCELE POSITION [Accelerator peda uly opened 59—100% From closed poston to wide open aeceloratorpodal ‘Gradvaly increases VEHICLE SPD During erving (Comparison wih speed moter) No large diferences AC SIG [AiG switch ON on. DL SIG Accelerator pedal ful closed ON STARTER SIG uring ranking ON ‘AC CUTSIG [NG switch OFF ON EGR SYSTEM ing ON NSW" Neutral start svtch signal or N poston ON PS OIL PRESS SW Power storing oll pressure switch signal “Tum stoeting wheel: ON ‘ACCEL CLOSE SW [Accelerator pedal uly dosed on. HINT: "1: All accessories and A/C are switched OFF. "2: If the water temp. sensor circuit is open or shorted, the engine ECU. *3: ATT onlywe ENGINE. Discwosmics _— — DIAGNOSTIC TROUBLE CODE CHART HINT: ' : Parameters listed in the chart may not be exactly the same as you reading due to the type of instrument or other factors. 1a malfunction code is displayed during the DTC check in check(test) mode, check the circuit for that code listed in the table below. For details of each code, turn to the page referred to under the "See Page” for the respective "DTC No." in the DTC chart. a ChockEngine |.» ae Waring Light Detection item Trouble Area, ng Lg (S00 Page) (NormaMode’ | M0" Test Mode) Open or shor in crankshaft postion sensor circuit 12 |(rankshaft Postion Sensor "OP ae ony ° (0L21) | Circuit Maltuncion SegEvEGU Open or shorn engine speed sensor circuit 12 | Engine Speed Sensor Grcut | +Engine speed sensor oo . (0-29) | Mattunction /+Open or shortin STA circuit Engine ECU. Open or shor in timing control valve circuit + Fuel iter (Clogging) ae ls (Contsol System + Fuel Freezing, Airin) — 2 ore ‘Injection pump (internal pressure and timing control valve) Engine ECU 17 [nero Matuncton Engine ECU ona | O {ony | AttleraorPedal Postion | “Open or hort in accelerator pedal potion sensor creut (0-27) ‘Sensor Circuit Malfunction + Accelerator pedal position sensor ONION ° (Open Shon) Engine ECU 1o1a) | Aetlrator Pal Postion | Open or shor in czlorator dal pasion sensor ret (Ones) | SensorceutMatinetin | eAcclerator pata pston sensor onna | 0 (OL Swich/ Range) Engine ECU oye) | Aerator Poca Closed Post | -Shorn accelerator pedal dosed postion awich cout (ory |YnSwich cut Matuncion | -Accolerator pedal eased poston switch ona | oo (Shoe) +Engine ECU ae toa) | Asleraor Pedal Giosoa Post | -Openin acoso podal dosed postion wich cout (baa) |" Sten Creu Natnction | +Acceleratr pedal sed poston sich onna | 0 (Open) Engine ECU Open or shot in wala tmp. sensor cout Water Temp, Sensor Cie 2 eee ‘+ Water temp. sensor ONION, fo} (Obs1) | Mattunction Engine ECU *1:"ON" displayed in the diagnosis mode column indicates that the check engine warning light is lighted up when a malfunction is detected. "N.A.” indicates that the item is not included in malfunction diagnosis. *2:"O" inthe memory column indicates that a diagnostic trouble code is recorded in the engine ECU memory when a malfunction occurs. Accordingly, output of diagnostic results in normal or test mode is done with the IG switch ON.Dis DIAGNOSTICS _— ENGINE 7 a create | bento lean vero era a : aad (NormaiMode! | M "ea '*Open or short in intake air temp. sensor circuit ox atop Snort (ore) | Mat celia ‘+Intake air temp. sensor OFFION ° non “engneEOd *Open or shor in injection pump correction unit cuicuit | netoaroe atm oy |i “epg crm | o ron “Cre we ortnasGoonten | Se nena Saabs corey |tatocen pe 25 | Tuo Pressure Setar crcut | “OPH shot no presse sense : (ors fiat “Ton won 22 [fran snare [open ate tow sre cot onon | 0 corey fate “Fat “Oreo sen wioe de Sa tz |wcespnssousrsona | vonce nonce (01-69) | Circuit Matfunction '*Combination meter om eres a [reer Camas [rors ou cma [6 97 /*Open or short in EDU circuit covcicatincion | Sper oma | o “Ogee tn bn wa ao ‘ catorsnhenn 2 | emesis Bo feeeestinreeal e + Transponder key computer OFFINA, ° van “rte “ened “1:"ON" displayed in the diagnosis mode column indicates that the check engine warning light is lighted up when a malfunction is detected. "OFF" indicates that the “CHECK ENGINE" does not light up during malfunction diagnosis, even if a malfunction is detected. "N.A.” indicates that the item is not included in malfunction diagnosis. *2:"0" in the memory column indicates that a diagnostic trouble code is recorded in the engine ECU memory when a malfunction occurs. Accordingly, output of diagnostic results in normal or test mode is done with the IG switch ON. *3: See Pub. No. RM616E1 BE section.ie ENGINE piagosmics_— PARTS LOCATION \VSV for Turbo Pressure Sensor Shift Position Switch (M/T) VSV for EGR _ Neutral Start Switch (AT) Turbo Pressure Sensor Intake Air Temp. Sensor Engine ECU Intake Heater VSV for Intake Shutter ‘Accelerator Pedal Switch ‘Actuator for L] SJ Spill Valve Relay (Marking: SPILIVLV) Lc3 EGR Valve, ECD Main Relay (Marking: ECD) Crankshaft Position Sensor PS Oil Pressure Switcty Water Temp. Sensor Engine Speed Sensor Spill Control Valve Fuel Temp. Sensor PUMP ROM (Injection Pump Correction Unit)DHoi7 DIAGNOSTICS — ENGINE Engine ECU Terminals ED @ @ @ n n Bathory a ape apap opel y ab ey sa TAT Pot spay ayatey petra [os Tse pslododasladz ipl dialrhilshil belishalaialviiolo) lizlvhol a el7| belesaolohalirhajsh|ala oO a) Ty cI Syrisermrals No) [Wig Goer Conaten STO vonage) BATT (e1e-1)-E1 17-14 | e-A-eR [Aways a1 +B (E1a-12)e1(e17-14 [| _BY=8R | GemicnOn ona Vo(E16-1)-E2 616-9) | R-BRW [IG etcn ON 45-55 Voc (16-6) - £20 (E184) | L-R-BR-W [IG emicn ON 45-55 Accelerator paa uy ed e818 VA (E18-5) ~ E20 (E18-4) PLY-BR-W my Accra peda uly pened 28-45 ‘Acclalor pul uy ose 06-13 VAS (E18-12) — E20 (E18-4) P4-BR-W = Acolrtr peda uy opened 28-45 Acclrator padal uy sed oo IDL (E18-9) ~ E2C (E18-4) LG-B-BR-W pedalivty Acclarao peda ity opened o-a Pop vacum 40a S00 mg HO To-te PIM (E16-2) —E2 (E16-9) P4-BR-W “ 2 Apply vacuum 135 kPa (1,000 mmHg, 39.4 in.Hg)_ 23-42 Trim 169216168) | WHS BAW [ang rink temp 0°C 92°F) 19 60°C (40H 02-38 Te ire-a2 ese wi | erat en wal ai oasaaniener oan wimio ae yl) alors BA _oR-W"T Tar e165) -e2e1-9) PERHPRM Ag stan oat nga cot) os-ae @A-eR-wee SAC -ereT) | ewer |oaning Soom TOs (E17-17)=TOC- rice generation (E1716) ca ald (See page DI-21) use generation neveraig-ne er} L-0 fing ue generation TG ontch ON sreeo-ciemo | veer [CeMenOn Pals geneaton 1G swich ON na rover corer) | rey-ws | Pulse goneraton abe (See page DI-24) Seve err=va)— evei7-14 | van [iG omen on s-14 use generaion sovecerra5-erera | Laer |taing = EGR (17-24) - E01 Geren — e17-13)| FE-W8 | ecpon Pulse generation (Seo 890-85) 4: LHD *2:RHDpes DIAGNOSTICS — ENGINE 7 ‘Symbols (TeminaisNo} | _Wiring Color Cenaiton ‘STO VotageV) VSV OFF (ing) o-14 erm er7-19-€01 17-19) | WL W8 PET eam ass SV for atmasphes pressure wearing OFF n14 201 (e171 -we gee, jones {SV for aumosphoi pressure tearing ON 0-3 MREL E18-9) E01 E1713) | _BW-WB [1G wich ON 14 TSW (E1614) EN(E17—14) | _B-A-BA__|Gswtch ON 14 an [ACS ON arising 9-15 acrere2)-er (err) | we-pR FE rari sich ON oni ree ‘ANG cut conto ACTIEI-S)-EI (EIT I4) | LB=BR__ Jing blow 30 kn, acelrator pedal tly opened for o-s 5s2e) onan [A=zersor pel y cased on 14 4 (e17= A PDL (E18-9) Et (E17-14) a pa as TAG (E16-7)— EF E1714) 2-0R _[1oing Pulse generation To (€19-4) 1 (€17-14) P-8—8R__[iGswich on 9-14 Check engine warning ight ighs up 0-3 1 (E17-14 weer eer Except check engine warning ght igh up ga14 (Gow inciator ight igs up o-3 ono ere4)-er e714) | v-r-en FE Except glow incicto light ghs up a8 DATA(EIG-6)—E1(E17-14) | G-B-BA | For05 00 after IG wich ON Pulse generation CLK (E16-14)—E1(E17—14) | G-W—BA |For 05-soc. ator IG swich ON Pulse generation Pause generation THWO(EIS-8)-E1(E17-14) | ¥-B-BR | 1G switch ON one IG ewich ON 0-3 Eonc(e17-9)-Er 17-19) | ABR Maintain engine speed at 1500 1pm ater waming up on IG swich ON 0-8 REL (E19-2)~€1 17-14, | G-Y-8R —| Alinake heater ON oe Pause generation [sPvo (€17-12)—E1 (E1714) | Lev t (617-12) £1 (€17-14) BA} ing cna Heater blower ew Zi vou (e17-29)-E1 E1714 | YR-8R ten it Heater blower switch OFF oa [svn e119) (e714 | wR [IG ewich ON [Oo-is 4 Heat biowor ow zi Vor (e16-7)-€1€17-14 | Leen | Hesterblowerewich On = Heater blower switch OFF a1 sh on power hear switch = How(ers-20)-E1€17-14) | e1—en PPeP oes Push of power heater wich oe i in rst pos = Fsweeren-erer14 | rian [A stpestionin tet poston a ‘other hit pesto ines postion o-3) ing, Tur steering whoo = PS €16-8)-E1 (E1714) Peon oe IG switch ON a SL (EI15)—E1 17-14) | v-W=BA _ | Connect hand-hetdester to DLOS Pulse generation IMEI -ENEV7—14) | C8—BA__ | ding Pulse generation WMO (619-6) =E1(€17-14) | -8-8R | Atowsee. ater engine sang Pulse ganeraionDH9 DIAGNOSTICS _— ENGINE PROBLEM SYMPTOMS TABLE When the malfunction code is not confirmed the DTC check and the problem still can not be confirmed in the basic inspection, then proceed to this step and perform troubleshooting according to the numbered order given in the table below. Sree Sapa Sopa Taare sr-a0 Dees ne crank ts sa) Sry ora Sch ere cst AT) ore ine er erat oF80 Stason ors {huaeiip ote ons cota tio st ctor ee Sra rs f-tnone EU on > mp an 1 Stas ck br 2 inert ross rain etek oat Piel on Seronoetu mor sng poe ros 1 Fil Rit 2 ECUpomer once ro soon str sng Es 2 Ener soe tt oe ono ros 1 ECU pve ee Sat ove 2 Siar ly ra outs hie oa 8. Engine ECU ED-17 cro po roe 1 Fs te a ere ti Pore 2 Eng EU oe anon pa iia 1 NO soo nas 2 Stason Ew hero te sed Posi ee : ba 3. Engine ECU E0417 presetad nos 1 AC sr ere one Einar nao re 2 eamcoetoret Bes Corps fet Lower engine idle speed (Poor i - mo a 5. Valve clearance: M9 2 ratio tot : 1 Ege E00 eo econ ep a eon ia 2 Peano he z {nae col ce oreo Enna seat Rough idling (Poor idl : DS ma) a 5. Compression EM? 2 va ceaee aie ‘eng tou mon fran rosENGI ‘Symptom ‘Suspect rea See page {injection nozzle rus 2 ECU power source cout o-76 3. Compression eme Hunting at hot engine (Poor ting) 4. Fue line (Air boed) . 5. Valve clearance Ems 6.Engine ECU 0-17 nection pump runs 1- Injection nozzle rua 2. ECU power source cieuit Di76: 3. Intake heater contro circuit Die 4. Compression eM Hunting at cok engine (Poor ting) eee = 6. Valve doarance emo 7. Engine ECU £0.17 8. Injection pump Fung 1- Injection nozzle FU-86 2. Fual iter Fut 3. EGR conto cuit Dies, Hesitation! Poor acceleration (Poor criveabity) bypsectaatet ae 5. Engine ECU 0-17 6. nection pump Fura 1 Injection nozzle FU-36 Knocking (Poor ckveabilty) 2. EGR control creuit ores: 3. Engine ECU e017 1. rjection nozzle FU6 2. EGR contol ert bbs Black smoke (Poor iveabil : a. 8. Engine ECU 0417 4 Injection pump runs EGR contol cicut Dees: 2. Intake heater contro circuit Di80 8. nection nozzle Fu-36 ‘White smoke (Poor criveabt u Y 4 Fuel iter Fut 8. Engine ECU eD-17 6. Injection pump Fut "Injection nozzle Fue ‘Surging! Hunting (Poor ceivesbilty) 2. Engine ECU 0-17 3. Injection pump Fusn9Di2t DIAGNoSTICS_—_ENGINE CIRCUIT INSPECTION DTC 12 Crankshaft Position Sensor Circuit Malfunction CIRCUIT DESCRIPTION The crankshaft position sensor in the Engine Control System contains signal plate and a pickup coil for TDC signal. The TDC signal plate has 1 tooth on its outer circumference. The TDC signal sensor generates 1 signal for every engine revolution. The engine ECU detects the top dead center by the TDC signals. The engine speed sensor in the Engine Control System contains signal plate and a pickup coil for NE signal. ‘The NE signal plate has 78 teeth and is mounted in the injection pump. The NE signal sensor generates 78 signals of engine 2 revolutions. The engine ECU detects the engine speed and cam lift position of the injec- tion pump. The engine ECU uses TDC signal and NE signals for injection timing control. And NE signal is used for injection volume control, also. DTONe. DIC Detecting Condition Trouble Area ‘Open or shonin crankshat postion sensor cout 12 | No TDC signal to engine ECU at 400 rpm or more ‘Crankshaft poston sensor +Enging ECU TDG Signal Waveforms Reference: INSPECTION USING OSCILLOSCOPE During cranking or idling, check between terminals TDC+ and ‘TDC- of engine ECU. HINT: The correct wavaforms are as shown. aviv 20msec./Division(Ialing) yrs WIRING DIAGRAM Crankshaft Position Bene Engine ECU Engine Speed Sensor (inside the Injection Pump)Di-22 DIAGNOSTICS _—_ENGINE INSPECTION PROCEDURE 1 | Check resistance of crankshaft position sensor (TDC) (See page ED-8). > Replace crankshaft position sensor. [J 2 | Check for open and short in harness and connector between engine ECU and crankshaft position sensor (See page IN-19).. > Repair or replace harness or connector. [oJ 3. | Inspection sensor installation. > Tighten sensor. [«] ‘Check and replace engine ECU (See page IN-19).DI-23 DIAGNOSTICS_—_ENGINE DTC 13 Engine Speed Sensor Circuit Malfunction CIRCUIT DESCRIPTION Refer to DTC12 (Crankshaft Position Sensor Circuit Malfunction) on page Di-21. DIONe. DTC Detecting Condition “Trouble Area 'NONE signal to engine ECU for 0.5 sec. or more at 580 rpm oF No NE signal to engine ECU for 2.0 sec. or more during crank ing +‘Opon or shor in engine speed sensor circuit + Engine speed sensor +Engine ECU WIRING DIAGRAM INSPECTION PROCEDURE Refer to DTC12 (Crankshaft Position Sensor Circuit Malfunction) on page DI-21. 1 ones resistance of engine speed sensor (See page FU-113). NG \\| Check and replace injection pump (See page FU-113). [J engine speed sensor (See page IN-19). 2 | Check for open and short in harness and connector between engine ECU and NG | Repair or replace harness or connector. [J 3 | Inspection sensor installation. re) Tighten sensor. OK Check and replace engine ECU (See page IN-19).Di24 DIAGNOSTICS — ENGINE DTC 14 Timing Control System Malfunction CIRCUIT DESCRIPTION The engine ECU control the injection timing by actuating the timing control valve. The timing control valve is mounted on the injection pump and delay one by duty control of pump internal fuel pressure. The engine ECU detects the injection advance angle by TDC and NE signals. DTONe, DTC Detecting Condition Trouble Area, ‘Alter engine warm up and during, actual injection timing is itferent trom target valu of engine ECU calculated for several ‘Open oF shor in iming control valve circuit ‘Timing control valve + Fue iter (Clogging) + Fuel (Freezing, Airin) + Injection pump (Internal pressure and timing contol valve) +Engine EOU WIRING DIAGRAM Engine Room J/B Engine ECU ; £00) Epona 2 Be B-¥_[]v18iC (LHD) (SSH Jit ic HD) gMain Fusible Link Block Timing ControlINSPECTION PROCEDURE Di-25 DIAGNOSTICS _—_ ENGINE 1 | Check timing control valve (See page FU-113). («J NG \\| Check and replace injection pump (See page FU-113). 2. | Check voltage between terminal TCV of engine ECU connector and body ground. ‘ON E17 Connector NG —— PREPARATION: (a) Remove the glove compartment door. (b) Disconnect the "E17" connector of engine ECU. (c) Turn the ignition switch ON. CHECK: Measure voltage between terminal TCV of engine ECU con- nector and body ground. Ok: Voltage: 9-14V > Go to step 3. Check for open or short in harness and connector between timing control valve and engi timing control valve and ECD main relay (Marking: ECD) (See pege IN-19).. engine ECU,i268 DIAGNOSTICS = ENGINE. Check voltage between terminal TCV of engine ECU and body ground. ev Tov 1 TCV Signal Waveforms 10V/DIV| |Omsec/ Division (Idling) ace («J PREPARATION: (@)_ Remove the glove compartment door. (b) Tum the ignition switch ON. (CHEC! Measure voltage between terminal TCV of engine ECU and body ground. a1 “~~ Voltage: 9-14 V Reference: INSPECTION USING OSCILLOSCOPE During idling, check waveform between terminals TCV and E1 of engine ECU. HINT: The correct waveform is as shown. Check and replace engine ECU (See page INNIS. re) 4 Check fuel filter clogging, fuel freezing and fuel air in. iJ Replace or repair. > Check and replace injection pump (See page FU-113).Di27 DIAGNOSTICS _—_ ENGINE DTC 19(1) | Accelerator Pedal Position Sensor circuit Malfunction (Open /Short) CIRCUIT DESCRIPTION The accelerator pedal position sensor is mounted at the accelerator pedal and detects the accelerator pedal opening angle. When the accelerator pedal is fully closed, a voltage of approximately 1.0 V is applied to ter- minals VA, VAS of the engine ECU. The voltage applied to the terminals VA, VAS of the engine ECU in- creases in proportion to the opening angle of the accelerator pedal and becomes approximately 3.8 V when the accelerator pedal is fully opened. The engine ECU judges the vehicle driving conditions from these sig- nals input from terminals VA, VAS and uses them as one of the conditions to control the injection volume and diesel throttle valve position. The idle switch is mounted in the accelerator pedal position sensor and sends the IDL signal to the engine ECU when accelerator pedal is fully closed. This system has 2 way accelerator pedal position sensor and accelerator pedal closed position switch for fail safe. DTC Ne, (DTC Detecting Gonaition Trouble Area, ‘Open or short in accelerator pedal postion sensor cult + Accelerator pedal poston sensor Engine ECU ‘Open or shor in accelerator pedal postion sensor cult for 191) | 0.08 see. or more HINT. After confirming DTC 19 (1) use the hand-held tester to confirm the accelerator pedal opening percentage and accelerator pedal close position switch condition. ‘Acoelerator pedal opening postion expressed as percentage “Trouble area ‘Accelerator peda uly closed ‘Accelerator pedal fully open ‘VCC line open 0% 0% \VA, VAS line open or short ‘Approx. 100% ‘Approx. 100% 2G line openDi-28 DIAGNOSTICS —_ENGINE WIRING DIAGRAM ‘Accelerator Pedal Position Sensor Engine ECU Accelerator Pedal Closed Position Switch BR s7sIC BR BR ALIA >xfINI ED (LHD) ) Y EC (RHD)Di-29 DIAGNOSTICS_—_ENGINE INSPECTION PROCEDURE When using hand-held tester 1 | Connect the hand-held tester, read the accelerator pedal opening percentage. PREPARATION: (@) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the hand-held tester main switch ON. CHECK: Read the accelerator pedal opening percentage. Ok: ‘Accelerator pedal opening postion Accelerator pod rat expressed as percentage: aly open Aero. 65% uly dosed ‘Approx. 18% OK \\] Check for intermittent problems (See page DI-4). [J 2 Check voltage between terminal 4 of wire harness side connector and body ground. om PREPARATION: @ a (@) Disconnect the accelerator pedal position sensor con- nector. (b) | Turn the ignition switch ON. c iy V CHECK: XS Jy oO Measure voltage between terminal 4 of wire harness side con- a + | nector and body ground. oO so ose Voltage: 4.5-5.5V > Go to step 5.Dr30 DIAGNOSTiCs_—_ENGINE 3 | Check voltage between terminals VA, VAS and E2C of engine ECU. PREPARATION: (@) Remove the glove compartment door. (b) Tum the ignition switch ON. CHECK: Measure voltage between terminals VA, VAS and E2C of en- gine ECU. ol Fewer po Ty cbse ov yen I 28-48 o*) Check and replace engine ECU (See page IN-19). [J 4 | Check for open and short in harness and connector between engine ECU and accelerator pedal position sensor (VA, VAS line) (See page IN-19). [«] Replace accelerator pedal position sensor. NG )| Repair harness or connector.DEs1 DIAGNOSTICS _— ENGINE 5 | Check voltage between terminals VCC and E2C of engine ECU. Q” vec 2c Lo] PREPARATION: (@) Remove the glove compartment door. (b) _ Turn the ignition switch ON. CHECK: Measure voltage between terminals VCC and E2C of engine ECU connector. Ok: Voltage: 4.5-5.5V re) Check and replace engine ECU (See page IN-19). ‘sensor (VCC line) (See pat Check for open in harness and ¢ Se between engine ECU and accelerator pedal position When not using hand-held tester ground. 1 | Check voltage between terminal 4 of wire harness side connector and body ‘ON 4 t 7 CUL ey AW; i [«] PREPARATION: (@) Disconnect the accelerator pedal position sensor con- nector. () Tum the ignition switch ON. CHECI Measure voltage between terminal 4 of wire hamess side con- nector and body ground. ol ~~ Voltage: 4.5 -5.5V NG | Go to step 4.pi32 DIAGNOSTICS _— ENGINE 2 | Check voltage between terminals VA, VAS and E2C of engine ECU. ON PREPARATION: (b) Turn the ignition switch ON. CHECK: (@) Remove the glove compartment door. Measure voltage between terminals VA, VAS and E2C of en- gine ECU. Ok: Accelerator pda votage Fuly coved 06-199 Fuly open 28-45 OK \\ Check and replace engine ECU (See page IN-19). [»« J 3 | Check for open and short in harness and connector between engine ECU and accelerator pedal position sensor (VA, VAS line) (See page IN-19). NG_ | Repair harness or connector. [«] Replace accelerator pedal position sensor.DI-33 DIAGNOSTICS_—_ ENGINE 4 | Check voltage between terminals VCC and E2C of engine ECU. @ ON vec Eec [J PREPARATION: (@) Remove the glove compartment door. (b) Turn ignition switch ON. CHECK: Measure voltage between terminals VCC and E2C of engine ECU connector. or Voltage: 4.5- 5.5 V Check and replace engine ECU NG » (See page IN-19). ‘sensor (VCC line) (See page IN-19). Check for open in harness and connector between engine ECU and accelerator pedal positionDi34 DIAGNOSTICS = ENGINE DTC 19 (2) | Accelerator Pedal Position Sensor Circuit Malfunction (IDL Switch/Range Malfunction) CIRCUIT DESCRIPTION Refer to DTC 19 (1) (Accelerator Pedal Position Sensor Circuit Malfunction (Open/Short)) on page DI-27. DTC No. DTC Detecting Conciion “Trouble Area ‘Conaition (a) oF (6) continue 0.5 sec, or mor: (@) IDL ONand VA> 1.4 (6) IDL ONand VAS >1.4V Condition (a) or (@) continue 0.5 see. or mor: Open or sent in accolerator pedal postion sensor circuit 19) | (a) IDLOFFandVA<06V + Aceolorator pedal postion sensor (b) IDL OFF and VAS <0.6 V Engine ECU ‘Conditions (a) and (b) continue 0.05 see. or mor! (@)08V0.5 V WIRING DIAGRAM Refer to DTC 19 (1) (Accelerator Pedal Position Sensor Circuit Malfunction (Open/Short)) on page DI-27. INSPECTION PROCEDURE When using hand-held tester 1 | Connect the hand-held tester, read the IDL signal. PREPARATION: (a) Connect the hand-held tester to the DLC3. (b) Tum the ignition switch ON and push the hand-held tester main switch ON. CHECK: Read the IDL signal. Ok: ‘Accelerator pod IDL signal Fully open OFF Fully losed on > Goto step 4. NGDIAGNOSTICS _— ENGINE DI-35 2 | Check voltage between terminals IDL and E2C of engine ECU. PREPARATION: (@) Remove the glove compartment door. {b) Tum the ignition switch ON. CHECK: Measure voltage between terminals IDL and E2C of engine [J ECU. Ok: ‘Accelerator pedal vottage Fully closed aay Fully open o-3v Ok \,| Check and replace engine ECU (See page IN-19). 3 | Check for open and short in harness accelerator pedal position sensor (IDL line) (See page IN-19). connector between engine ECU and [«] ve) Repair harness or connector. Replace accelerator pedal position sensor. (See page DI-27 , Step 1). 4 | Connect the hand-held tester, read the accelerator pedal operating percentage [x] OK \\| Check for intermittent problems (See page Di-4).DE36 DIAGNOSTICS_— ENGINE 5 | Check voltage between terminal VCC of wire harness side connector and body ground (See page DI-27, Step 2). > Go to step 8. [*] 6 | Check voltage between terminals VA, VAS and E2C of engine ECU (See page DI-27, Step 3). OK \\| Check and replace engine ECU (See page IN-19). Le] 7 | Check for open and short in harness and connector between engine ECU and accelerator pedal position sensor (VA, VAS line) (See page IN-18). NG_)| Repair harness or connector. Replace accelerator pedal position sensor. 8 | Check voltage between terminals VCC and E2C of engine ECU (See page DI-27, Step 5). NG \\| Check and replace engine ECU (See page IN-19). [*] Check for open in harness and connecter between engine ECU and accelerator pedal position sensor (VCC line) (See page IN-19)..DI-87 DIAGNOSTICS —_ ENGINE When not using hand-held tester 1 | Check voltage between terminals IDL and E2C of engine ECU. ON or PREPARATION: @ Eee (@) Remove the glove compartment door. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals IDL and E2C of engine ECU. Ok: = ‘Accelerator pedal Votage reste so Fully closed o-uv Fully open 0-3v «> Go to step 3. NG nN 2. | Check for open and short in harness and connector between engine ECU and accelerator pedal position sensor (IDL line) (See page IN-19). NG_)| Repair harness or connector. oK —— Replace accelerator pedal position sensor. 3 | Check voltage between terminal 4 of wire harness side connector and body- ground (See page DI-27, Step 2). [«] ve) Goto step 6.Di38 DIAGNOSTICS _— ENGINE 4 | Gheck voltage between terminals VA, VAS and E2C of engine ECU (See page Di-27, Step 3). OK \\| Check and replace engine ECU (See page IN-19). [J 5 | Check for open and short in harness and connector between engine ECU and accelerator pedal position sensor (VA, VAS line) (See page IN-19). > Repair harness or connector. [«] Replace accelerator pedal position sensor. 6 | Check voltage between terminals VCC and E2C of engine ECU (See page DI-27, Step 5). NG \ | Check and replace engine ECU (See page INNIS). [J Check for open in harness and connector bet Sensor VCE ane) anes and connector between engine ECU and accelerator pedal positionDIAGNOSTICS _— ENGINE DTC 19 (3) | Accelerator Pedal Closed Position Switch Circuit Malfunction (Short) DTC 19(4) | Accelerator Pedal Closed Position Switch Circuit Malfunction (Open) CIRCUIT DESCRIPTION Refer to DTC 19 (1) (Accelerator Pedal Position Sensor Circuit Malfunction (Open/Short)) on page DI-27. (b) VA> Ful closed study votage +0.41 V (6) VAS > Fully closod study voltage 40.41 V STONE DTC etna Caron Tie wea Cae (and (0) oie 008 oma Const, @)aacotnn 05 “Satin crt padal cored poston owe 190 eer pda Seed poston en Engine EOU 1944) PDL does not tun ON even once while driving vehicle (2 tip detection loge) ‘Conditions (a) and (b) continue 5 sec. or more: (a) POL OFF (b)1OL ON, Open in accolerator pedal closed poston switch ecuit erator pedal closed position switch + Engine ECU WIRING DIAGRAM Refer to DTC 19 (1) (Accelerator Pedal Position Sensor Circuit Malfunction (Open/Short)) on page Dl-27.DL40 DIAGNOSTICS _—_ ENGINE INSPECTION PROCEDURE 1 | Check accelerator pedal closed position switch. PREPARATION Disconnect the accelerator pedal closed position switch con- nector. CHECK: Measure resistance between terminals of accelerator pedal closed position switch. OK: Terminals ‘Accelerator pedal Resistance a 122 Ful closed a 1-2 Fuly open 0-208 NG \, | Replace accelerator pedal closed position switch (See page ED-9). [*] 2 | Check voltage between terminal PDL of engine ECU and body ground. ON a PREPARATION: @ (a) Remove the glove compartment door. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminal PDL of engine ECU and body ground. Ok: pezara pada vetage uly cose e-1v Fly open onav (See page IN-19), > Check and replace engine ECU [J Check for open and short in harness and connector between engine ECU and accelerator pedal closed position switch and body ground (See page IN-19). beDat DIAGNOSTICS _—_ ENGINE Resistance k 200 20 40 60 80 100 (4) (32) (68) (108) (140) (176) (212) ‘Temperature °C (°F) DTC 22 Water Temp. Sensor Circuit Malfunction CIRCUIT DESCRIPTION ‘The water temperature sensor senses the coolant temperature. A thermistor built into the sensor changes the resistance value (Fig.1) according to the coolant temperature. The lower the coolant temperature, the greater the thermistor resistance value, and the higher the coolant temperature, the lower the thermistor re- sistance value (See Fig.1). The water temperature sensor is connected to the engine ECU (See below). The 5 V power source voltage in the engine ECU is applied to the water temperature sensor from the terminal THW via a resistor R. That is, the resistor R and the water tem- perature sensor are connected in series. When the resistance value of the water temperature sensor changes in accordance with changes in the coolant temperature, the potential at the ter- minal THW also changes. Based on this signal, the engine ECU increases the fuel injection volume to improve driveability dur- ing cold engine operation. Water Temp. Sensor DIC No. DIC Detecting Condition Trouble Area Open or shor in water temp. sensor circuit 2 (Open or shert in water temp. sensor circuit for 0.5 sec. or more | + Water temp. sensor +Engine ECU. HINT: After confirming DTC22 use the hand-held tester to confirm the water temperature from,"CURRENT DATA". Temperature displayed Waifanction OCA ‘Open circuit 140°C (284°F) or mor ‘Shon erouit WIRING DIAGRAM Engine ECU WeTC coDia42 DIAGNOSTICS —_ENGINE INSPECTION PROCEDURE HINT: If DTC "22" (Water Temp. Sensor Circuit Malfunction), "24" (Intake Air Temp. Sensor Circuit Malfunction) and "39" (Fuel Temp. Sensor Circuit Malfunction) are output simultaneously, E2 (sensor ground) may be open. When using hand-held tester 1 | Connect the hand-held tester, and read value of water temperature. PREPARATIOI (@) Connect the hand-held tester to the DLC 3. (b) Turn the ignition switch ON and push the hand-held tester main switch ON. CHECK: Read temperature value on the hand-held tester. Ok: ‘Same as actual water temperature. HINT: + If there is open circuit, hand-held tester indicates ~40°C (40°F). + If there is short circuit, hand-held tester indicates 140°C (284°F) or more. [J Check for intermittent problems (See page DI-4). 140°C (284°F) or more ... Go to step 4. "= 40°C (40°F) ... Go to step 2.Das DIAGNOSTICS_— ENGINE 2 | Check for open in harness or engine ECU. oo Water Temp. Sensor rex [=] PREPARATION: @ _ Disconnect the water temp. sensor connector. (b) Connect sensor wire harness terminals ‘together. (c) Turn the ignition switch ON. CHECK: Read temperature value on the hand-held tester. Ok: ‘Temperature val |40°C (284°F) or more Ok \\| Confirm good connection at sensor. If OK, replace water temp. sensor. 3. | Check for open in harness or engine ECU. am Water ‘Temp. Sensor Engine ECU PREPARATION: {@) Remove the glove compartment door. (b) Connect between terminals THW and E2 of engine ECU connector. HINT: Water temp. sensor connector is disconnected. Before checking, do a visual and contact pressure check for the ‘engine ECU connector (See page IN-19). (c) Turn the ignition switch ON. (CHECK: Read temperature value on the hand-held tester. OK: “~~ Temperature value: 140°C (284°F) or more OK \\| Open in harness between terminal E2 or THW, repair or replace harness. Confirm good connection at engine ECU. If OK, replace engine ECU.Deas DIAGNOSTICS_—_ENGINE 4 | Check for short in harness and engine ECU. ON PREPARATIOI A (@) _ Disconnect the water temp. sensor connector. wae cxnoeco () Turn the ignition switch ON. E ‘Sensor CHECK: Read temperature value on the hand-held tester. Ok: Temperature value: -40°C (40°F) nse sa} | OK | Replace water temp. sensor. [ve ] 5 | Check for short in harness or engine ECU. on PREPARATION @ (@) Remove the glove compartment door. Water Eninetcu | (b) Disconnect the "E16" connector of engine ECU. Temp. Sensor HINT: ge Water temp. sensor connector is disconnected, (6) Tur the ignition switch ON. ' ° CHECK: Read temperature value on the hand-held tester. ol ~~ Temperature value: ~40°C (-40°F) cones eae E16 Connector ssa > Repair or replace harness or connector. [ ] Check and replace engine ECU (See page IN-19).DIAGNOSTICS _— ENGINE When not using hand-held tester 1 | Check voltage between terminals THW and E2 engine ECU connector. PREPARATION: (b) Turn the ignition switch ON. CHECK: ECU connector. (a) Remove the glove compartment door. Measure voltage between terminals THW and E2 of engine ox: ae veins 06 (Engine is cool) Cy eure O1-15V) egrentes ot OK \\| Check for intermittent problems. (See page Di-4). [J 2 | Check water temp. sensor (See page ED-5). NG_)| Replace water temp. sensor. OK water temp. sensor (See page IN-19). 3° | Check for open and short in harness and connector between engine ECU and NG >} Repair or replace harness or connector. [*] ‘Check and replace engine ECU (See page IN-19).Dias DIAGNOSTICS — ENGINE DTC 24 Intake Air Temp. Sensor Circuit Malfunction CIRCUIT DESCRIPTION (Fig.1) 20 10 gee Resistance ko. nou SB 2 0 20 40 60 80 100 (4) 32 68 104 140 176 212 The intake air temp. sensor is built into the intake manifold and senses the intake air temperature. A thermistor builtin the sen- sor changes the resistance value according to the intake air temperature. The lower the intake air temperature, the greater the thermistor, the lower the thermistor resistance value (See Fig.1). The intake air temperature sensors connected to the en- gine ECU. The 5 V power source voltage in the engine ECU is applied to the intake air temperature sensor from the terminal THA via a resistor R. That is the resistor R and the intake air temperature sensor are connected in series. When the resis- tance value of the intake air temperature sensor changes. Based on this signal, the engine ECU increases the fuel injec- tion volume to improve drivabilty during cold engine operation. Temp. °C ("F) DTC No. DTC Detecting Condition ‘Trouble Area, 24 | Open or short in intake air temp. sensor cxcuit for 0.5 sec. or | “OPEN O shertin intake a temp. sensor circuit oe “Intake air temp. sensor + Engine EOU HINT: After confirming DTC 24 use the hand-held tester to confirm the water temperature from "CURRENT DATA". Temperature displayed Matfunction 40°C (40°F) Open cout 140°C (284°F) oF more Short circuitD7 DIAGNOSTICS —_ ENGINE WIRING DIAGRAM Engine ECU. Intake Air Temp. Sensor BR-W (AT) INSPECTION PROCEDURE HINT: IfDTC"22" (Water Temp. Sensor Circuit Malfunction), *24” (Intake Air Temp. Sensor Circuit Malfunction), "35" (Turbo Pressure Sensor Circuit Malfunction) and *39” (Fuel Temp. Sensor Circuit Malfunction) are output simultaneously, E2 (sensor ground) may be open.Dias DIAGNOSTICS _—_ ENGINE When using hand-held tester 1 ] Connect the hand-held tester, and read value of water temperature. PREPARATION: (@) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the hand-held tester main switch ON. (CHECK: Read temperature value on the hand-held tester. OK: ~~ Same as actual intake air temperature. HINT: + If there is open circuit, hand-held tester indicates 40°C (40°F). . Ifthere is short circuit, hand—held tester indicates 140°C (284°F) or more. NG \\| -40°c (40°F) 140°C (284° Goto i more oo to step 4. OK Check for intermittent problems (See page DI). 2 | Check for open in harness or engine ECU. ON PREPARATION: @” (2) Disconnect the intake air temp. sensor connector. ae (b) Connect sensor wire harness terminals together. (c) Tum the ignition switch ON. CHECK: Read temperature value on the hand-held tester. ol “~~ Temperature value: 140°C (284°F) or more ‘Temp. Sensor OK \\| Confirm good connection at sensor. Hf OK, replace intake air temp. sensor.DLs DIAGNOSTICS _— ENGINE 3 | Check for open in harness or engine ECU. @™ Intake Air Temp. [J PREPARATION: (@) Remove the glove compartment door. (b) Connect between terminals THA and E2 of engine ECU connector. HINT: Intake air temp. sensor connector is disconnected. Before checking, do a visual and contact pressure check for the engine ECU connector (See page IN—19). (c) Turn the ignition switch ON. CHEC! Read temperature value on the hand-held tester. OK: ~~ ‘Temperature value: 140°C (284°F) or more repair or replace harness. om) Open in harness between terminal E2 or THA, Confirm good connection at engine ECU. If OK, replace engine ECU. 4 | Check for short in harness and engine ECU. on Intake Air Temp. Sensor i bo [=] PREPARATION: (@) Disconnect the intake air temp. sensor connector. (©) _ Turn the ignition switch ON. CHECK: Read temperature value on the hand-held tester. OK: ~_Temperature value: -40°C (-40°F) > Replace intake air temp. sensor.DESO DIAGNOSTICS _— ENGINE 5 | Check for short in harness or engine ECU. ON PREPARATION: Ge (a) Remove the glove compartment door. Intake Air Engineecu | (b) Disconnect the "E16" connector of engine ECU. ‘Temp. Sensor HINT: Intake air temp. sensor connector is disconnected. (c) Tum the ignition switch ON. CHECK: Read temperature value on the hand-held tester. Ok: “~~ Temperature value: ~40°C (-40°F) cj cee E16 Connector posse > Repair or replace harness or connector. L«] ‘Check and replace engine ECU (See page IN-19).DLS1 DIAGNOSTICS _—_ ENGINE When not using hand-held tester 1 | Check voltage between terminals THA and E2 engine ECU connector. ON THA S PREPARATION: (@) Remove the glove compartment door. () Turn the ignition switch ON. 7 (CHECK: E ca) Measure voltage between terminals THA and E2 of engine 4 ECU connector. fp OK: aWs5 intako or tem, sous. “ocr 20,68) (Engine coo) 20376) (Engines nod) Vottage 02-38 o1-15V Ok \\| Check for intermittent problems. (See page D4). [J 2 | Check intake air temp. sensor (See page ED-7). [J 3. | Check for open and short in harness and connector between engine ECU and intake air temp. sensor (See page IN—19). [«] Check and replace engine ECU (See page IN-19). NG | Replace intake air temp. sensor. NG )| Repair or replace harness or connector.Di-52 DIAGNOSTICS —_ ENGINE DTC 32 Injection Pump Correction System Malfunc- tion CIRCUIT DESCRIPTION The correction system is correcting a few vary between each injection pumps. DTCNe. DTC Detecting Conation| “Trouble rea a2 Injection pump correction unit ckeut | Open or shor in injection pump correction unit circuit + Injection pump corection unit Engine ECU. WIRING DIAGRAM Injection Pump Correction Unit, Engine ECU ED (LHD) EC (RHD) INSPECTION PROCEDURE 1 | Check for open and short in harness and connector between the engine ECU and injection pump correction unit (See page IN-19). LJ NG_)| Repair harness or connector.Disa DIAGNOSTICS _—_ ENGINE 2 | Try to change the injection pump correction unit to another one. PREPARATION: (@)_ Remove the injection pump correction unit from injection pump. (b) _ Install the another injection pump correction unit. (©) Clear DTC. (d) Turn the ignition switch ON. (CHECK: Read DTC again. Ok: Does not output DTC "32" (Injection Pump Correction System Malfunction). [*] Check and replace engine ECU (See page IN-19). OK \\| Check and replace injection pump. (See page FU-113).I-54 DIAGNOSTICS = ENGINE DTC 33 Intake Shutter Control Circuit Malfunction CIRCUIT DESCRIPTION controlling the VSV. When the ignition switch turned OFF, the intake shutter control system shuts off the air intake by closing the intake shutter for the engine stopping smoothly. The actuator shuts the intake shutter by the engine ECU DICNo. DTC Detecting Condition “Trouble Area eae) (Open or shor in VSV for intake shutter cei for 05 sec. oF Open or short in VSV for intake shuttor cuit + V8V for intake shuttor Intake shuter + Vacuum hose disconnected or blocked Engine EU WIRING DIAGRAM Engine Room J/B Engine ECU Y Ji8J/C (LHD) OER J sit gic (RH) VSV for Intake Shutter LEY ap WL al m2 | E01 B-w. 1 Bw @ MRE INSPECTION PROCEDURE 1 | Check resistance of VSV for intake shutter (See page EM-20). [«] > Replace the VSV for intake shutter.DLS DIAGNOSTICS _— ENGINE 2 | Check the VSV for intake shutter. oy a oN E17 Connector [J PREPARATION: (@) Remove the glove compartment door. (b) Disconnect the "17" connector of engine ECU. (©) _ Turn the ignition switch ON. CHECK: Check VSV function (@) Connect between terminal S/TH of engine ECU and body ground (VSV is ON). (b) Disconnect between terminal S/TH of engine ECU and body ground (VSV is OFF). OK: VSV is ON: Air from pipe E flows out through pipe F. VSV Is OFF: Air from pipe E flows out through the alr filter. 0K \\| Check and replace engine ECU (See page IN-19). (See page IN-19). 3” [Check for open and short in harness and connector between engine ECU and VSV for intake shutter, VSV for intake shutter and ECD main relay (Marking: ECD) («J NG >| Repair harness or connector. Replace VSV for intake shutter.DES DIAGNOSTICS — ENGINE DTC 35 Turbo Pressure Sensor Circuit Malfunction CIRCUIT DESCRIPTION The turbo pressure sensor is connected to the intake manifold. The engine ECU detects the intake manifold pressure as a volt- age by the sensor. The engine ECU uses the intake manifold pressure signal for correction of injection volume control and in- jection timing control. The VSV for turbo pressure sensor switches the atmosphere applied to the turbo pressure sensor to the intake manifold pressure. The turbo pressure sensor monitors both the atmo- spheric pressure and intake manifold pressure and transmits bag ae Ha | te output voltage to the engine ECU, and the engine ECU uses mig, this atmospheric pressure value for correcting the injection vol 100 1,900 ume. (3.9) (74.8) (inHg) Intake Manifold Pressure BIEN. (TC Detecting Condition rosie Area *Opon or shot in turbo pressure sensor ckeut + Turbo pressure sensor ‘as {Pen orshort in uto possure sensor circuit for2 sec. or | +Opon or sho in VS for tuto pressure sensor rut more + VSV or turbo pressure sensor cuum hose dsconnacte or Blocked Engine ECU HINT: After confirming DTC 35, use the hand-held tester to confirm the intake manifold pressure from "CURRENT DATA". Intake manifold pressure (KPa) Mattunction| ‘Approx. 0 Pint crcuit shor VC circuit open or shor 130.0rmore +PIM circuit open +£2 crouit openDi-S7 DIAGNOSTICS_—_ ENGINE WIRING DIAGRAM Engine ECU ‘Turbo Pressure Sensor Engine Room J/B 1B JIC (LHD) JBWIG(RHD) BY BY ae feoda 8 {icek Fusible Link Block Battery te INSPECTION PROCEDURE HINT: lt DTC "22" (Water Temp. Sensor Circuit Malfunction), "24” (Intake Air Temp, Sensor Circuit Malfunction), "35" (Turbo Pressure Sensor Circuit Malfunction) and "39" (Fuel Temp. Sensor Circuit Malfunction) are out- put simultaneously, E2 (sensor ground) may be open.Dis DIAGNOSTICS — ENGINE When using hand-held tester 1 | Connect the hand-held tester, and read value of intake manifold pressure. PREPARATION: {@) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the hand-held tester main switch ON. Goto step 5. CHECK: Read value of intake manifold pressure on the hand-held tester. Ok: ~~ Same as atmospheric pressure. ok NG LO 2 |Check turbo pressure sensor (See page TC-17). We) Repla turbo pressure sensor. oK nN 3 | Check voltage between terminals VC and E2 of engine ECU. CHECK: Ok: On 2 PREPARATION: @ ve (a) Remove the glove compartment door. (b) _ Turn the ignition switch ON. Measure voltage between terminals VC and E2 of engine ECU. “~~ Voltage: 4.5-5.5 V voveso] | NG Check and replace engine ECU (See page Wess 3Dis9 DIAGNOSTICS _— ENGINE 4 | Check voltage between terminals PIM and E2 of engine ECU. Q « # Le] PREPARATION: (@)__ Remove the glove compartment door. (b) Turn the igr n switch ON. CHECK: Measure voltage between terminals PIM and E2 of engine ECU. Ok: ~~ Voltage: 1.7-2.9V OK \\} Check and replace engine ECU (See page IN-19). sure sensor (See page IN—19). Check for open and short in harness and connector between engine ECU and turbo pres- 5 | Check the connection of vacuum hose between turbo pressure sensor and VSV for turbo pressure sensor, VSV for turbo pressure sensor and intake manifold. OK NS NG | Repair or replace. 6 | Check resistance of VSV for ti lurbo pressure sensor (See page TC-19). OK Wa) Replace VSV for turbo pressure sensor.Dro DIAGNOsTics_—_ENGINE Check the VSV for turbo pressure sensor. sczess VSV: ON VSV: OFF PREPARATION: (@ Remove the glove compartment door. (b) Disconnect the "E17" connector of engine ECU. ()_ Tum the ignition switch ON. CHECK: Check VV function (@) Connect between terminal PA of engine ECU and body ground (VSV is ON). (b) Disconnect between terminal PA of engine ECU and body ground (VSV is OFF). ol “~~ VSV Is ON: Air from pipe E flows out through the air filter. VSV is OFF: Air from pipe E flows out through pipe G. Ok \\| Check and replace engine ECU (See page IN-19). 8 [Check for open and short in harness and connector between engine ECU and VSV for turbo pressure sensor, VSV for turbo pressure sensor and ECD main relay (Marking: ECD) (See page IN-19). [x] NG_)| Repair harness or connector. Replace VSV for turbo pressure sensor.Dist DIAGNOSTICS _— ENGINE When not using hand-held tester 1 | Check turbo pressure sensor (See page TC-17). [oJ > Replace turbo pressure sensor. 2 | Check voltage between terminals VC and E2 of engine ECU. PREPARATION: (@) Remove the glove compartment door. (b) Tum the ignition switch ON. CHECK: Measure voltage between terminals VC and E2 of engine ECU. ok: ~~ Voltage: 4.5- 5.5 V NG \\} Check and replace engine ECU (See page IN-19). 3 | Check voltage between terminals PIM and E2 of engine ECU. PIM PREPARATION: (a) Remove the glove compartment door. (0) _ Turn the ignition switch ON. CHECK: Measure voltage between terminals PIM and E2 of engine ECU. Ok: Voltage: 1.7-2.9V Ok \\| Check and replace engine ECU (See page IN-19).DIAGNOSTICS _— ENGINE 4 | Check for open and short in harness and connector between engine ECU and turbo pressure sensor (See page IN-19). v) Repair or replace harness or connector. [J 5 | Check the connection of vacuum hose between turbo pressure sensor and VSV for turbo pressure sensor, VSV for turbo pressure sensor and intake manifold. W) Repair or replace. [«] 6 | Check resistance of VSV for turbo pressure sensor (See page TC-19). NG | Replace VSV for turbo pressure sensor. OKDI-63 DIAGNOSTICS — ENGINE 7 | Check the VSV for turbo pressure sensor. PREPARATION: (@) Remove the glove compartment door. (b) Disconnect the "E17" connector of engine ECU. () _ Turn the ignition switch ON. CHECK: 17 Connector oe Check VSV function (a) Connect between terminal PA of engine ECU and body ground (VSV is ON). (b) _ Disconnect between terminal PA of engine ECU and body ground (VSV is OFF). Ok: “~~ VSV is ON: Air from pipe E flows out through the air filter. VSV is OFF: ‘Air from pipe E flows out through pipe G. =) (See page IN-19). Check for open and short in harness and connector between engine ECU and VSV for turbo pressure sensor and ECD main relay (Marking: ECD) «J > Repair harness or connector. Replace VSV for turbo pressure sensor.Dies DIAGNOSTICS — ENGINE DTC 39 Fuel Temp. Sensor Circuit Malfunction CIRCUIT DESCRIPTION The fuel temperature sensor senses the fuel temperature. A thermistor built into the sensor changes the resistance value ig.1) according to the fuel temperature. The lower the fuel tempera- ture, the greater the thermistor resistance value, and the higher the fuel temperature, the lower the thermistor resistance value (See Fig. 1). The fuel temperature sensor is connected to the engine ECU g (See below). The 5 V power source voltage in the engine ECU 8 is applied to the fuel temperature sensor from the terminal THF § via a resistor R. That is, the resistor R and the fuel temperature 3 sensor are connected in series. When the resistance value of « the fuel temperature sensor changes in accordance with changes in the fuel temperature, the potential at the terminal THF also changes. Based on this signal, the engine ECU in- creases the fuel injection volume to improve driveability during low engine revolution and high fuel temperature -2 0 20 49 60 80 100 CH) (2) (68) (104 (1409 (176) (212) ‘Temperature °C (°F) DFO Ne. TC Detecting Gonation Toute Area 5 *Opon or hort infueltemp, sensor rout 39 | open or shonin el temp. sensor cet or 05sec. ormore_ | +Fuol tome. sensor Engine ECU HINT: After confirming DTC 39, use the hand-held tester to confirm the water temperature from "CURRENT DATA’. “Temperature slaved Malnation 40°C 40°F Open rut 140°0 (24°F or more Shot aaa WIRING DIAGRAM Engine ECU Fuel Temp. Sensor B-R (LHD)DHS DIAGNOSTICS_—_ ENGINE INSPECTION PROCEDURE HINT: If DTC "22" (Water Temp. Sensor Circuit Malfunction), “24” (Intake Air Temp. Sensor Circuit Malfunction), "5" (Turbo Pressure Sensor Circuit Malfunction) and "39" (Fuel Temp. Sensor Malfunction) are output simul- taneously, E2 (sensor ground) may be open. When using hand-held tester 1 | Connect the hand-held tester, and read value of fuel temperature. PREPARATION: (@) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the hand-held tester main switch ON. CHECK: Read temperature value on the hand-held tester. Ok: ‘Same as actual fuel temperature. HINT: + Ifthere is open circuit, hand-held tester indicates 40°C (40°F). + If there is short circuit, hand-held tester indicates 140°C (284°F) or more. («J Check for intermittent problems (See page DI-4 ). Na | -49°C (40°F) .. Go to step 2. 140°C (284°F) or more ... Go to step 4.wie DIAGNOSTICS_— ENGINE (3 2 | Check for open in harness or engine ECU. PREPARATION: Qa (a) Disconnect the fuel temp. sensor connector. Act cy | (0) Connect sensor wire harness terminals together. a Engine (©) Tum the ignition switch ON. ‘Temp. Sensor CHECK: Read temperature value on the hand-held tester. ‘Temperature value: 140°C (284°F) or more OK \,| Confirm good connection at sensor. If OK, replace fuel temp. sensor. 3. | Check for open in harness or engine ECU. a Fuel Tomp. Sensor, [= ] Engine ECU PREPARATION: (@) Remove the glove compartment door. (b) Connect between terminals THF and E2 of engine ECU connector. HINT: Fuel temp. sensor connector is disconnected. Before checking, do a visual and contact pressure check for the engine ECU con- nector (See page IN~19). (c) Turn the ignition switch ON. perature value on the hand-held tester. OK: ‘Temperature value: 140°C (284°F) or more OK \,| Open in harness between terminal E2 or THF, re- Pair or replace harness. Confirm good connection at engine ECU. If OK, replace engine ECU.Di-67 DIAGNOSTICS _—_ ENGINE 4 | Check for short in harness or engine ECU. oo Fuel ‘Temp. Sensor PREPARATION: (@) _ Disconnect the fuel temp. sensor connector. (b) Turn the ignition switch ON. CHEC! Read temperature value on the hand-held tester. Ok: “Temperature value: ~40°C (-40°F) [=] Repl e fuel temp. sensor. on) 5 | Check for short in harness or engine ECU. o———0 E16 Connector ‘ON Fuel Engine EOU Temp. Sensor ———, [J PREPARATION: {@)_ Remove the glove compartment door. (b) Disconnect the "E16" connector of engine ECU. HINT: Fuel temp. sensor connector is disconnected. (c) Tum the ignition switch ON. CHECK: Read temperature value on the hand-held tester. Ok: ~~ Temperature value: -40°C (-40°F) Repair or replace harness or connector. on) Check and replace engine ECU (See page IN-19).pies DIAGNOSTICS —_ ENGINE When not using hand-held tester 1 | Check voltage between terminals THF and E2 engine ECU connector. PREPARATION: (@) Remove the glove compartment door. (6) Tum the ignition switch ON. CHEC! Measure voltage between terminals THF and E2 of engine ECU connecter. Ok: Fuel emp. a Votage 20 (68) {Engines coe) peste 20 176) 7 (Engine is hot) ay 0K \,| Check for intermittent problems (See page DI-4). [J 2 | Check fuel temp. sensor (See page ED-6). [J 3 | Check for open and short in harness and connector bet fuel temp. sensor (See page IN-19). Ca ah laa [«] Check and replace engine ECU (See page IN-19). > Replace fuel temp. sensor. > Repair or replace harness or connector.Dio DIAGNOSTICS — ENGINE DTC 42 Vehicle Speed Sensor Signal Circuit Malfunction CIRCUIT DESCRIPTION The vehicle speed sensor outputs a 4—pulse signal for every revolution of the rotor shaft, which is rotated by the transmission output shaft via the driven gear. Atter this signal is converted into a more precise rectan- gular waveform by the waveform shaping circuit inside the combination meter, itis then transmitted to the ‘engine ECU. The engine ECU determines the vehicle speed based on the frequency of these pulse signals. 4-pulse 4-pulse > > Vehicle Speed Sensor ‘Combination Engine ECU Lisdaeh ord DIC No. DTC Detecting Condtion| “Trouble Area All conditions below are detected continuously for 8 sec. or mote: + Open o short in vehicle spead sensor circuit 2 (a) Vehicle speed signa: 0 knvh (0 mph) *Vohicie speed sensor (b) Engine speed: 2,400 — 4,000 rpm + Combination meter (6) Engine coolant temp.: 60°C (176"F) or more Engine ECU (@)_Accelerator pedal opening angle : 60% or more WIRING DIAGRAM Combination Meter Engine ECU @- sv 19 29 ie 18 srg yie SB 8 v v Pt ui (1) SL —SLoe 79) (THD) v TRHD)DLO DIAGNOSTICS _—_ENGINE INSPECTION PROCEDURE 1 | Check operation of speedometer. CHECK: HINT: [*] Drive the vehicle and check if the operation of the speedometer in the combination meter is normal. The vehicle speed sensor is operating normally if the speedometer display is normal. > Check speedometer. 2 | Check voltage between terminal SP1 of engine ECU and body ground. on PREPARATION: (a) Remove the glove compartment door. (b) Shift the shift lever to neutral. (c) Jack up one of the front wheels. (d) Turn the ignition switch ON. CHECK: Measure voltage between terminal SP1 of engine ECU and body ground when the wheel is turned slowly. OK: 45-5.5V Voltage is generated intermittently. NG\ [Check and repair harness and connector be- tween combination meter and engine ECU (See page IN-19). Check and replace engine ECU (See page IN-19).DTI DIAGNOSTICS —_ ENGINE DTC 97 EDU Circuit Malfunction CIRCUIT DESCRIPTION ‘The EDU has been adopted to drive the spill control valve at high speeds. The EDU has realized high-speed driving under high fuel pressure conditions through the use of a DC/DC converter that provides a high-volt- age, quick-charging system. The engine ECU constantly monitors the EDU and stops the engine in case an abnormal condition is de- tected. The battery voltage is increased by the DC/DC converter. A voltage of approximately 150 V is applied to the spill control valve in accordance with the lW+ signal received from the engine ECU. Also at ths time, the injec- tion verification signal (lif) is sent to the engine ECU. + Signal SPV Signal Time (DC Converter \ Battery [ DGIDC Converter & leet 1 \ 4B n verb | [= | Lge E pe! j Control ECU |SPVD a Controller i jae TON. TO Detecting oonation “Trouble Area, Although the SPVD is ouput to EDU withthe engine speed at |+Open or short in EDU circuit 97 | 500 rpm or more, the SPVF isnot input continuously tines or | +EDU. more. + Spit contol vaivepee DIAGNOSTICS —_ ENGINE WIRING DIAGRAM EDU From SPILVLY Relay Engine ECU GC ye | EN} rts 3 33 G 9 4 EPAEPS Ly Ley Erde ie Ni Spill Control Val 44 4 B R 7 1p 3 ENT 3 Hf ae oe “LHD *2: RHD INSPECTION PROCEDURE 1 | Check voltage between terminal 2 of wire harness side connector and body ground. PREPARATION: (@) Disconnect the EDU connector. (0) _ Turn the ignition switch ON. CHECK: Measure voltage between terminal 2 of wire hamess side con- nector and body ground. Ok: 2 Voltage: 10-14 V NG \ | Check ECU power source circuit (See page Di-76).DI-73 DIAGNOSTICS _— ENGINE 2 | Check continuity EDU ground bolt and body ground. [«] 3 | Check resistance between terminals 4 and 5 of wire harness side connector. NG | Tighten EDU ground bolt. CHECK: Measure resistance between terminals 4 and 5 of wire hamess side connector. Ok: Resistance: Approx. 1.7.2 > Go to step 6. NG ~~ 4 | Check spill control valve (See page FU-113). NG \\| Check and replace injection pump (See page FU-113). [x] 5 | Check for open and short in hamess and connector between spill control valve and EDU. (See page IN-19). ve) Repalr or replace harness or connector. [Jvera DIAGNOSTICS —_ ENGINE. EDU (See page IN-19). 6 | Check for open and short in harness and connector between engine ECU and [*] NG_)| Repair or replace harness or connector. ground. 7 | Check voltage between terminal SPVD of engine ECU connector and body PVD “V) [x] PREPARATION: {@) Remove the glove compartment door. (0) _ Turn the ignition switch ON. (CHECK: Measure voltage between terminal SPVD of engine ECU con- nector and body ground. OK: Voltage: 9-14 Reference: INSPECTION USING OSCILLOSCOPE During idling, check waveform between terminals SPVD and 1 of engine ECU HINT: The correct waveform is as shown. NG \\| Check and replace engine ECU (See page IN-19).DLS DIAGNOSTICS_—_ENGINE 8 | Check voltage between terminal SPVF of engine ECU and body ground. SPVF 'SPVF Signal Waveforms ignal Wavelorms sviDIV oa | GND 10 msec/ DIV (Idling) [oJ PREPARATION: (@) Remove the glove compartment door. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals SPVF of engine ECU and body ground. OK: Voltage: 9-14 V Reference: INSPECTION USING OSCILLOSCOPE. During idling, check waveform between terminals SPVF and E1 of engine ECU. HINT: The correct waveform is as shown. (See page IN-19). re) | Check and replace engine ECU ‘Check and replace EDU (See page ED-15).E76 DIAGNOSTICS _—_ ENGINE ECU Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery positive voltage is applied to the coil, closing the contacts of the ECD main relay (Marking: ECD) and supplying power to the terminal +B of the engine ECU. WIRING DIAGRAM Engine ECU Cow! Side J/B LH Ignition Switch fA WA stray] W-R. Engine Room J/B J18 J/C (LHD) Jit WIC (RHD) . BW Tepe BW Fusible Link Block [MAIN Act fy ee it 1 YS £0 (LHD) EC (RHD)D7 DIAGNOSTICS_—_ ENGINE INSPECTION PROCEDURE 1 | Check voltage between terminals +B and E1 of engine ECU. on PREPARATION: @ eI 8 (@ Remove the glove compartment door. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminals +B and E1 of engine ECU Ok: ~~ Voltage: 9-14 OK \\| Proceed to next circuit inspection shown on problem symptoms table (See page DI-19). [Le] 2 | Check for open in harness and connector between terminal E1 of engine ECU and body ground (See page IN-19). NG_)| Repair or replace harness or connector. OK 3 | Check ECD main relay (Marking: ECD) (See page ED-3). [«] NG | Replace ECD main relay.Di-78 DIAGNOSTICS _— ENGINE 4 | Check ECD tuse. PREPARATION: Remove t CHEC! Check cor the ECD fuse from the engine room J/B. ntinuity of ECD fuse. NG \\| Check for short in all the harness and Components connected to ECD fuse. («J 5 | Check for open in harness and connector between engine ECU and ECD main relay (Marking: ECD), ECD main relay and battery (See page IN-19). > Repair harness or connector. [« J 6 | Check voltage between terminals IGSW and E1 of engine ECU. o™ PREPARATION: 1 'esw (a) Remove the glove compartment door. (b) _ Turn the ignition switch ON. CHECK: Measure voltage between terminals IGSW and E1 of engine Eou. Ok: Voltage : 9-14 on) Go to step 9.DI-79 DIAGNOSTICS_—_ENGINE 7 | Check ignition switch (See Pub. No. RM616E1 BE section). [=] ve) Replace ignition switch. 8 | Check for open in harness and connector between ignition switch and engine ECU (See page IN-19). [J > Repair or replace harness or connector. 9 | Check voltage between terminal MREL of engine ECU and body ground. Oo MREL, [ve] PREPARATION: (a) Remove the glove compartment door. (b) _ Turn the ignition switch ON. CHECK: Measure voltage between terminal MREL of engine ECU and body ground. Ok: Voltage: 9-14 V OK \\| Check and replace engine ECU (See page IN-19). Check for open in harness and connector between engine ECU and ECD main relay (Marking: ECD), ECD main relay and body ground (See page IN-19). . aDi-80 DIAGNOSTICS —_ ENGINE Intake Heater Control Circuit CIRCUIT DESCRIPTION When the engine coolant temperature is below 40°C (104°F), turning the ignition switch ON causes the in- take heater relay to turn ON, allowing the intake heater to operate. The intake heater operates until the en- gine coolant temperature becomes higher than 40°C (104°F), or the maximum of 90 seconds. ‘At the same time, the glow indicator lamp is illuminated in accordance with the engine coolant temperature (maximum 10 seconds). WIRING DIAGRAM Engine ECU Cow! Side J/B LH 1 83 Lees & ake J15 JIC (LHD) J13/C (RHD) LB a A Ignition Switch Intake Heater Relay w-8 Fusible Link BlockDI-8t DIAGNOSTICS _— ENGINE INSPECTION PROCEDURE 1 | Does glow indicator light up? Does the glow indicator light up? Ok: The glow indicator lights up for 0.5 sec. or more. [= J OK )| Goto step 5. ground. 2 | Check voltage between terminal GIND of engine ECU connector and body o* E18 Connector GIND Lv] PREPARATION: (@) Remove the glove compartment door. (b) Disconnect the "E18" connector of engine ECU. (c) Turn the ignition switch ON. CHECK: Measure voltage between terminal GIND of engine ECU con- nector and body ground. OK: ~~ Voltage: 9-14 V OK \\| Check and replace engine ECU (See page IN-19).DIAGNOSTICS _—_ ENGINE 3 | Check GAUGE fuse. PREPARATION: Remove the GAUGE fuse from the cowl side J/B LH. CHECK: Measure continuity of GAUGE fuse. OK: ~~ Continuity NG \\| Check for short in all the harness and compo- nents connected to GAUGE fuse. oK NA 4 | Check glow indicator light bulb. Ne) Replace bulb. OK NA ‘Check for open in harness and connector between combination meter and engine ECU, combina- tion meter and GAUGE fuse (See page IN-19). 5 | Check glow indicator lighting time (See page ST-1). NG \\| Check and replace engine ECU » (See page INN).DI-83 DIAGNOSTICS _—_ENGINE 6 | Are there any DTC being output? [J 7 | Check intake heater relay (See page ST-7). ves) Go to relevant DTC chart (See page Di-14). vy Replace intake heater relay. Lo] 8 | Check voltage between terminal IREL of engine ECU and body ground at crank- ing. STA PREPARATION: @ E19 Connector IREL (@) Remove the glove compartment door. = (b) Disconnect the "E19" connector of engine ECU. (c) Start the engine. (CHECK: Measure voltage between terminal IREL of engine ECU and body ground at cranking. Ok: Voltage: 9-14. V NG \\| Check and replace engine ECU (See page IN-19).DES8a DIAGNOSTICS_—_ENGINE 9 | Check for open and short in harness and connector between intake heater relay and engine ECU, intake heater relay and body ground (See page IN-19). > Repair harness or connector. OK NU 10 | Check resistance of intake heater (See page ST-5). > Replace intake heater. oK nN 11 | Inspect intake heater installation. NG )| Tighten intake heater. [J 12 | Check for open in harness and connector between intake heater relay and intake heater (See page IN-19). NG | Repair harness or connector. («J Proceed to next circuit inspection shown on problem symptoms table (See page DI-19).Dias DIAGNOSTICS —_ ENGINE EGR Control Circuit CIRCUIT DESCRIPTION The EGR system recirculates exhaust gas, which is controlled to the proper quantity to suit the driving condi- tions into the intake air mixture to slow down combustion, reduce the combustion temperature and reduce NOx emissions, The lift amount of EGR valve is controlled by the vacuum which is regulated by the E-VRV operated by the engine ECU. even one of the following conditions is fulfilled, the VSV is turned ON by a signal from the ECU. This results in atmospheric air acting on the EGR valve, closing the EGR valve and shutting off the exhaust gas (EGR cut-off, Under the following conditions, EGR is cut to maintain driveability. + Before the engine is warmed up + During deceleration (Diesel throttle valve closed) + Light engine load (amount of intake air very small) + Engine speed over 3,000 rpm WIRING DIAGRAM Engine Room J/B J18 J/C (LHD) Jit J/G (RHD) Teak 24} 1 8-¥ sing} 4 8 BA Ww _fragke —B-/ Fusible Link Block MAIN ALT Battery jogo — oo.Dias DIAGNOSTICS _— ENGINE INSPECTION PROCEDURE When using hand-held tester 1 | Check the connection of vacuum hose. [x] NG | Repair or replace. 2 | Check the vacuum between EGR valve and VSV for EGR at 1,500 rpm. PREPARATION: (@)_ Using a3-way connector, connect a vacuum gauge to the hose between the VSV and EGR valve. (b) Warm up the engine to above 80°C (176°F). CHECK: Check the vacuum at 1,500 rpm. RESULT: “Type Vacuum i (0 kPa (O mmHg, On. Ha) u (kPa (0 mig, in Hg) ~ 28 KPa (210 mmHg, 8.9, Hg) L ‘Above 28 kPa (210 mmbig, 8.3 in. Ha) "ve Go to step 7. Go to step 10DI-87 DIAGNOSTICS _— ENGINE 3 | Check the VSV circuit for EGR. NG PREPARATION: (@) Disconnect the vacuum hose from the VSV for EGR. (o) Connect the hand-held tester to the DLC3. (c) Turn the ignition switch ON and push the hand-held tes- ter main switch ON. (d) Select the ACTIVE TEST mode on the hand-held tester. CHECK: Check operation of VSV for EGR, when it is operated by the hand-held tester. Ok: VSVis 01 Air from pipe E flows out through air filter. VSV is OFF: Air does not flow from pipe E to air filter. OK ‘ Check the connection, damage and blockage of vacuum hose. 4 | Check VSV for EGR (See page EC-9). [~] w=) Replace VSV for EGR.Di-88 pignosmi¢s — ENGINE 5 | Check voltage between terminal EGR of engine ECU and body ground. Q cor nz War 7 EGR Signal EGR msec Division (1,500.rpm) __ posse Waveforms §V/ DIV # GND [«] PREPARATION: (@)__ Remove the glove compartment door. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminal EGR of engine ECU and body ground. Ok: Voltage: 9-14 V Reference: INSPECTION USING OSCILLOSCOPE During EGR systemis ON (engine speed 1 500 rpm), check wa- veform between terminals EGR and E1 of engine ECU. HINT: The correct waveform is as shown. NG \\| Check and replace engine ECU (See page IN-19). 6 | Check for engine ECI 9} of en and short in harness and connector between V: peta idl een VSV for EGR and NG >| Repair or replace harness or connector.I-89 DIAGNOSTICS_—_ENGINE 7 | Check operation of E-VRV. AirFiter $2) E-VAV: OFF E-VRV: ON NG NF PREPARATION: (@ Disconnect the vacuum hoses from the E-VRV. (b) Connect the hand-held tester to the DLC3. (c) Turn the ignition switch ON and the push hand-held tes- ter main switch ON. (@)_ Select the ACTIVE TEST mode on the hand-held tester. CHECK: Check operation of E-VRV, when it is operated by the hand~ held tester. OK: E-VRV ON: Air from pipe E is flowing out through pipe F. E-VRV OFF: Air from pipe E is flowing out through air fl oe) Go to step 10. 8 | Check E-VRV for EGR (See page EC-9). oK nN Replace E-VRV. ne) 9 | Check for open and short in harness and connector between E-VRV and engi ECU, E-VRV and ECD main relay (Marking : ECD) (See page IN-19). ae [«] Repair or replace harness or connector. ve)Di-90 DIAGNOSTICS — ENGINE 10 [ore EGR valve (See page EC-9). S [«] Replace the EGR valve. Check and replace engine ECU (See page IN-19). When not using hand-held tester 1 Check the connection of vacuum hose. [oJ NG Repair or replace. OK 2 eta Hecyumm between EGR valve and VSV for EGR at 1,500 rpm Type || Go to step 6. hve ty Go to step 9. Type it 3 | Check VSV for EGR (See page EC-8). va) Replace VSV for EGR.DESI DIAGNOSTICS _— ENGINE [-85, Step 5). (See page DI 4 |Check voltape, between terminal EGR of engine ECU and body ground («J NG \\| Check and replace engine ECU (See page IN-19). 5 | Check for open and short in harness and connector between VSV for EGR and engine ECU (See page IN-19). [«] ne) Repair or replace harness or connector. 6 [neck operation of E~VRV. Air Filter SS E-VRV: OFF ses E-VRV: ON [J PREPARATION: (@) Remove the glove compartment door. {b) Disconnect the "E17" connector of engine ECU. () Turn the ignition switch ON. CHECI Check E-VRV operation. (1) Connect between terminal EGR of engine ECU connector and body ground (ON). (2) Disconnect between terminal EGR of engine ECU connector and body ground (OFF) E-VRV ON: Air from pipe E is flowing out through pipe F. E-VRV OFF: Air from pipe E Is flowing out through air filter. OK )| Goto step 9.pi-92 DIAGNOSTICS —_ENGINE 7 | Check E-VRV (See page EC-9). NG | Replace E-VRV. [J 8 | Check for open and short in harness and connector between E-VRV and engine ECU, E-VRV and ECD main relay (Marking : ECD) (See page IN-19). NG_)| Repair or replace harness or connector. OK 9 | Check EGR valve (See page EC-9). NG | Replace EGR valve. OK Check and replace engine ECU (See page IN-19).DI-93 DIAGNosTics_—_ENGINE AIC Signal Circuit CIRCUIT DESCRIPTION When the A/C compressor is ON, the A/C amplifier sends the A/C signal to the engine ECU, then engine ECU increases the fuel injection volume to improve driveability during engine idling. WIRING DIAGRAM AIC Amplifier INSPECTION PROCEDURE When using hand-held tester 1 | Connect the hand-held tester and check A/C signal. PREPARATION: (a) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the hand-held tester main switch ON. CHECK: Read AVC signal on the hand-held tester while A/C compressor is ON. Ok: ‘AC switch condition OFF ON ‘AG signal OFF, ON OK Proceed to next circuit inspection shown on problem symptoms table (See page DI-19). [ve JDios DIAGNOSTICS_—_ENGINE 2 | Check voltage between terminal AC1 of engine ECU and body ground. QD ‘STA Pe PREPARATION: (@) Remove the glove compartment door. (b) _ Start the engine. CHECK: Measure voltage between terminal AC1 of engine ECU and body ground when A/C switch is turned to ON and OFF. [= J OK: ‘A ewitoh contin Voltage ON Below 15V, OFF, e-uv (See page IN-19). OK \\| Check and replace engine ECU 3. | Check for open and short in harness and connector between engine E AIC amplifier (See page IN-19). ngine ECU and [«] re) Repair or replace harness or connector. Check and replace A/C amplifier.DIAGNOSTICS _— ENGINE When not using hand-held tester DI-95 1 | Check voltage between terminal AC1 of engine ECU and body ground. Le] PREPARATION: (@ Remove the glove compartment door. (b) Start the engine. (CHECK: Measure voltage between terminal AC1 of engine ECU and body ground when A/C switch is turned to ON and OFF. Ok: 'AG switch contin ‘otage ON Below 15V. OFF gn14v OK \\| Proceed to next circuit inspection shown on problem symptoms table (See page DI-19). 2 | Check for open and short in harness and connector between engine ECU and AIC amplifier (See page IN—19). [J ve) Repair or replace harness or connector. Check and replace A/C amplifier.DL96 DIAGNOSTICS _—_ENGINE A/C Cut Control Circuit CIRCUIT DESCRIPTION This circuit cuts air conditioning operation during vehicle acceleration in order to increase acceleration per- formance. During acceleration with the vehicle speed at 30 knvh (19 mph) or less and accelerator pedal opening angle at 45° or more, the A/C magnetic switch is turned OFF for several seconds. The air conditioning is also controlled by the ECU out putting the engine coolant temperature to A/C amplifier. WIRING DIAGRAM AIC Amplifier Engine ECU.1-97 DIAGNOSTICS _—_ENGINE INSPECTION PROCEDURE When using hand-held tester 1 |Connect the hand-held tester and check operation of air conditioning cut con- trol. PREPARATION: (@) Connect the hand held tester to the DLC3. (b) Turn the ignition switch ON and push the hand-held tester main switch ON. (©) _ Start the engine and air conditioning switch ON. HINT: AVC magnetic clutch is turned ON. (4) Select the ACTIVE TEST mode on the hand-held tester. GHECK: ‘Check operation of A/C magnetic clutch cut when air conditioning cut control is operated by the hand-held tester. Ok: AIC magnet clutch Is turned OFF. [J 2 | Check for open and short in harness and Ale ‘amplifier (See Bags eo connector between engine ECU and [x] OK \\| Proceed to next circuit Inspection shown on problem symptoms table (See page Di-19). > Repair or replace harness or connector.Di-98 DIAGNOSTICS _— ENGINE Check voltage between terminal ACT of engine ECU and body ground. 3 Sia PREPARATION: @ ACT (@ Remove the glove compartment door. (b) Start the engine. CHECK: Measure voltage between terminal ACT of engine ECU con- nector and body ground when A/C switch is turned to ON and OFF. OK: 7 "AG wich condtion votage ON a-4Vv OFF 0-3 > Check and replace A/C amplifier. [J 4 | Check voltage between terminal THWO of engine ECU and body ground. ON PREPARATION: @ Ue (@)_ Remove the glove compartment door. ‘| (b) Turn the ignition switch ON. CHEC! Measure voltage between terminal THWO of engine ECU and body ground. Ok: Voltage Is generated intermittently. TTHWO Signal Wavetorms 6v/ bv | Reference: INSPECTION USING OSCILLOSCOPE TTT) During idling, check waveform between terminals THWO and “| E1 of engine ECU. HINT: The correct waveform is as shown. | GND Water temp. | 30°C orless_| Approx. 75°C | 90°C or more A @5msec. | 395.8msec. | 363msec. THWO} CCeCCe Coo }00 msec/ Division (Idling) soso NG | Check and replace A/C amplifier.I-99 DIAGNOSTICS_—_ENGINE Check and replace engine ECU (See page IN-19). When not using hand-held tester 1 | Check voltage ee terminal ACT of engine ECU and body ground Gee page DI p 3). = OK \\| Check and replace engine ECU (See page IN-19). [J 2 | Check voltage between terminal THWO of engine ECU and body ground (See page DI-96, Step 4). OK \\| Check and replace engine ECU (See page IN-19). [J 3 | Check for open and short in harness and connector between engine ECU and AIC amplifier (See page IN-19). [oJ Check and replace A/C amplifier. NG | Repair or replace harness or connector.DE100 DIAGNOSTICS _~ ENGINE Diagnostic Connector (DLC3) Circuit CIRCUIT DESCRIPTION Terminals TC and CG are located in the DLC3. The DLC3 is located under the finish lower panel. When terminals TC and CG are connected, DTC in normal ‘mode or test mode can be read from the check engine waming light in the combination meter. Also, terminal SIL is located in the DLC3. This terminal is used by the M-OBD communication with hand— held tester. WIRING DIAGRAM Ci) Combination wow Meter 15 12 5 $B $B w 4 ike ame ‘CHEOK ENGINE IGT NO.1 Relay etal err a8 G aed Ge’ aa igike No.2 4h af oS 8 1 anno o 158 al? Engine Room JB Cowl Side pica J16 WiC PB 13 al J14 WiC a fl wep tc 4 ¥ E HB Battery ioDi-401 DIAGNosTICs_—_ENGINE RHO ‘Combination Meter 30/8 se] sa $8__ fife act Tike Cow Side JB LH GAUGE gg GAUGE 4 J BR 6p )e—fo-] Gn) isike— TeiKey ® Fusible Link Block Ee ei coo! J13UIC ENO? | [2 7 F Engine Room JB Le 8 eecae Ignition Switch owl Si pLc3 JBL 6 J22JI6 PB PB P-8 Tos 20 atte ie wesc § v-w v-w - [§ food sup >i A oY Ww a AUC TG ¥ 1 Wa A We | + TIRE ware “Ope Lax De VY iw =a V + JBLDi-102 DIAGNOSTICS _— ENGINE INSPECTION PROCEDURE 1 | Check the check engine warning light condition. [J PREPARATION: (@) Turn the ignition switch ON. (b) Using SST, connect the terminals TC and CG of DLC3. SST 09843-18040 CHECK: Check the check engine warming light condition. Ok: Check engine warning light : Blinking HINT: If this inspection OK and there is no hand-held tester, do not need to do the following steps and this circuit is OK. Proceed to next circuit inspection shown on problem symptom table (See page DI-19). OK | Goto step 7. 2 | Check voltage between terminals TC and CG of DLC3. Oe pica — cree PREPARATION: Tum the ignition switch ON. CHECK: Measure the voltage between terminals TC and CG of DLC3. Ok: Te [*] Voltage 9-14 V > Goto step 5.Di-103 DIAGNOSTICS_—_ENGINE 3 | Check continuity terminal CG of DLC3 and body ground. [*] NG_)| Repair or replace harness or connector. 4 | Check for open and short in harness and connector between terminal TC of DLC3 and terminal TC of engine ECU (See page IN-19). [x] NG | Repair or replace harness or connector. Check and replace engine ECU (See page IN-19). 5 | Check voltage between terminal W of engine ECU connector and body ground. Q™ ©, w O) E19 Connector srs te] PREPARATION: (a) Remove the glove compartment door. (b) Disconnect the "E19" connector of engine ECU. (c) _ Tum the ignition switch ON. CHECK: Measure voltage between terminal W of engine ECU connector and body ground. OK: Voltage :9-14V OK \\| Check and replace engine ECU (See page IN-19).Di-104 DIAGNOSTICS _—_ ENGINE 6 | Check the bulb of check engine warning light. Ne) Replace bulb. [J Check for open In harness and connector between terminal W of engine ECU and combination meter (See page IN-19). 7 |Can you read the DTC (including normal DTC) using hand-held tester? YES \\| Proceed to next circuit inspection shown on problem symptom table (See page D+-19). [J 8 | Check voltage between terminal BATT of DLC3 and body ground. ON DLC3 CHECK: - @ Measure voltage between terminal BATT of DLC3 and body fal ground. Ok: oy > | ~~ Voltage :9-14V Bart WY 1 val [NG\ [Check for open and short in harness and con- nector between terminal BATT of DLC3 and fus- ible link block (See page IN-19). OK KN Check for open and short in harness and connector between terminal SIL of DLC3 and terminal SIL of engine ECU (See page IN-19).DI-105 DIAGNOSTICS _— ENGINE Starter Signal Circuit CIRCUIT DESCRIPTION When the engine is being cranked, the intake air flow is slow, so fuel vaporization is poor. A rich mixture is therefore necessary in order to achieve good start ability. While the engine is being cranked, the battery posi- tive voltage is applied to terminal STA of the engine ECU. The starter signal is mainly used to increase the fuel injection volume for the starting injection control and after-start injection control. WIRING DIAGRAM Engine Room J/B Engine ECU ‘STARTER STARTER Rela 14 Efe 7 [2] Starter Neutral Start Switch Bw Hy sta GP BW f From ignition Switch =Di-106 DIAGNOSTICS _— ENGINE INSPECTION PROCEDURE When using hand-held tester HINT: This diagnostic chart is based on the premise that the engine is being cranked under normal conditions. If the engine does not crank, proceed to the problem symptoms table on page DI-19. 1 | Connect the hand-held tester and check STA signal. PREPARATION: (@) Connect the hand-held tester to the DLC3. (b) Tur the ignition switch ON and push the hand-held tester main switch ON. CHECK: Read STA signal on the hand-held tester while starter operates. Ok: Ignition switch poston ON STA, ‘STA signal ON, OK \\| Proceed to next circuit ing, problem symptoms table (§ tion shown on page Di-19). [] 2 (Marking : STARTER) (See page IN-19). Check for open in harness and connector between engine ECU and starter relay Repair or replace harness or connector. va) [J Check and replace engine ECU (See page IN-19).DI-107 DIAGNOSTICS — ENGINE When not using hand-held tester HINT: This diagnostic chart is based on the premise that the engine is being cranked under normal conditions. If the engine does not crank, proceed to the problem symptoms table on page DI-19. 1 | Check the starter signal. Oo STA PREPARATION: (@)_ Remove the glove compartment door. (b) Tum the ignition switch ON. CHECK: G v (+) [= J Measure voltage between terminal STA of engine ECU connec- tor and body ground during cranking. Ok: Voltage: 6.0 V or more OK \\| Proceed to next circuit inspection shown on problem symptoms table (See page DI-19), 2 | Check for open in harness and connector between engine ECU and starter relay (Marking : STARTER) (See page IN-19). NG | Repair or replace harness or connector. Check and replace engine ECU (See page IN-19).DH108 DIAGNOSTICS — ENGINE Neutral Start Switch Circ! (only for vehicles with A/T) CIRCUIT DESCRIPTION The neutral start switch goes on when the shift leveris in the N or P shift position. When it goes on the terminal NSW of the engine ECU is grounded to body ground via the starter relay thus the terminal NSW voltage be- comes 0 V. When the shift lever is in the D, 2, L or R position, the neutral start switch goes off, so the voltage of the engine ECU terminal NSW becomes battery positive voltage, the voltage of the engine ECU internal power source. Ifthe shift lever is moved from the N position to the D position, this signal is used for air-fuel ratio correction, for idle speed control (estimated control), etc. WIRING DIAGRAM Engine ECU Ignition Switch From Battery From 4 Battery BR 14. STARTER RELAY We Eo] et! BR Bw eS ©} Engine Room JBDi-109 DIAGNOSTICS _—_ENGINE INSPECTION PROCEDURE HINT: This diagnosis chart is based on the premise that the engine is being cranked under normal conditions. If the engine does not crank, proceed to the problem symptoms table on page DI-19. 1 | Check neutral start switch. PREPARATION: Disconnect the neutral start switch connector. CHECK: Check continuity between each terminal shown below when the shift lever is shifted to each pos Ok: Shit postion “orminal Noto continuity P 5-6 27) cores a 28 = N 5-6 2-9) ° 2-10 = 2 2-3 = L 24 a v0) Replace neutral start switch.Di-110 DIAGNOSTICS _~ ENGINE ground. 2 | Check voltage between terminal NSW of engine ECU connector and body [J PREPARATION: (@) Remove the glove compartment door. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminal NSW of engine ECU con- nector and body ground after the shift ever is moved to the fol lowing positions. Ok: ‘Shit lever postion Porn LadorR otege o-9v ontav > ‘Check and replace engine ECU (See page IN-19). engine ECt Check for open and short in harness and connector b i O’See page IN-19)- lor between neutral start switch andDein DIAGNOSTICS _—_ENGINE 4st Gear Position Switch Circuit (only for vehicles with M/T) CIRCUIT DESCRIPTION The shift position switch on the side of transmission detects the 1st gear and limits the engine output when the high load is applied during running in the 1st gear. WIRING DIAGRAM Engine ECU. JTC 2 Shift Position Switch 1 BR Poo eed ; 7 E64] ED (LHD) EC (RHD)benz INSPECTION PROCEDURE DIAGNOSTICS _— ENGINE 1 Check shift position switch (See page ED-12). [*] NG_ | Replace shift position switch. ground. 2 | Check voltage between terminal FSW of engine ECU connector and body NG — PREPARATION: (a) Remove the glove compartment door. (b) Turn the ignition switch ON. CHECI Measure voltage between terminal FSW of engine ECU con- nector and body ground after the shift lever is moved to the fol- lowing positions. Ok: ‘Shit over poston itgeer Except st gear Votage a-1v o-3v. OK \\| Check and replace engine ECU (See page IN-19). engine EC! Check for open and short in harness and connector between shift position swit gree ond sheet inh n shift position switch andDi413 DIAGNOSTICS _— ENGINE Spill Valve Relay Circuit CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery positive voltage is applied to the coil, closing the contacts of the spill valve relay (Marking : SPILIVLV) and supplying power to the terminal +B of the EDU. WIRING DIAGRAM Cow! Side J/B LH Engine ECU. SPILL BY re 8 Low 18 va 2h t : 9) l oe I From EFI Relay From EDU E01pena DIAGNOSTICS —_ENGINE INSPECTION PROCEDURE 1 | Check spill vaive relay (Marking : SPIL/VLV) (See page ED~). [o] NG )] Replace spill valve relay. 2 | Check voltage between terminal SVR of engine ECU connector and body ground. SVR [=] PREPARATION (@)_ Remove the glove compartment door. (b) Tum the ignition switch ON. CHECK: Measure voltage between terminal SVR of engine ECU con- ector and body ground. Ok: “~~ Voltage: -15V OK \\| Check and replace engine ECU (Gee page IN-19). Check for open in harness and connector between engine ECU and spill valve relay (Marking : SPIL/VLV) and spill valve relay and EDU (See page IN-19).Deis DIAGNOSTICS — ENGINE Heater Idle-Up Switch Circuit CIRCUIT DESCRIPTION When the vehicle is stopped with the power heater switch on the left side (LHD) or right side (RHD) of the ignition switch ON, the engine ECU controls the spill control valve to idle-up. However, itis OFF during en- gine starting, A/C operating and acceleration (with the vehicle speed at less than 30 km/h (19 mph) and ac- celerator pedal opening at 45 % or more for 5 seconds). Viscous Heater Magnetic Clutch Viscous Heater | Power Heater Switch vuc. vsw Idle-Up From AC MG _ACS. VCH HSW Clutch Signal | Macous el ear Tl injection mn Ecu Pump From Ignition >| Amplifier Switch 16 eee’ ver | Engine Speed Control Water Temperature Control 2000 2500 (rpm) 69 74 (0)pen6 DIAGNOSTICS ENGINE WIRING DIAGRAM LHD Cow! Side J/B LH Jc w-8 28) 7 x Viscous Heater Ampitier Engine ECU. Engine Room J/B 10 B-Y _figake8- ‘S15 JIC 3 8 gtk BA . 8 | |v 2 Viscous 6 [IF2. Heater Relay 7% 16 eke 1S Cow! Side J/B RH 2) 2 ae J32uic' $8 77 $B, Viscous Heater LE eta | Battery la] Magnetic Clutch 5 VvDIAGNOSTICS_—_ENGINE peN7 RHD Cowl Side WB LH i 28 we8 Viscous 1 Heater VY Bol 5 eB Amplifier Engine ECU P WB 4 YR 2 2 iN 8 i MG CLT Engine Room J/B rg SiNt 10 J11 WC fea Bt cl XB VB fe u \7 < rc g g IF Bj2 |b p59 8 8 e [Fz 2] 19| Heater Relay Ietke 8} 8. 5[b sie ; z ar i AUT § {Tink Biock par ke Pots ng} Pot Cow! Side JIB RH i rea oglSQ'oe * | patter Viscous Heater LET B fide ole Magnetic Clutch + YDig DIAGNOSTICS ENGINE INSPECTION PROCEDURE 1 | Check power heater switch. HEATER [x] PREPARATION: (@)_ Remove the lower finish panel, (b) Remove the power heater switch. CHECK: ‘Check continuity between each terminal. ‘Switch postion Tester connection Spoctied condtion OFF, 3-4 No contiity ON 3-4 Continuity Niunination excuit 12 Continuity > Replace power heater switch. 2 | AIC Cut Control Ci uit (See page DI-96). NG | Check and replace A/C amplifier. 3 | Check voltage between terminal VCH of engine ECU and body ground. PREPARATION: (@) Remove the glove compartment door. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminal VCH of engine ECU con- nector and body ground when heater blower switch is turned to OFF and ON. o ce soos Heater ower svch condition ‘vokage OFF on 14v ‘ON, 0-3V "> Goto step 5.pine DIAGNOSTICS _—_ENGINE 4 | Check for open and short in harness and connector between engine ECU and viscous heater amplifier (See page IN-19) [*] va) Repair or replace harness or connector. Check and replace viscous heater ampli 5 | Check voltage between terminal VCT of engine ECU and body ground. PREPARATION: (@) Remove the glove compartment door. (b) Turn the ignition switch ON. CHECK: ‘Measure voltage between terminal VCT of engine ECU con- nector and body ground when heater blower switch is turned to OFF and ON. [J OK: Hele blower swish condition Yotage OFF o14v on o-3v OK \\| Check and replace engine ECU (See page IN-19). 6 | Check for open and short in harness and connector between engine ECU and viscous heater amplifier (See page IN-19). [*] > Repair or replace harness or connector.Di-120 DIAGNOSTICS —_ENGINE 7 | Check voltage between terminal HSW of engine ECU and body ground. On PREPARATION: (a) Remove the glove compartment door. (b) Turn the ignition switch ON. CHECK: Measure voltage between terminal HSW of engine ECU con- nector and body ground when power heater switch is pushed to OFF and ON. Ok: Power neater switch condtion Votage OFF ov ON o-3V ‘OK \\| Check and replace engine ECU (See page IN-19). 8 | Check for open and short in harness and connector between injection pump and viscous heater amplifier (See page IN-19). [«] Check and replace injection pump (See page FU-113). NG _ | Repair or replace harness or connector.ENGINE MECHANICAL AIR FILTER . EM+4 COMPRESSION EM2 VALVE CLEARANCE (1HZ, 1HD-T) EMS VALVE CLEARANCE (1HD-FTE) EM INJECTION TIMING (HZ, 1HD-T) EM-i1 INJECTION TIMING (1HD-FTE) EM-14 IDLE SPEED AND MAXIMUM SPEED (1HZ, 1HD-T) ews El IDLE SPEED AND MAXIMUM SPEED (HD-FTE) 2. sees = EMH7 AIR CONDITIONER IDLE-UP SPEED (1HZ, THD=T) oe. ; EM-18 AIR CONDITIONER IDLE-UP SPEED (1HD-FTE) . : EM-49 INTAKE SHUTTER (1HO-FTE) . EM-20 TIMING BELT. EM-25 TIMING GEAR EM-34 CYLINDER HEAD (1HZ, 1HD-T) .. EN-47 CYLINDER HEAD (1HD-FTE) ~ EN-74 CYLINDER BLOCK . EM-100EM ENGINE MECHANICAL — AIR FILTER. A ON-VEHICLE CLEANING 1. (a) (b) (©) (@) IR FILTER PAPER FILTER TYPE: Remove air filter Inspect air filter Visually check that the fitter element is not excessively dirty, damaged or oily. Clean air filter ‘Clean the filter element with compressed air. First blow from the inside thoroughly. Then blow off the outside of the filter element. Reinstall air filter WASHABLE TYPE: Remove air filter Inspect air filter Visually check that the filter element is not excessively dirty, damaged or oily. Clean air filter (1) Blow dirt off in the filter element with compressed air. (2) Submerge the fiter element in the water and agitate it up and down more than 10 times. (3) Repeat ringing in clean water until rinsing water is clear. (4) Remove excess water by shaking the filter element or blowing with compressed air. NOTICE: Do not beat or drop filter element. (6) Wipe off dust on the air cleaner case interior. Reinstall air filterENGINE MECHANICAL COMPRESSION COMPRESSION INSPECTION HINT: IF there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature. 2. REMOVE INTAKE PIPE ASSEMBLY 1HZ, 1HD-T: (See page EM-48) 1HD-FTE: (See page EM-77) 3. 1HD-FTE: REMOVE NO.2 CYLINDER HEAD COVER (See page EM-77) 4, 1HD-FTE: REMOVE NO.1 CYLINDER HEAD COVER (See page EM-77) 5. 1HZ, 1HD-T: REMOVE CYLINDER HEAD COVER (See page EM-48) 6. REMOVE INJECTION PIPES 1HZ, 1HD-T: (See page FU-7) 1HD-FTE: (See page FU-33) 7. REMOVE NOZZLE LEAKAGE PIPE 1HZ, 1HD-T: (See page EM-48) 1HD-FTE: (See page EM-48) 8. DISCONNECT INJECTION PUMP (FUEL CUT SOLE- NOID) CONNECTOR 9. _ CHECK CYLINDER COMPRESSION PRESSURE NOTICE: When measuring the compression pressure of each, the other 5 injection nozzles must be installed in the cylinder head. (a) Remove the injection nozzle. 1HZ: (See page FU-7) 1HD-T: (See page FU-17) 1HD FTE: (See page FU-33)EM3 ENGINE MECHANICAL _— COMPRESSION (b) Install the gasket and SST (attachment) to the injection nozzle hole with the nozzle holder clamp and bolt. SST 09992-00400 Torque: 25 N-m (255 kgf-cm, 18 ft-lbf) (©) Connect SST (compression gauge) to the SST (attach- ment). SST 09992-00025 (09992-00160) () While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine revolution of 250 rpm or more. (e) _ Repeat steps (b) through (d) for each cylinder. NOTICE: ‘This measurement must be done in as short a time as pos- sible. Compression pressure: STD: 4HZ: 3,628 kPa (37.0 kgf/cm?, 526 psi) or more 4HD-T, 1HD-FTE: 3,432 kPa (35.0 kgt/cm?, 498 psi) or more Minimum pressure: 4HZ: 2,648 kPa (27.0 kgt/om?, 384 psi) 1HD-T, 1HD-FTE: 2,452 kPa (25.0 kgf/cm?, 356 psi) Difference between each cylinder: 490 kPa (5.0 kgficm?, 71 psi) or less (f) Ifthe cylinder compression in one or more cylinders is low, pour a small amount of engine oil into the oylinder through the injection nozzle hole and repeat steps (b) through (d) for the cylinder with low compression.eM4 ENGINE MECHANICAL — COMPRESSION _ @ (h) 10. 1". 12. 13. 14, 15. 16. 17. If adding oil helps the compression, chances are that the piston rings and or cylinder bore are worn or damaged. If pressure stays low, a valve may be sticking or seating improperly, or there may be leakage past the gasket. Remove the SST. SST 09992-00400, 09992-00025 (09992-00160) Reinstall the injection nozzle. AHZ: (See page FU-13) 1HD-T: (See page FU-30) 1HD-FTE: (See page FU-44) RECONNECT INJECTION PUMP (FUEL CUT SOLE- NOID) CONNECTOR REINSTALL NOZZLE LEAKAGE PIPE 1HZ, 1HD-T: (See page EM-66) 1HD-FTE: (See page EM-94) REINSTALL INJECTION PIPES 1HZ, 1HD-T: (See page FU-13) 1HD-FTE: (See page FU-44) 4HZ, 1HD-T: REINSTALL CYLINDER HEAD COVER (See page EM-66) 4HD-FTE: REINSTALL NO.1 CYLINDER HEAD COVER (See page EM-94) 4HD-FTE: REINSTALL NO.2 CYLINDER HEAD COVER (See page EM-94) REINSTALL INTAKE PIPE ASSEMBLY 1HZ, 1HD-T: (See page EM-66) 1HD-FTE: (See page EM-94) START ENGINE AND CHECK FOR LEAKSEMS ENGINE MECHANICAL — VALVE CLEARANCE (1HZ, 1HO-T) VALVE CLEARANCE (1HZ, 1HD-T) INSPECTION 1. REMOVE INTAKE PIPE ASSEMBLY (See page EM-48) 2. REMOVE CYLINDER HEAD COVER (See page EM-77) 3. SETNO.1 CYLINDER TO TDC/COMPRESSION (2) Turncrankshatt pulley clockwise, and align its groove with the timing gear cover groove. (b) Check that the valve lifters on the No.1 cylinder are loose and valve liters on the No.6 cylinder are tight. If not, turn the crankshaft one revolution (360°) and align the mark as above. 4, INSPECT VALVE CLEARANCE (a) Check only those valves indicated in the illustration. + Using a feeler gauge, measure the clearance be- tween the valve lifter and camshaft. + Record the out of specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): EX Xe neX a Intake 0.15 — 0.25 mm (0.006 - 0.010 in.) Exhaust 0.35 - 0.45 mm (0.014 - 0.018 in.) (b) Turn the crankshaft one revolution (360°) and align the mark as above (See step 3). (c) Check only the valves indicated in the illustration. Measure the valve clearance (See step 3).ENGINE MECHANICAL — VALVE CLEARANCE (1H2, 1HO-1) (d) Remove the adjusting shim. + Tum the crankshatt to position the cam lobe of the camshaft on the adjusting valve upward. + Using SST press down the valve litter. SST 09248-64011 HINT: Before pressing down the valve lifter position the notch on the ‘exhaust manifold side. + Remove the adjusting shim with a small screwdriver and magnetic finger. (@) Determine the replacement adjusting shim size by using following (Formula or Charts). + Using a micrometer measure the thickness of the removed shim, + Calculate the thickness of the new shim so the valve clearance comes within specified valve. T..... Thickness of used shim A... Measured valve clearance N. Thickness of new shim Intake N= T + (A-0.20 mm (0.008 in.)) Exhaust N = T + (A —0.40 mm (0.016 in.)) + Select anew shim with a thickness as close as pos- sible to the calculated values. HINT: Shims are available in twenty sizes in increments of 0.05 mm (0.0020 in.) from 2.35 mm (0.0825 in.) to 3.30 mm (0.1299 in.) (f)__ Install a new adjusting shim. + Place anew adjusting shim on the valve lifter. + Remove SST. SST 09248-64011 (g) Recheck the valve clearance. 5. REINSTALL CYLINDER HEAD COVER (See page EM-66) 6. REINSTALL INTAKE PIPE ASSEMBLY (See page EM-66)eEM7 ENGINE MECHANICAL _— VALVE CLEARANCE (1HZ, 1HD-7) Adjusting Shim Selection Using Chart (Intake) =e Newshimthickness _mm{(in.) ‘shin ‘shir Stin| Thickness | St} Trckness 709 |2:35(0.0925)] «5 _[205(0.1122) 704] 240(0-0945), 21 [290 0.1142) 710 245;0.0868)| 46 01 [2so:0.0984)| 26 {a.00,0.1181 [ee [2s8610.1000] «7 |3.05¢0.1200) {05 [ecowo.1020)! 31_|5.1010.1220)| 43 [2.65(0.1065)| 4e_[815(0.1240) 1 |270(01069)| 95 [3200-1260 4 |2.75(0.1085)| 49 |.25(0.1200) [is J280(0.1102] 41_[8:30(0.1200) Intake valve clearance (Cold): (0.15 — 0.25 mm (0.006 0.010 in.) EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed and the measured clearance is 0.300 mm (0.0118 in.) Replace the 2.800 mm (0.1102 in.) shim with a No. 21 shim.