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Motor cd20 PDF
Motor cd20 PDF
SECTION EC
EC
CONTENTS
CD20T ON BOARD DIAGNOSTIC SYSTEM
DESCRIPTION ......................................................... 25
PRECAUTIONS AND PREPARATION ..................... 3
DTC and MI Detection Logic ............................... 25
Special Service Tools ............................................ 3
Diagnostic Trouble Code (DTC) .......................... 25
Engine Fuel & Emission Control System .............. 4
Malfunction Indicator (MI) .................................... 26
Precautions ............................................................ 5
CONSULT-II......................................................... 30
ENGINE AND EMISSION CONTROL OVERALL
TROUBLE DIAGNOSIS — Introduction................ 36
SYSTEM..................................................................... 7
Introduction .......................................................... 36
Engine Control Module Component Parts
Diagnostic Worksheet .......................................... 37
Location.................................................................. 7
TROUBLE DIAGNOSIS — Work Flow .................. 38
Circuit Diagram ...................................................... 9
Work Flow ............................................................ 38
System Diagram .................................................. 10
Description for Work Flow ................................... 39
Vacuum Hose Drawing ........................................ 11
TROUBLE DIAGNOSIS — Basic Inspection ........ 40
System Chart ....................................................... 12
Basic Inspection................................................... 40
ENGINE AND EMISSION BASIC CONTROL
TROUBLE DIAGNOSIS — General Description .. 42
SYSTEM DESCRIPTION ......................................... 13
Diagnostic Trouble Code (DTC) Chart ................ 42
Glow Control System ........................................... 13
Symptom Matrix Chart ......................................... 50
Fuel Injection System .......................................... 13
CONSULT-II Reference Value in Data Monitor
Fuel Injection Timing System .............................. 16
Mode .................................................................... 53
Air Conditioning Cut Control ................................ 18
Major Sensor Reference Graph in Data
Cooling Fan Control............................................. 18
Monitor Mode ....................................................... 54
CRANKCASE VENTILATION SYSTEM ................. 19
ECM Terminals and Reference Value................. 55
Description ........................................................... 19
TROUBLE DIAGNOSIS FOR POWER SUPPLY.... 62
Blow-by Control Valve ......................................... 19
Main Power Supply and Ground Circuit .............. 62
Ventilation Hose................................................... 19
TROUBLE DIAGNOSIS FOR DTC 12 .................... 65
INJECTION NOZZLE............................................... 20
Mass Air Flow Sensor (MAFS) ............................ 65
Removal and Installation ..................................... 20
TROUBLE DIAGNOSIS FOR DTC 13 .................... 69
Test and Adjustment............................................ 20
Engine Coolant Temperature (ECT) Sensor ....... 69
ELECTRONIC FUEL INJECTION PUMP................ 22
TROUBLE DIAGNOSIS FOR DTC 14 .................... 73
Removal ............................................................... 22
Vehicle Speed Sensor (VSS) .............................. 73
Installation ............................................................ 23
TROUBLE DIAGNOSIS FOR DTC 15 .................... 76
Disassembly and Assembly................................. 24
Control Sleeve Position Sensor (CSPS) ............. 76
TROUBLE DIAGNOSIS FOR DTC 18 .................... 80 TROUBLE DIAGNOSES FOR DTC 83, 98........... 123
Electric Governor ................................................. 80 Glow Control System ......................................... 123
TROUBLE DIAGNOSIS FOR DTC 21 .................... 85 TROUBLE DIAGNOSES FOR DTC 85................. 131
Injection Timing Control Valve............................. 85 Air Conditioner Cut Control................................ 131
TROUBLE DIAGNOSIS FOR DTC 31, 82, 84, TROUBLE DIAGNOSES FOR DTC 86................. 134
91, 93 ....................................................................... 90 EGRC-Solenoid Valve ....................................... 134
Engine Control Module (ECM)............................. 90 TROUBLE DIAGNOSES FOR DTC 87................. 141
TROUBLE DIAGNOSIS FOR DTC 28 .................... 91 Brake Switch ...................................................... 141
Cooling Fan (Overheat) ....................................... 91 TROUBLE DIAGNOSES FOR DTC 92................. 145
TROUBLE DIAGNOSIS FOR DTC 34 .................. 101 ECCS-D Relay ................................................... 145
Needle Lift Sensor (NLS)................................... 101 TROUBLE DIAGNOSES FOR DTC 97................. 146
TROUBLE DIAGNOSIS FOR DTC 36 .................. 104 MI & Data Link Connectors ............................... 146
Fuel Cut Solenoid Valve .................................... 104 TROUBLE DIAGNOSES FOR
TROUBLE DIAGNOSIS FOR DTC 42 .................. 108 NON-DETECTABLE ITEMS .................................. 149
Fuel Temperature Sensor (FTS) ....................... 108 Start Signal ........................................................ 149
TROUBLE DIAGNOSIS FOR DTC 43 .................. 112 SERVICE DATA AND SPECIFICATIONS (SDS) . 151
Accelerator Position Sensor & Switch ............... 112 General Specifications ....................................... 151
TROUBLE DIAGNOSIS FOR DTC 47 .................. 119 Injection Nozzle.................................................. 151
Crankshaft Position Sensor (TDC) .................... 119 Inspection and Adjustment ................................ 151
EC-CD-2
PRECAUTIONS AND PREPARATION CD20T
Tool number
Description
Tool name
KV11289004
Nozzle cleaning kit
V1 KV11290012
Box
V KV11290110
2
Brush
V KV11290122
3
Nozzle oil sump
scraper
V KV11290140
4
X
Nozzle needle tip
cleaner
V KV11290150
5
Nozzle seat scraper
V KV11290210
6
Nozzle holder
V KV11290220
7
Nozzle hole cleaning
needle
NT296
KV11292010
Nozzle centering device
NT293
KV11100300
No. 2-4 injection nozzle
holder socket
X
NT563
KV119E0030
No. 1 injection nozzle
holder socket
NT648
EC-CD-3
PRECAUTIONS AND PREPARATION CD20T
ECM mainframe
ELECTRONIC FUEL INJECTOR PUMP
● Do not disconnect pump harness connectors
with engine running.
● Do not disassemble or adjust electronic fuel
injection pump, except for the following
parts.
Camshaft position sensor (pump)
Injection timing control valve
Fuel cut solenoid valve
NEF390
EC-CD-4
PRECAUTIONS AND PREPARATION CD20T
Precautions
● Before connecting or disconnecting the ECM harness
connector, turn ignition switch OFF and disconnect
negative battery terminal. Failure to do so may damage
the ECM because battery voltage is applied to ECM even
if ignition switch is turned off.
SEF289H
Tighten
NEF754
PULL
to open
ports
Slider
Harness connector NEF755
MEF040D
EC-CD-5
PRECAUTIONS AND PREPARATION CD20T
Precautions (Cont’d)
● When measuring ECM signals with a circuit tester, never
allow the two tester probes to contact.
Battery Accidental contact of probes will cause a short circuit
voltage and damage the ECM power transistor.
Harness connector
Short
for solenoid valve ECM
NG
Solenoid valve
OK
Circuit tester
SEF348N
EC-CD-6
ENGINE AND EMISSION CONTROL OVERALL SYSTEM CD20T
Fuel filter
Engine coolant temperature sensor
Mass air flow sensor
Glow relay
Glow plugs
NEF767
EC-CD-7
ENGINE AND EMISSION CONTROL OVERALL SYSTEM CD20T
Engine Control Module Component Parts
Location (Cont’d)
Electric governor.
Control sleeve position sensor
and fuel temperature sensor
(built-in)
Accelerator pedal
Crank pulley
.
Crankshaft position
sensor (TDC)
ECM
.
Accelerator pedal (LHD)
NEF768
EC-CD-8
DATA LINK
CONNECTOR
FUSIBLE LINK
FUSE
30 64 38 61
MALFUNCTION
IGNITION SWITCH
INDICATOR LAMP
26 ON or START
ENGINE CONTROL
MODULE RELAY 68 GLOW INDICATOR
FUSE LAMP
23 27
45
42
43
GLOW RELAY SPEED-
9 IGNITION SWITCH
OMETER
50 ON
11 NEEDLE
BATTERY
LIFT
12 SENSOR
IGNITION SWTICH BATTERY
OFF ON ON ST ACCELERATOR WORK UNIT VEHICLE
SPEED
ACCELERATOR
SENSOR
POSITION SWITCH
FUSE GLOW PLUG 65
16
55 ACCELERATOR
15 POSITION
SENSOR AIR
57 CONDITIONER
THERMO
INJECTION PUMP CONTROL CONTROL
MASS AIR AMP. PANEL
13 INJECTION TIMING
FLOW
RELAY-3
RELAY-2
RELAY-1
19 CONTROL VALVE
SENSOR
51
COOLING FAN
COOLING FAN
COOLING FAN
EC-CD-9
THERMISTOR
FUEL CUT SOLENOID
47 VALVE
54 53
Circuit Diagram
MOTOR-1
MOTOR-2
63
TEMPERATURE
29 CONTROL
SENSOR
COOLING FAN
COOLING FAN
SLEEVE
(INJECTION PUMP) 52
POSITION
7 SENSOR
NATS IMMU 59
RDNT
BRAKE TACHOMETER 2 33
SWITCH
20 62
39
STOP LAMP SWITCH CRANKSHAFT TRIPLE- AIR
44 21
POSITION PRESSURE CONDITIONER
46 8 RELAY
SENSOR SWITCH
24
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
(TDC)
EGRC-SOLENOID 1
VALVE 28 To compressor
25
CD20T
YEC080
Battery
EVAP canister
Injector Vehicle speed sensor
EVAP canister purge volume Heated oxygen sensor
control solenoid valve
EC-CD-10
Throttle
position
sensor
Three way Neutral position/
System Diagram
SR20De
Mass air flow IACV-AAC manifold
IACV-FICD solenoid valve
sensor (Hot wire type) valve
Power steering oil
Muffler pressure switch
SR20DE
under oilpan
Three way catalyst
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
SEF830S
ENGINE AND EMISSION CONTROL OVERALL SYSTEM CD20T
V
2
V
3
Vacuum pump
Air duct
V
1
EGR valve
NEF770
V
1 EGRC-solenoid valve to EGR valve
V
2 EGRC-solenoid valve to air duct
V
3 EGRC-solenoid valve to vacuum pump
EC-CD-11
ENGINE AND EMISSION CONTROL OVERALL SYSTEM CD20T
System Chart
Vehicle speed sensor c Air conditioning cut control Air conditioner relay
c c
Brake switch c
EC-CD-12
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION CD20T
START CONTROL
Input/output signal line
Engine coolant temperature
Engine coolant temperature sensor c
When starting, the ECM adapts the fuel injection system for the
start control. The amount of fuel injected at engine starting is a
Coolant temperature preset program value in the ECM. The program is determined by
Fuel injection volume
getting lower
the engine speed and engine coolant temperature.
For better startability under cool engine conditions, the lower the
coolant temperature becomes, the greater the amount of fuel
injected. The ECM ends the start control when the engine speed
reaches a coolant temperature dependent value.
Engine rpm
SEF648S
EC-CD-13
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION CD20T
Fuel Injection System (Cont’d)
IDLE CONTROL
Input/output signal line
Engine coolant temperature
Engine coolant temperature sensor c
Engine speed
Crankshaft position sensor (TDC) c
Idle position
Accelerator position switch c
Vehicle speed
Vehicle speed sensor c
When the ECM determines that the engine speed is at idle, the fuel injection system is adapted for the idle
control. The ECM regulates the amount of fuel injected corresponding to changes in load applied to the
engine to keep engine speed constant. During the first 270s after a cold start, the ECM also provides the
system with a fast idle control in response to the engine coolant temperature.
NORMAL CONTROL
Input/output signal line
Engine speed
Crankshaft position sensor (TDC) c
Vehicle speed
Vehicle speed sensor c
EC-CD-14
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION CD20T
Fuel Injection System (Cont’d)
FUEL TEMPERATURE COMPENSATION
Input/output signal line
Fuel temperature
Fuel temperature sensor c
The amount of fuel leaking at or around high-pressure parts inside the fuel injection pump varies with fuel
temperature and engine speed. This will result in a difference between the target amount of fuel injected
and the actual amount. The ECM compensates for the actual amount depending on the signal from the fuel
temperature sensor, the control sleeve position sensor and the crankshaft position sensor.
DECELERATION CONTROL
Input/output signal line
Accelerator position
Accelerator sensor c
Electric
ECM c governor
Engine speed
Camshaft position sensor (PUMP) c
The ECM cuts power supply delivery to the electric governor during deceleration for better fuel efficiency.
The ECM determines the time of deceleration according to signals from the accelerator sensor and cam-
shaft position sensor (PUMP).
EC-CD-15
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION CD20T
Small
Engine rpm
SEF650S
Injection timing
Needle lift sensor c
Fuel temperature
Fuel temperature sensor c
For better drivability in high altitude areas, the fuel injection tim-
ing is advanced and the fuel quantity is reduced according to the
atmospheric pressure.
timing compensation
Normal
Fuel injection
High altitude
Engine rpm
NEF771
EC-CD-16
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION CD20T
Fuel Injection Timing System (Cont’d)
ENGINE COOLANT TEMPERATURE COMPENSATION (During driving)
Input/output signal line
Engine speed
Crankshaft position sensor (TDC) c
temperature
Low
Fuel injection
High
Engine rpm
SEF652S
Injection
Engine coolant temperature ECM
Engine coolant temperature sensor c c timing con-
trol valve
Ignition timing
Needle lift sensor c
For better startability under cool engine conditions, the fuel injec-
tion timing is compensated according to the engine coolant tem-
Engine coolant
perature.
timing compensation
temperature
Fuel injection
High
Low
Engine rpm
SEF651S
EC-CD-17
ENGINE AND EMISSION BASIC CONTROL SYSTEM DESCRIPTION CD20T
SYSTEM DESCRIPTION
This system improves acceleration when the air conditioner is used.
When the accelerator pedal is fully depressed, the air conditioner is turned off for a few seconds.
When engine coolant temperature becomes excessively high, the air conditioner is turned off. This contin-
ues until the coolant temperature returns to normal.
The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, and air
conditioner ON signal. The control system has 3-step control [OFF/LOW/HIGH].
Operation
Air conditioner is OFF Air conditioner is ON
temperature °C (°F)
temperature °C (°F)
Engine coolant
Engine coolant
. .
102 (216) 102 (216)
. .
96 (205) 96 (205)
. . . .
20 80 20 80
(12) (50) (12) (50)
Vehicle speed km/h (mph) Vehicle speed km/h (mph)
Cooling fans do not operate Cooling fans operate at low speed Cooling fans operate at high speed
NEF772
EC-CD-18
CRANKCASE VENTILATION SYSTEM CD20T
Blow-by control
Description
valve ● In this system blow-by gas is sucked into the air inlet pipe
through the control valve after oil separation by the oil sepa-
rator in the rocker cover.
Baffle plate
FRESH AIR
BLOW BY
GAS
SEF851S
Intake
manifold
Rocker cover
SEC586B
Ventilation Hose
1. Check hoses and hose connections for leaks.
2. Disconnect all hoses and clean with compressed air.
If any hose cannot be freed of obstructions, replace.
SEC692
EC-CD-19
INJECTION NOZZLE CD20T
CAUTION:
● Do not disassemble injection nozzle assembly. Entrust
disassembly or adjustment to BOSCH service shop.
● Plug flare nut with a cap or rag so that no dust enters the
nozzle.
NEF774
EF791A
EC-CD-20
INJECTION NOZZLE CD20T
Test and Adjustment (Cont’d)
2. Pump the tester handle slowly (one time per second) and
watch the pressure gauge.
3. Read the pressure gauge when the injection pressure just
starts dropping.
Initial injection pressure:
Used
14,423 - 15,651 kPa
(144.2 - 156.5 bar,
148 - 159 kg/cm2, 2,091 - 2,269 psi)
New
SEF672A 15,000 - 16,000 kPa
(150.0 - 160.0 bar,
153 - 163 kg/cm2, 2,175 - 2,320 psi)
Always check initial injection pressure using a new nozzle.
If the pressure is not correct, replace nozzle assembly.
LEAKAGE TEST
1. Maintain the pressure at about 981 to 1,961 kPa (9.8 to 19.6
bar, 10 to 20 kg/cm2, 142 to 284 psi) below initial injection
pressure.
2. Check that there is no dripping from the nozzle tip or around
the body.
3. If there is leakage, replace nozzle.
Good Faulty
SEF674A
EC-CD-21
ELECTRONIC FUEL INJECTION PUMP CD20T
13 - 18
(1.3 - 1.8, 9 - 13)
Front of engine
16 - 21
(1.6 - 2.1, 12 - 15)
31 - 37 (3.2 - 3.8, 23 - 27)
V
1 Rear back cover V
4 Water connector V
7 Electronic fuel injection pump
V
2 Injection pump sprocket V
5 Bracket V
8 Key
V
3 Injection pump bracket V
6 Bracket
Removal
1. Remove battery.
Disconnect electronic injection pump harness connectors.
SEF655S
EC-CD-22
ELECTRONIC FUEL INJECTION PUMP CD20T
Removal (Cont’d)
6. Remove injection pump sprocket with Tool.
● Remove key from injection pump shaft and store safely.
SEF656S
SEF657S
NEF866
EC-CD-23
ELECTRONIC FUEL INJECTION PUMP CD20T
Installation (Cont’d)
O-ring
Washer
EC-CD-24
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CD20T
1. Touch ‘‘Engine’’. 2. Touch ‘‘SELF-DIAG RESULTS’’. 3. Touch ‘‘ERASE’’. (The DTC in the
ECM will be erased.) C2SSE03
EC-CD-25
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CD20T
Diagnostic Trouble Code (DTC) (Cont’d)
HOW TO ERASE DTC (No Tools)
1. If the ignition switch stays ‘‘ON’’ after repair work, be sure to turn ignition switch to ‘‘LOCK’’ position once.
Wait at least 5 seconds and then turn it ‘‘ON’’ again.
2. Change the diagnostic test mode from Mode II to Mode I twice. When changing modes, wait at least 2
seconds. (Refer to EC-CD-27.)
1. BULB CHECK : This function checks the MI bulb for damage (blown, open circuit, etc.).
2. MALFUNCTION : This is a usual driving condition. When a malfunction is detected, the
WARNING MI will light up to inform the driver that a malfunction has been
detected.
3. SELF-DIAGNOSTIC : This function allows diagnostic trouble codes to be read.
RESULTS
EC-CD-26
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CD20T
Malfunction Indicator (MI) (Cont’d)
HOW TO SWITCH DIAGNOSTIC TEST MODES
.
DIAGNOSTIC TEST MODE II
— SELF-DIAGNOSTIC RESULTS
Data link connector for CONSULT-II (Connect ● Switching the diagnostic test mode is not possible when
CHK and IGN terminals with a suitable harness.) the engine is running.
EC-CD-27
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CD20T
Malfunction Indicator (MI) (Cont’d)
DIAGNOSTIC TEST MODE I — BULB CHECK
In this mode, the MALFUNCTION INDICATOR on the instrument panel should stay ON. If it remains OFF,
check the bulb. Refer to EL section (‘‘WARNING LAMPS AND CHIME’’) or see EC-CD-27.
DIAGNOSTIC TEST MODE I — MALFUNCTION WARNING
MALFUNCTION
Condition
INDICATOR
When the malfunction is detected or the ECM’s CPU is malfunctioning. (The ‘‘MI Illumination’’ of the
ON
‘‘DTC Chart’’.) Refer to EC-CD-43.
OFF No malfunction.
● These Diagnostic Trouble Code Numbers are clarified in Diagnostic Test Mode II (SELF-DIAGNOSTIC
RESULTS).
DIAGNOSTIC TEST MODE II — SELF-DIAGNOSTIC RESULTS
In this mode, a diagnostic trouble code is indicated by the number of flashes of the MALFUNCTION INDI-
CATOR as shown below.
Example: Diagnostic trouble code No. 12 and code No. 43
0.6 0.3 0.6 0.3
ON
OFF
Long (0.6 second) flashes indicate the number of ten digits, and short (0.3 second) flashes indicate the
number of single digits. For example, the malfunction indicator flashes 4 times for 0.6 sec and then it flashes
three times for about 0.3 sec. This indicates the DTC ‘‘43’’ and refers to the malfunction of the accelerator
position sensor.
In this way, all the detected malfunctions are classified by their diagnostic trouble code numbers. The DTC
‘‘55’’ refers to no malfunction. (See DIAGNOSTIC TROUBLE CODE CHART, EC-CD-44.)
HOW TO ERASE DIAGNOSTIC TEST MODE II (Self-diagnostic results)
The diagnostic trouble code can be erased from the backup memory in the ECM when the diagnostic test
mode is changed twice from Diagnostic Test Mode II to Diagnostic Test Mode I. (Refer to ‘‘HOW TO SWITCH
DIAGNOSTIC TEST MODES’’ on previous page.)
● If the battery terminal is disconnected, the diagnostic trouble code will be lost from the backup
memory within 24 hours.
● Be careful not to erase the stored memory before starting trouble diagnoses.
● If the MI blinks or ‘‘NATS MALFUNCTION’’ is displayed
on ‘‘SELF-DIAG RESULTS’’ screen, perform self-diag-
nostic results mode with CONSULT-II using NATS pro-
gram card (NATS-E940). Refer to EL section.
● Confirm no self-diagnostic results of NATS is displayed
before touching ‘‘ERASE’’ in ‘‘SELF-DIAG RESULTS’’
mode with CONSULT-II.
● When replacing ECM, initialisation of NATS system and
registration of all NATS ignition key IDs must be carried
out with CONSULT-II using NATS program card (NATS-
C2SDR02 E940).
Therefore, be sure to receive all keys from vehicle
owner. Regarding the procedures of NATS initialisation
and NATS ignition key ID registration, refer to CON-
SULT-II operation manual, NATS.
EC-CD-28
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CD20T
Malfunction Indicator (MI) (Cont’d)
RELATIONSHIP BETWEEN MI, DTC, CONSULT-II AND DRIVING PATTERNS
SELF-DIAGNOSTIC FINISH
TIME
START
1*
MI ON
OFF
STOP
4*
CONSULT-II
SELF- DTC exist
DIAGNOSTIC
RESULTS
DTC does
SCREEN
not exist
&
DATA MONITOR
(AUTO TRIG) 39
4 5
SCREEN 3
2
0 0 0 1
SELF- COUNTER
DIAGNOSTIC
RESULTS
SCREEN
NEF764
*1: When a malfunction is detected, MI will light up. *4: Other screens except SELF-DIAGNOSTIC RESULTS &
*2: When a malfunction is detected for the first time, the DTC DATA MONITOR (AUTO TRIG) cannot display the mal-
will be stored in ECM. function. DATA MONITOR (AUTO TRIG) can display the
malfunction at the moment it is detected.
*3: The DTC will not be displayed any longer after vehicle is
driven 40 times without the same malfunction.
(The DTC still remains in ECM.)
EC-CD-29
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CD20T
Fuse box
CONSULT-II
CONSULT-II INSPECTION PROCEDURE
1. Turn off ignition switch.
2. Connect ‘‘CONSULT-II’’ to data link connector for CON-
SULT-II.
(Data link connector for CONSULT-II is located behind the
fuse box cover.)
PEF895K
PEF216U
EC-CD-30
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CD20T
CONSULT-II (Cont’d)
ENGINE CONTROL MODULE COMPONENT PARTS/CONTROL SYSTEMS APPLICATION
DIAGNOSTIC TEST MODE
Item SELF-DIAG-
DATA ACTIVE
NOSTIC
MONITOR TEST
RESULTS
Camshaft position sensor (PUMP) *1 X *2 X
Mass air flow sensor X X
Engine coolant temperature sensor X X
Control sleeve position sensor X X X
ENGINE CONTROL MODULE COMPONENT PARTS
EC-CD-31
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CD20T
CONSULT-II (Cont’d)
SELF-DIAGNOSTIC MODE
Regarding items detected in ‘‘SELF-DIAG RESULTS’’ mode, refer to ‘‘Diagnostic Trouble Code (DTC)
chart’’. (See EC-CD-28.)
DATA MONITOR MODE
Monitored item ECM
Main
[Unit] input Description Remarks
signals
signals
CKPSvRPM ● The engine speed computed from the
(TDC) [rpm] j j crankshaft position sensor (TDC) sig-
nal is displayed.
CMPSvRPM - ● The engine speed computed from the
PUMP [rpm] j j camshaft position sensor (PUMP) sig-
nal is displayed.
COOLAN TEMP/S ● The engine coolant temperature (deter- ● When the engine coolant temperature
[°C] or [°F] mined by the signal voltage of the sensor is open or short-circuited, ECM
j j engine coolant temperature sensor) is
displayed.
enters fail-safe mode. The engine cool-
ant temperature determined by the
ECM is displayed.
VHCL SPEED SE ● The vehicle speed computed from the
[km/h] or [mph] j j vehicle speed sensor signal is dis-
played.
FUEL TEMP SEN ● The fuel temperature (determined by
[°C] or [°F] j j the signal voltage of the fuel tempera-
ture sensor) is displayed.
ACCEL POS SEN ● The accelerator position sensor signal
[V] j j voltage is displayed.
OFF ACCEL POS ● Indicates [ON/OFF] condition from the
[ON/OFF] j j accelerator position switch signal.
C/SLEEV POS/S [V] ● The control sleeve position sensor sig-
j j nal voltage is displayed.
BATTERY VOLT [V] ● The power supply voltage of ECM is
j j displayed.
START SIGNAL ● Indicates [ON/OFF] condition from the ● After starting the engine, [OFF] is dis-
[ON/OFF] j j starter signal. played regardless of the starter signal.
AIR COND SIG ● Indicates [ON/OFF] condition of the air
[ON/OFF] j j conditioner switch as determined by
the air conditioner signal.
BRAKE SW ● Indicates [ON/OFF] condition of the
[ON/OFF] j stio lamp switch.
BRAKE SW2 ● Indicates [ON/OFF] condition of the
[ON/OFF] j stio lamp switch 2.
IGN SW ● Indicates [ON/OFF] condition from igni-
[ON/OFF] j j tion switch.
MAS AIR/FL SE [V] ● The signal voltage of the mass air flow ● When the engine is stopped, a certain
j j sensor is displayed. value is indicated.
ACT INJ TIMG [°] ● The actual injection timing angle deter-
mined by the ECM (an approximate
j average angle between injection start
and end from TDC) is displayed.
TARGET F/INJ ● The target fuel injection quantity
[mm3/STROKE] j (determined by the ECM according to
the input signal) is indicated.
NOTE:
Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.
EC-CD-32
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CD20T
CONSULT-II (Cont’d)
Monitored item ECM
Main
[Unit] input Description Remarks
signals
signals
FUEL CUT S/V ● The control condition of the fuel cut ● When the fuel cut solenoid valve is not
[ON/OFF] solenoid valve (determined by ECM operating, fuel supply is shut off.
according to the input signal) is indi-
cated.
● OFF ... Fuel cut solenoid valve is not
operating.
ON ... Fuel cut solenoid valve is oper-
ating.
AIR COND RLY ● The air conditioner relay control condi-
[ON/OFF] j tion (determined by ECM according to
the input signal) is indicated.
GLOW RLY ● The glow relay control condition (deter-
[ON/OFF] j mined by ECM according to the input
signal) is displayed.
COOLING FAN ● Indicates the control condition of the
[LOW/HI/OFF] cooling fans (determined by ECM
according to the input signal).
j ● LOW ... Operates at low speed.
HI ... Operates at high speed.
OFF ... Stopped.
EGRC SOL/V A ● The control condition of the EGRC-
[ON/OFF] solenoid valve (determined by ECM
according to the input signal) is indi-
cated.
● OFF ... EGRC-solenoid valve is not
operating.
ON ... EGRC-solenoid valve is oper-
ating.
EC-CD-33
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CD20T
CONSULT-II (Cont’d)
ACTIVE TEST MODE
TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY)
● Engine: Return to the original
trouble condition If trouble symptom disappears, see
TARGET F/INJ ● Control sleeve position sensor
● Fix the target injection quantity CHECK ITEM.
using CONSULT-II.
● Ignition switch: ON
● Operate the cooling fan at ‘‘LOW’’, Cooling fan moves at ‘‘LOW’’, ‘‘HI’’ ● Harness and connector
COOLING FAN
‘‘HI’’ speed and turn ‘‘OFF’’ using speed and stops. ● Cooling fan motor
CONSULT-II.
● Ignition switch: ON
● Turn solenoid valve ‘‘ON’’ and Solenoid valve makes an operating ● Harness and connector
FUEL CUT SOL/V
‘‘OFF’’ with the CONSULT-II and sound. ● Solenoid valve
listen to operating sound.
● Ignition switch: ON
● Turn solenoid valve ‘‘ON’’ and Solenoid valve makes an operating ● Harness and connector
EGRC SOL/V A
‘‘OFF’’ with the CONSULT-II and sound. ● Solenoid valve
listen to operating sound.
● Ignition switch: ON (Engine
stopped)
Glow relay makes the operating ● Harness and connector
GLOW RLY ● Turn the glow relay ‘‘ON’’ and
sound. ● Fuel pump relay
‘‘OFF’’ using CONSULT-II and
listen to operating sound.
● Engine: Return to the original
trouble condition If trouble symptom disappears, see
INJ TIMING ● Adjust initial injection timing
● Retard the injection timing using CHECK ITEM.
CONSULT-II.
EC-CD-34
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION CD20T
CONSULT-II (Cont’d)
REAL TIME DIAGNOSIS IN DATA MONITOR MODE
CONSULT-II has two kinds of triggers and they can be selected by touching ‘‘SETTING’’ in ‘‘DATA MONI-
TOR’’ mode.
1. ‘‘AUTO TRIG’’ (Automatic trigger):
● The malfunction will be identified on the CONSULT-II screen in real time.
In other words, DTC and malfunction item will be displayed at the moment the malfunction is detected
by ECM.
DATA MONITOR can be performed continuously until a malfunction is detected. However, DATA
MONITOR cannot continue any longer after the malfunction detection.
2. ‘‘MANU TRIG’’ (Manual trigger):
● DTC and malfunction item will not be displayed automatically on CONSULT-II screen even though
a malfunction is detected by ECM.
DATA MONITOR can be performed continuously even though a malfunction is detected.
Use these triggers as follows:
1. ‘‘AUTO TRIG’’
● While trying to detect the DTC by performing the ‘‘DTC CONFIRMATION PROCEDURE’’, be sure
to select to ‘‘DATA MONITOR (AUTO TRIG)’’ mode. You can confirm the malfunction at the moment
it is detected.
● While narrowing down the possible causes, CONSULT-II should be set in ‘‘DATA MONITOR (AUTO
TRIG)’’ mode, especially in case the incident is intermittent.
Inspect the circuit by gently shaking (or twisting) suspicious connectors, components and harness in
the ‘‘DTC CONFIRMATION PROCEDURE’’. The moment a malfunction is found the DTC will be
displayed. (Refer to GI section, ‘‘Incident Simulation Tests’’ in ‘‘HOW TO PERFORM EFFICIENT
DIAGNOSIS FOR AN ELECTRICAL INCIDENT’’.)
2. ‘‘MANU TRIG’’
● If the malfunction is displayed as soon as ‘‘DATA MONITOR’’ is selected, reset CONSULT-II to
‘‘MANU TRIG’’. By selecting ‘‘MANU TRIG’’ you can monitor and store the data. The data can be
utilized for further diagnosis, such as a comparison with the value for the normal operating condi-
tion.
PEF529Q
EC-CD-35
TROUBLE DIAGNOSIS — Introduction CD20T
Introduction
The engine has an ECM to control major systems such as fuel
injection control, fuel injection timing control, glow control
system, etc. The ECM accepts input signals from sensors and
instantly drive the electronic fuel injection pump use the data to
based on current ambient conditions. It is essential that both
input and output signals are correct and stable. At the same time,
it is important that there are no problems such as vacuum leaks,
or other problems with the engine.
SEF858S It is much more difficult to diagnose a problem that occurs inter-
mittently rather than catastrophically. Most intermittent problems
are caused by poor electric connections or faulty wiring. In this
case, careful checking of suspected circuits may help prevent the
INFO.
replacement of good parts.
CAUSE A visual check only may not be sufficiënt to determine the cause
of the problems. A road test with CONSULT-II or a circuit tester
connected should be performed. Follow the ‘‘Work Flow’’ on the
next page.
Before undertaking actual checks, take a few minutes to talk with
a customer who approaches with a driveability complaint. The
customer can supply good information about such problems,
SEF233G especially intermittent ones. Find out what symptoms are present
and under what conditions they occur. A ‘‘Diagnostic Worksheet’’
like the example on next page should be used.
Start your diagnosis by looking for ‘‘conventional’’ problems first.
This will help troubleshoot driveability problems on a vehicle with
an electronically controlled engine.
SEF234G
EC-CD-36
TROUBLE DIAGNOSIS — Introduction CD20T
Diagnostic Worksheet
There are many operating conditions that lead to the malfunction
KEY POINTS
of engine components. A good grasp of such conditions can
WHAT ..... Vehicle & engine model make troubleshooting faster and more accurate.
WHEN ..... Date, Frequencies In general, each customer feels differently about a problem. It is
WHERE ..... Road conditions important to fully understand the symptoms or conditions for a
HOW ..... Operating conditions, customer complaint.
Weather conditions, Utilize a diagnostic worksheet like the one shown below in order
Symptoms to organize all the information for troubleshooting.
SEF907L
WORKSHEET SAMPLE
Customer name MR/MS Model & Year VIN
Vehicle speed
0 10 20 30 40 50 60 70 80 90 100 mph
EC-CD-37
TROUBLE DIAGNOSIS — Work Flow CD20T
Work Flow
CHECK IN
.
Listen to customer complaints. (Get symptoms.) .......................................... STEP I
.
Check, print out or write down, and erase Diagnostic Trouble Code (DTC).
..................................... STEP II
Symptoms No symptoms, except MI
collected. lights up, or Malfunction
Code exists at STEP II.
.
Verify the symptom by driving in the condition the
customer described. ....................................................................................*1 STEP III
. .
Verify the DTC by performing the ‘‘DTC CONFIRMATION PROCEDURE’’. .....................................*1 STEP IV
.
Choose the appropriate action. ..................................... STEP V
c
*2
Malfunction Code (at STEP II or IV) Normal Code (at both STEP II and IV)
.
BASIC INSPECTION
. .
TROUBLE DIAGNOSIS FOR SPECIFIC DTC. STEP VI
.
REPAIR/REPLACE
.
NG FINAL CHECK
Confirm that the incident is completely fixed by performing BASIC INSPECTION
..................................... STEP VII
and DTC CONFIRMATION PROCEDURE (or OVERALL FUNCTION CHECK).
Then, erase the unnecessary (already fixed) DTCs in ECM.
OK
.
CHECK OUT
*1: If the incident cannot be duplicated, refer to GI section (‘‘Incident Simulation Tests’’, ‘‘HOW TO PERFORM EFFICIENT
DIAGNOSIS FOR AN ELECTRICAL INCIDENT’’).
*2: If the on board diagnostic system cannot be performed, check main power supply and ground circuit. Refer to
‘‘TROUBLE DIAGNOSIS FOR MAIN POWER SUPPLY AND GROUND CIRCUIT’’, EC-CD-62.
EC-CD-38
TROUBLE DIAGNOSIS — Work Flow CD20T
EC-CD-39
TROUBLE DIAGNOSIS — Basic Inspection CD20T
Basic Inspection
Precaution:
Perform Basic Inspection without electrical or mechanical
loads applied;
● Headlamp switch is off,
● Air Conditioner switch is off,
● Rear defogger switch is off,
● Steering wheel is in the straight-ahead position, etc.
.
CONNECT CONSULT-II TO THE
VEHICLE.
Connect ‘‘CONSULT-II’’ to the data link
connector for CONSULT-II and select
.
Data link connector
‘‘ENGINE’’ from the menu. Refer to
for CONSULT-II EC-CD-30.
SAT703J
.
DOES ENGINE START? No Turn ignition switch to
.
c
Diesel tacho tester the ‘‘LOCK’’ position,
Yes wait 5 seconds and then
start engine. If engine
. fails to start, check diag-
Injection tube
nostic trouble code
(DTC).
.
Run engine for 10 minutes.
SEF689S .
CHECK IDLE SPEED.
Read engine idle speed in
‘‘DATA MONITOR’’ mode with
CONSULT-II.
825 rpm ± 25 (in N position)
----------------------------------------------------------------- OR -----------------------------------------------------------------
Check idle speed using tacho-
meter tester.
825 rpm ± 25 (in N position)
.
(Go to V
A on next page.)
PEF190P
EC-CD-40
TROUBLE DIAGNOSIS — Basic Inspection CD20T
Basic Inspection (Cont’d)
V
A
.
OK
CHECK INJECTION TIMING. c Bleed air from fuel sys-
1. Set No. 1 piston at TDC on its com- tem.
pression stroke. After this inspection,
TDC: Without painted mark unnecessary diagnostic
2. Remove injection tubes and air trouble code No. might
bleeder on the back of injection be displayed.
pump. Erase the stored
3. Set dial gauge so its indicator points memory in ECM.
SEF661S
to somewhere between 1.0 and 2.0 Refer to ‘‘ON BOARD
mm (0.039 and 0.079 in) on the DIAGNOSTIC SYSTEM
Plunger lift timing mark scale. DESCRIPTION’’
(Yellow painted mark) 4. Turn crankshaft 2 turns clockwise (EC-CD-25).
and check that dial gauge indicates
the same value again. OK
5. Turn crankshaft counterclockwise
about 100 degrees, then turn crank- .
shaft slowly clockwise, and set dial INSPECTION END
gauge indicator to 0 mm at the posi-
tion it stops.
TDC (Without painted mark)
6. Turn crankshaft clockwise and set it
at plunger lift timing mark using the
mark on the crankshaft pulley.
SEF655S
plunger lift timing mark: Yellow
painted mark
7. Read plunger lift.
Plunger lift:
0.89 ± 0.08 mm (0.0350 ± 0.0031
in) at plunger lift timing mark
Increase ● When repeating the checking,
Decrease
start with step 5.
NG
.
Adjusting c Go to
1. If plunger lift is not within the speci-
SEF662S fied value, adjust by turning injec-
tion pump.
● If indication is smaller than the
specified value, turn pump body
away from engine.
● If indication is larger than the
specified value, turn pump body
towards engine.
2. Tighten injection pump securing
bolts and nuts.
Nut:
: 20 - 25 N·m
(2.0 - 2.6 kg-m, 15 - 18 ft-lb)
Bolt:
SEF657S : 25 - 35 N·m
(2.6 - 3.6 kg-m, 18 - 26 ft-lb)
3. Remove dial gauge and install air
bleeder with new washer.
4. Install injection tubes.
Flare nut:
: 14 - 20 N·m
(1.4 - 2.0 kg-m, 10 - 15 ft-lb)
5. Bleed air from fuel system.
Refer to ‘‘Water Draining, Fuel Filter
Check and Replacement’’ of
‘‘ENGINE MAINTENANCE’’ in MA
section.
EC-CD-41
TROUBLE DIAGNOSIS — General Description CD20T
21 Fuel injection timing feed- ● The fuel injection timing feedback system (consists of the ECM, fuel injection tim-
back ing control valve and needle lift sensor) does not operate properly.
(F/INJ TIMG F/B)
EC-CD-42
TROUBLE DIAGNOSIS — General Description CD20T
Diagnostic Trouble Code (DTC) Chart
(Cont’d)
—: Not applicable
DTC *1 *2
Confirmation Overall MI Reference
Check Items
Procedure Function Illumination Page
(Possible Cause)
Quick Ref. Check
● Harness or connectors
(The sensor circuit is open or shorted.) IGN: ON — — EC-CD-65
● Mass air flow sensor
● Harness or connectors
(The sensor circuit is open or shorted.) IGN: ON — Lighting up EC-CD-69
● Engine coolant temperature sensor
● Harness or connectors
(The sensor circuit is open or shorted.) — LIFTING — EC-CD-73
● Vehicle speed sensor
● Harness or connectors
(The sensor circuit is open or shorted.) RUNNING — Lighting up EC-CD-76
● Control sleeve position sensor
● Main power supply circuit (ECM terminals 23 , 45 ),
68 and fuse
● Harness or connectors
(Electric governor and control sleeve position sensor cir- RUNNING
— Lighting up EC-CD-80
cuit) (DRIVING)
● Electronic fuel injection pump
● ECM
● Electric governor
● Harness or connectors
(Injection timing control valve, Needle lift sensor and
Crankshaft position sensor (TDC) circuit]
RUNNING
● Injection timing control valve — Lighting up EC-CD-85
(DRIVING)
● Needle lift sensor
● Crankshaft position sensor
● Air in fuel line
*1: ● This is Quick Reference of ‘‘DTC CONFIRMATION PROCEDURE’’.
Details are described in each TROUBLE DIAGNOSIS FOR DTC.
*2: ● The ‘‘OVERALL FUNCTION CHECK’’ is a simplified and effective way to inspect a component or circuit.
In some cases, the ‘‘OVERALL FUNCTION CHECK’’ is used rather than a ‘‘DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE’’.
When no DTC CONFIRMATION PROCEDURE is available, the ‘‘NG’’ result of the OVERALL FUNCTION CHECK can be con-
sidered to mean the same as a DTC detection.
● During an ‘‘NG’’ OVERALL FUNCTION CHECK, the DTC might not be confirmed.
● This is Quick Reference of ‘‘OVERALL FUNCTION CHECK’’.
Details are described in each TROUBLE DIAGNOSIS FOR DTC.
EC-CD-43
TROUBLE DIAGNOSIS — General Description CD20T
Diagnostic Trouble Code (DTC) Chart
(Cont’d)
ENGINE RELATED ITEMS
Detected items
Diagnostic
trouble
(Screen terms for Malfunction is detected when ...
code
CONSULT-II, ‘‘SELF-
No.
DIAG RESULTS’’ mode)
28 Cooling fan ● An excessive high engine coolant temperature sensor signal is detected by the
(OVER HEAT) ECM. (Overheat)
36 Fuel cut solenoid valve 1 ● Fuel cut solenoid valve circuit is malfunctioning.
(FUEL CUT S/V 1)
42 Fuel temperature sensor ● An excessively high or low voltage from the sensor is detected by the ECM.
circuit
(FUEL TEMP SENSOR)
43 Accelerator position sen- ● An excessively high or low voltage from the sensor is detected by the ECM.
sor circuit
(ACCEL POS SENSOR)
47 Crankshaft position sensor ● An incorrect signal from the sensor is detected by the ECM during engine running
(TDC) and cranking.
[CRANK POS SEN (TDC)]
55 No failure No malfunction is detected by the ECM.
(NO SELF DIAGNOSTIC
FAILURE INDICATED)
Abbreviations for Quick Reference of ‘‘DTC CONFIRMATION PROCEDURE’’
IGN: ON : Turning the ignition switch ON is required for checking the function of the sensor, switch, solenoid and circuit.
RUNNING : Running engine is required for checking the function of the sensor, switch, solenoid and circuit.
LIFTING : Lifting up the vehicle, running engine and spinning wheels are required.
DRIVING : Driving the vehicle in the specified pattern is required.
EC-CD-44
TROUBLE DIAGNOSIS — General Description CD20T
Diagnostic Trouble Code (DTC) Chart
(Cont’d)
—: Not applicable
DTC *1 *2
Confirmation Overall MI Reference
Check Items
Procedure Function Illumination Page
(Possible Cause)
Quick Ref. Check
● Harness or connectors
(The cooling fan circuit is open or shorted.)
● Cooling fan
● Radiator hose
● Radiator
● Fan belt
● Engine coolant temperature sensor
For more information, refer to ‘‘12 MAIN CAUSES OF
OVERHEATING’’. (EC-CD-99)
● ECM
IGN: ON — Lighting up EC-CD-90
● Harness or connectors
(The sensor circuit is open or shorted.)
● Needle lift sensor RUNNING — Lighting up EC-CD-101
● Air in fuel line
● Clogging No. 1 injection nozzle
● Harness or connectors
(The solenoid valve circuit is open or shorted.) RUNNING — Lighting up EC-CD-104
● Fuel cut solenoid valve
● Harness or connectors
(The sensor circuit is open or shorted.) IGN: ON — — EC-CD-108
● Fuel temperature sensor
● Harness or connectors
(The sensor circuit is open or shorted.)
IGN: ON — Lighting up EC-CD-112
● Accelerator position sensor
● Accelerator position switch
● Harness or connectors
(The sensor circuit is open or shorted.) RUNNING — Lighting up EC-CD-119
● Crankshaft position sensor (TDC)
● No failure
— — — —
EC-CD-45
TROUBLE DIAGNOSIS — General Description CD20T
Diagnostic Trouble Code (DTC) Chart
(Cont’d)
ENGINE RELATED ITEMS
Detected items
Diagnostic
trouble
(Screen terms for Malfunction is detected when ...
code
CONSULT-II, ‘‘SELF-
No.
DIAG RESULTS’’ mode)
82 Atmospheric pressure ● An excessively high or low voltage from the sensor is detected by the ECM.
sensor *5
(—) *3
83 Glow relay circuit ● Glow relay circuit is open or shorted.
(GLOW RELAY)
93 Ignition switch ‘‘ON’’ sig- ● Ignition switch ‘‘ON’’ signal evaluation circuit in ECM is malfunctioning.
nal circuit
(—)*3
94 Injection timing control ● Injection timing control valve circuit is open or shorted.
valve circuit
(INJ TIMING CONT/V)
EC-CD-46
TROUBLE DIAGNOSIS — General Description CD20T
Diagnostic Trouble Code (DTC) Chart
(Cont’d)
—: Not applicable
DTC *1 *2
Confirmation Overall Func- MI Reference
Check Items
Procedure tion Check Illumination Page
(Possible Cause)
Quick Ref.
● ECM
IGN: ON — — EC-CD-90
● Harness or connectors
(The glow relay circuit is open or shorted.) IGN: ON — — EC-CD-123
● Glow relay
● ECM
IGN: ON — — EC-CD-90
● Harness or connectors
(The air conditioner relay circuit is open or shorted.) IGN: ON — — EC-CD-131
● Air conditioner relay
● Harness or connectors
(The EGRC-solenoid valve A circuit is open or shorted.) RUNNING — Lighting up EC-CD-134
● EGRC-solenoid valve
● Harness or connectors
(Brake switch circuits are open or shorted.)
RUNNING — Lighting up EC-CD-141
● Brake lamp switch
● RDNT brake switch
● ECM
IGN: ON — — EC-CD-90
● Harness or connectors
(The ECCS-D relay circuit is shorted.)
IGN: ON — Lighting up EC-CD-90
● ECCS-D relay
● ECM
● ECM
IGN: ON — Lighting up EC-CD-90
● Harness or connectors
(The injection timing control valve circuit is open or
IGN: ON — Lighting up EC-CD-85
shorted.)
● Injection timing control valve
● ECM
● Needle lift sensor RUNNING — Lighting up EC-CD-101
● Low battery voltage
*1: ● This is Quick Reference of ‘‘DTC CONFIRMATION PROCEDURE’’.
Details are described in each specific TROUBLE DIAGNOSIS FOR DTC.
*2: ● The ‘‘OVERALL FUNCTION CHECK’’ is a simplified and effective way to inspect a component or circuit.
In some cases, the ‘‘OVERALL FUNCTION CHECK’’ is used rather than a ‘‘DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE’’.
When no DTC CONFIRMATION PROCEDURE is available, the ‘‘NG’’ result of the OVERALL FUNCTION CHECK can be con-
sidered to mean the same as a DTC detection.
● During an ‘‘NG’’ OVERALL FUNCTION CHECK, the DTC might not be confirmed.
● This is Quick Reference of ‘‘OVERALL FUNCTION CHECK’’.
Details are described in each specific TROUBLE DIAGNOSIS FOR DTC.
*3: CONSULT-II may not detect, but self-diagnostic results are available with MI.
*4: Imaginary sensor, which produces secondary engine revolution signal using needle lift sensor pulse.
*5: The atmospheric pressure sensor is located inside the ECM and is not replaceable.
EC-CD-47
TROUBLE DIAGNOSIS — General Description CD20T
Diagnostic Trouble Code (DTC) Chart
(Cont’d)
ENGINE RELATED ITEMS
Detected items
Diagnostic
trouble
(Screen terms for Malfunction is detected when ...
code
CONSULT-II, ‘‘SELF-
No.
DIAG RESULTS’’ mode)
97 MI ● MI (malfunction indicator) circuit is open or shorted.
(—)*3
EC-CD-48
TROUBLE DIAGNOSIS — General Description CD20T
Diagnostic Trouble Code (DTC) Chart
(Cont’d)
—: Not applicable
DTC *1 *2
Confirmation Overall Func- MI Reference
Check Items
Procedure tion Check Illumination Page
(Possible Cause)
Quick Ref.
● Harness or connectors
(The MI circuit is open or shorted.)
IGN: ON — — EC-CD-146
● MI lamp
● ECM
● Harness or connectors
(The glow indicator lamp circuit is open or shorted.) IGN: ON — — EC-CD-123
● Glow lamp
*1: This is Quick Reference of ‘‘DTC CONFIRMATION PROCEDURE’’.
●
Details are described in each specific TROUBLE DIAGNOSIS FOR DTC.
*2: ● The ‘‘OVERALL FUNCTION CHECK’’ is a simplified and effective way to inspect a component or circuit.
In some cases, the ‘‘OVERALL FUNCTION CHECK’’ is used rather than a ‘‘DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE’’.
When no DTC CONFIRMATION PROCEDURE is available, the ‘‘NG’’ result of the OVERALL FUNCTION CHECK can be con-
sidered to mean the same as a DTC detection.
● During an ‘‘NG’’ OVERALL FUNCTION CHECK, the DTC might not be confirmed.
● This is Quick Reference of ‘‘OVERALL FUNCTION CHECK’’.
Details are described in each specific TROUBLE DIAGNOSIS FOR DTC.
*3: CONSULT-II may not detect, but self-diagnostic results are available with MI.
EC-CD-49
TROUBLE DIAGNOSIS — General Description CD20T
ENGINE STALL
WHEN DECELERATING
ROUGH IDLE/HUNTING
POOR ACCELERATION
IDLING VIBRATION
DURING DRIVING
LACK OF POWER
BLACK SMOKE
WHITE SMOKE
Reference page
LOW IDLE
AT IDLE
HI IDLE
Fuel cut
New CT/CS AA AB AC AD AE AF AG AH AJ AK AL AM AP HA
Injec- Advanced j j ● ● j ● j j ● j EC-CD-41
tion
timing Retarded j j ● ● j ● j j ● j EC-CD-41
Electric injection
● ● ● ● j j j j j ● j j j ● ● j j ● j j j j — *1
pump mainframe
Injection nozzle j j j j j j j ● j j j ● ● ● EC-CD-20 *2
Glow system j j ● ● ● ● EC-CD-123
EM-
Engine body j j ● ● j j j ● j j j ● ● j j j ● *3
section
EGR system ● ● ● EC-CD-134
Air cleaner and MA-
● ● ● j *4
ducts section
● ; High Possibility Item
j; Low Possibility Item
*1: Insufficient or excess amount. Governor malfunction may be the cause.
*2: Depends on open-valve pressure and spray pattern.
*3: Caused mainly by insufficient compression pressure.
*4: Symptom varies depending on off-position of air duct, etc.
EC-CD-50
SYMPTOM
HI IDLE
Fuel cut
LOW IDLE
ENGINE STALL
LACK OF POWER
HARD/NO START/
IDLING VIBRATION
SPARK KNOCK/DETONATION
Malfunction indicator illuminates.
Can be detected by CONSULT-II?
AT IDLE
EXCESSIVE FUEL CONSUMPTION
HESITATION/SURGING/FLAT SPOT
DEAD BATTERY (UNDER CHARGE)
Malfunction
Check point
Reference page
DURING DRIVING
Feature of symptom
WHEN DECELERATING
EC-CD-51
circuit
does not function.
Vehicle speed sensor circuit open, short j j EC-CD-73
Control sleeve position sensor cir- open, short j j j j j j EC-CD-76
cuit
open, ground short j j j j j j j
Electric governor circuit EC-CD-80
short j j
HI IDLE
Fuel cut
LOW IDLE
ENGINE STALL
LACK OF POWER
HARD/NO START/
IDLING VIBRATION
SPARK KNOCK/DETONATION
Malfunction indicator illuminates.
Can be detected by CONSULT-II?
AT IDLE
EXCESSIVE FUEL CONSUMPTION
HESITATION/SURGING/FLAT SPOT
DEAD BATTERY (UNDER CHARGE)
Malfunction
Check point
Reference page
DURING DRIVING
Feature of symptom
WHEN DECELERATING
EC-CD-52
open, ground short j j j j j
Accelerator position switch (Idle)
EC-CD-112 Accelerator position sensor NG
circuit short j j j j j
signal is output.
open j j j j
Ignition switch circuit (ON signal) EC-CD-62
short Engine does not stop.
open j j j
Power supply for ECM circuit EC-CD-62
short j j
open, short j j
EGRC-solenoid valve circuit EC-CD-134
ground short j j j Does not stop operating.
open j j j j j j j Glow lamp does not turn on.
Glow relay circuit EC-CD-123
short j j Glow lamp does not turn off.
open j j j j
EC-CD-53
TROUBLE DIAGNOSIS — General Description CD20T
NEF780
EC-CD-54
TROUBLE DIAGNOSIS — General Description CD20T
NEF853
Connector
When measuring:
● Use extreme care not to touch 2 pins at the same time.
● Note that the data is for comparison and may not be exact.
● Use care not to enlarge the opening to keep the seal in good
condition.
SGI841
EC-CD-55
TROUBLE DIAGNOSIS — General Description CD20T
ECM Terminals and Reference Value
(Cont’d)
ECM HARNESS CONNECTOR TERMINAL LAYOUT
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
NEF781
TER- DATA
WIRE
MINAL ITEM CONDITION (DC Voltage and
COLOR
NO. Pulse Signal)
Engine ground
1 Engine is running. (Probe this terminal with
24 B ESSC ground
Idle speed @ tester probe when
46
measuring.)
Idle speed
SEF550S
2 L/OR Tachometer
Approximately 1.1 - 1.5V
Engine is running.
SEF551S
EC-CD-56
TROUBLE DIAGNOSIS — General Description CD20T
ECM Terminals and Reference Value
(Cont’d)
TER- DATA
WIRE
MINAL ITEM CONDITION (DC Voltage and
COLOR
NO. Pulse Signal)
Approximately 10.5V
Idle speed
4 SEF562S
5 B/L Electric governor ground
49 Approximately 10.5
SEF563S
Approximately 2.6V
SEF559S
Approximately 0V
Idle speed
Engine is running.
NEF868
EC-CD-57
TROUBLE DIAGNOSIS — General Description CD20T
ECM Terminals and Reference Value
(Cont’d)
TER- DATA
WIRE
MINAL ITEM CONDITION (DC Voltage and
COLOR
NO. Pulse Signal)
Idle speed
NEF869
12 W Needle lift sensor
Approximately 3.8 - 4.0V
NEF870
0.6 - 4.8V
Engine coolant tempera- Output voltage varies
14 L/OR Engine is running.
ture sensor with engine coolant tem-
perature.
EC-CD-58
TROUBLE DIAGNOSIS — General Description CD20T
ECM Terminals and Reference Value
(Cont’d)
TER- DATA
WIRE
MINAL ITEM CONDITION (DC Voltage and
COLOR
NO. Pulse Signal)
23
BATTERY VOLTAGE
45 R Power supply for ECM Ignition switch ‘‘ON’’
(11 - 14V)
68
Engine is running.
Approximately 2.6V
SEF561S
Engine is running.
33 B Sensors’ ground Approximately 0V
Idle speed
EC-CD-59
TROUBLE DIAGNOSIS — General Description CD20T
ECM Terminals and Reference Value
(Cont’d)
TER- DATA
WIRE
MINAL ITEM CONDITION (DC Voltage and
COLOR
NO. Pulse Signal)
Engine is running.
0 - Approximately 4.2V
Engine is running.
SEF552S
Approximately 9V
Idle speed
SEF565S
EC-CD-60
TROUBLE DIAGNOSIS — General Description CD20T
ECM Terminals and Reference Value
(Cont’d)
TER- DATA
WIRE
MINAL ITEM CONDITION (DC Voltage and
COLOR
NO. Pulse Signal)
Approximately 2.6V
SEF560S
Engine is running.
BATTERY VOLTAGE
Cooling fan is not operating. (11 - 14V)
Cooling fan relay Cooling fan is operating at low speed.
54 LG
(High speed)
Engine is running.
Approximately 0.5V
Cooling fan is operating at high speed.
Engine is running.
0.6 - 4.8V
63 R/Y Fuel temperature sensor Engine is running. Output voltage varies
with fuel temperature.
EC-CD-61
TROUBLE DIAGNOSIS FOR POWER SUPPLY CD20T
B/Y BR
W/R W/R
ENGINE
2 3 CONTROL
MODULE
RELAY
E91
1 5
W/G R
B/Y BR W/G R
M50 M52 E43 E89
24 2 7 2
F104 F103 F2 F96
B/Y BR W/G R
B/Y BR W/G R R R
16 38 42 45 23 68
ANL K15 HRL-0 BAT+ BAT+ BAT+
ECM
F106
BAT- BAT- BAT-
1 24 46 B B B
B B B
F15 F18
1 2 1 2 3 4 5 6 7 8 9 10
F103 F104
3 4 5 6 11 12 13 14 15 16 17 18 19 20 21 22 23 24
W W
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC307
EC-CD-62
TROUBLE DIAGNOSIS FOR POWER SUPPLY CD20T
Main Power Supply and Ground Circuit
(Cont’d)
INSPECTION START
.
No
Start engine. CHECK POWER SUP-
c
Is engine running? PLY-I.
1. Disconnect ECM harness
Yes connector.
2. Turn ignition switch to
‘‘ON’’ position.
NEF863 3. Check voltage between
ECM connector terminal
V 38 and ground
.
OK
CHECK POWER SUPPLY-II. Go to ‘‘CHECK
c
1. Short between ECM connector terminal GROUND CIRCUIT’’ on
V42 and engine ground with a jump wire. page EC-CD-64.
2. Check voltage between ECM terminals
V23 , V
45 , V
68 and ground.
Voltage: Battery voltage
NG
.
NG
NEF782 CHECK HARNESS CONTINUITY Check the following:
c
BETWEEN ENGINE CONTROL MODULE ● Harness connectors
RELAY AND ECM M89 , F96
Check harness continuity between ECM ● Harness for open or
connector terminals V23 , V 68 and engine
45 V short-circuit between
control module relay connector terminal V
5 . engine control module
Continuity should exist. relay and ECM.
If OK, check harness for short. If NG, repair harness or
connectors.
. OK
V
A
NEF783
ECCS-D relay
connector
YEC351
EC-CD-63
TROUBLE DIAGNOSIS FOR POWER SUPPLY CD20T
Main Power Supply and Ground Circuit
(Cont’d)
V
A
ECCS-D relay
connector .
NG
CHECK VOLTAGE BETWEEN ENGINE Check the following:
c
CONTROL MODULE RELAY AND ● 15A fuse
GROUND. ● Harness for open or
Check voltage between engine control mod- short-circuit between
ule relay connector terminals V
2 , V
3 and engine control module
ground with CONSULT-II or tester. relay and battery.
Voltage: Battery voltage If NG, replace fuse or repair
YEC352 harness or connectors.
OK
.
NG
CHECK OUTPUT SIGNAL CIRCUIT. ● Check harness connec-
c
Check harness continuity between ECM tors E43 , F2
Engine control module
relay connector connector terminal V
42 and engine control Repair harness or connec-
module relay connector terminal V 1 . tors.
Continuity should exist.
If OK, check harness for short-circuit.
OK
.
NG
CHECK ENGINE CONTROL MODULE Replace engine control
c
YEC353
RELAY. module relay.
1. Apply 12V direct current between engine
control module relay connector terminals
V1 and V 2 .
2. Check continuity between engine control
module relay connector terminals V3 and
V5 .
12V (V1 -V 2 ) applied:
ECCS-D relay Continuity exists.
connector No voltage applied:
No continuity
OK
.
NG
YEC354 CHECK GROUND CIRCUIT. Repair harness or connec-
c
1. Turn ignition switch to ‘‘LOCK’’ position. tors.
2. Check harness continuity between ECM
connector terminals V 1 , V24 , V
46 and
engine ground.
Continuity should exist.
If resistance is too high, loosen, clean and
retighten engine ground.
If OK, check harness for short-circuit.
OK
.
Check ECM pin terminals for damage and
check the connection of ECM harness con-
nector.
NEF787
.
INSPECTION END
Engine ground
NEF399
EC-CD-64
TROUBLE DIAGNOSIS FOR DTC 12 CD20T
Diagnostic
Check Items
Trouble Malfunction is detected when . . .
(Possible Cause)
Code No.
12 ● An excessively high or low voltage from the sensor ● Harness or connectors
is entered to ECM. (The sensor circuit is open or shorted.)
● Mass air flow sensor
EC-CD-65
TROUBLE DIAGNOSIS FOR DTC 12 CD20T
Mass Air Flow Sensor (MAFS) (Cont’d)
BATTERY EC-MAFS-01
15A Refer to EL-POWER.
36
W/R
W/R W/R R
ENGINE
2 3 CONTROL 2
MODULE MASS AIR
RELAY FLOW
SENSOR
E91
F38
1 5 3 4 5
W/G R OR W L/W
W/G R
E43 E89
7 2
F2 F96
W/G R
W/G R R R OR W L/W
42 23 45 68 21 19 13
HRL-0 BAT+ BAT+ BAT+ GND-D HFM-2 HFM-1
ECM
F106
3
E91 1 2 3 4 F2 F38 1 2 F96
5 1 2 3 4 5
L 5 6 7 8 GY 3 4 B
1 2
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC308
EC-CD-66
TROUBLE DIAGNOSIS FOR DTC 12 CD20T
Mass Air Flow Sensor (MAFS) (Cont’d)
Mass air flow sensor harness connector DIAGNOSTIC PROCEDURE
INSPECTION START
.
NG
CHECK POWER SUPPLY. Repair harness or connec-
c
1. Turn ignition switch to ‘‘LOCK’’ position. tors.
2. Disconnect mass air flow sensor harness
connector.
3. Turn ignition switch to ‘‘ON’’ position.
4. Check voltage between mass air flow
NEF788
sensor connector terminal V 2 and
ground.
Voltage: Battery positive voltage
OK
OK
.
NG
CHECK INPUT SIGNAL CIRCUIT. Repair harness or connec-
c
Check harness continuity between mass air tors.
flow sensor connector terminal V4 and
ECM connector terminal V 19 , mass air flow
Mass air sensor connector terminal V 5 and ECM
flow: sensor connector terminal V
13 .
connector
Continuity should exist.
If OK, check harness for short.
OK
NEF790
.
NG
CHECK COMPONENT Replace mass air flow sen-
c
(Mass air flow sensor). sor.
Refer to ‘‘COMPONENT INSPECTION’’ on
Mass air flow sensor
connector next page.
OK
.
Disconnect and reconnect harness connec-
tors in the circuits. Then retest.
NEF791 .
Check ECM pin terminals for damage or the
connection of ECM harness connector.
.
INSPECTION END
EC-CD-67
TROUBLE DIAGNOSIS FOR DTC 12 CD20T
Mass Air Flow Sensor (MAFS) (Cont’d)
COMPONENT INSPECTION
Mass air flow sensor
Mass air flow sensor
connector 1. Turn ignition switch to ‘‘ON’’ position.
2. Start engine and warm it up sufficiently.
3. Check voltage between mass air flow sensor connector ter-
minal V5 and ground.
Conditions Voltage V
Ignition switch ‘‘ON’’ position (Engine stopped.) Approximately 1.0
NEF792 Idle (Engine is warmed-up sufficiently.) 1.9 - 2.3
4. If NG, remove mass air flow sensor from air duct. Check hot
film for damage or dust.
NEF669
EC-CD-68
TROUBLE DIAGNOSIS FOR DTC 13 CD20T
Gasket
SEF594K
20
〈Reference data〉
10
8 Engine coolant
6 Voltage Resistance
4 Acceptable
temperature
(V) (kΩ)
Resistance kΩ
2 °C (°F)
1.0 −10 (14) 4.4 7.0 - 11.4
0.8
0.4 20 (68) 3.5 2.1 - 2.9
0.2 50 (122) 2.3 0.68 - 1.00
0.1
(−4) (32) (68) (104)(140)(176) (212)
90 (194) 1.0 0.236 - 0.260
Temperature °C (°F) SEF012P
Diagnostic
Check Items
Trouble Code Malfunction is detected when ...
(Possible Cause)
No.
13 ● An excessively high or low voltage from the sensor ● Harness or connectors
is entered to ECM. (The sensor circuit is open or shorted.)
● Engine coolant temperature sensor
EC-CD-69
TROUBLE DIAGNOSIS FOR DTC 13 CD20T
Engine Coolant Temperature (ECT) Sensor
(Cont’d)
EC-ECTS-01
ENGINE COOLANT
TEMPERATURE
SENSOR
F12
2 1
L/OR B
L/OR B
14 33
WTFI GND-A
ECM
F106
1 2 F12
GY
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC417
EC-CD-70
TROUBLE DIAGNOSIS FOR DTC 13 CD20T
Engine Coolant Temperature (ECT) Sensor
(Cont’d)
.
RH strut tower DIAGNOSTIC PROCEDURE
INSPECTION START
.
.
CHECK POWER SUPPLY. NG Repair harness or con-
Engine coolant temperature c
sensor harness connector 1. Turn ignition switch to ‘‘LOCK’’ posi- nectors.
tion.
2. Disconnect engine coolant tempera-
NEF401
ture sensor harness connector.
3. Turn ignition switch to ‘‘ON’’ posi-
tion.
4. Check voltage between engine cool-
Engine coolant temperature ant temperature sensor connector
sensor connector terminal V2 and ground with CON-
SULT-II or tester.
Voltage:
Approximately 4.9V
OK
.
SEF541P CHECK GROUND CIRCUIT. NG Repair harness or con-
c
1. Turn ignition switch to ‘‘LOCK’’ posi- nectors.
tion.
2. Check harness continuity between
engine coolant temperature sensor
Engine coolant temperature connector terminal V 1 and engine
sensor connector
ground.
Continuity should exist.
If OK, check harness for short-cir-
cuit.
OK
.
SEF542P NG
CHECK COMPONENT c
Replace engine coolant
(Engine coolant temperature sensor). temperature sensor.
Refer to ‘‘COMPONENT INSPEC-
TION’’
on next page.
OK
.
Disconnect and reconnect harness
connectors in the circuit. Then retest.
.
INSPECTION END
EC-CD-71
TROUBLE DIAGNOSIS FOR DTC 13 CD20T
Engine Coolant Temperature (ECT) Sensor
(Cont’d)
COMPONENT INSPECTION
Engine coolant temperature sensor
Check resistance as shown in the figure.
2
1.0
0.8
0.4
0.2
0.1
(−4) (32) (68) (104)(140)(176) (212)
EC-CD-72
TROUBLE DIAGNOSIS FOR DTC 14 CD20T
AEC110
Diagnostic
Check Items
Trouble Code Malfunction is detected when ....
(Possible Cause)
No.
14 ● The almost 0 km/h (0 mph) signal from vehicle ● Harness or connector
speed sensor is sent to ECM even when vehicle is (The vehicle speed sensor circuit is open or
being driven. shorted.)
● Vehicle speed sensor
NEF794
EC-CD-73
TROUBLE DIAGNOSIS FOR DTC 14 CD20T
Vehicle Speed Sensor (VSS) (Cont’d)
BATTERY
IGNITION SWITCH
ON or START
EC-VSS-01
FUSE
10A 10A BLOCK Refer to EL-POWER.
16 12 (J/B)
M1
LG/R
L 2 3 L/Y
L/Y Y
M50 M52
OR/W 9 1 B 7 5
COMBINATION F104 F103
8 METER L/Y Y
(SPEEDOMETER)
R M38
L/Y Y
2 1
VEHICLE
SPEED
SENSOR
OR/W R
F25
M50
8 6
F104 3
OR/W R
B
F104
11
M50
B
OR/W R
B B B B
43 9
FGG-1
FGG-1 TQS-A
TQS-A
ECM
F106
M6 M28 M26
1 2 1 2 3 4 5 6 7 8 9 10
F103 F104
3 4 5 6 11 12 13 14 15 16 17 18 19 20 21 22 23 24
W W
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC309
EC-CD-74
TROUBLE DIAGNOSIS FOR DTC 14 CD20T
Vehicle Speed Sensor (VSS) (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START
Combination meter
connector
.
CHECK INPUT SIGNAL CIRCUIT. NG Check the following:
c
1. Turn ignition switch to ‘‘LOCK’’ posi- ● Harness connectors
tion. M50 , F104
2. Disconnect ECM harness connector ● Harness for open or
YEC355
and combination meter harness con- short-circuit between
nector. ECM and combination
3. Check harness continuity between meter.
ECM connector terminal V 43 and If NG, repair harness or
combination meter connector termi- connectors.
nal V 9 .
Continuity should exist.
If OK, check harness for short-cir-
cuit.
OK
.
CHECK SPEEDOMETER FUNCTION. NG Check the following:
c
Make sure that speedometer functions ● Harness connectors
correctly. M50 , F104
● Harness for open or
OK
short-circuit between
combination meter and
vehicle speed sensor.
If NG, repair harness or
connectors.
Check vehicle speed
sensor and its circuit.
Refer to EL section.
.
Disconnect and reconnect harness
connectors in the circuit. Then retest.
.
INSPECTION END
EC-CD-75
TROUBLE DIAGNOSIS FOR DTC 15 CD20T
Sensor coil
SEF641S
Diagnostic
Check Items
Trouble Code Malfunction is detected when ....
(Possible cause)
No.
15 ● An excessively high or low voltage from the sensor ● Harness or connectors
is detected by ECM. (The control sleeve position sensor circuit is open
.................................................................................. or shorted.)
● An incorrect voltage signal from the sensor is ● Control sleeve position sensor
detected by ECM during engine running.
.
Electronic injection pump DIAGNOSTIC TROUBLE CODE CONFIRMATION
harness connector (control
sleeve position sensor)
PROCEDURE
1) Turn ignition switch to ‘‘ON’’ position and select
‘‘DATA MONITOR’’ mode with CONSULT-II.
2) Start engine and run it for at least 2 seconds at idle
speed.
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
1) Start engine and run it for at least 2 seconds at idle
speed.
2) Turn ignition switch to ‘‘LOCK’’ position, wait at least
NEF796 5 seconds and then turn to ‘‘ON’’ position.
3) Perform ‘‘Diagnostic Test Mode II (Self-diagnostic
results)’’.
EC-CD-76
TROUBLE DIAGNOSIS FOR DTC 15 CD20T
Control Sleeve Position Sensor (CSPS)
(Cont’d)
INJECTION PUMP
(CONTROL SLEEVE
EC-CSPS-01
POSITION SENSOR)
F50
1 2 3
R B W B
29 52 7 33
RWH-R RWG-M RWG-Y GND-A
ECM
F106
1
7 2
F50
6 3
B
5 4
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC418
EC-CD-77
TROUBLE DIAGNOSIS FOR DTC 15 CD20T
Control Sleeve Position Sensor (CSPS)
(Cont’d)
DIAGNOSTIC PROCEDURE
Control sleeve position INSPECTION START
sensor connector
.
NG
CHECK POWER SUPPLY CIRCUIT. Repair harness or connec-
c
1. Turn ignition switch to ‘‘LOCK’’ position. tors.
2. Disconnect ECM harness connector and
electronic injection pump harness connec-
YEC356 tor.
3. Check harness continuity between control
sleeve position sensor connector terminal
V 3 and ECM connector terminal V 7 .
Continuity should exist.
If OK, check harness for short-circuit.
Control sleeve position
sensor connector
OK
.
NG
CHECK INPUT SIGNAL CIRCUIT. Repair harness or connec-
c
Check harness continuity between control tors.
sleeve position sensor connector terminal
V 2 and ECM terminal V 52 .
Continuity should exist.
YEC357
If OK, check harness for short-circuit.
OK
.
NG
CHECK REFERENCE SIGNAL CIRCUIT. Repair harness or connec-
Control sleeve position c
sensor connector Check harness continuity between control tors.
sleeve position sensor connector terminal
V 1 and ECM connector terminal V 29
Continuity should exist.
If OK, check harness for short-circuit.
OK
.
NG
CHECK COMPONENT Have the injection pump
YEC358 c
(Control sleeve position sensor). assembly serviced by an
Refer to ‘‘COMPONENT INSPECTION’’ on authorised service represen-
next page. tative.
OK
.
Disconnect and reconnect harness connec-
tors in the circuit. Then retest.
.
INSPECTION END
EC-CD-78
TROUBLE DIAGNOSIS FOR DTC 15 CD20T
Control Sleeve Position Sensor (CSPS)
(Cont’d)
COMPONENT INSPECTION
Control sleeve
position sensor,
Control sleeve position sensor
electric governor & 1. Disconnect electronic injection pump harness connector.
fuel temperature
sensor connector 2. Check continuity between terminals V 1 and V3 , V
2 and V 3 .
Resistance: Approximately 6.0Ω [at 25°C (77°F)]
If NG, take proper action.
NEF680
EC-CD-79
TROUBLE DIAGNOSIS FOR DTC 18 CD20T
Electric Governor
Return spring
The electric governor is built into the fuel injection pump. It
moves the control sleeve to increase or decrease the amount of
Coil
fuel injected.
Rotor When current flows through the coil, a magnetic force is
produced, rotating the rotor. The rotor shaft is installed to the
control sleeve via a ball pin which is eccentrically situated in
relation to the rotor shaft. With this arrangement, the control
sleeve can be moved in relation to rotor rotation.
Core The rotor’s rotating angle is determined by a balanced condition
Shaft
of magnetic force (generated by current flow regulated by means
of the ECM ) and tension of return spring (installed to rotor). The
Ball pin larger the current flow through the coil, the greater the rotor’s
rotating angle. This means that the control sleeve moves to the
right, increasing the amount of fuel injected.
The ECM regulates the current flow through the coil by chang-
ing the duty cycle ratio which controls the ON-OFF operation of
the electric governor grounding circuit.
Decrease Increase
Control sleeve
SEF632S
Magnet Core
Rotor
Coil
SEF633S
Diagnostic
Check Items
Trouble Code Malfunction is detected when ....
(Possible cause)
No.
18 ● Fuel injection feedback system does not operate ● Main power supply circuit (ECM connector termi-
properly. [This system consists essentially of ECM, nals V23 , V
45 , V
68 ) and fuse
electric governor and control sleeve position sen- ● Harness or connectors
sor.] (Electric governor and control sleeve position sen-
sor circuit)
● Electric governor
● ECM
EC-CD-80
TROUBLE DIAGNOSIS FOR DTC 18 CD20T
Electric Governor (Cont’d)
DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE
1) Turn ignition switch to ‘‘ON’’ position and select
‘‘DATA MONITOR’’ mode with CONSULT-II.
2) Start engine above 1,200 rpm.
3) Run it for 2 seconds above 1,200 rpm. Return engine
speed to idle.
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
1) Start engine above 1,200 rpm.
2) Run engine for 2 seconds above 1,200 rpm. Return
engine speed to idle.
3) Turn ignition switch to ‘‘LOCK’’ position, wait at least
5 seconds and then turn to ‘‘ON’’ position.
4) Perform ‘‘Diagnostic Test Mode II’’ (Self-diagnostic
results).
EC-CD-81
TROUBLE DIAGNOSIS FOR DTC 18 CD20T
Electric Governor (Cont’d)
BATTERY EC-GOVNR-01
: Detectable line for DTC
15A Refer to EL-POWER.
: Non-detectable line for DTC
36
INJECTION PUMP
W/R (ELECTRIC
GOVERNOR)
F50
7 4
R B/L
W/R W/R
ENGINE
2 3 CONTROL
MODULE
RELAY
E91
1 5
W/G R
W/G R
E43 E89
7 2
F2 F96
W/G R
42 23 45 68 4 49 5
HRL-0 BAT+ BAT+ BAT+ MES-0 MES-0 MES-0
ECM
F106
1
3 7 2
E91 1 2 3 4 F2 F50 1 2 F96
5 6 3
L 5 6 7 8 GY B 3 4 B
1 2
5 4
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC310
EC-CD-82
TROUBLE DIAGNOSIS FOR DTC 18 CD20T
Electric Governor (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
CHECK MAIN POWER SUPPLY.
Refer to EC-CD-62.
.
Electronic injection pump harness
connector (Electric governor)
.
NEF800 NG
CHECK POWER SUPPLY CIRCUIT. Repair harness or con-
c
1. Turn ignition switch to ‘‘LOCK’’ posi- nectors.
tion.
2. Disconnect ECM harness connector
Injection pump and electronic injection pump har-
connector
ness connector.
3. Check harness continuity between
injection pump connector terminal
V 7 and ECM connector terminals
V23 , V
45 , V
68 .
Continuity should exist.
YEC359 If OK, check harness for short-circuit.
OK
.
CHECK GROUND CIRCUIT. NG Repair harness or con-
Injection pump c
connector Check harness continuity between nectors.
injection pump connector terminal V 4
and ECM connector terminals V 4 , V5 ,
V49 .
Continuity should exist.
If OK, check harness for short-circuit.
YEC360 OK
.
CHECK COMPONENT NG Have the injection pump
c
(Electric governor). assembly serviced by an
Refer to ‘‘COMPONENT INSPECTION’’ authorised service repre-
on next page. sentative.
OK
.
Disconnect and reconnect harness con-
nectors in the circuit. Then retest.
.
INSPECTION END
EC-CD-83
TROUBLE DIAGNOSIS FOR DTC 18 CD20T
Electric Governor (Cont’d)
COMPONENT INSPECTION
Electric governor
Electronic injection pump
harness connector 1. Disconnect electronic injection pump harness connector.
2. Check continuity between injection pump connector termi-
nals V4 and V 7 .
Resistance: Approximately 1.0Ω [at 25°C (77°F)]
If NG, replace.
YEC361
EC-CD-84
TROUBLE DIAGNOSIS FOR DTC 21 CD20T
Diagnostic
Check Items
Trouble Code Malfunction is detected when ....
(Possible cause)
No.
21 ● Injection timing feedback system does not operate ● Harness or connectors
properly. (This system consists essentially of ECM, [Injection timing control valve, needle lift sensor,
injection timing control valve and needle lift sen- crankshaft position sensor (TDC) circuits]
sor.) ● Injection timing control valve
● Needle lift sensor
● Crankshaft position sensor (TDC)
● Air in fuel line
94 ● Injection timing control valve circuit it open or ● Harness or connectors
shorted. (The Injection timing control valve is open or
shorted.)
● Injection timing control valve
EC-CD-85
TROUBLE DIAGNOSIS FOR DTC 21 CD20T
Injection Timing Control Valve (Cont’d)
DIAGNOSTIC TROUBLE CODE 94 CONFIRMATION
PROCEDURE
1) Turn ignition switch to ‘‘ON’’ position.
2) Select ‘‘DATA MONITOR’’ mode with CONSULT-II.
3) Wait at least 2 seconds.
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
1) Turn ignition switch to ‘‘ON’’ position.
2) Wait at least 2 seconds.
3) Turn ignition switch to ‘‘LOCK’’ position, wait at least
5 seconds and turn to ‘‘ON’’ position.
4) Perform ‘‘Diagnostic Test Mode II’’ (Self-diagnostic
results).
EC-CD-86
TROUBLE DIAGNOSIS FOR DTC 21 CD20T
Injection Timing Control Valve (Cont’d)
BATTERY EC-TCV-01
15A Refer to EL-POWER.
36
W/R
W/R W/R
ENGINE R
2 3 CONTROL
MODULE 3 INJECTION PUMP
RELAY
(INJECTION TIMING
E91 CONTROL VALVE)
1 5 F49
2
W/G R
B/Y
W/G R
E43 E89
7 2
F2 F96
W/G R
W/G R R R B/Y
42 68 45 23 51
HRL-0 BAT+ BAT+ BAT+ MVS-0
ECM
F106
3
E91 1 2 3 4 F2 1 2 3 F49 1 2 F96
5
L 5 6 7 8 GY BR 3 4 B
1 2
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC311
EC-CD-87
TROUBLE DIAGNOSIS FOR DTC 21 CD20T
Injection Timing Control Valve (Cont’d)
DIAGNOSTIC PROCEDURE
Priming pump
INSPECTION START
.
CHECK FOR AIR IN FUEL FILTER.
1. Move priming pump up and down to
purge air from fuel filter.
2. Perform ‘‘DIAGNOSTIC TROUBLE
SEF671S CODE CONFIRMATION PROCE-
DURE’’.
.
CHECK POWER SUPPLY. NG Check the following:
c
1. Turn ignition switch to ‘‘LOCK’’ posi- ● Harness connectors
tion. E89 , F96
2. Disconnect injection timing control ● Electronic injection
valve harness connector. pump harness connec-
Fuel injection timing 3. Turn ignition switch to ‘‘ON’’ position. tor F49
control valve harness
connector 4. Check voltage between injection tim- ● 15A fuse
NEF804
ing control valve connector terminal ● Harness for open or
.
CHECK OUTPUT SIGNAL CIRCUIT. NG Check the following:
c
YEC362 1. Turn ignition switch to ‘‘LOCK’’ posi- ● Electronic injection
tion. pump harness connec-
2. Disconnect ECM harness connector. tor F49
3. Check harness continuity between ● Harness for open or
injection timing control valve connec- short-circuit between
Injection timing control tor terminal V 2 and ECM terminals injection timing control
valve harness connector
V51 . valve and ECM.
Continuity should exist. If NG, repair harness or
If OK, check harness for short-cir- connectors.
cuit.
OK
.
YEC363
V
A
EC-CD-88
TROUBLE DIAGNOSIS FOR DTC 21 CD20T
Injection Timing Control Valve (Cont’d)
V
A
.
CHECK COMPONENT NG Replace injection timing
c
(Injection timing control valve). control valve.
Refer to ‘‘COMPONENT INSPECTION’’
below.
OK
.
Disconnect and reconnect harness con-
nectors in the circuit. Then retest.
.
INSPECTION END
COMPONENT INSPECTION
Injection timing control valve
Injection timing 1. Disconnect injection timing control valve harness connector.
control valve
2. Check resistance between terminals V 2 and V3 .
Resistance: Approximately 15Ω [at 25°C (77°F)]
If NG, replace injection timing control valve.
YEC364
EC-CD-89
TROUBLE DIAGNOSIS FOR DTC 31, 82, 84, 91, 93 CD20T
NEF807
Diagnostic
Check Item
Trouble Code Malfunction is detected when ....
(Possible Cause)
No.
31 ● ECM calculation function is malfunctioning. ● ECM *
82 ● An excessively high or low voltage from the ● ECM *
atmospheric pressure sensor is detected by the
ECM.
84 ● ECM reference voltage (2.5V) is excessively high ● ECM *
or low.
91 ● ECM version number or switching function is not ● ECM *
plausible.
93 ● Ignition switch ‘‘ON’’ signal evaluation circuit in ● ECM *
ECM is malfunctioning.
* Actually inspecting the ECM inside circuit is impossible. Then, ECM may be replaced.
EC-CD-90
TROUBLE DIAGNOSIS FOR DTC 28 CD20T
The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, air con-
ditioner system pressure and air conditioner ON signal. The control system has 3-step control [HIGH/LOW/
OFF]. This system indirectly relates to diagnostic trouble code 28 (Overheat).
Operation
Air conditioner is OFF Air conditioner is ON
temperature °C (°F)
temperature °C (°F)
Engine coolant
Engine coolant
. .
102 (216) 102 (216)
.
.
96 (205) 96 (205)
. . . .
20 80 20 80
(12) (50) (12) (50)
Vehicle speed km/h (mph) Vehicle speed km/h (mph)
Cooling fans do not operate Cooling fans operate at low speed Cooling fans operate at high speed
NEF772
● Radiator cap
● Water pump
● Thermostat
● Fan belt
EC-CD-91
TROUBLE DIAGNOSIS FOR DTC 28 CD20T
Cooling Fan (Overheat) (Cont’d)
OVERALL FUNCTION CHECK
Use this procedure to check the overall function of the cooling
fan. During this check, a DTC might not be confirmed.
WARNING:
Never remove the radiator cap when the engine is hot. Seri-
MAX.
ous burns could be caused by high pressure fluid escaping
OK
from the radiator.
MIN.
Wrap a thick cloth around the cap. Carefully remove the cap
by turning it a quarter turn to allow built-up pressure to
escape. Then turn the cap all the way off.
AEC640 1) Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is
below the proper range, skip the following steps and go to
‘‘DIAGNOSTIC PROCEDURE’’, EC-CD-94.
2) Confirm whether customer filled the coolant or not. If cus-
tomer filled the coolant, skip the following steps and go to
‘‘DIAGNOSTIC PROCEDURE’’, EC-CD-94.
3) Turn ignition switch to ‘‘ON’’ position.
4) Perform ‘‘COOLING FAN’’ in ‘‘ACTIVE TEST’’
mode with CONSULT-II (LOW speed and HI
speed).
SEF111X
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
3) Start engine.
Cooling fan
Be careful not to overheat engine.
4) Set temperature control switch to full cold position.
5) Push Air Conditioner switch to ‘‘ON’’ position.
6) Turn blower fan switch to ‘‘ON’’ position.
7) Run engine at idle for a few minutes with Air Con-
ditioner operating.
Be careful not to overheat engine.
8) Make sure that both cooling fans operate at low
speed.
SEC163BA 9) Turn ignition switch to ‘‘LOCK’’ position.
10) Push Air Conditioner switch and blower fan switch
to ‘‘OFF’’ position.
Cooling fan
11) Disconnect engine coolant temperature sensor
Engine coolant harness connector.
temperature sensor
harness connector 12) Connect 150Ω resistor to engine coolant tempera-
ture sensor harness connector.
13) Restart engine and make sure that both cooling
fans operate at higher speed than low speed.
150Ω resistor
Be careful not to overheat engine.
MEC475B
EC-CD-92
TROUBLE DIAGNOSIS FOR DTC 28 CD20T
Cooling Fan (Overheat) (Cont’d)
BATTERY IGNITION SWITCH
ON or START
EC-COOL/F-01
100A FUSE
a 10A BLOCK
(J/B) Refer to EL-POWER.
11
E127 : Detectable line for DTC
5H : Non-detectable line for DTC
40A 50A BR
c b
G W/G
LG W/L
G/B
2 1
COOLING
2 TRIPLE-
LG LG/R FAN
COOLING PRESSURE
FAN
8
E43
5
HIGH SWITCH M MOTOR-2
M MOTOR-1
E29
F2 LOW
E20
E18
LG LG/R 2
3
1
B B
G
LG LG/R
54 47
ECM B B
F106
E37 E11
1 2 3 4 F2
5 6 7 8 GY
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC312
EC-CD-93
TROUBLE DIAGNOSIS FOR DTC 28 CD20T
Cooling Fan (Overheat) (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
Cooling fan relay 2
.
CHECK COOLING FAN LOW NG Check cooling fan low
c
SPEED OPERATION. speed control circuit.
1. Disconnect cooling fan relay-3. (Go to PROCEDURE A .)
2. Turn ignition switch to
Cooling fan relay-3 ‘‘ON’’ position.
Cooling fan relay-1 YEC383 3. Perform ‘‘COOLING FAN’’
in ‘‘ACTIVE TEST’’ mode
with CONSULT-II.
------------------------------------------------------------- OR -------------------------------------------------------------
2. Start engine.
3. Set temperature switch at
full cold position.
4. Turn Air Conditioner switch
to ‘‘ON’’ position.
5. Turn blower fan switch to
‘‘ON’’ position.
6. Run engine at idle speed
for a few minutes with Air
SEF111X
Conditioner operating.
7. Make sure that both cool-
ing fans operate at low
speed.
OK
.
Cooling fan
CHECK COOLING FAN HIGH NG Check cooling fan high
c
SPEED OPERATION. speed control circuit.
1. Turn ignition switch to ‘‘LOCK’’ (Go to PROCEDURE B .)
position.
2. Reconnect cooling fan relay-3.
NEF809 3. Disconnect cooling fan relay-1.
4. Turn ignition switch to
‘‘ON’’ position.
5. Perform ‘‘COOLING FAN’’
in ‘‘ACTIVE TEST’’ mode
with CONSULT-II.
------------------------------------------------------------- OR -------------------------------------------------------------
4. Turn Air Conditioner switch
and blower fan switch to
‘‘OFF’’ position.
5. Disconnect engine coolant
temperature sensor har-
ness connector.
SEF111X 6. Connect 150Ω resistor to
engine coolant temperature
sensor harness connector.
Cooling fan 7. Restart engine and make
Engine coolant sure that both cooling fans
temperature sensor operate at higher speed
harness connector
than low speed.
OK
.
V
B
(Go to EC-CD-98.)
resistor
YEC384
EC-CD-94
TROUBLE DIAGNOSIS FOR DTC 28 CD20T
Cooling Fan (Overheat) (Cont’d)
PROCEDURE A
.
CHECK POWER SUPPLY. NG Check the following:
c
1. Turn ignition switch to ‘‘LOCK’’ posi- ● 10A fuse
tion. ● 40A, 100A, fusible
YEC385
2. Disconnect cooling fan relay-1 and links
fan motor-1 connector. ● Harness for open or
. 3. Turn ignition switch to ‘‘ON’’ position. short-circuit between
Under the vehicle A/C compressor
4. Check voltage between cooling fan cooling fan motor-1
motor-1 connector terminal V 1 , fan and battery.
.
Cooling fan motor-1 relay-1 connector terminal V 1 and ● Harness for open or
harness connector ground. short-circuit between
Voltage: Battery voltage cooling fan relay-1 and
fuse.
OK
If NG, replace fuse or
fusible links or repair har-
ness or connectors.
NEF416 .
. CHECK GROUND CIRCUIT. NG Repair harness or con-
Under the vehicle . c
Radiator 1. Turn ignition switch to ‘‘LOCK’’ posi- nectors.
lower hose tion.
2. Disconnect cooling fan relay-2 and
.
Cooling fan fan motor-2 harness connector.
motor-2
harness 3. Check harness continuity
connector between cooling fan relay-1 con-
nector terminal V 5 and cooling
fan relay-2 connector terminal
V 4 ; cooling fan motor-1 connec-
tor terminal V 2 and cooling fan
NEF417
relay-2 connector terminal V 3 .
Continuity should exist.
If OK, check harness for short-
circuit.
Cooling fan motor-1
connector Cooling fan relay-2
4. Check harness continuity
Cooling fan connector between cooling fan motor-2
relay-1 connector terminal V 1 and cool-
connector
ing fan relay-1 connector termi-
nal V 3 ; cooling fan motor-2 con-
nector terminal V 2 and ground.
Continuity should exist.
YEC386 If OK, check harness for short-
circuit.
OK
.
Cooling fan Cooling fan motor-2 V
C
relay-1 connector connector
YEC387
EC-CD-95
TROUBLE DIAGNOSIS FOR DTC 28 CD20T
Cooling Fan (Overheat) (Cont’d)
V
C
.
INSPECTION END
PROCEDURE B
EC-CD-96
TROUBLE DIAGNOSIS FOR DTC 28 CD20T
Cooling Fan (Overheat) (Cont’d)
V
D
.
CHECK GROUND CIRCUIT. NG Repair harness or connec-
Cooling fan motor-1 Cooling fan relay-2 c
connector connector 1. Turn ignition switch to ‘‘LOCK’’ position. tors.
2. Disconnect cooling fan motor-2 harness
connector.
3. Check harness continuity between
cooling fan motor-1 connector termi-
nal V2 and cooling fan relay-2 con-
nector terminal V 3 ; cooling fan
motor-2 connector terminal V 1 and
cooling fan relay-3 connector termi-
nal V5 ; cooling fan relay-2 connector
terminal V5 and ground.
Continuity should exist.
If OK, check harness for short-circuit.
4. Check harness continuity between
Cooling fan relay-3 cooling fan motor-2 terminal V 2 and
connector
Cooling fan ground.
motor-2
connector OK
.
CHECK OUTPUT SIGNAL CIRCUIT. NG Check the following:
c
1. Disconnect ECM harness connector. ● Harness connectors
NEF876 2. Check harness continuity between ECM E43 , F2
terminal V54 and cooling fan relay-3 con- ● Harness for open or
nector terminal V2 & cooling fan relay-2 short-circuit between
connector terminal V2 . cooling fan relay-2, 3 and
Continuity should exist. ECM.
If OK, check harness for short-circuit. If NG, repair harness or
Cooling fan motor-2
connectors.
connector E18 OK
.
CHECK COMPONENT NG Replace cooling fan relays.
c
(Cooling fan relay-2, 3).
Refer to ‘‘COMPONENT INSPECTION’’,
EC-CD-100.
OK
YEC389 .
CHECK COMPONENTS NG Replace cooling fan motors.
c
(Cooling fan motors).
Refer to ‘‘COMPONENT INSPECTION’’,
EC-CD-100.
Cooling fan OK
relay-3 .
connector Disconnect and reconnect harness connec-
tors in the circuit. Then retest.
.
INSPECTION END
EC-CD-97
TROUBLE DIAGNOSIS FOR DTC 28 CD20T
Cooling Fan (Overheat) (Cont’d)
V
B
Hose adapter
.
NG
CHECK COOLING SYSTEM FOR LEAK. c Check the following
Apply pressure to the cooling system with a for leaks:
tester, and check if the pressure drops. ● Hose
Testing pressure: ● Radiator
157kPa (1.57 bar, 1.6 kg/cm2, 23 psi) ● Water pump
Pressure should not drop. Refer to LC section
CAUTION: (‘‘Water Pump’’).
Higher than the specified pressure may
cause radiator damage.
.
SLC754AA
OK
.
NG
CHECK RADIATOR CAP. c Replace radiator
Apply pressure to cap with a tester. cap.
Radiator cap relief pressure:
Standard
78 - 98 kPa (0.78 - 0.98 bar,
0.8 - 1.0 kg/cm2, 11 - 14 psi)
Limit
59 - 88 kPa (0.59 - 0.88 bar,
0.6 - 0.9 kg/cm2, 9 - 13 psi)
OK
.
SLC755AA NG
CHECK THERMOSTAT. c Replace thermostat.
1. Check valve seating condition at normal
room temperatures.
It should seat tightly.
2. Check valve opening temperature and
maximum valve lift.
Valve opening temperature:
76.5°C (170°F) [standard]
Maximum valve lift:
More than 8 mm/90°C
(0.31 in/194°F)
3. Check if valve is closed at 5°C (9°F)
below valve opening temperature.
For details, refer to LC section
SLC343 (‘‘Thermostat’’).
OK
.
NG
Check engine coolant temperature sensor. c Replace engine cool-
Refer to ‘‘COMPONENT INSPECTION’’, ant temperature sen-
EC-72. sor.
OK
.
If the cause can not be isolated, go to ‘‘12
MAIN CAUSES OF OVERHEATING’’ on
next page.
.
INSPECTION END
EC-CD-99
TROUBLE DIAGNOSIS FOR DTC 28 CD20T
Cooling Fan (Overheat) (Cont’d)
COMPONENT INSPECTION
Cooling fan relay 1 Cooling fan relays-1, -2, -3
Check continuity between terminals V
3 and 5 .
V
Conditions Continuity
12V direct current supply between relay
5 Yes
terminals V1 and V 2
1 2
3 No current supply No
If NG, replace cooling fan relay.
5
2 4 1
3
YEC391
EC-CD-100
TROUBLE DIAGNOSIS FOR DTC 34 CD20T
NEF689
Diagnostic
Check Items
Trouble Code Malfunction is detected when ....
(Possible Cause)
No.
34 ● An improper signal from the sensor is sent to ● Harness or connectors
ECM. (The sensor circuit is open or shorted.)
● Needle lift sensor
● Air in fuel line
● Clogging No. 1 injection nozzle
EC-CD-101
TROUBLE DIAGNOSIS FOR DTC 34 CD20T
Needle Lift Sensor (NLS) (Cont’d)
NEEDLE EC-NLS-01
LIFT
SENSOR
F48
1 2
W B
W B
12 11
NBF-1 NBF-0
ECM
F106
1 2 F48
BR
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC419
EC-CD-102
TROUBLE DIAGNOSIS FOR DTC 34 CD20T
Needle Lift Sensor (NLS) (Cont’d)
DIAGNOSTIC PROCEDURE
Priming pump INSPECTION START
.
CHECK FOR AIR IN FUEL FILTER.
1. Move priming pump up and down to
purge air from fuel filter.
2. Perform ‘‘DIAGNOSTIC TROUBLE
CODE CONFIRMATION PROCE-
SEF671S DURE’’.
.
Disconnect and reconnect harness
connectors in the circuit. Then retest.
Trouble is not fixed
YEC392 .
Check ECM pin terminals for damage
and check the connection of ECM har-
ness connector. Reconnect ECM har-
ness connector and retest.
.
INSPECTION END
EC-CD-103
TROUBLE DIAGNOSIS FOR DTC 36 CD20T
SEF667S
Diagnostic
Check Items
Trouble Malfunction is detected when ...
(Possible Cause)
Code No.
36 ● Fuel cut solenoid valve circuit is malfunctioning. ● Harness or connectors
(The solenoid valve circuit is open or shorted.)
● Fuel cut solenoid valve
EC-CD-104
TROUBLE DIAGNOSIS FOR DTC 36 CD20T
Fuel Cut Solenoid Valve (Cont’d)
BATTERY
EC-FCUT-01
15A Refer to EL-POWER.
36 : Detectable line for DTC
: Non-detectable line for DTC
W/R
INJECTION PUMP
(FUEL CUT
SOLENOID VALVE)
F49
1
SB
W/R W/R
ENGINE
2 3 CONTROL
MODULE
RELAY
E91
1 5
W/G R
W/G R
E43 E89
7 2
F2 F96
W/G R
W/G R R R SB
42 68 45 23 53
K15 BAT+ BAT+ BAT+ EAB-1
ECM
F106
3
E91 1 2 3 4 F2 1 2 3 F49 1 2 F96
5
L 5 6 7 8 GY BR 3 4 B
1 2
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC313
EC-CD-105
TROUBLE DIAGNOSIS FOR DTC 36 CD20T
Fuel Cut Solenoid Valve (Cont’d)
.
DIAGNOSTIC PROCEDURE
Electronic injection
pump harness connector
(Fuel cut solenoid valve)
INSPECTION START
.
CHECK MAIN POWER SUPPLY.
Check power supply. Refer to
EC-CD-62.
.
NEF815
CHECK OUTPUT SIGNAL CIRCUIT. NG Repair harness or con-
c
1. Turn ignition switch to ‘‘ON’’ nectors.
position.
2. Select ‘‘FUEL CUT SOL/V’’ in
‘‘ACTIVE TEST’’ mode with
CONSULT-II.
3. Touch ‘‘ON’’ and ‘‘OFF’’ alter-
nately.
4. Check that operating sound is
emitted.
----------------------------------------------------------------- OR -----------------------------------------------------------------
C2FCS01 1. Turn ignition switch to
‘‘LOCK’’ position.
2. Disconnect ECM harness
connector and electronic
injection pump harness con-
Electronic injection pump nector.
harness connection
3. Check harness continuity
between fuel cut solenoid
valve connector terminal V 1
and ECM connector terminal
V 53 .
Continuity should exist.
YEC365
If OK, check harness for
short.
OK
.
CHECK COMPONENT NG Replace fuel cut solenoid
c
(Fuel cut solenoid valve). valve.
Refer to ‘‘COMPONENT INSPECTION’’
on next page.
OK
.
Disconnect and reconnect harness
connectors in the circuit. Then retest.
.
INSPECTION END
EC-CD-106
TROUBLE DIAGNOSIS FOR DTC 36 CD20T
Fuel Cut Solenoid Valve (Cont’d)
COMPONENT INSPECTION
Fuel cut solenoid valve
FUSE
1. Remove fuel cut solenoid valve.
2. Check for lifting shaft when applying 12V direct current to
terminals.
If NG, replace fuel cut solenoid valve.
Shaft SEF859S
EC-CD-107
TROUBLE DIAGNOSIS FOR DTC 42 CD20T
Diagnostic
Check Items
Trouble Code Malfunction is detected when ...
(Possible Cause)
No.
42 ● An excessively high or low voltage from the sensor ● Harness or connectors
is detected by ECM. (The sensor circuit is open or shorted.)
● Fuel temperature sensor
EC-CD-108
TROUBLE DIAGNOSIS FOR DTC 42 CD20T
Fuel Temperature Sensor (FTS) (Cont’d)
EC-FTS-01
INJECTION PUMP
(FUEL TEMPERATURE
SENSOR)
F50
6 5
R/Y B
R/Y B
63 33
KTF-1 GND-A ECM
F106
1
7 2
F50
6 3
B
5 4
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC420
EC-CD-109
TROUBLE DIAGNOSIS FOR DTC 42 CD20T
Fuel Temperature Sensor (FTS) (Cont’d)
. DIAGNOSTIC PROCEDURE
Electronic injection
pump harness connector
(Fuel temperature sensor) INSPECTION START
.
CHECK POWER SUPPLY. NG Repair harness or con-
c
1. Turn ignition switch to ‘‘LOCK’’ posi- nectors.
tion.
2. Disconnect fuel temperature sensor
harness connector.
NEF818
3. Turn ignition switch to ‘‘ON’’ position.
4. Check voltage between injection
pump connector terminal V 6 and
ground with CONSULT-II or voltage
Injection pump tester.
connector
Voltage:
Approximately 5V
OK
.
CHECK GROUND CIRCUIT. NG Repair harness or con-
c
NEF819 1. Turn ignition switch to ‘‘LOCK’’ posi- nectors.
tion.
2. Check harness continuity between
injection pump connector terminal
Injection pump V 5 and ECM connector terminal V 33 .
connector Continuity should exist.
If OK, check harness for short-cir-
cuit.
F50
OK
.
CHECK COMPONENT NG Have the injection pump
c
NEF820 (Fuel temperature sensor). assembly serviced by an
Refer to ‘‘COMPONENT INSPECTION’’ authorised service repre-
on next page. sentative.
OK
.
Disconnect and reconnect harness
connectors in the circuits. Then retest.
Trouble is not fixed.
.
Check ECM pin terminals for damage
and check the connection of ECM har-
ness connector. Reconnect ECM har-
ness connector and retest.
.
INSPECTION END
EC-CD-110
TROUBLE DIAGNOSIS FOR DTC 42 CD20T
Fuel Temperature Sensor (FTS) (Cont’d)
COMPONENT INSPECTION
Fuel temperature sensor
Wait until fuel temperature sensor reaches room temperature.
Check resistance between terminals V 5 and V 6 .
EC-CD-111
TROUBLE DIAGNOSIS FOR DTC 43 CD20T
NEF822
Diagnostic
Check Items
Trouble Malfunction is detected when ...
(Possible Cause)
Code No.
● An excessively low or high voltage from the sensor ● Harness or connectors
is detected by the ECM. (The sensor or switch circuit is open or shorted.)
43
● Accelerator position sensor
● Accelerator position switch
EC-CD-112
TROUBLE DIAGNOSIS FOR DTC 43 CD20T
Accelerator Position Sensor & Switch
(Cont’d)
DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE (For accelerator stiching)
1) Turn ignition switch to ‘‘ON’’ position.
2) Select ‘‘DATA MONITOR’’ mode with CONSULT-II.
3) Start engine and rev it up above 1,300 rpm.
4) Depress brake pedal immediately after releasing
accelerator pedal and keep it at least 5 seconds.
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
1) Start engine and rev it up above 1,300 rpm.
2) Depress brake pedal immediately after releasing
accelerator pedal and keep it at least 5 seconds.
3) Turn ignition switch to the ‘‘LOCK’’ position, wait at
least 5 seconds and then turn to the ‘‘ON’’ position.
4) Perform ‘‘Diagnostic Test Mode II’’ (Self-diagnostic
results) with ECM.
EC-CD-113
TROUBLE DIAGNOSIS FOR DTC 43 CD20T
Accelerator Position Sensor & Switch
(Cont’d)
EC-APS-01
ACCELERATOR
POSITION
SENSOR
M68
5 2 4
: Detectable line for DTC
LG/W W BR : Non-detectable line for DTC
LG/W W BR
M50
21 22 23
F104
LG/W W BR
LG/W W BR
57 15 55
TVO+ TVO TVO-
ECM
F106
1 2 3 4 5 6 7 8 9 10
1 2 3 4 5 M68 F104
11 12 13 14 15 16 17 18 19 20 21 22 23 24
B W
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC314
EC-CD-114
TROUBLE DIAGNOSIS FOR DTC 43 CD20T
Accelerator Position Sensor & Switch
(Cont’d)
ECM
EC-APP/SW-01
F106
LGS-E
65
GY
GY
ACCELERATOR
DEPRESSED WORK UNIT
M68
RELEASED
1
B
M52
6
F103
B
B B B
F18 F15
1 2
1 2 3 4 5 M68 F103
3 4 5 6
B W
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC315
EC-CD-115
TROUBLE DIAGNOSIS FOR DTC 43 CD20T
Accelerator Position Sensor & Switch
(Cont’d)
DIAGNOSTIC PROCEDURE
Accelerator
Accelerator position
pedal INSPECTION START
sensor harness
connector (Accelerator position sensor)
.
NG
CHECK POWER SUPPLY. Check the following:
c
1. Turn ignition switch to ‘‘LOCK’’ position. ● Harness connectors
2. Disconnect accelerator position sensor M50 , F104
NEF823
harness connector. ● Harness for open or
3. Turn ignition switch to ‘‘ON’’ position. short-circuit between
4. Check voltage between accelerator posi- ECM and accelerator
tion sensor connector terminal V 5 and position sensor.
ground with CONSULT-II or voltage If NG, repair harness or
tester. connectors.
Accelerator position Voltage: Approximately 5V
sensor connector
OK
.
CHECK GROUND CIRCUIT. NG Check the following:
c
1. Turn ignition switch to ‘‘LOCK’’ position. ● Harness connectors
2. Check harness continuity between accel- M50 , F104
NEF824 erator position sensor connector terminal ● Harness for open or
V 4 and engine ground. short-circuit between
Continuity should exist. ECM and accelerator
If OK, check harness for short-circuit. position sensor.
If NG, repair harness or
OK connectors.
Accelerator position
sensor connector
.
CHECK INPUT SIGNAL CIRCUIT. NG Check the following
c
1. Disconnect ECM harness connector. ● Harness connectors
2. Check harness continuity between ECM M50 , F104
terminal V
15 and accelerator position sen- ● Harness for open or
sor connector terminal V2 . short-circuit between
NEF825 Continuity should exist. ECM and accelerator
If OK, check harness for short-circuit. position sensor
If NG, repair harness or
OK connectors.
Accelerator position .
sensor connector CHECK COMPONENT NG
Replace accelerator pedal
c
(Accelerator position sensor). assembly.
Refer to ‘‘COMPONENT INSPECTION’’
EC-CD-118.
OK
.
Disconnect and reconnect harness connec-
NEF826 tors in the circuit. Then retest.
.
INSPECTION END
EC-CD-116
TROUBLE DIAGNOSIS FOR DTC 43 CD20T
Accelerator Position Sensor & Switch
(Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START
(Accelerator position switch)
.
OK
CHECK OVERALL FUNCTION. c
INSPECTION END
1. Turn ignition switch to ‘‘ON’’
position.
2. Check ‘‘OFF ACCEL POS’’ in
PEF123W ‘‘DATA MONITOR’’ mode with
CONSULT-II.
Accelerator pedal released:
ON
Accelerator pedal depressed:
OFF
---------------------------------------------------------------- OR ----------------------------------------------------------------
1. Turn ignition switch to ‘‘LOCK’’
position.
2. Check continuity between ECM
connector terminal V 65 and
ground.
Continuity:
Accelerator pedal released:
No
NEF705 Accelerator pedal depressed:
Yes
NG
.
NG
CHECK GROUND CIRCUIT. c
Check the following:
1. Disconnect accelerator switch harness ● Harness connectors
connector. M52 , F103
Accelerator
2. Check harness continuity between ● Harness for open circuit
switch accelerator switch connector terminal between accelerator switch
connector V1 and engine ground. and engine ground.
Continuity should exist. If NG, repair harness or con-
nectors.
OK
.
NEF828 NG
CHECK INPUT SIGNAL CIRCUIT. c
Check the following:
Check harness continuity between ECM ● Harness connectors
connector terminal V65 and accelerator F103 , M52
switch connector terminal V3 . ● Harness for open or short-
Continuity should exist. circuit between accelerator
switch and ECM
Accelerator OK
switch connector .
NG
CHECK COMPONENT c
Replace accelerator switch.
(Accelerator switch).
Refer to ‘‘COMPONENT INSPECTION’’
on next page.
OK
.
Disconnect and reconnect harness connec-
YEC367 tors in the circuit. Then retest.
Trouble is not fixed
.
Check ECM pin terminals for damage and
check the connection of ECM harness con-
nector. Reconnect ECM harness connector
and retest.
.
INSPECTION END
EC-CD-117
TROUBLE DIAGNOSIS FOR DTC 43 CD20T
Accelerator Position Sensor & Switch
Accelerator position
(Cont’d)
sensor connector
COMPONENT INSPECTION
M68
Accelerator position sensor
1 2 3 4 5 M68
1. Disconnect accelerator position sensor harness connector.
2 4 2. Make sure that resistance between accelerator position sen-
sor terminals V 2 and V 4 changes when opening throttle
valve manually.
Throttle valve conditions Resistance [at 25°C (77°F)]
YEC368
Completely closed Approximately 1.2 kΩ
Partially open 1.2 - 1.9 kΩ
Completely open Approximately 1.9 kΩ
If NG, replace accelerator pedal assembly.
CAUTION:
● Do not disassemble accelerator pedal assembly.
Conditions Continuity
Accelerator pedal released No
Accelerator pedal depressed Yes
YEC369
If NG, replace accelerator pedal assembly.
CAUTION:
● Do not disassemble accelerator pedal assembly.
EC-CD-118
TROUBLE DIAGNOSIS FOR DTC 47 CD20E
Coil
SEF615S
Crank pulley
Crankshaft position
sensor (TDC)
SEF616S
Diagnostic
Check Items
Trouble Code Malfunction is detected when ....
(Possible Cause)
No.
47 ● An incorrect signal from the sensor is detected by ● Harness or connectors
ECM during engine running and cranking. (The sensor circuit is open.)
● Crankshaft position sensor (TDC)
EC-CD-119
TROUBLE DIAGNOSIS FOR DTC 47 CD20E
Crankshaft Position Sensor (TDC) (Cont’d)
EC-CKPS-01
CRANKSHAFT
POSITION SENSOR
(TDC)
F53
2 3 1
OR W
OR W
21 8
GND-D DZG-1
ECM
F106
1 2 3 F53
B
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC350
EC-CD-120
TROUBLE DIAGNOSIS FOR DTC 47 CD20E
Crankshaft Position Sensor (TDC) (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
CHECK INPUT SIGNAL CIRCUIT. NG Repair harness or con-
c
1. Turn ignition switch to ‘‘LOCK’’ posi- nectors.
tion.
Crankshaft position
sensor (TDC) 2. Disconnect crankshaft position sen-
harness connector sor (TDC) and ECM harness con-
SEF617S
nectors.
3. Check continuity between ECM ter-
minal V 8 and crankshaft position
sensor (TDC) connector terminal V 3 .
.
CHECK GROUND CIRCUIT. NG Repair harness or con-
c
Crankshaft position
Check harness continuity between nectors.
sensor connector crankshaft position sensor (TDC) con-
nector terminal V2 and ECM connector
terminal V21 .
F53 Continuity should exist.
If OK, check harness for short-circuit.
OK
NEF833
.
CHECK COMPONENT NG Replace crankshaft posi-
c
[Crankshaft position sensor (TDC)]. tion sensor (TDC).
Refer to ‘‘COMPONENT INSPECTION’’
on next page.
OK
.
Disconnect and reconnect harness
connectors in the circuit. Then retest.
Trouble is not fixed
.
Check ECM pin terminals for damage
and check the connection of ECM har-
ness connector. Reconnect ECM har-
ness connector and retest.
.
INSPECTION END
EC-CD-121
TROUBLE DIAGNOSIS FOR DTC 47 CD20E
Crankshaft Position Sensor (TDC) (Cont’d)
COMPONENT INSPECTION
Crankshaft position sensor (TDC)
1. Disconnect crankshaft position sensor (TDC) harness con-
nector.
2. Loosen the fixing bolt of the sensor.
3. Remove the sensor.
4. Visually check the sensor for chipping.
5. Check resistance between crankshaft position sensor (TDC)
terminals V2 and V 3 .
Crankshaft position
sensor (TDC)
connector
NEF440
EC-CD-122
TROUBLE DIAGNOSES FOR DTC 83, 98 CD20T
.
Glow Control System
Glow lamp indicator When coolant temperature is lower than 75°C (167°F):
● Ignition switch ON
After ignition switch has been turned to ON, the glow relay
turns ON for a period of time depending on engine coolant
temperature, allowing current to flow through the glow plugs.
Time → [S]
● Starting
.
After starting the engine, current will flow through the glow
1.5
plugs for 300 seconds, or until the coolant temperature
exceeds 50°C (122°F).
.
(-40) (-4) (32) (68) (104) (140)
Pre-glow
Time → [S]
.
(-40) (-4) (32) (68) (104) (140)
.
Engine coolant temperature → °C (°F)
.
Post glow
Time → [S]
.
.
(-40) (-4) (32) (68). (104)
. (140)
Engine coolant temperature → °C (°F) NEF834
COMPONENT DESCRIPTION
Glow plug
Ceramic heater
Resistor The glow plug is provided with a ceramic heating element to
obtain a high-temperature resistance. It glows in response to a
signal sent from the ECM, allowing current to flow through the
glow plug via the glow relay.
SEF857S
Diagnostic
Check Items
Trouble Code Malfunction is detected when ....
(Possible cause)
No.
83 ● Glow relay signal circuit is open or shorted. ● Harness or connectors
(The glow relay signal circuit is open or shorted)
● Glow relay
98 ● Glow indicator lamp circuit is open or shorted. ● Harness or connectors
(The glow indicator lamp circuit is open or
shorted.)
● Glow lamp
EC-CD-123
TROUBLE DIAGNOSES FOR DTC 83, 98 CD20T
Glow Control System (Cont’d)
DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE
1) Turn ignition switch to ‘‘ON’’ position.
2) Select ‘‘DATA MONITOR’’ mode with CONSULT-II.
3) Wait at least 5 seconds.
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
1) Turn ignition switch to ‘‘ON’’ position, and wait for at
least 5 seconds.
2) Turn ignition switch off, wait for at least 5 seconds
and then turn on.
3) Perform ‘‘Diagnostic Test Mode II’’ (Self-diagnostic
results).
EC-CD-124
TROUBLE DIAGNOSES FOR DTC 83, 98 CD20T
Glow Control System (Cont’d)
IGNITION SWITCH
ON or START
BATTERY EC-GLOW-01
FUSE
BLOCK
10A (J/B) Refer to EL-POWER.
15A 80A
12 M1 36 i
13C
W/R B/R
LG/R
5
COMBINATION
METER (GLOW
INDICATOR LAMP)
: Detectable line for DTC
7 M38 : Non-detectable line for DTC
OR
W/R W/R ENGINE R B/R
CON-
2 3 TROL 1 5 GLOW
MODULE RELAY
RELAY E22 , E23 ,
E91
E24
1 5 2 3
W/G R W/R R
W/R R
E89 E2
1 1
F96 F46
W/R R
OR W/G R
M50 E43 E89
20 7 2
F104 F2 F96
OR W/G R
OR W/G R R R W/R
27 42 23 45 68 50 GLOW
GAZ-0 HRL-0 BAT+ BAT+ BAT+ GRL-0 PLUG
ECM
F47
F106
3
1 2 1 2 3 4 5 6 7 8 9 10
5 E91 1 2 3 4 F2 F96 F104
3 4 11 12 13 14 15 16 17 18 19 20 21 22 23 24
L 5 6 7 8 GY B W
1 2
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC316
EC-CD-125
TROUBLE DIAGNOSES FOR DTC 83, 98 CD20T
Glow Control System (Cont’d)
DIAGNOSTIC PROCEDURE
Glow relay
INSPECTION START
(Glow relay signal circuit)
.
CHECK MAIN POWER SUPPLY.
Check power supply to ECCS-D relay.
Refer to ‘‘TROUBLE DIAGNOSIS FOR
Glow relay
harness connector POWER SUPPLY’’ (EC-CD-62).
NEF835
.
CHECK POWER SUPPLY. NG Check the following:
c
1. Turn ignition switch to the ‘‘LOCK’’ ● 15A fuse
position. ● 80A fusible link
Glow relay
connector
2. Disconnect glow relay. ● Harness continuity bet-
3. Turn ignition switch to the ‘‘ON’’ ween glow relay and
position. fuse.
4. Check voltage between glow relay If NG, replace fuse or
connector terminals V 1 , V
5 and fusible link or repair har-
ground with tester. ness or connectors.
Voltage: Battery voltage
YEC370
OK
.
CHECK OUTPUT SIGNAL CIRCUIT. NG Check harness connec-
c
1. Turn ignition switch to the ‘‘LOCK’’ tors F96 , E89
Glow relay position. Repair harness or con-
connector
2. Disconnect ECM harness connector. nectors.
3. Check harness continuity between
ECM connector terminal V 50 and
glow relay connector terminal V 2 .
Continuity should exist.
If OK, check harness for short-cir-
cuit.
YEC371
OK
.
CHECK GLOW PLUG AND GLOW NG Replace glow plug or
c
RELAY. glow relay.
Refer to ‘‘COMPONENT INSPECTION’’
(EC-CD-129, 130).
OK
.
Disconnect and reconnect harness
connectors in the circuit. Then retest.
Trouble is not fixed
.
Check ECM pin terminals for damage
and check the connection of ECM har-
ness connector. Reconnect ECM har-
ness connector and retest.
.
INSPECTION END
EC-CD-126
TROUBLE DIAGNOSES FOR DTC 83, 98 CD20T
Glow Control System (Cont’d)
INSPECTION START
(Glow indicator lamp circuit)
Combination meter connector
(speedometer)
.
CHECK POWER SUPPLY CIRCUIT. NG Check the following:
c
1. Turn ignition switch to ‘‘LOCK’’ posi- ● Harness for open or
tion. short-circuit between
2. Disconnect combination meter har- combination meter and
ness connector. battery.
YEC372 3. Turn ignition switch to ‘‘ON’’ position. ● 10A fuse
4. Check voltage between combination If NG, replace fuse or
meter harness connector terminal repair harness or con-
V 5 and body ground. nectors.
Voltage: Battery voltage
Combination meter
connector OK
(speedometer)
.
CHECK GROUND CIRCUIT. NG Check the following:
M38 c
1. Turn ignition switch to ‘‘LOCK’’ posi- ● Harness connectors
tion. M50 , F104
2. Disconnect ECM harness connector. ● Harness for open or
YEC373
3. Check harness continuity between short-circuit between
ECM connector terminal V 27 and ECM and combination
combination meter connector termi- meter.
nal V 7 . If NG, repair harness or
Continuity should exist. connectors.
If OK, check harness for short-cir-
cuit.
OK
.
CHECK GLOW INDICATOR LAMP. NG Replace glow indicator
c
Make sure that glow indicator lamp is lamp.
not burnt out.
OK
.
Disconnect and reconnect harness
connectors in the circuit. Then retest.
Trouble is not fixed
.
Check ECM pin terminals for damage
and check the connection of ECM har-
ness connector. Reconnect ECM har-
ness connector and retest.
.
INSPECTION END
EC-CD-127
TROUBLE DIAGNOSES FOR DTC 83, 98 CD20T
Glow Control System (Cont’d)
INSPECTION START
(Glow plug circuit)
.
CHECK POWER SUPPLY-I. NG Check the following:
c
1. Turn ignition switch to ‘‘LOCK’’ posi- ● Harness for open or
tion. short-circuit between
2. Disconnect glow relay harness con- glow relay and battery.
nector. ● 80A fusible link
NEF873 3. Check voltage between glow relay If NG, replace fusible link
harness connector terminal V 5 and and repair harness con-
engine ground. nectors.
Voltage: Battery voltage
Glow relay Glow plug OK
connector connector
.
CHECK POWER SUPPLY-II. NG Check the following:
c
1. Disconnect glow plug harness con- ● Harness connectors
nector. E2 , F46
2. Check harness continuity between ● Harness for open or
glow plug harness connector and short-circuit between
YEC374
glow relay harness connector termi- glow plug and glow
nal V 3 . relay.
Continuity should exist. If NG, repair harness or
If OK, check harness for short-cir- connector.
cuit.
OK
.
CHECK GLOW PLUG AND GLOW NG Replace glow plug or
c
RELAY. glow relay.
Refer to ‘‘COMPONENT INSPECTION’’
(EC-CD-129, 130).
OK
.
Disconnect and reconnect harness
connectors in the circuit. Then retest.
.
INSPECTION END
EC-CD-128
TROUBLE DIAGNOSES FOR DTC 83, 98 CD20T
Glow Control System (Cont’d)
SYSTEM OPERATION CHECK
Set voltmeter between glow plug and engine body.
SEC554B
2. After-glow system
Start engine and read voltage.
Voltage:
After glow time (sec.)
COMPONENT INSPECTION
Glow relay Glow relay
1. Check relay for coil continuity between glow relay terminals
V
2 V 1 and V 2 .
V3
12V dc
Ohmmeter
SEC564B
EC-CD-129
TROUBLE DIAGNOSES FOR DTC 83, 98 CD20T
Glow Control System (Cont’d)
Glow plug
1. Remove glow plug connecting plate.
2. Check each glow plug for continuity.
Continuity should exist:
Approximately 0.5Ω [at 25°C (77°F)]
Ohmmeter
● If NG, replace glow plug.
SEF630K
EC-CD-130
TROUBLE DIAGNOSES FOR DTC 85 CD20T
Diagnostic
Check Items
Trouble Code Malfunction is detected when ....
(Possible cause)
No.
85 ● Air conditioner relay signal circuit is shorted. ● Harness or connectors
(The air conditioner relay signal circuit is shorted).
● Air conditioner relay
EC-CD-131
TROUBLE DIAGNOSES FOR DTC 85 CD20T
Air Conditioner Cut Control (Cont’d)
IGNITION SWITCH
ON or START EC-A/CCUT-01
FUSE
10A BLOCK
(J/B) Refer to EL-POWER. : Detectable line for DTC
20
M1 , : Non-detectable line for DTC
E104
9G 19A
LG/R LG/R
LG/R LG/R
2 5
AIR CONDITIONER
RELAY
E56
1 3
L/W L/R
To compressor
(Refer to HA-A/C.)
A/C
L/OR 4 L/OR A/C CONTROL
LG 10 SENS PANEL
L/OR E125 M70 M44
LG/R LG
1
1 2 THERMO
TRIPLE- CONTROL
HIGH PRESSURE L/OR 3 AMP.
LOW
SWITCH
M55
E20
NORMAL
4 THERMISTOR
GY
L/W
E43
2 1
F2
L/W GY
L/W GY
28 62
KLI-0 ELI-E ECM
F106
3
1 2 1 2 3 4 5 6 7 1 2 3 4
E20 5 E56 E125 F2
3 4 8 9 10 11 12 13 14 15 16 5 6 7 8
B L BR GY
1 2
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC317
EC-CD-132
TROUBLE DIAGNOSES FOR DTC 85 CD20T
Air Conditioner Cut Control (Cont’d)
INSPECTION START
(Air conditioner relay signal circuit)
Air conditioner relay
harness connector
.
CHECK POWER SUPPLY. NG Check the following:
c
1. Turn ignition switch to ‘‘LOCK’’ posi- ● Harness and connec-
tion. tors for open or short-
2. Disconnect air conditioner relay har- circuit between ignition
ness connector. switch and air condi-
YEC375 3. Turn ignition switch to ‘‘ON’’ position. tioner relay.
4. Check voltage between air condi- ● 10A fuse
tioner relay connector terminals V 2 , If NG, replace or repair
V 5 and engine ground. the parts affected.
Voltage: Battery voltage
Air conditioner relay
harness connector
OK
.
CHECK GROUND CIRCUIT. NG Check the following:
c
1. Turn ignition switch to ‘‘LOCK’’ posi- ● Harness connectors
tion. E43 , F2
2. Disconnect ECM harness connector. ● Harness for open or
YEC376
3. Check harness continuity between short-circuit between
ECM harness connector terminal V 28 ECM and air condi-
and air conditioner relay harness tioner relay.
connector terminal V 1 . If NG, repair harness or
Continuity should exist. connectors.
If OK, check harness for short-cir-
cuit.
OK
.
CHECK AIR CONDITIONER RELAY. NG Replace air conditioner
c
Refer to HA section for inspection. relay.
OK
.
Disconnect and reconnect harness
connectors in the circuit. Then retest.
Trouble is not fixed
.
Check ECM pin terminals for damage
and check the connection of ECM har-
ness connector. Reconnect ECM har-
ness connector and retest.
.
INSPECTION END
EC-CD-133
TROUBLE DIAGNOSES FOR DTC 86 CD20T
EGRC-Solenoid Valve
SYSTEM DESCRIPTION
Engine speed
Camshaft position sensor (TDC)
c
Atmospheric pressure
Atmospheric pressure sensor
c
The ECM receives signals sent from the engine coolant tempera-
ture sensor, crankshaft position sensor (TDC), atmospheric pres-
sure sensor, mass air flow sensor and air conditioner switch to
determine engine speed and operating conditions. Based on
these signals, the ECM controls the EGR control solenoid valve
operation.
No EGR operation will take place when the engine coolant tem-
perature is below 70°C (158°F), when idling, at starting and dur-
ing a period of time after starting the engine (70 - 200 seconds,
depending on engine coolant temperature).
Engine coolant Load EGRC-solenoid valve EGR valve Amount of EGR gas
temperature °C (°F)
COMPONENT DESCRIPTION
To control valve
The EGR control solenoid valves control vacuum pressure act-
To intake
air flow ing on the EGR valve. The EGR control valve will then be fully
opened or fully closed, as required.
Thus, intake air passages are opened or closed in relation to
Vacuum
signal
exhaust gas and intake air. Utilizing the relationship between
exhaust gas pressure and intake air pressure control, the amount
of EGR (exhaust gas recirculated) is regulated in large or small
volumes.
SEF240PH
Diagnostic
Check Items
Trouble Code Malfunction is detected when ....
(Possible cause)
No.
86 ● EGRC-solenoid valve A circuit is shorted. ● Harness or connectors
(EGRC-solenoid valve A circuit is open or shorted).
● EGRC solenoid valve A
EC-CD-134
TROUBLE DIAGNOSES FOR DTC 86 CD20T
EGRC-Solenoid Valve (Cont’d)
DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE
1) Turn ignition switch to the ‘‘ON’’ position.
2) Select ‘‘DATA MONITOR’’ mode with CONSULT-II.
3) Wait at least 2 seconds.
------------------------------------------------------------------------------------------------------------------------- OR -------------------------------------------------------------------------------------------------------------------------
1) Turn ignition switch to the ‘‘ON’’ position and wait at
least 2 seconds.
2) Turn ignition switch to the ‘‘LOCK’’ position, wait at
least 5 seconds and then turn to the ‘‘ON’’ position.
3) Perform ‘‘Diagnostic Test Mode II’’ (Self-diagnostic
results).
EC-CD-135
TROUBLE DIAGNOSES FOR DTC 86 CD20T
EGRC-Solenoid Valve (Cont’d)
BATTERY EC-EGRC/V-01
15A Refer to EL-POWER.
36
W/R
W/R W/R
ENGINE
2 3 CONTROL
MODULE
RELAY
E91 R
1 5 2
EGRC-
W/G R SOLENOID
VALVE
F55
1
W/G R
E43 E89
7 2
F2 F96
W/G R
W/G R R R P
42 68 45 23 25
K15 BAT+ BAT+ BAT+ ARSI-0
ECM
F106
3
E91 1 2 3 4 F2 F55 1 2 F96
5 1 2
L 5 6 7 8 GY B 3 4 B
1 2
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC318
EC-CD-136
TROUBLE DIAGNOSES FOR DTC 86 CD20T
EGRC-Solenoid Valve (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START
EGRC solenoid valve A (Circuit for EGRC-solenoid valve A)
harness connector
.
CHECK MAIN POWER SUPPLY.
Refer to Trouble Diagnosis for main
power supply (EC-CD-62)
NEF844
.
CHECK POWER SUPPLY. NG Check the following:
c
1. Turn ignition switch to the ‘‘LOCK’’ ● Harness continuity bet-
position. ween ECCS-D relay
2. Disconnect EGRC-solenoid valve A and EGRC-solenoid
EGRC solenoid
valve A harness harness connector. valve A connector.
connector 3. Turn ignition switch to the ‘‘ON’’ If NG, repair harness or
position. connectors.
4. Check voltage between connector
terminal V 2 and engine ground.
Voltage: Battery voltage
OK
NEF845
.
CHECK OUTPUT SIGNAL CIRCUIT. NG Check the following:
c
1. Turn ignition switch to the ‘‘LOCK’’ ● Harness for open or
position. short-circuit between
2. Disconnect ECM harness connector. ECM and solenoid
3. Check harness continuity between valve.
ECM harness connector terminal V 25 If NG, repair harness or
and EGRC solenoid valve A connec- connectors.
tor terminal V1 .
Continuity should exist.
If OK, check harness for short-cir-
cuit.
OK
.
CHECK COMPONENTS NG Replace malfunctioning
c
(EGRC-solenoid valve). component(s).
Refer to ‘‘COMPONENT INSPECTION’’
EC-CD-140.
OK
.
Disconnect and reconnect harness
connectors in the circuit. Then retest.
Trouble is not fixed
.
Check ECM pin terminals for damage
or the connection of ECM harness con-
nector. Reconnect ECM harness con-
nector and retest.
.
INSPECTION END
EC-CD-137
TROUBLE DIAGNOSES FOR DTC 86 CD20T
EGRC-Solenoid Valve (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START
EGR EGR CONTROL OPERATION
valve
.
CHECK OVERALL FUNCTION. OK INSPECTION END
c
1. Start engine and warm it up suffi-
ciently. (Air conditioner is ‘‘OFF’’).
2. Perform diagnostic test mode II
NEF433
(Self-diagnostic results).
Make sure that diagnostic trouble
code No. 55 is displayed.
3. Make sure that EGR diaphragm
moves up and down (Use your finger
EGR or a suitable tool) under the following
valve conditions:
At idle:
Spring does not move.
Racing engine from idle to 2800
rpm:
NEF434 Spring moves up and down.
NG
.
CHECK VACUUM SOURCES TO EGR OK CHECK COMPONENTS
c
VALVE. (EGR valve).
1. Disconnect vacuum hoses to EGR (See page EC-CD-140.)
valve.
NG
2. Make sure that vacuum exists under
the following conditions:
At idle:
.
Vacuum should not exist.
Replace malfunctioning
Racing engine from idle to 2800
component(s).
rpm:
Vacuum should exist.
NG
.
V
A
EC-CD-138
TROUBLE DIAGNOSES FOR DTC 86 CD20T
EGRC-Solenoid Valve (Cont’d)
V
A
.
CHECK CONTROL FUNCTION. OK CHECK VACUUM
c
1. Turn ignition switch to ‘‘ON’’ HOSE.
position. Check vacuum hose
2. Turn EGRC-solenoid valve for clogging, cracks or
‘‘ON’’ and ‘‘OFF’’ in ‘‘ACTIVE improper connection.
TEST’’ mode with CONSULT-II
C2ESA01 and check operating sound.
-------------------------------------------------------------------- OR --------------------------------------------------------------------
1. Check voltage between EGRC
solenoid valve connector termi-
nal V 1 , and ground with tester
under the following conditions:
Voltage:
At idle
Battery voltage
Engine speed is 2,800 rpm
Approximately 0.4V
NEF435 NG
.
Perform electrical circuit inspection.
Refer to EC-CD-137.
Crack
OK
.
V
B
Clogging
Improper connection
NEF846
.
EGRC-solenoid valve
harness connector
NEF436
EC-CD-139
TROUBLE DIAGNOSES FOR DTC 86 CD20T
EGRC-Solenoid Valve (Cont’d)
COMPONENT INSPECTION
EGR valve
EGR valve
Apply vacuum to EGR vacuum port with a hand vacuum pump.
EGR valve spring should lift.
If NG, replace EGR valve.
MEF137D
EGRC-solenoid valve
FUSE
Check air passage continuity.
Air passage Air passage
Condition continuity continuity
between V A and V
B between V A and V
C
EC-CD-140
TROUBLE DIAGNOSES FOR DTC 87 CD20T
Brake Switch
The ECM receives signals from two brake switches. One is a
conventional brake lamp switch, the other is referred to as a
redundant (RDNT) brake switch.
In case the accelerator pedal does not return to the idle position
(pedal sticks), the driver will react by depressing the brake. In
this (emergency) situation, the ECM will disregard the accelera-
tor pedal signal and bring back the engine speed to 1200 rpm.
Diagnostic
Check Items
Trouble Malfunction is detected when ...
(Possible Cause)
Code No.
● Brake switch circuits are open or shorted. ● Harness or connectors
(Brake switch circuits are open or shorted.)
87
● Stop lamp switch
● RDNT brake switch
EC-CD-141
TROUBLE DIAGNOSES FOR DTC 87 CD20T
Brake Switch (Cont’d)
ECM EC-BRK/SW-01
F106
BRA-E BRK-E BRA-E
39 20 44
R : RHD models
STOP LAMP
: Detectable line for DTC
SWITCH
: Non-detectable line for DTC
(EL section)
R/B R/B
F2 F104
4 15
E43 M50
R/B R/B
R/B R/B
1 1
RDNT RDNT
BRAKE BRAKE
SWITCH SWITCH
E122 M64
2 2
B B
B B B B
B B
2 1 2 3 4 5 6 7 8 9 10 1 2 3 4
M64 , E122 F104 F2
1 11 12 13 14 15 16 17 18 19 20 21 22 23 24 5 6 7 8
BR BR W GY
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC319
EC-CD-142
TROUBLE DIAGNOSES FOR DTC 87 CD20T
Brake Switch (Cont’d)
INSPECTION START
(RDNT brake switch)
V39 .
If NG, repair harness or
connectors.
YEC378
.
CHECK GROUND CIRCUIT. NG Repair harness or con-
c
1. Turn ignition switch to ‘‘LOCK’’ posi- nectors.
tion.
2. Check harness continuity between
RDNT brake switch harness connec-
tor terminal V2 and body ground.
Continuity should exist.
If OK, check harness for short-
circuit.
OK
.
CHECK COMPONENT.
(RDNT brake switch)
Refer to ‘‘COMPONENT INSPECTION’’
on next page.
OK
.
Disconnect and reconnect harness
connectors in the circuit. Then retest.
Trouble is not fixed
.
Check ECM pin terminals for damage
and check the connection of ECM har-
ness connector. Reconnect ECM har-
ness connector and retest.
.
INSPECTION END
EC-CD-143
TROUBLE DIAGNOSES FOR DTC 87 CD20T
Brake Switch (Cont’d)
COMPONENT INSPECTION
2
1 Stop lamp switch and RDNT brake switch
1. Turn ignition switch to ‘‘LOCK’’ position.
1 2
2. Disconnect switch harness connectors.
3. Check continuity between terminals V 1 and 2 .
V
Continuity:
Brake pedal Stop lamp switch RDNT brake switch
Released No No
YEC379 Depressed Yes Yes
EC-CD-144
TROUBLE DIAGNOSES FOR DTC 92 CD20T
ECCS-D Relay
The ECCS-D Relay shuts off the main power supply to the ECM
within 5 seconds after the ignition switch has turned to the
‘‘LOCK’’ position.
Diagnostic
Check Items
Trouble Code Malfunction is detected when ....
(Possible cause)
No.
92 ● ECCS-D relay shut-off time is too late. ● Harness or connectors
(The ECCS-D relay circuit is shorted).
● ECCS-D relay
● ECM
DIAGNOSTIC PROCEDURE
Refer to ‘‘Trouble Diagnosis for Power Supply’’ (EC-CD-62) for
ECCS-D relay circuit inspection.
EC-CD-145
TROUBLE DIAGNOSES FOR DTC 97 CD20T
Diagnostic
Check Items
Trouble Code Malfunction is detected when ....
(Possible cause)
No.
97 ● MI circuit is open or shorted. ● Harness or connectors
(MI circuit is open or shorted).
● MI lamp
● ECM
EC-CD-146
TROUBLE DIAGNOSES FOR DTC 97 CD20T
MI & Data Link Connectors (Cont’d)
IGNITION SWITCH
ON or START
EC-MIL-01
FUSE
BLOCK Refer to EL-POWER.
10A 10A (J/B)
12 24 M1
13C 15C
LG/R G
5 9
COMBINATION METER DATA LINK
(MALFUNCTION CONNECTOR
INDICATOR)
M59
M38
13 5 4 16 12 13
4B FUSE
BLOCK
OR/L GY/L G/B G/R B (J/B)
M50
19 17 16 18 4 M1
F104 1B
OR/L GY/L G/B G/R B
B
26 61 30 64 33
DLA-0 SCITX SCIRX CHECK GND-A
ECM
F106
M6 M28 M26
1 2 3 4 5 6 7 8 9 10
F104
11 12 13 14 15 16 17 18 19 20 21 22 23 24
W
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC320
EC-CD-147
TROUBLE DIAGNOSES FOR DTC 97 CD20T
MI & Data Link Connectors (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START
Combination meter (MI circuit)
harness connector
.
CHECK MI BULB. NG Replace MI bulb.
c
1. Turn ignition switch to ‘‘LOCK’’ posi-
tion.
YEC380 2. Disconnect combination meter har-
ness connector.
3. Apply battery voltage between com-
bination meter terminal V 5 and V13 .
4. Check that MI lits on.
Combination meter OK
harness connector
.
CHECK POWER SUPPLY. NG Check the following:
c
1. Turn ignition switch to ‘‘ON’’ position. ● Harness for open or
2. Check voltage between combination short-circuit between
meter terminal V 5 and body ground. combination meter and
YEC381
Voltage: Battery voltage ignition switch.
● 10A fuse
OK
If NG, repair or replace
harness or fuse.
.
Combination meter CHECK GROUND CIRCUIT. NG Check the following:
harness connector c
1. Turn ignition switch to ‘‘LOCK’’ posi- ● Harness connectors
.
INSPECTION END
EC-CD-148
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS CD20T
Start Signal
BATTERY EC-S/SIG-01
40A Refer to EL-POWER.
g
OFF ST IGNITION
SWITCH
E109
ACC ON
6
W/G
W/G
3G
FUSE
BLOCK
10A (J/B)
17 Refer to EL-POWER.
M1 ,
5B E104
B/Y
B/Y
M50
24
F104
B/Y
B/Y
16
ANL
ECM
F106
23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 F106
68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 GY
YEC321
EC-CD-149
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS CD20T
Start Signal (Cont’d)
DIAGNOSTIC PROCEDURE
INSPECTION START
.
CHECK OVERALL FUNCTION. OK INSPECTION END
c
1. Turn ignition switch to ‘‘ON’’
position.
2. Check ‘‘START SIGNAL’’ in
‘‘DATA MONITOR’’ mode with
C2DMM04 CONSULT-II.
-------------------------------------------------------------------- OR --------------------------------------------------------------------
1. Turn ignition switch to the
‘‘LOCK’’ position.
2. Disconnect ECM harness con-
nector.
3. Turn ignition switch to ‘‘START’’
position.
4. Check voltage between ECM
NEF851
connector terminal V 16 and
ground.
Voltage:
Ignition switch ‘‘START’’ —
Battery voltage
Except above —
Approximately 0V
NG
.
Check if 10A fuse is OK. NG Replace 10A fuse.
c
OK
NEF852 .
CHECK INPUT SIGNAL CIRCUIT. NG Check the following:
c
1) Turn ignition switch to ‘‘LOCK’’ posi- ● Harness or connec-
tion. tors M50 , F104
2) Disconnect 10A fuse. ● Harness for open or
3) Check harness continuity between short-circuit between
ECM connector terminal V 16 and fuse ECM and fuse block.
block. If NG, repair harness
Continuity should exist. or connectors.
If OK, check harness for short-circuit.
OK
.
Disconnect and reconnect harness con-
nectors in the circuit. Then retest.
Trouble is not fixed
.
Check ECM pin terminals for damage
and check the connection of ECM har-
ness connector. Reconnect ECM harness
connector and retest.
.
INSPECTION END
EC-CD-150
SERVICE DATA AND SPECIFICATIONS (SDS) CD20T
General Specifications
Unit : rpm Pump numbers
Engine CD20T
Pump assembly
Engine Part number
Maximum engine speed 5,400 number
Injection Nozzle
INSPECTION AND ADJUSTMENT
Injection nozzle assembly
Unit: kPa (bar, kg/cm2, psi)
GLOW PLUG
Resistance [at 25°C (77°F)] Ω 0.5
ENGINE COOLANT TEMPERATURE
SENSOR
Temperature °C (°F) Resistance kΩ
ACCELERATOR POSITION SENSOR
20 (68) 2.1 - 2.9
Resistance kΩ
50 (122) 0.68 - 1.00 Throttle valve conditions
[at 25°C (77°F)]
90 (194) 0.236 - 0.260
Completely closed Approximately 1.2
Partially open 1.2 - 1.9
Completely open Approximately 1.9
CONTROL SLEEVE POSITION SENSOR
Resistance [at 25°C (77°F)] Ω 6.0
EC-CD-151
SERVICE DATA AND SPECIFICATIONS (SDS) CD20T
Inspection and Adjustment (Cont’d)
NOTE
EC-CD-152