MPX English Final Version VOLUME 1

Edition: September 2010 VOLUME 1
Printing: October 2010 INTRODUCTION 01

Pulication NO: FXSM-201009 PREPARATION 02
Printed in China SERVICE SPECIFICATIONS 03
DIAGNOSTICS 04
VOLUME 2
ENGINE CONTROL SYSTEM 11A
FUEL 12A
EMISSION CONTROL 13A
INTAKE AIR 14A
ENGINE MECHANICAL 15A
EXHAUST 16A
COOLING 17A
LUBRICATION 18A
IGNITION 19A
STARTING AND CHARGING 20A
ENGINE CONTROL SYSTEM 11B
FUEL 12B
EMISSION CONTROL 13B
INTAKE AIR 14B
ENGINE MECHANICAL 15B
EXHAUST 16B
COOLING 17B
LUBRICATION 18B
STARTING AND CHARGING 20B
FRONT SUSPENSION 31
REAR SUSPENSION 32
TIRE AND WHEEL 33
AXLE AND PROPELLER SHAFT 34
BRAKE 35
PARKING BRAKE 36
TRANSMISSION 41
VOLUME 3
CLUTCH 42
STEERING COLUMN 51
POWER STEERING 52
HEATER AND AIR CONDITIONING 61
SUPPLEMENTAL RESTRAINT SYSTEM 62
SEAT BELT 63
LIGHTING 64
WIPER AND WASHER 65
AUDIO SYSTEM 66
WIRING 71
COMMUNICATION SYSTEM 81
WINDSHIELD 82
© 2010 Beiqi Foton Motor Co., Ltd INSTRUMENT PANEL 83
SEAT 84
All right reserved. No part of this service DOOR LOCKS 85
manual may be reproduced or stored in a
SLIDING ROOF 86
retrieval system, or transmitted in any form, or
by any means, electronic, mechanical, photo- ENGINE HOOD AND DOORS 87
copying, recording or otherwise, without the EXTERIOR AND INTERIOR TRIM 88
proir written permission of Foton. VEHICLE CONTROL SYSTEM 91
INDEX
INTRODUCTION
01
HOW TO USE THIS MANUAL ........................................................... 01-1
GENERAL INFORMATION.......................................................... 01-1 01
IDENTIFICATION INFORMATION..................................................... 01-6
VEHICLE IDENTIFICATION NUMBER (VIN) .............................. 01-6 01
SERIAL NUMBER (SN) ............................................................... 01-8
REPAIR INSTRUCTION..................................................................... 01-9 01
PRECAUTION.............................................................................. 01-9
VEHICLE LIFT AND SUPPORT LOCATIONS........................... 01-18 01
HOW TO TROUBLESHOOT ............................................................ 01-20
GENERAL INFORMATION........................................................ 01-20 01
HOW TO PROCEED WITH TROUBLESHOOTING .................. 01-22
ELECTRONIC CIRCUIT INSPECTION PROCEDURE ............. 01-31 01
TERMS ............................................................................................. 01-35
ABBREVIATIONS USED IN THIS MANUAL ............................. 01-35
01
01
01
01
01
01
01
01
01
01
01
01
01
INTRODUCTION - HOW TO USE THIS MANUAL 01-1
HOW TO USE THIS MANUAL

INTRODUCTION
GENERAL INFORMATION
1. GENERAL DESCRIPTION. 01
(a) Carrying out operations described in this manual in the correct sequence may help you improve the
quality and efficiency during servicing. 01
(b) Generally, service operations can be separated in the following 3 main processes:
• Diagnosis 01
• Removal / Installation, Replacement, Disassembly / Reassembly, (On-vehicle) Inspection and
Adjustment
01
• Final Inspection
01
(c) This manual explains the 1st process of “Diagnosis” (Refer to “Chapter 04 diagnostics”) and the 2nd
process of “Removal / Installation, Replacement, Disassembly / Reassembly, (On-vehicle) Inspection 01
and Adjustment”, but the 3rd process of “Final Inspection” is omitted.
(d) The following essential operations are not written in this manual. However, these operations must be 01
performed in actual situations.
• Operations with a jack or lift 01
• Cleaning of a removed part when necessary
• Visual check 01
2. INDEX.
01
(a) An alphabetical INDEX section is provided at the end of this manual as a reference to help you find the
item to be repaired.
01
3. PREPARATION.
(a) Special service tools (SST) and special service materials (SSM) may be required depending on the 01
repair situation. Be sure to use SST and SSM when they are required and follow the correct operation
sequence. A list of SST and SSM is in the “Chapter 02 preparation” of this manual. 01
4. SERVICING PROCEDURES.
(a) The components’ illustration is placed under the title where necessary. 01
01
01
01
01
01
01
01-2 INTRODUCTION - HOW TO USE THIS MANUAL
(b) The components’ illustration shows the assembly relationship of all parts in the system. A table follow-
ing the illustration lists names of parts.
Example:
(c) If installation is performed in the reverse order of removal, only important points will be described.
(d) In this manual, only items with points are described in the procedure, and the operation portion and
content are shown in an illustration. In the explanations, details of the operational method, standard
value and notices are placed. 01
(e) Some illustrations in this manual for similar models may be the same. In such a case, specific details
may be different from the actual vehicle. 01
(f) The procedures are presented in a step-by-step format:
• The illustration shows what to do and where to do it. 01
• The task title tells what to do.
• The explanation text tells how to perform the task and gives other information such as specifications 01
and warnings.
Example:
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01-4 INTRODUCTION - HOW TO USE THIS MANUAL
5. SERVICE SPECIFICATIONS.
(a) Specifications are presented in bold type throughout this manual. You never have to leave the
procedure to look for the specifications. The specifications can also be found in the “Chapter 03 service
specifications” for quick reference.
6. TERMS DEFINITION.
WARNING Indicates the possibility of injury to you or other persons.

Indicates the possibility of damage to the components being repaired
CAUTION
and the equipments being operated.
Provides additional information to help you perform the service
NOTE
operations efficiently.
7. SI UNIT.
(a) The units given in this manual are expressed according to the SI UNIT (International System of Units).
Example:
Torque: 30 N•m
8. APPLICABLE VEHICLES.
L / RHD Series Engine Transmission Models

6526B1DXA-01ZA01 6526B1DXA-01ZA02 01
4G64S4M 6476B1DXA-01ZA01 6476B1DXA-01ZA02
01
6476B1DXA-01ZA03 6476B1DXA-01ZA04
01
R5M21 - GEA5A 6526B1DXA-S1ZA01 6526B1DXA-S1ZA02
6476B1DXA-S1ZA01 6476B1DXA-S1ZA02 01
4G64S4N
6476B1DXA-S1ZA03 6476B1DXA-S1ZA04
01
6476B1DXA-S1ZA06 6476B1DXA-S1ZA07
01
4G64S4M 6526B1DXA-01ZA03 6476B1DXA-01ZA05
R5M21 - GEA5A
4G64S4N 6526B1DXA-S1ZA03 6476B1DXA-S1ZA05 01
6526B1DDA-S1ZA01 6526B1DDA-S1ZA02
BJ493ZQ3 ZM001AJ2 01
6526B1DDA-S2ZA01
LHD 01
4G63S4M R5M21 - GEA5A 6526B1DVA-01ZA01 6526B1DVA-01ZA02
MPX BJ493ZQ3 ZM001AJ2 6526B1DDA-S1ZA03 6526B1DDA-S1ZA03 01
4G63S4M + 6526B1EVA-S1Z044 6526B1EVA-S1Z045

01
OBD 6526B1EVA-S1Z046
R5M21 - GEA5A 01
6526B1DXA-X1ZA03 6526B1DXA-X1ZA04
4G64S4N
6526B1DXA-X2ZA02 01
4G63S4M + 6526B1EVA-S1Z040 6526B1EVA-S1Z041

R5M21 - GEA5A 01
OBD 6526B1EVA-S1Z042
01
BJ493ZQ3 ZM001AJ2 6526B1DDA-S1ZA06 6526B1DDA-S1ZA07
6526B1DXA-X1ZA01 6526B1DXA-X1ZA02 01
4G64S4N R5M21 - GEA5A
6526B1DXA-X2ZA01
01
6476B1DXA-RAZ001 6476B1DXA-RAZ002
01
RHD 4G64S4N R5M21-GEA5A 6476B1DXA-RAZA06 6476B1DXA-RAZA07
6476B1DXA-RAZA08 6476B1DXA-RAZA09 01
01
01-6 INTRODUCTION - IDENTIFICATION INFORMATION
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION NUMBER (VIN)
1. VEHICLE IDENTIFICATION NUMBER (VIN).
(a) The Vehicle Identification Number (VIN) is stamped on the vehicle identification number label and
vehicle certification plate as shown in the illustration.
• Vehicle identification number label: Can be found through the windshield at front left corner of the
instrument panel.
• Vehicle certification plate: Can be found next to the front wiper motor assy after opening the engine
hood.
• Vehicle identification number label: Can be found at co-driver foot pedal side.
INTRODUCTION - IDENTIFICATION INFORMATION 01-7
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01-8 INTRODUCTION - IDENTIFICATION INFORMATION
SERIAL NUMBER (SN)

1. FINAL DRIVE SERIAL NUMBER.
(a) The final drive serial number is stampe on the final drive
housing.
2. PROPELLER SHAFT SERIAL NUMBER.

(a) The propeller shaft serial number is stamped on the tube.
INTRODUCTION - REPAIR INSTRUCTION 01-9
REPAIR INSTRUCTION
PRECAUTION
1. BASIC REPAIR NOTE. 01
(a) Notes on operation.
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
• Be sure to wear a clean uniform. 01

1 Looks
• Be sure to wear hat and safety shoes.
01
2 Vehicle protection • Before starting the operation, set the grille cover, fender cover,
seat cover and floor mat.
01
• In case of working with 2 or more persons, be sure to check safety
of one another.
• When working with the engine running, pay attention to the
ventilation of the workshop.
3 Safe operation • In case of operating on high temperature parts, rotating, moving
and vibrating parts, pay attention not to burn or injury yourself.
• When jacking up the vehicle, be sure to support the specified
location with a safe stand.
• When lifting up the vehicle, apply a safe equipment.
01-10 INTRODUCTION - REPAIR INSTRUCTION
Preparation of tools and • Before starting the operation, prepare a tool stand, SST, gauge,
4
measuring gauge oil, shop rag and parts for replacement.
• Diagnose with a thorough understanding of the trouble

phenomenon and perform effective operations.
• Before removing the parts, check the assembly for general
Removal and installstion, condition, deformation and damage.
5 disassembly and reassembly • When the structure is complicated, take a note or make match
operations marks so as not to make mistakes that affect the function of the
parts.
• Clean and wash the removed parts if necessary, and assemble
them after a thorough check.
• Place the removed parts in the correct order to avoid mixing up or

making them dirty.
• As for non-reusable parts such as gasket, O-rings, and self lock
6 Removed parts nut, replace them with new ones following the instruction of this
manual.
• Sort out the parts for replacement in a box and show them to the
customer.
(b) Jacking up and supporting vehicle.

• Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle
at the proper locations. (Refer to “Chapter 01 introduction - repair instruction, vehicle lift and support
locations”)
(c) Precoated part.
• Precoat parts are bolts, nuts, etc. that are coated with sealant at the factory.
• If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the
sealant.
• When reusing precoated parts, clean off the old sealant and dry the part with compressed air. Then
apply the specified sealant to the bolts, nut or threads.
WARNING
Perform the torque check with the lower limit value of the torque tolerance.
• Sometimes, it is necessary to leave the installed precoated parts for a specified time until the sealant
hardens.
(d) Gasket.
• If necessary, use a sealer or gasket to prevent leakage.
(e) Bolts, nuts and screws.
• Always tighten the bolts, nuts and screws at the specified torque with a torque wrench.
(f) Fuse.
• When replacing a fuse, make sure the amperage rating of new fuse is correct. The amperage rating of
new fuse should be same as what of old fuse, neither more nor less.
Illustration Symbol Part Name Abbreviation
01
Fuse F
01
01
Fusible Link F/L
01
01
Circuit Breaker CB 01
01
(g) Clips.
• The removal and installation methods of typical clips used in body parts are shown in the table below. 01
NOTE
01
If the clip is damaged during the operation, replace with a new one.
Shape (Example) Removal / Installation 01
01
01
01
01
01
01
01
01
01
01
Shape (Example) Removal / Installation

(h) Removal and installation of vacuum hoses.

• To disconnect the vacuum hoses, pull the hoses by
holding the end, not the middle of them.
01
01
01
01
• When disconnecting vacuum hoses, use tags to identify
where they should be reconnected. 01
01
01
01
01
• After performing the operation, check carefully whether
01
the hoses are connected properly.
• When using a vacuum gauge, never force the hose onto 01
a connector that is too large. Always use a step-down
adapter for adjustment. The stretched hose may cause 01
leakage.
(i) Torque when using a torque wrench with extension tool. 01
• In case of tightening with a torque wrench which has an
extended length by combining the torque wrench with 01
SST or extension tool, if you tighten until the reading of
the torque wrench reaches the specified torque value, 01
the actual value becomes excessive.
• In this manual, only the specified torque is described. In 01
case of using SST or an extension tool, calculate the
reading of the torque wrench by the following formula. 01
• Formula: T’ = T × L2 / (L1 + L2) 01
T’ Reading of torque wrench (N·m) 01

T Torque (N•m)
01
L1 Length of SST or extension tool (mm)
L2 Length of torque wrench (mm)

2. FOR VEHICLES EQUIPPED WITH SUPPLEMENTAL RESTRAINT SYSTEM.

WARNING
Some MPX vehicles are equipped with SRS (Supplemental Restraint System), which contains a driver
airbag. Failure to carry out service operations in the correct sequence could cause the SRS to
unexpectedly deploy during servicing. It may lead to a serious accident. Furthermore, if a mistake is
made in servicing the SRS, it is possible that the SRS may failure to operate when required. Before
servicing (including removal or installation of parts, inspection or replacement), be sure to read the
following items carefully, then follow the correct procedures described in the service manual.
(a) General notices.
• Malfunction symptoms of the SRS are difficult to confirm, so the DTCs become the most important
source of information when troubleshooting. When troubleshooting the SRS, always inspect the DTCs
before disconnecting the battery.
• Operation must be started 90 seconds after the ignition switch is turned to the “LOCK” position and the
negative (-) cable and positive (+) cable are disconnected from the battery. (The SRS is equipped with
a back-up power source. If operation is started within 90 seconds after disconnecting the battery
negative (-) cable and positive (+) cable, the SRS may deploy.)
• When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and
audio system will be cleared. So before repairing, record the necessary data of the clock and audio
system. After repairing, reset the clock and audio system. Never use a back-up power supply from
another battery to avoid erasing the memory in each memory system. The back-up power supply will
supply power to the SRS system. It could cause the SRS to unexpectedly deploy during servicing.
• Even in case of a minor collision that the SRS does not deploy, the horn switch assy should be
inspected. (Refer to “Chapter 62 supplemental restraint system - horn switch assy, replacement”,
“Chapter 62 supplemental restraint system - RCM, replacement”)
• Never use SRS related parts from another vehicle. Be sure to replace them with new parts when
necessary.
• Before repairing, remove the RCM first if shocks may be applied to it during repairs.
• Do not disassemble and repair the horn switch assy.
• If the horn switch assy has been dropped, or there are cracks, dents or other faults, replace it with a
new one.
• Do not expose the horn switch assy (with driver airbag) directly to hot air or flames.
• Use a multimeter with high impedance (10 kΩ / V minimum) for troubleshooting of the SRS electrical
circuits.
• Information labels are attached to the SRS components. Be sure to follow the instructions on the labels
when performing operations.
• After repairing on the SRS system, perform the inspection of airbag warning light. (Refer to “Chapter 04
diagnostics - supplemental restraint system, precheck”, “Chapter 04 diagnostics - supplemental
restraint system, SRS warning light is always on”, “Chapter 04 diagnostics - supplemental restraint
system, SRS warning light is inoperative”)
(b) Clock spring.

• The steering wheel must be installed correctly to the
steering column with the clock spring at the neutral
position, otherwise wire harness disconnection and other
troubles may occur. (Refer to “Chapter 51 steering column -
steering wheel assy, overhaul”, “Chapter 62 supplemental
restraint system - spring clock, replacement”)
• When removing the horn switch assy or handling a new

horn switch assy, it should be placed with the pad top
surface upward. Placing it with the pad top surface
downward may lead to a serious accident if the airbag 01
accidently inflates. Also, do not place horn switch assy
on top of one another. 01
01
01
01
01
01
• Never measure the resistance of the airbag squib.
Perform this operation may cause the airbag to inflate, 01
which is very dangerous.
• Never coat the grease on the horn switch assy and never 01
clean the pad with any kinds of detergents.
• Store the horn switch assy where the ambient 01
temperature remains below 93 ℃ without high humidity
and away from electrical noise. 01
• When using electric welding, disconnect the airbag connector
firstly before starting operation. 01
• When disposing of the vehicle or the horn switch assy
01
alone, the airbag should be deployed with a SST before
disposal. (Refer to “Chapter 62 supplemental restraint
01
system - horn switch assy, disposal”)
3. ELECTRONIC CONTROL. 01
(a) Disconnection and connection of battery terminal.
01
• Before performing electrical operations, disconnect the
battery negative terminal cable beforehand so as to prevent
burnt-out damage by short. 01
• Disconnect the battery terminal completely without twist
01
after turn off all switches.
• When the negative (-) terminal cable is disconnected from 01
the battery, the memory of the clock and audio system will
be cleared. So before repairing, record the necessary data 01
of the clock and audio system. After repairing, reset the
clock and audio system.
(b) Handling of electronic parts.

• Do not open the cover or case of the module unless
absolutely necessary. If the IC terminals are touched, the
IC may be destroyed by static electricity.
• To disconntect electronic connectors, pull the connector
itself, not the wire harness.
• Do not drop electronic components, such as sensors or

relays. If they are dropped on a hard floor, they should be
replaced and not be reused.
• When cleaning the engine with steam, protect the
electronic components, air filter and emission-related
components from water.
• Never use an impact wrench to remove or install
temperature switches or temperature sensors.
• When checking the continuity at the wire harness
connector, insert the tester probe carefully to prevent
terminals from bending.
• After replacing electronic components, always perform
operation check.
4. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS.
(a) Place for removing and installing of fuel system parts.
• Work in a place with good air ventilation and without anything flammable such as welder, grinder, drill,
electric motor or stove in the surroundings.
• Never work in a place such as a pit or nearby a pit, as there is a possibility that vaporized fuel is filled in
those places.
(b) Removing and installing of fuel system parts.
• Prepare a fire extinguisher before starting the operation.
• For prevention of static electricity, install a ground on the fuel changer, vehicle and fuel tank and do not
spray much water so as to prevent slipping.
• Never use any electric equipment like an electric motor or a working light, as they may cause sparks or
high temperature.
• Never use an iron hammer, as it may cause sparks.
• Dispose of the shop rag separately from any fuel deposit.
5. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS.
CAUTION
If any metal chips are mixed in the inlet pass, this may give a bad effect to the engine and turbocharger.
(a) When removing and installing the inlet system parts,

close the opening of the removed inlet system parts and
the engine with a clean shop rag or tape.
(b) When installing the inlet system parts, check that there is
no mixing of metal chips.
6. HANDLING OF HOSE CLAMPS.

01
(a) Before removing the hose, check the depth of the
inserting portion and the clamp position in order to 01
reinstall it surely.
(b) If deformation or dent is found, replace the clamp with a 01
new one.
(c) In case of reusing the hose, install the clamp on the hose 01
where it has a clamp track.
(d) For a spring type clamp, adjust it by applying force to the 01
arrow mark direction after the installation.
01
7. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER.
CAUTION 01
If large amount of unburned fuel flows into the converter, it may cause overheating and a fire hazard.
To prevent this, observe the following precautions. 01
(a) Use only unleaded gasoline (gasoline vehicles).
01
(b) Avoid running the engine at idle speed for more than 20 minutes.
(c) Avoid a spark jump test.
01
• Perform a spark jump test only when absolutely necessary. Perform this test as quickly as possible.
• While testing, never race the engine. 01
(d) Avoid a prolonged engine compression measurement. This operation must be performed as quickly as
possible. 01
(e) Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and
create an extra load on the catalytic converter. 01
01
01
01
01
01
01
01
VEHICLE LIFT AND SUPPORT LOCATIONS

1. NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP.
(a) As a rule, the vehicle must be unloaded when jacking up. Never jack up or lift up the vehicle loaded with
things of heavy weight.
(b) When removing any parts of heavy weight like the engine transmission, the center of gravity of the
vehicle moves. Place a balance weight so as to keep it from rolling, or hold the jacking support location
using the jack.
2. NOTICE FOR USING JACK AND 4 POSE LIFT.
(a) Follow the instruction in this manual for a safety operation.
(b) Do not damage tires or wheels with a pry bar.
(c) Park the vehicle on a level road with applying parking brake.
(d) Shift in the reverse position.
(e) Using a wheel stopper, fix the vehicle.
(f) Jack up the vehicle using a jack with rubber attachment.
WARNING
Be sure to jack up the vehicle at the correct support location.
(g) Lift the vehicle up by using a 4 pose lift with rubber attachment.
WARNING
Be sure to lift up the vehicle at the correct support location.
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01-20 INTRODUCTION - HOW TO TROUBLESHOOT
HOW TO TROUBLESHOOT
GENERAL INFORMATION
There are many electronic controlled systems in the MPX. In general, electronic controlled system is consid-
ered to be very intricate and require a high level of technical knowledge and expert skill to troubleshoot.
However, the fact is that if you proceed by inspecting the circuits one by one, troubleshooting of these systems
is not complex. If you have adequate understanding of the system and basic knowledge of electricity, the
problem can be accurately diagnosed and fixed.
This manual is designed based on the above principle to help service technicians perform accurate and
effective troubleshooting.
The troubleshooting procedures are described on the following pages.
System Reference
Anti-lock Brake System Chapter 04 diagnostics - anti-lock brake system
Audio System Chapter 04 diagnostics - audio system
Combined Display Chapter 04 diagnostics - combined display
Chapter 04 diagnostics - gasoline engine control system

Engine Control System
Chapter 04 diagnostics - diesel engine control system
Heater And Air Conditioning Chapter 04 diagnostics - heater and air condition system
Horn Chapter 04 diagnostics - horn system
Instrument Cluster Chapter 04 diagnostics - instrument cluster
Lighting Chapter 04 diagnostics - light system
Outside Mirror Chapter 04 diagnostics - outside mirrors
Power Door Locks Chapter 04 diagnostics - power door locks
Power Windows Chapter 04 diagnostics - power windows
Rear Window Defrost System Chapter 04 diagnostics - rear window defrost system
Reverse Radar Chapter 04 diagnostics - reverse radar system
Sliding Roof Chapter 04 diagnostics - sliding roof system
Supplemental Restrait System Chapter 04 diagnostics - supplemental restraint system
Wiper And Washer Chapter 04 diagnostics - wiper and washer

INTRODUCTION - HOW TO TROUBLESHOOT 01-21
FOR USING HAND-HELD TESTER

NOTE
• Before using the tester, be sure to read thoroughly the tester operating manual.
01
• Connect the tester to the diagnosis wire harness connector and turn the ignition switch to “ON”
position. If the tester can not communicate with the module, there is a problem on the vehicle 01
side or tester side.
• If the communication is normal when the tester is connected to another vehicle, inspect the 01
diagnosis data link or module power circuit of the vehicle.
• If the communication is still impossible when the tester is connected to another vehicle, the 01
problem is probably in the tester itself, so perform the self test procedures described in the
“Tester Operating Manual”. 01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
HOW TO PROCEED WITH TROUBLESHOOTING

NOTE
• Here, only the basic procedures are shown.
• Carry out troubleshooting in accordance with the procedures on the following pages.
• Details are provided in Chapter 04 diagnostics, showing the most effective methods for each
circuit.
• Confirm the troubleshooting procedures first for the relevant circuit before beginning
troubleshooting of that circuit.
1. VEHICLE BROUGHT TO WORKSHOP
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment when the problem occurred.
3. SYMPTOM CONFIRMATION AND DTC (INCLUDING DATA STREAM) CHECK
(a) Check the battery positive voltage.

Voltage: 11 ～ 14 V (Engine stopped)
(b) Visually check the wire harness, connectors and fuses for open and short, etc.
(c) Warm up the engine to the normal operating temperature.
(d) Confirm the problem symptoms and conditions and check for DTCs according to the related chart.
Does the DTC display?
YES > Go to step 4.
NO > Go to step 5.
4. DTC CHART
(a) Check the results obtained in step 3, then confirm the inspection procedures for the system or the part
which should be checked using the DTC chart.
Go to step 6 directly.
5. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in step 3, then confirm the inspection procedures for the system or the part
which should be checked using the problem symptoms table.
6. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Inspect the circuit or parts according to results obtained in step 4 and 5.
(b) Confirm the circuil or parts which should be repaired.
7. REPAIR
(a) Perform adjustment, repair or replacement according to the results obtained in step 6.
8. CONFIRMATION TEST
(a) After repairing, confirm that the problem has been solved.
(b) If the problem does not recur, perform a confirmation test under the same conditions and in the same
enviroment as when it occurred for the first time.
9. END
CUSTOMER PROBLEM ANALYSIS

NOTE
• In troubleshooting, the problem symptoms must be confirmed accurately, meaning that all
01
preconceptions must be set aside in order to make an accurate judgement.
• To ascertain what the problem symptoms are, it is extremely important to ask the the customer 01
about the problem and conditions when it occurred.
• The following 5 items are important points in the problem analysis. 01
What? Vehicle model, system name
01
When? Date, time, occurrence frequency
01
Where? Road conditions
Under what conditions? Running conditions, driving conditions, weather conditions 01

How did it happen? Problem symptoms
01
• Past problems which are thought to be unrelated and the repair history, etc. may also help in
01
some cases. Therefore, as much information as possible should be gathered and its
relationship with the problem symptoms should be correctly ascertained for use as reference in
01
troubleshooting.
01
01
01
01
01
01
01
01
01
01
01
SYMPTOM CONFIRMATION AND DTC (INCLUDING DATA STREAM) CHECK

NOTE
The diagnosis system in MPX has various functions.
• The firs function is the Diagnostic Trouble Code (DTC) check, in which a malfunction in the
signal circuits to the module is stored in code form in the module memory.
• Another function is the Input Signal Check, which checks whether the signals from various
switches are sent to the module correctly.
By using these check functions, it is possible to quickly narrow down potential problem areas
and troubleshooting can be performed effectively.
System System Description DTC Input signal check Data stream Symptom
Anti-lock Brake System - ○ ○ ○ ○
Audio System - - - - ○
Combined Display - - - - ○
Engine Control System ○ ○ ○ ○ ○
Heater And Air
- - - - ○
Conditioning
Horn - - - - ○
Instrument Cluster - - - - ○
Lighting - - - - ○
Outside Mirror - - - - ○
Power Door Locks - - - - ○
Power Windows - - - - ○
Rear Window Defrost
○ - - - ○
System
Reverse Radar ○ - - - ○
Sliding Roof ○ - - - ○
Supplemenal Restraint
- ○ - - ○
System
Wiper And Washer ○ - - - ○
(a) In the DTC check, it is very important to determine whether the problem indicated by the DTC is still
occurring or has occurred in the past but returned to normal at present. In addition during the problem
symptom confirmation, a check must be made on whether the malfunction indicated by the DTC is
directly related to the problem symptom or not. For this reason, the DTC should be checked before and
after symptom confirmation to determine the current conditions. If this is not done, it may, depending on
the case, result in unnecessary troubleshooting for systems which are operating normally. It would
make more difficult to detect the problem area or to try to repair irrelevant areas. Therefore, always
follow the procedures in the correct order and perform the DTC check.
(b) A flow chart showing how to proceed with troubleshooting using the DTC check is shown below. This
flow chart shows how to utilize the DTC check effectively. Then, by carefully checking the results, this
chart indicates how to proceed either to the DTC troubleshooting or to the troubleshooting of problem
symptoms table.
1. DTC CHECK
2. MAKE A NOTE AND CLEAR THE DTC

01
NOTE
If a DTC is displayed in the initial DTC check, it indicates that a trouble may have occurred in a wire 01
harness or connectors in that circuit in the past. Therefore, check the wire harness and connectors.
(Refer to “Chapter 01 introduction - how to troubleshoot, electronic circuit inspection procedure”) 01
3. SYMPTOM CONFIRMATION 01
Do the problem symptoms still exist? 01

YES > Go to step 4.
NO > Go to step 5. 01
4. SIMULATION TEST WITH THE METHODS OF SYMPTOM SIMULATION (Refer to “Chapter 01 01

introduction - how to troubleshoot, how to proceed with troubleshooting”)
01
5. DTC CHECK AGAIN
01
Does DTC display?
01
YES > Proceed with DTC chart.
NO > Go to step 6. 01
6. SYMPTOM CONFIRMATION
01
Does any symptom exist?
01
YES > Go to step 7.
NO > The system is normal. 01
7. PROCEED WITH PROBLEM SYMPTOMS TABLE
01
The problem is still occurring in a place beyond the diagnostic circuit. The DTC displayed first is either for a
past problem or for a secondary problem. 01
8. END
01
01
01
01
SYMPTOM SIMULATION
NOTE
• The most difficult case in troubleshooting is when no symptoms occurs. In such cases, be sure
to carry out a thorough customer problem analysis. Then simulate the same or similar
conditions and enviroment in which the customer’s vehicle was and when the problem
occurred. No matter how much experience a technician has, or how skilled he may be, if he
proceeds to troubleshoot without the confirmation of problem symptoms, he will tend to
overlook something important during repairing and make a wrong guess somewhere, which will
only lead to a standstill.
• For example, for a problem which only occurs when the engine is cold, or for a problem which
occurs due to vibration caused by the road during driving, etc., the problem can never be
determined when the engine is hot or when the vehicle is stopped. Since vibration, heat or water
pentration (moisture) is a likely cause for the problem which is difficult to reproduce, the
symptom simulation tests introduced here are effective measures in a point that the external
causes are applied to the vehicle in a stationary condition.
• Important points in the symptom simulation test:
• In the symptom simulation test, the problem symptoms should be confirmed and the problem
area or parts must also be discovered. To do so, reduce the possible problem cirecuits
according to the symptom before starting this test and have the hand-held tester connected
beforehand.
• After that, carry out the symptom simulation test, judging whether the circuit being tested is
defective or normal and also confirming the problem symptoms at the same time. Refer to the
problem symptoms table of each system, narrow down the possible causes of the symptom.
1. VIBRATION METHOD: When vibration seems to be

the major cause.
(a) Part and sensor.
• Apply slight vibration with your finger to the part or the
sensor considered to be the problem cause and check
whether the malfunction occurs.
CAUTION
Applying strong vibration to relays may result in open.
(b) Connectors.
• Lightly shake the connector vertically and horizontally.
(c) Wire harness.
• Lightly shake the wire harness vertically and horizontally.
The connector joint and fulcrum of the vibration are the major
areas that should be checked thoroughly.
2. HEAT METHOD: If the problem seems to occur when

the area in question is heated.
(a) Heat the component that is the possible cause of the
malfunction with a hair dryer or similar object. Check if 01
the malfunction occurs.
CAUTION 01
• Never heat the components to more than 60 ℃ to
prevent from being damaged.
01
• Never apply heat directly to parts in the module.
01
3. WATER SPRINKLING METHOD: When the malfunction
seems to occur on a rainy day or in high-humidity. 01
(a) Sprinkle water on the vehicle and check whether the
malfunction occurs. 01
CAUTION 01
• Never sprinkle water directly on the engine hood, but
change the temperature and humidity indirectly by 01
spraying a mist of water on the radiator front surface.
• Never apply water directly on the electronic 01
components.
CAUTION 01
If a vehicle is subject to water leakage, the leaking water
may contaminate the module. When testing a vehicle with a 01
water leakage problem, this factor must also be considered.
01
4. OTHERS: If the malfunction seems to occur when
electrical load is excessive. 01
(a) Turn on all the electrical equipment including the heater
blower, headlights, rear windows defrost, etc. and check 01
whether the malfunction occurs.
01
01
01
01
01
01
DTC CHART
Take the engine control system as an example, inspection procedures are shown in the illustration below.
The chart indicates the DTCs of the engine control system and lists the corresponding troubleshooting
procedures. It will be more effective and accurate to proceed with troubleshooting in accordance with the
inspection procedures listed in the chart.
PROBLEM SYMPTOMS TABLE

The problem symptoms table indicates the suspect circuits or parts for each problem symptom, as shown in
the illustration below. Using this table to troubleshoot the problem when the problem is occuring but no DTC
displayed. The number in the table indicates the procedures of troubleshooting. 01
NOTE
When the problem is not detected by the diagnostic system even though the problem symptoms is 01
present, it may be that the problem is occuring outside the detection range of the dignostic system.
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
CIRCUIT INSPECTION
How to read and use each page is shown below.
ELECTRONIC CIRCUIT INSPECTION PROCEDURE

1. BASIC INSPECTION.
(a) Resistance measuring condition of electronic parts.
01
• Unless special instruction, all resistance is measured at an ambient temperature of 20 ℃ .
• As the resistance may be out of the specifications when measured at high temperature (such as the 01
engine is hot). So measurements should be performed when the engine is cooled down.
(b) Handling of connectors. 01

• When disconnecting the connector with a lock, press the
01
connector in the direction of engagement and remove
the lock by lightly pressing the lock claw.
01
• When removing the connector, do not hold the wire har-
ness but hold the connector. 01
• Make sure there is no deformation, damage or missing
terninals before connecting the connector. 01
• The connector with a lock should be securely connected
until hearing a “click”. 01
• When checking the connector with a mutimeter, be sure
to check it from the backside (wire harness side) of the 01
connector by using a mini test lead.
NOTE 01
• As a water proof connector can not be checked from
01
the backside, check it by a connecting the sub-har-
ness.
01
• Do not damage the terminals when moving the
inserted tester needle.
01
(c) Connector checking points.
Check when the connector is connected:
01
• Hold the connector and check the inserting condition and
01
locking efficiency (engaged condition).
Check when the connector is disconnected: 01

• Pull the wire harness lightly and check the connector for
missing terminal, terminal crimping condition and core 01
wire break.
• Check visually for any rust, metal chips, water and bent 01
terminals.
01
01
Check the contact pressure of the terminal:

• Prepare a spare male terminal and insert it into a female
terminal. Check the engaged condition and sliding resis-
tance.
CAUTION
Always use a gold-plated male terminal, to test a gold-
plated female terminal.
(d) Repair method of connector terminal.

• If there is dirty on the contact point, clean the contact
point by using an air gun or shop rag. However, never
polish the contact point using sand paper as the plating
may come off.
• In case of abnormal contact pressure, replace the female
terminal. However, if a male terminal is gold-plated (gold
colour), use a gold-plated female termina. If it is silver-
plated (silver colour), use a silver-plated female terminal.
(e) Handling of wire harness.

• When removing the wire harness, check the position of
the wire harness and clamps before starting operations
to be able to reinstall it correctly.
• Never twist, pull or loosen the wire harness more than
necessary.
• Never allow the wire harness to come into contact with a
high-temperature, rotating, moving, vibrating or sharp
(edge of the panel, tip of the screw, etc.) part.
• When installing parts, never let the wire harness be inter-
fered with.
• Never cut or break the cover of the wire harness. If one is
cut or broken, replace it or securely repair it with electri-
cal tape.
2. CHECK OPEN CIRCUIT.

(a) For the open circuit shown in the illustration, perform a
resistance check in step (b) or voltage check in step (c)
to locate the section.
(b) Check the resistance.

• Disconnect connector A & C and measure the resistance
between them.
Resistance: ＜ 2 Ω 01
NOTE
01
Measure the resistance while lightly shaking the wire har-
ness vertically and horizontally.
01
For this circuit:
The resistance between terminal 1 of connector A and terminal
01
1 of connector C: ≥ 1 MΩ
The resistance between terminal 2 of connecor A and terminal 2 01
of connector B: ＜ 2 Ω
Therefore, the cause is an open circuit between terminal 1 of 01
connector A and terminal 1 of connector C.
01
• Disconnect connector B and measure the resistance
between the connectors.
01
For this circuit:
The resistance between terminal 1 of connector A and terminal
01
1 of connector B1: ＜ 2 Ω
The resistance between terminal 1 of connector B2 and terminal 01
1 of connector C: ≥ 1 MΩ
Therefore, the cause is an open circuit between terminal 1 of 01
connector B2 and terminal 1 of connector C.
01
(c) Check the voltage.
• An open circuit which voltage is applied can be checked by 01
conducting a voltage check.
• For the open circuit which each connector is still connected 01
shown in the illustration, measure the voltage orderly
between body ground and terminal 1 of connector A at the 01
ECU 5 V output terminal, terminal 1 of connector B and
terminal 1 of connector C. 01
For this circuit:
The voltage between terminal 1 of connector A and body 01
ground: 5 V
The voltage between terminal 1 of connector B and body 01
ground: 5 V
The voltage between terminal 1 of connector C and body 01
ground: 0 V
Therefore, the cause is an open circuit in the wire harness 01
between terminal 1 of connector B and terminal 1 of connector
C.
3. CHECK SHORT CIRCUIT.

(a) For the short circuit shown in the illustration, perform a
resistance check in step (b) to locate the section.
(b) Check the resistance.

• Disconnect connector A & C and measure the resistance
between terminal 1 and 2 of connector A and body
ground.
Resistance: ＞ 1 MΩ
NOTE
Measure the resistance while lightly shaking the wire
harness vertically and horizontally.
For this circuit:
The resistance between terminal 1 of connector A and body
ground: ＜ 2 Ω
ground: ≥ 1 MΩ
Therefore, the cause is an short circuit between terminal 1 of
connector A and terminal 1 of connector C.
• Disconnect connector B and measure the resistance between

terminal 1 of connector A and B2 and body ground.
For this circuit:
ground: ≥ 1 MΩ
The resistance between terminal 1 of connector B2 and body
ground: ＜ 2 Ω
Therefore, the cause is a short circuit between terminal 1 of
connector B2 and terminal 1 of connector C.
INTRODUCTION - TERMS 01-35
TERMS
ABBREVIATIONS USED IN THIS MANUAL
01
Abbreviations Meaning
A/C Air Conditioning 01
A/F Air-fuel Ratio
01
ABS Anti-lock Brake System
01
ACC Accessory
ASSY Assembly 01
BAT Battery
01
B-joint Ball Joint
01
BTDC Before Top Dead Center
CKP Crankshaft Position 01

CMP Camshaft Position
01
DLC3 Data Link Connector 3
01
DTC Diagnostic Trouble Code
ECM Engine Control Module 01

ECT Engine Coolant Temperature
01
ECU Engine Control Unit
01
EFI Engine Fuel Injection
EGR Exhaust Gas Recirculation 01

EVAP Evaporative Emission
01
GEN Generator
01
GND Ground
HO2S Heated Oxygen Sensor 01

HVAC Heater And Air Conditioning
01
IAT Intake Air Temperature
01
ISC Idle Speed Control
KS Knock Sensor 01
MAF Mass Air Flow
MIL Malfunction Indicator Lamp
No. Number
O2S Oxygen Sensor
OBD On-Board Diagnostic
PCV Positive Crankcase Ventilation

01-36 INTRODUCTION - TERMS
Abbreviations Meaning
RCM Restraint Control Module
RPM Revolutions Per Minute
SFI Sequential Multiport Fuel Injection
SRS Supplemental Restraint System
SSM Special Service Materials
SST Special Service Tools
TC Turbocharger
TPS Throttle Position Sensor
U-joint Universal Joint

PREPARATION
02
DIAGNOSTICS ................................................................................... 02-1
PREPARATION ........................................................................... 02-1 02
ENGINE CONTROL SYSTEM............................................................ 02-2
PREPARATION ........................................................................... 02-2
FUEL .................................................................................................. 02-3
PREPARATION ........................................................................... 02-3
EMISSION CONTROL........................................................................ 02-4
PREPARATION ........................................................................... 02-4
INTAKE AIR ....................................................................................... 02-5
PREPARATION ........................................................................... 02-5
ENGINE MECHANICAL ..................................................................... 02-6
PREPARATION ........................................................................... 02-6
EXHAUST......................................................................................... 02-10
PREPARATION ......................................................................... 02-10
COOLING ......................................................................................... 02-11
PREPARATION ......................................................................... 02-11
LUBRICATION ................................................................................. 02-12
PREPARATION ......................................................................... 02-12
STARTING AND CHARGING .......................................................... 02-14
PREPARATION ......................................................................... 02-14
FRONT SUSPENSION ..................................................................... 02-15
PREPARATION ......................................................................... 02-15
REAR SUSPENSION ....................................................................... 02-16
PREPARATION ......................................................................... 02-16
TIRE AND WHEEL ........................................................................... 02-17
PREPARATION ......................................................................... 02-17
AXLE AND PROPELLER SHAFT.................................................... 02-18
PREPARATION ......................................................................... 02-18
BRAKE ............................................................................................. 02-21
PREPARATION ......................................................................... 02-21
PARKING BRAKE............................................................................ 02-22
PREPARATION ......................................................................... 02-22
TRANSMISSION .............................................................................. 02-23
PREPARATION ......................................................................... 02-23
CLUTCH ........................................................................................... 02-25
PREPARATION ......................................................................... 02-25
STEERING COLUMN....................................................................... 02-26
PREPARATION ......................................................................... 02-26
POWER STEERING ......................................................................... 02-27
PREPARATION ......................................................................... 02-27
HEATER AND AIR CONDITIONING................................................ 02-28
PREPARATION ......................................................................... 02-28
SUPPLEMENTAL RESTRAINT SYSTEM ....................................... 02-30
PREPARATION ......................................................................... 02-30
SEAT BELT ...................................................................................... 02-31
PREPARATION ......................................................................... 02-31
WIPER AND WASHER .................................................................... 02-32
PREPARATION ......................................................................... 02-32
WINDSHIELD ................................................................................... 02-33
PREPARATION ......................................................................... 02-33
INSTRUMENT PANEL ..................................................................... 02-34
PREPARATION ......................................................................... 02-34
SEAT ................................................................................................ 02-35
PREPARATION ......................................................................... 02-35
DOOR LOCKS.................................................................................. 02-36
PREPARATION ......................................................................... 02-36
SLIDNG ROOF ................................................................................. 02-37
PREPARATION ......................................................................... 02-37
ENGINE HOOD AND DOORS ......................................................... 02-38
PREPARATION ......................................................................... 02-38
VEHICLE CONTROL SYSTEM........................................................ 02-39
PREPARATION ......................................................................... 02-39
PREPARATION - DIAGNOSTICS 02-1
DIAGNOSTICS
PREPARATION
PREPARATION
02
RECOMMENDED TOOLS
02
ANTI-LOCK BRAKE SYSTEM
KT600 Collective
ENGINE CONTROL SYSTEM
Intellegence Scan Tool
SUPPLEMENTAL RESTRAINT SYSTEM

AUDIO SYSTEM
COMMUNICATION SYSTEM
HEATER AND AIR CONDITIONING
INSTRUMENT CLUSTER
LIGHTING
Digital Multimeter
OUTSIDE MIRROR
POWER DOOR LOCKS
POWER WINDOWS
REAR WINDOW DEFROST SYSTEM
SLIDING ROOF
WIPER AND WASHER

AUDIO SYSTEM
COMMUNICATION SYSTEM
INSTRUMENT CLUSTER
LIGHTING
Test Lead Set 19A
OUTSIDE MIRROR
POWER DOOR LOCKS
POWER WINDOWS
REAR WINDOW DEFROST SYSTEM
SLIDING ROOF
WIPER AND WASHER
Torque Wrench -
EQUIPMENT
Oscilloscope -
SSM
Item Capacity Specification
Thread sealant - 3M No.4171 or equivalent
02-2 PREPARATION - ENGINE CONTROL SYSTEM

PREPARATION
RECOMMENDED TOOLS
FUEL INJECTION SYSTEM

IGNITION SYSTEM
KT600 Collective Intellegence Scan Tool SENSOR
ACTUATOR
ECM
SENSOR
Digital Multimeter ACTUATOR
ECM
SENSOR
Test Lead Set ACTUATOR
ECM
Torque Wrench -
EQUIPMENT
Oscilloscope -
SSM
Thread sealant - 3M No.4171 or equivalent
PREPARATION - FUEL 02-3
FUEL
PREPARATION
02
RECOMMENDED TOOLS
02
Niddle Nose Pliers FUEL PRESSURE REGULATOR
Hydraulic Jack FUEL TANK ASSY
Fuel Filter Remover FUEL FILTER ASSY
EQUIPMENT
Fuel injector leakage tester -
19A
02-4 PREPARATION - EMISSION CONTROL
EMISSION CONTROL
PREPARATION
RECOMMENDED TOOLS
VAPER CANISTER
Air Blow Gun CANISTER CONTROL SOLENOID VALVE
PCV
PREPARATION - INTAKE AIR 02-5
INTAKE AIR
PREPARATION
SSM 02
Item Capacity Specification 02

Coolant - Foton long life coolant
19A
02-6 PREPARATION - ENGINE MECHANICAL
ENGINE MECHANICAL
PREPARATION
SST
Camshaft Pulley Spanner Wrench

CAMSHAFT TIMING PULLEY
MB-990767
Balance Shaft Bearing Puller Limiter

BALANCE SHAFT BEARING
MB-991603
Cylinder Cover Bolt Spanner

CYLINDER COVER BOLT
MB-991654
Plug Spanner
ENGINE FRONT CASE
MD-998162
Crankshaft Front Oil Seal Guide

CRANKSHAFT FRONT OIL SEAL
MD-998285
Balance Shaft Bearing Puller BALANCE SHAFT FRONT

MD-998371 BEARING
Balance Shaft Bearing Puller

BALANCE SHAFT REAR BEARING
MD-998372
Crankshaft Front Oil Seal Installer

MD-998375
Hydraulic Tappet Adjuster Leakage

Tester HYDRAULIC TAPPET ADJUSTER
MD-998440
Hydraulic Tappet Adjuster Keeper

HYDRAULIC TAPPET ADJUSTER
MD-998441
Hydraulic Tappet Adjuster Wiring

MD-998442
PREPARATION - ENGINE MECHANICAL 02-7
Hydraulic Tappet Adjuster Keeper

MD-998443
02
Balance Shaft Bearing Installer 02

MD-998705
Camshaft Oil Seal Installer

CAMSHAFT OIL SEAL
MD-998713
Pin For Belt Gear

CAMSHAFT TIMING PULLEY
MD-998719
Oil Pan Remover

OIL PAN
MD-998727
Valve Spring Compressor VALVE AND INTERRELATED

MD-998772 PARTS
Valve Oil Seal Installer

VALVE OIL SEAL
MD-998774 19A
Crankshaft Rear Oil Seal Installer

CRANKSHAFT REAR OIL SEAL
MD-998776
Crankshaft Pulley Puller

CRANKSHAFT TIMING PULLEY
MD-998778
Piston Disassembling and

Assembling Tool PISTON
MD-998780
Flywheel Holder
FLYWHEEL
MD-998781
02-8 PREPARATION - ENGINE MECHANICAL
Plug Spanner Fixer

ENGINE FRONT CASE
MD-998783
Upper Balance Shaft Pulley Holder

BALANCE SHAFT TIMING PULLEY
MD-998785
RECOMMENDED TOOLS
Dial Indicator CRANKSHAFT
Micrometer Calipers PISTON
Snap Ring Pliers PISTON PIN
Hydraulic Jack ENGINE ASSY
Vernier Calipers CAMSHAFT
Feeler Gauge CRANKSHAFT
Niddle Nose Pliers CLAMP
Torque Wrench -
PREPARATION - ENGINE MECHANICAL 02-9
SSM
Sealant - Foton sealant 02
Coolant 6.5 L Foton long life coolant 02

Engine oil gasoline 4.0 L SAE 0W-30
SAE 5W-30
SAE 5W-40
diesel 4.5 ～ 5 L CF-4 or above, 15W-30
CF-4 or above, 15W-40
19A
02-10 PREPARATION - EXHAUST
EXHAUST
PREPARATION
RECOMMENDED TOOLS
Feeler Gauge EXHAUST MANIFOLD
Torque Wrench -
SSM
Exhaust pipe sealant - Foton sealant
PREPARATION - COOLING 02-11
COOLING
PREPARATION
02
RECOMMENDED TOOLS
02
Radiator Cap Tester COOLANT RESERVOIR
Air Blow Gun COOLANT RESERVOIR
Thermometer THERMOSTAT
EQUIPMENT
Steam cleaner -
SSM
Sealant - Foton sealant
19A
Coolant 6.5 L Foton long life coolant
02-12 PREPARATION - LUBRICATION
LUBRICATION
PREPARATION
SST
Oil Filter Wrench

OIL FILTER
MB-991828
Oil Pan Remover

OIL PAN
MD-998727
Engine Oil Pressure Switch

ENGINE OIL PRESSURE SWITCH
Remover
Balance Shaft Bearing Puller BALANCE SHAFT FRONT

MD-998371 BEARING
Balance Shaft Bearing Puller

BALANCE SHAFT REAR BEARING
MD-998372
Balance Shaft Bearing Puller Limiter

MB-991603
Balance Shaft Bearing Installer

MD-998705
Crankshaft Front Oil Seal Installer

MD-998375
Plug Spanner
ENGINE FRONT CASE
MD-998162
PREPARATION - LUBRICATION 02-13
RECOMMENDED TOOLS
Feeler Gauge OIL PUMP 02
02
Hammer OIL PAN
Torque Wrench -
SSM
Sealant - Foton sealant
Engine oil gasoline 4L SAE 0W-30

SAE 5W-30
SAE 5W-40
diesel 4.5 ～ 5 L CF-4 or above, 15W-30
CF-4 or above, 15W-40
19A
02-14 PREPARATION - STARTING AND CHARGING
STARTING AND CHARGING

PREPARATION
RECOMMENDED TOOLS
Digital Multimeter GENERATOR
GENERATOR
Dial Indicator
STARTER
Vernier Calipers STARTER
Puller STARTER
Soldering Gun GENERATOR
Snap Ring Pliers STARTER
Torque Wrench -
EQUIPMENT
Battery charger -
SSM
Grease - -
PREPARATION - FRONT SUSPENSION 02-15
FRONT SUSPENSION
PREPARATION
RECOMMENDED TOOLS 02
02
Torque Wrench -
EQUIPMENT
Wheel alignment instrument -
Tire changer -
Tire dynamic balancer -
SSM
Grease - -
19A
02-16 PREPARATION - REAR SUSPENSION
REAR SUSPENSION
PREPARATION
RECOMMENDED TOOLS
Torque Wrench -
EQUIPMENT
Tire changer -
Tire dynamic balancer -
SSM
Grease - -
PREPARATION - TIRE AND WHEEL 02-17
TIRE AND WHEEL

PREPARATION
02
Tire Pressure Gauge TIRE AND WHEEL
Torque Wrench -
EQUIPMENT
Tire changer -
Tire inflater -
SSM
Balance block - -
19A
02-18 PREPARATION - AXLE AND PROPELLER SHAFT
AXLE AND PROPELLER SHAFT

PREPARATION
RECOMMENDED TOOLS
Tire Pressure Gauge TIRE
PROPELLER SHAFT SPLINE

Feeler Gauge
DIIFERENTIAL GEAR
PROPELLER SHAFT U-JOINT

CENTER SUPPORT BEARING
FRONT AXLE HUB GREASE CAP
Hammer REAR AXLE HUB GREASE CAP
REAR AXLE HUB BEARING
STEERING KNUCKLE
DIFFERENTIAL PINION SHAFT

CENTER SUPPORT BEARING
FRONT AXLE HUB GREASE CAP
Brass Bar REAR AXLE HUB GREASE CAP
STEERING KNUCKLE
DIFFERENTIAL PINION SHAFT
PROPELLER SHAFT U-JOINT CROSS

Micrometer Calipers
SPIDER

FRONT AXLE HUB BEARING
DRIVE PINION
Dial Indicator
CROWN GEAR
DIFFERENTIAL GEAR
DIFFERENTIAL PINION
PINION FLANGE

Snap Ring Pliers REAR AXLE HUB BEARING
OUTPUT FLANGE
Puller PROPELLER SHAFT END YOKE
FRONT AXLE HUB BEARING

Grease Gun REAR AXLE HUB BEARING
STEERING KNUCKLE
PREPARATION - AXLE AND PROPELLER SHAFT 02-19
FRONT AXLE HUB STARING TORQUE

Spring Scale
REAR AXLE HUB STARING TORQUE
02
COTTER PIN
CENTER SUPPORT BEARING OIL SEAL 02
Niddle Nose Pliers
OUTPUT FLANGE OIL SEAL
DRIVE PINON OIL SEAL
Tapeline TRANSAXLE BACK LASH
FINAL DRIVE FILLER PLUG

Allen Wrenchs (Key)
FINAL DRIVE DRAIN PLUG
Hydraulic Jack FINAL DRIVE ASSY
DIFFERENTIAL GEAR THRUST WASHER

DIFFERENTIAL PINION THRUST WASHER
Vernier Calipers DIFFERENTIAL BEARING ADJUSTING
WASHER
DRIVE PINION ADJUSTING SHIM
Torque Wrench DRIVE PINION STARTING TORQUE 19A
EQUIPMENT
V-block -
Propeller dynamic balancer -
Vice -
Press machine -
02-20 PREPARATION - AXLE AND PROPELLER SHAFT
SSM
Balance block - -
Red lead - -
Grease propeller shaft U-joint -

Lithium base grease No.2
center support bearing -
Lithium base grease No.2
U-joint -
front axle hub -
front axle hub -
axle shaft -
output flange oil seal -
drive pinion oil seal -
Final drive oil ≤ 18 ℃ API GL-5 SAE 90W

1.8 L
＞ 18 ℃ API GL-5 SAE 80W
Sealant ouput flange -

LOCTITE 204
longitudinal hanger - LOCTITE 204
transverse hanger - LOCTITE 204
crown gear -
differential bearing -
final drive rear cover 350 mL LOCTITE 587
LOCTITE 204
final drive rear cover -
PREPARATION - BRAKE 02-21
BRAKE
PREPARATION
02
Micrometer Calipers FRONT BRAKE DISK
Dial Indicator FRONT BRAKE DISK
REAR BRAKE DRUM

Vernier Calipers
REAR BRAKE SHOE
REAR BRAKE SHOE

Nipper Piliers
WHEEL BRAKE CYLINDER
Tapeline BRAKE PAD
Snap Ring Pliers BRAKE MATER CYLINDER 19A
FRONT AXLE HUB

Grease Gun
REAR AXLE HUB
FRONT AXLE HUB

REAR AXLE HUB
Puller FRONT AXLE HUB OIL SEAL
REAR AXLE HUB OIL SEAL
AXLE SHAFT
Torque Wrench -
SSM
Brake fluid 1L DOT3
02-22 PREPARATION - PARKING BRAKE
PARKING BRAKE
PREPARATION
RECOMMENDED TOOLS
REAR BRAKE DRUM

Vernier Calipers
REAR BRAKE SHOE
FRONT PARKING BRAKE PULL CABLE ASSY

Niddle Nose Pliers REAR PARKING BRAKE PULL CABLE ASSY LH
REAR PARKING BRAKE PULL CABLE ASSY RH
EQUIPMENT
Vice -
SSM
Brake fluid 1L DOT3
PREPARATION - TRANSMISSION 02-23
TRANSMISSION
PREPARATION
02
SYNCHRONIZER ASSY
Feeler Gauge
COUNTER SHAFT WASHER
Niddle Nose Pliers RETURN SPRING
Brass Bar REVERSE IDLER GEAR SHAFT
Hammer REVERSE IDLER GEAR SHAFT
Dial Indicator OUTPUT SHAFT
INPUT SHAFT WASHER 19A

Micrometer Calipers
OUTPUT SHAFT
INPUT SHAFT ASSY

Snap Ring Pliers OUTPUT SHAFT ASSY
SHIFT MECHANISM
GEARSHIFT FORK
Vernier Calipers
SYNCHRONIZER ASSY
OUTPUT FRONT BEARING

Puller OUTPUT MIDDLE BEARING
OUTPUT REAR BEARING
Torque Wrench -
EQUIPMENT
V-block -
02-24 PREPARATION - TRANSMISSION
SSM
Transmission fluid GL-5 75W/90
2.0 L GL-5 80W/90
GL-5 85W/90
Grease - Mitsubishi No.0101011
Sealant - Mitsubishi No.997740

- 3M No.4170
PREPARATION - CLUTCH 02-25
CLUTCH
PREPARATION
02
FLYWHEEL
Dial Indicator
CLUTCH DISK
CLUTCH DISK
Vernier Calipers
CLUTCH COVER
Snap Ring Pliers CLUTCH MASTER CYLINER ASSY
Torque Wrench -
EQUIPMENT
Vice -
SSM 19A
Brake fluid 1L DOT3
Grease - Mitsubishi No.0101011

02-26 PREPARATION - STEERING COLUMN
STEERING COLUMN
PREPARATION
RECOMMENDED TOOLS
Tapeline OFF TRACK
Allen Wrenchs (Key) HORN SWITCH ASSY
Spring Scale STEERING WHEEL TURNING FORCE
Dial Indicator STEERING PROPELLER SHAFT U-JOINT
Torque Wrench -
EQUIPMENT
V-block -
PREPARATION - POWER STEERING 02-27
POWER STEERING
PREPARATION
02
RECOMMENDED TOOLS
02
Tapeline OFF TRACK
Torque Wrench -
SSM
Steering fluid 0.4 L ATF - Ⅲ
Grease power steering gear - QL-5 80W/90
Sealant low-pressure hose - -
19A
02-28 PREPARATION - HEATER AND AIR CONDITIONING

PREPARATION
RECOMMENDED TOOLS
REFRIGERANT
Manifold Gauge
COMPRESSOR
REFRIGERANT
Service Hoses
COMPRESSOR
REFRIGERANT
Service Couplers
COMPRESSOR
REFRIGERANT
3-way Joint
COMPRESSOR
REFRIGERANT
Service Tank
COMPRESSOR
REFRIGERANT
Vacuum Pump Connector
COMPRESSOR
Refrigerant Leakage Tester REFRIGERANT
Digital Multimeter A/C PIPE
Thermometer ENVIORMENT TEMPERATURE
Thermistance Type Thermometer OUTLET TEMPERATURE
Belt Tension Gauge PULLEY

PREPARATION - HEATER AND AIR CONDITIONING 02-29
Refrigerant Recovery / Recycling

Station REFRIGERANT
(With this device, vacuum pump is COMPRESSOR
not required.) 02
REFRIGERANT 02
Vacuum Pump
COMPRESSOR
SSM
Refrigerant front and rear A/C 1250 +0 / -25 g R-134a
only front A/C 850 ± 25 g R-134a
Compressor oil - -
19A
02-30 PREPARATION - SUPPLEMENTAL RESTRAINT SYSTEM

PREPARATION
SST
SRS Airbag Deployment Tool HORN SWITCH WITH AIRBAG ASSY
RECOMMENDED TOOLS
Torque Wrench -
PREPARATION - SEAT BELT 02-31
SEAT BELT
PREPARATION
02
RECOMMENDED TOOLS
02
Digital Multimeter ELECTRIC BUCKLE ASSY
Torque Wrench -
19A
02-32 PREPARATION - WIPER AND WASHER
WIPER AND WASHER

PREPARATION
RECOMMENDED
WASHER MOTOR WITH PUMP ASSY
WIPER AND WASHER SWITCH ASSY
Digital Multimeter MULTI-FUNCTION CONTROLLER (3-IN-1)
FRONT WIPER MOTOR ASSY
REAR WIPER MOTOR WITH LINK ASSY
Torque Wrench -
EQUIPMENT
Oscilloscope -
PREPARATION - WINDSHIELD 02-33
WINDSHIELD
PREPARATION
02
RECOMMENDED TOOLS
02
WINDSHIELD
Scraper SIDE WINDOW
REAR WINDOW
WINDSHIELD
Suction Cup SIDE WINDOW
REAR WINDOW
WINDSHIELD
Knife SIDE WINDOW
REAR WINDOW
WINDSHIELD
Sealer Gun SIDE WINDOW
REAR WINDOW
WINDSHIELD
Rubber Hammer SIDE WINDOW
REAR WINDOW
SSM 19A

Protective Tape - -
Block - -
Plastic Paper - -
Piano Wire - -
Nylon Cord - -
Adhesive Tape - -
Primer - Reactive polyester primer, black
Sealant - Polyurethane sealant, black

02-34 PREPARATION - INSTRUMENT PANEL
INSTRUMENT PANEL
PREPARATION
RECOMMENDED TOOLS
KT600 Collective Intellegence Scan Tool INSTRUMENT CLUSTER

PREPARATION - SEAT 02-35
SEAT
PREPARATION
02
RECOMMENDED TOOLS
02
DRIVER / ASSISTANT DRIVER SEAT
BACKREST
Allen Wrenchs (Key)
DRIVER / ASSISTANT DRIVER SEAT BASE
WELIDING ASSY
DRIVER / ASSISTANT DRIVER SEAT

Niddle Nose Pliers
BACKREST
Torque Wrench -
19A
02-36 PREPARATION - DOOR LOCKS
DOOR LOCKS
PREPARATION
RECOMMENDED TOOLS
Snap Ring Pliers DOOR LOCK CORE
SSM
Grease - Lithium base grease No.2
PREPARATION - SLIDNG ROOF 02-37
SLIDNG ROOF
PREPARATION
02
RECOMMENDED TOOLS
02
Niddle Nose Pliers DRAIN HOSE
19A
02-38 PREPARATION - ENGINE HOOD AND DOORS
ENGINE HOOD AND DOORS

PREPARATION
RECOMMENDED TOOLS
Grease Gun DOOR
Torque Wrench -
SSM
Grease - Lithium base grease No.2
PREPARATION - VEHICLE CONTROL SYSTEM 02-39
VEHICLE CONTROL SYSTEM

PREPARATION
02
RECOMMENDED TOOLS
02
Digital Multimeter IGNITION SWITCH ASSY
Torque Wrench -
19A
MEMO
SERVICE SPECIFICATION
03
SPECIFIED TORQUE FOR SPECIFICATION BOLTS ...................... 03-1
ENGINE CONTROL SYSTEM............................................................ 03-2
SERVICE DATA........................................................................... 03-2
TORQUE SPECIFICATION ......................................................... 03-3 03
FUEL .................................................................................................. 03-4
SERVICE DATA........................................................................... 03-4
TORQUE SPECIFICATION ......................................................... 03-4
EMISSION CONTROL........................................................................ 03-5
INTAKE AIR ....................................................................................... 03-6
SERVICE DATA........................................................................... 03-6
ENGINE MECHANICAL ..................................................................... 03-7
SERVICE DATA........................................................................... 03-7
TORQUE SPECIFICATION ....................................................... 03-12
EXHAUST......................................................................................... 03-15
SERVICE DATA......................................................................... 03-15
COOLING ......................................................................................... 03-16
SERVICE DATA......................................................................... 03-16
LUBRICATION ................................................................................. 03-17
SERVICE DATA......................................................................... 03-17
IGNITION .......................................................................................... 03-18
SERVICE DATA......................................................................... 03-18
STARTING AND CHARGING .......................................................... 03-19
SERVICE DATA......................................................................... 03-19
FRONT SUSPENSION ..................................................................... 03-21
SERVICE DATA......................................................................... 03-21
REAR SUSPENSION ....................................................................... 03-22
SERVICE DATA......................................................................... 03-22
TIRE AND WHEEL ........................................................................... 03-23
SERVICE DATA......................................................................... 03-23
AXLE AND PROPELLER SHAFT.................................................... 03-24
SERVICE DATA......................................................................... 03-24
BRAKE ............................................................................................. 03-27
SERVICE DATA......................................................................... 03-27
PARKING BRAKE............................................................................ 03-28
TRANSMISSION .............................................................................. 03-29
SERVICE DATA......................................................................... 03-29
CLUTCH ........................................................................................... 03-34
SERVICE DATA......................................................................... 03-34
STEERING COLUMN....................................................................... 03-35
SERVICE DATA......................................................................... 03-35
POWER STEERING ......................................................................... 03-36
SERVICE DATA......................................................................... 03-36
HEATER AND AIR CONDITIONING................................................ 03-38
SERVICE DATA......................................................................... 03-38
SUPPLEMENTAL RESTRAINT SYSTEM ....................................... 03-39
SERVICE DATA......................................................................... 03-39
SEAT BELT ...................................................................................... 03-40
LIGHTING......................................................................................... 03-41
WIPER AND WASHER .................................................................... 03-42
SERVICE DATA......................................................................... 03-42
SEAT ................................................................................................ 03-43
SLIDING ROOF ................................................................................ 03-44
ENGINE HOOD AND DOORS ......................................................... 03-45
SERVICE DATA......................................................................... 03-45
EXTERIOR AND INTERIOR TRIM ................................................... 03-46
SERVICE SPECIFICATIONS - SPECIFIED TORQUE FOR SPECIFICATION BOLTS 03-1
SPECIFIED TORQUE FOR SPECIFICATION BOLTS

SERVICE SPECIFICATIONS
NOTE
The range of the tighten torques listed in the following table has already contained the error of the
used tools. 03
Torque （N·m）
Thread Standard
Grade 8.8 Grade 10.9 03
M5 9 ～ 11 12 ～ 14
M8 21 ～ 25 29 ～ 35
M8 × 1 22 ～ 27 32 ～ 39
M10 41 ～ 51 58 ～ 71
M10 × 1.25 45 ～ 55 63 ～ 77
M10 × 1 46 ～ 56 65 ～ 79
M12 73 ～ 89 105 ～ 128

M12 × 1.5 75 ～ 92 106 ～ 130
M12 × 1.25 78 ～ 96 113 ～ 138
M14 122 ～ 149 160 ～ 195

M14 × 1.5 126 ～ 154 178 ～ 218
M16 182 ～ 222 247 ～ 290

M16 × 1.5 199 ～ 243 265 ～ 311
M18 243 ～ 285 380 ～ 437

M18 × 1.5 287 ～ 336 397 ～ 457
M20 389 ～ 456 486 ～ 548

M20 × 1.5 396 ～ 465 540 ～ 596
03-2 SERVICE SPECIFICATIONS - ENGINE CONTROL SYSTEM

SERVICE DATA
GASOLINE ENGINE (4G63，4G64)
ECT sensor resistance 0℃ 5.1 ～ 6.5 Ω
20 ℃ 2.1 ～ 2.7 Ω
40 ℃ 0.9 ～ 1.3 Ω
80 ℃ 0.26 ～ 0.36 Ω
Engine idle speed Standard 750 ± 50 RPM
Idle air control motor coil resistance Standard 28 ～ 33 Ω （ 20 ℃）
TPS resistance (Terminal 1 and 2) Standard 3.5 ～ 6.5 Ω （ 20 ℃）
IAT resistance (Teminal 1 and 2) 0℃ 5.3 ～ 6.7 Ω

20 ℃ 2.3 ～ 3.0 Ω
40 ℃ 1.0 ～ 1.5 Ω
80 ℃ 0.30 ～ 0.42 Ω
KS resistance Terminal 1 and 2 ＞1MΩ

Terminal 1 and shell ＞1MΩ
Terminal 2 and shell ＞1MΩ
CKP resistance (Terminal 2 and 3) Standard 560 Ω ± 10% （ 20 ℃）
Upstream HO2S resistance Terminal 3 and 4 2.5 ～ 4.5 Ω （ 20 ℃）
Downstream HO2S resistance Terminal 3 and 4 2.5 ～ 4.5 Ω （ 20 ℃）
Canister solenoid valve Standard 19 ～ 22 Ω （ 20 ℃）
DIESEL ENGINE(BJ493ZQ3)
ECT sensor resistance - 40 ℃ 45.313 Ω
- 30 ℃ 26.114 Ω
- 20 ℃ 15.462 Ω
- 10 ℃ 9.397 Ω
0℃ 5.986 Ω
20 ℃ 2.500 Ω
40 ℃ 1.175 Ω
80 ℃ 0.323 Ω
100 ℃ 0.186 Ω
120 ℃ 0.113 Ω
140 ℃ 0.071 Ω
IAT sensor resistance - 20 ℃ 14785 ～ 16443 Ω

-0 ℃ 5605 ～ 6168 Ω
20 ℃ 2401.9 ～ 2619.3
80 ℃ 318.68 ～ 340.27 Ω
CMP sensor mounting clearance Standard 0.2 ～ 1.8 mm
Engine normal operating temperature 80 ± 5 ℃
Engine speed Standard 0 ～ 2200 RPM

SERVICE SPECIFICATIONS - ENGINE CONTROL SYSTEM 03-3
CKP sensor resistance (Terminal 2 and 3) Standard 860 ± 86 Ω （ 20 ℃）
CKP sensor mounting clearance Standard 0.5 ～ 1.5 mm

03
TORQUE SPECIFICATION
GASOLINE ENGINE (4G63, 4G64)
03
Part Tightened N•m
ECM × Body 19.6
ECT sensor × Engine cylinder block 29
Intake air hose bolt × Body 21 ～ 25
Idle air control motor × Throttle body 3.4
TPS × Throttle body 3.4
MAP sensor/IAT sensor × Intake manifold
KS × cylinder body 20 ± 5
CKP sensor × Clutch housing 8±2
Upstream HO2S × Exhaust pipe 40 ～ 60
Downstream HO2S × Exhaust pipe 40 ～ 60
DIESEL ENGINE (BJ493ZQ3)

ECM × Body 8 ~ 10
ECT sensor × Engine cylinder block 20 ~ 25
Intake air hose bolt × Body 21 ~ 25
CMP sensor × Engine timing belt cover 8 ± 0.5
APPS × Body 2 ~ 2.5
MAF × Intake air hose 4~5
CKP sensor × Clutch housing 6~8
Odometer sensor × Transmission 6~8

03-4 SERVICE SPECIFICATIONS - FUEL
FUEL
SERVICE DATA
FUEL
Gasoling engine fuel pressure
Ignition switch ON 329 kPa
Engine idling 329 ~ 350 kPa
Ignition switch OFF 350 kPa (In 10 minutes)
Max diesel engine fuel pressure 25 ~ 145 MPa
Fuel pump fuel supply pertour Maximun 843 ml
Injector electric power parameter

Peak current 17.5 ~ 18.5 A
Holding current 11.5 ~ 12.5 A
resistance 0.215 ~ 0.295 Ω
Injector sprue pretrusion 1.7 ~ 2.3 mm
Injector washer thickness 3.5 mm
Fuel pump filling quantity 60 ml
Fuel tank rear bracket × Body 21 ~ 25
Fuel tank retaining belt × Body 41 ~ 51
Gasoling engine fuel filter belt bolt 21 ~ 25
Fuel level sensor sealing cover 2.5 ~ 4
Fuel pump sealing cove 8 ~ 10
Fuel tank front fender × Fuel tank 13 ~ 17
Diesel filter hand pump bolt 15 ~ 18
High-pressure pump × Engine timing belt cover 25 ~ 35
High-pressure pump timing pulley bolt 65 ~ 75
High-pressure pump × Common rail 18 ~ 22
High-pressure tube ×Common rail 23 ~ 27
High-pressure tube × Injector 25 ~ 29
Injector pressing plate pad

1st step 7.5 ~ 9
2nd step Anaddation 40 ~ 45°
Engine cover bolt 21 ~ 25

SERVICE SPECIFICATIONS - EMISSION CONTROL 03-5
EMISSION CONTROL
03
Canister solenoid valve bolt 8 ~ 10
Diesel engine EGR valve × EGR connect pipe 15 ~ 19 03

Diesel engine EGR valve × Exhaust manifold 15 ~ 18
Vacuum regulator bolt 8 ~ 10

03-6 SERVICE SPECIFICATIONS - INTAKE AIR
INTAKE AIR
SERVICE DATA
Compressor blade and compressor case clearance
Minimum ≥ 0.10 mm
Turbocharger rotor axial clearance

Standard ≤ 0.1 mm
Limit ≤ 0.25 mm
Intake pressurizer tank bolt 21 ~ 25
Air filter assy bolt 21 ~ 25
Air filter intake duct bolt 21 ~ 25
Intake resonator assy × Body 21 ~ 25
Intake manifold bolt 15 ~ 18
Coolant temperature senor bracket bolt 17 ~ 19
Intake manifold lower bracket bolt 21 ~ 25
Turbo charger × Exhaust manifold 18 ~ 22
Turbo charger × Exhaust pipe 22 ~ 26
EGR valve × EGR exhaust pipe 18 ~ 22
Turbo charger oil return pipe bolt 7.5 ~ 8.5
Turbo charger oil inlet pipe bolt 8 ~ 10
EGR exhaust pipe × Intake connected pipe 18 ~ 22
Intake manifold × Intake connected pipe 21 ~ 25
High-pressure fuel tube × Common rail 23 ~ 27

SERVICE SPECIFICATIONS - ENGINE MECHANICAL 03-7
ENGINE MECHANICAL
SERVICE DATA
GASOLING ENGINE (4G63，4G64) 03
ENGINE ASSY
Type Four-stroke, four-cylinder, water-cooled, in-line, SOHC, 03
gasoling engine, 16 valves, SMP1
Cylinder 4
Combustion chamber Single pent roof combustion chamber
Displacement
4G63 1.997 L
4G64 2.351 L
Bore
4G63 85.0 mm
4G64 86.5 mm
Stroking
4G63 88.0 mm
4G64 100.0 mm
Maximum torque
4G63 167.7 N·m
4G64 198.1 N·m
Delivered power
4G63 92 kw （6000 r / min）
4G64 95 kw （5500 r / min）
Compression ratio
4G63 10
4G64 9.5
Lubrication system Pressure feed, splash
Fuel pump type Gear type
Coolant pump type Centrifugal vane wheel type
TIMING BELT
Tensioner rod protrusion
Standard 12 mm
Limit -
Tensioner rod indentation (98 ～ 196 N)

Standard ≤ 1 mm
Limit -
03-8 SERVICE SPECIFICATIONS - ENGINE MECHANICAL
CAMSHAFT
Cam height
Air-in Standard 37.39 mm
Limit 36.89 mm
Air-out Standard 36.83 mm
Limit 36.33 mm
Shaft diameter
Standard 45.0 mm
Limit -
CYLINDER HEAD
Lower surface flatness
Standard 0.03 mm
Limit 0.20 mm
Surface grinding limit

Standard -
Limit 0.2 mm
Full height
Standard 119.9 ～ 120.1 mm
Limit -
Bolt length
Standard 97.4 mm
Limit ≤ 99.4 mm
VALVE
Edge thickness
Limit 0.5 mm
Limit 0.5 mm
Valve rod diameter

Standard 6.0 mm
Limit -
Crest clearance between valve rod and guide

Air-in Standard 0.02 mm ~ 0.05 mm
Limit 0.10 mm
Air-out Standard 0.03 mm ~ 0.07 mm
Limit 0.15 mm
Inclination valve
Standard 45° － 45.5°
Limit -
Height
Limit 111.80 mm
Limit 113.61 mm
VALVE SPRING
Free height
Standard 51.0 mm 03
Limit 50.0 mm
Pre-loading force/operation height km/mm

Standard 27.2 kg / 44.2 mm
Limit - 03
Center line
Standard ≤ 2°
Limit ≤ 4°
VALVE GUIDE
Valve margin
Standard 0.9 mm ~ 1.3 mm
Limit -
Internal diameter
Standard 6.0 mm
Limit -
External diameter
Standard 11.0 mm
Limit -
Depression depth
Standard 14.0 mm
Limit -
Valve stem height

Standard 49.3 mm
Limit 49.8 mm
Engine oil pump side clearance

Driving gear Standard 0.08 mm ~ 0.14 mm
Limit -
Driven gear Standard 0.06 mm ~ 0.12 mm
Limit -
Position clearance
Limit -
PISTON RING
Lateral clearance
No.1 ring Standard 0.02 mm ~ 0.06 mm
Limit 0.1 mm
Limit 0.1 mm
End clearance
Limit 0.8 mm
Limit 0.8 mm
Oil ring Standard 0.10 mm ~ 0.40 mm
Limit 1.0 mm
PISTON PIN
External diameter
Standard 22.0 mm
Limit -
Depressing force 755 ~ 1750 kg
Depressing temperature Room temperature
Connecting rod big end clearance

Limit 0.40 mm
CRANKSHAFT
Crankshaft pin clearance
Limit 0.10 mm
Axial clearacne
Limit 0.25 mm
Main journal diameter

Standard 57 mm
Limit -
Connecting journal diameter

Standard 45 mm
Limit -
Main journal oil diameter

Limit 0.10 mm
CYLINDER BLOCK
Upper surface flatness
Standard 0.05 mm
Limit 0.10 mm
Upper surface grinding limit

Standard -
Limit 0.2 mm
Full height
Limit -
Cylinder hole inner diameter

Limit -
Cylinder out-of-round
Standard 0.01 mm
Limit -

ENGINE ASSY
Type Four-stroke, four-cylinder, water-cooled, in-line, 03
pressurize, high pressure common rail, electric
control EGR
Cylinder 4
03
Combustion chamber DI throat circular w-type
Displacement 2.771 L
Bore 93 mm
Stroking 102 mm
Maximum Torque 225 N·m （≤ 2300 r / min）
Delivered power 70 kw （3600 r / min）
Compression ratio 17.4
Lubrication system Pressure feed, splash
Fuel pump type Gear type
Coolant pump type Centrifugal vane wheel type
Idle oil pressure ≥ 0.1 MPa
Rev oil pressure 0.35 ~ 0.55 MPa
CAMSHAFT
Cam height
Standard 42.001 mm
Limit -
Shaft diameter
Standard 45.0 mm
Limit -
Valve guide inner diameter and intake valve rod clearance

Limit 0.200 mm
Valve guide inner diameter and outtake valve rod clearance

Limit 0.250 mm
Rocker arm hole and rocker shaft outer diameter clearance

Standard 0.01 mm ~0.05 mm
Limit 0.20 mm
Sleeve inner diameter and piston skirt clearance

Limit 0.200 mm
Valve push rod hole diameter and outer diameter clearance

Limit 0.100 mm
No. 1 ring goove height and No.1 ring height clearance

Standard 0.078 mm~ 0.137 mm
Limit 0.200 mm
No. 2 ring goove height and No.2 ring height clearance

Limit 0.150 mm
Oil control ring goove height and oil control ring height clearance
Limit 0.15 mm
PISTON RING END CLEARANCE (IN Φ 93MM CYLINDER BLOCK)

No.1 ring
Limit 0.8 mm
No.2 ring
Limit 1.5 mm
Oil ring
Limit 1.20 mm
Connecting rod brush hole and piston pin clearance

Limit 0.05 mm
Piston pin seat and piston pin clearance

Limit 0.030 mm
Camshaft pin key and connecting rod big end axial clearance
Limit 0.350 mm
Camshaft brush hole adn camshaft journal clearance

Limit 0.120 mm
Connecting rod big end bearing hole and crankshaft pin clearance
Limit 0.100 mm
Main bearing hole diameter and crankshaft thrust washer

clearance Standard 0.033 mm ~ 0.079 mm
Limit 0.110 mm
Crankshaft thrust washer axial clearance

Limit 0.30 mm
Camshaft thrust washer axial clearance

Limit 0.25 mm
03
Valve clearance
Exhaust valve 0.35 mm ~0.45 mm
Intake valve 0.35 mm ~0.45 mm
03

TIMING BELT
Lower timing belt cover 11
Tension pulley bolt 49
Tension pulley arm bolt 22
Auto tension pulley bolt 2.4
Idle pulley bolt 36
Tension pulley bracket 49
Rear timing belt cover 11
Oil pump belt pulley 55
Crankshaft belt pulley bolt 120
Tensioner “B” 19
Belance shaft belt pulley 46
Camshaft belt pulley bolt 90
Crankshaft belt pulley 46
Rocker arm and cam
Cylinder head cover bolt 4
Rocker arm and camshaft assy bolt 32
Thrust cover screw 19
Cylinder cover bolt

Step 1 20
Step 2 Anaddation 90°
Step 3 Anaddation 90°
FRONT COVER, OIL PUMP

Drain plug 45
Oil pan 7
Oil strainer bolt and nut 19
Oil pressure switch 10


Relief plug 45
Oil filter bracket bolt 19
Front cover bolt 24
Front cover plug 24
Flange bolt 37
Oil pump cover bolt 16
Oil pump cover screw 10
Connecting rod nut

Step 1 20
Step 2 Anaddation 90 ~ 100°
CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL, DRIVER BOARD

Flywheel bolt 135
Rear cover bolt 11
Oil seal cover bolt 11
Crankshaft main cap bolt

Step 1 25

TIMING BELT
Ttiming belt cover04—17 20 ~ 25
Tension pulley belt bolt 110 ~ 130
Timing belt idle pulley bolt 110 ~ 130
Coolant pump belt pulley bolt 21 ~ 25
High-pressure pump belt pulley bolt 65 ~ 75
Crankshaft timing belt pulley bolt 21 ~ 25
Timing belt tension rod bolt 21 ~ 25
Timing belt snap ring bolt 9 ~ 11
Cylinder head cover bolt 15 ~ 19
Camshaft oil seal assy 7 ~ 13
Camshaft belt pulley bolt 80 ~ 90
Rocker and rocker arm bolt 46 ~ 63


Cylinder block bolt
Step 1 35 03
Step 2 Completely loosen
Step 3 30 ~ 35
CRANKSHAFT, CYLINDER BLOCK, FLYWHEEL, DRIVER BOARD 03
Flywheel bolt 113 ~ 133
Crankshaft belt pulley bolt 260 ~ 300
Connecting rod nut 80 ~ 90
Crankshaft main cap bolt

Step 1 40 ~ 50
Step 2 90 ~ 100
Step 3 160 ~ 180
Cylinder block rear cover bolt 75 ~ 90

03-16 SERVICE SPECIFICATIONS - EXHAUST
EXHAUST
SERVICE DATA
Exhaust manifold and cylinder block cover flatness
Standard ≤ 0.15 mm
Limit 0.20 mm
Catalytic converter× Front exhaust manifold 41 ~ 51
Front exhaust pipe × Catalytic converter 41 ~ 51
Muffer × Front exhaust pipe 41 ~ 51
Exhaust manifold bolt 21 ~ 25
Heat shield 10 ~ 14
SERVICE SPECIFICATIONS - COOLING 03-17
COOLING
SERVICE DATA
03
Cooling system outlet temperature 75 ~ 85 ℃
Thermostat valve opening temperature 80 ~ 84 ℃
Thermostat valve lift 10 mm (At 95 ℃ ) 03
Coolant drain plug 8 ~ 10
Coolant reservior bolt 9 ~ 11
Radiator upper support bolt 21 ~ 25
Radiator lower support bolt 21 ~ 25
Cooling fan bolt 9 ~ 11
Coolant pump pulley bolt 25
Coolant pump bolt 14

03-18 SERVICE SPECIFICATIONS - LUBRICATION
LUBRICATION
SERVICE DATA
GASOLING ENGINE (4G63，4G64)
Oil pump side clearance

Driver gear Standard 0.08 mm ~ 0.14 mm
Limit -
Driven gear Standard 0.06 mm ~ 0.12 mm
Limit -

FRONT COVER, OIL PUMP
Drain plug 45
Oil pan 7
Oil strainer bolt and nut 19
Oil pressure switch 10
Relief plug 45
Oil filter bracket bolt 19
Front cover bolt 24
Front cover plug 24
Flange bolt 37
Oil pump cover bolt 16
Oil pump cover screw 10

Drain plug 35 ~ 45
Oil pan 25 ~ 29
Oil filter bracket bolt 20 ~ 25
Oil pump bolt 20 ~ 25

SERVICE SPECIFICATIONS - IGNITION 03-19
IGNITION
SERVICE DATA
03
Spark plug gap 0.7 ~ 0.8 mm
03
Spark plug 35
Ignition core 10
03-20 SERVICE SPECIFICATIONS - STARTING AND CHARGING
STARTING AND CHARGING

SERVICE DATA
GENERATOR
Nominal voltag 12 V
Rated current 80 A
Rated revolution 5000 r / min
Power 1120 W
Rotary mode clockwise
Polarity Negative ground
Work mode Contiguous rated type
Generator rotor coil resistance 3~5Ω
Generator rotor diameter

Limit 12.8 mm
Pinion-to-stopper clearance Standard 0.5 mm ~ 2.0 mm
Starter commutator run-out

Standard ≤ 0.05 mm
Limit 0.10 mm
Starter commutator diameter

Standard 29.4 mm
Limit 28.4 mm
Brush attrition value Limit 7.0 mm
REGULATOR
Type IC regulator
Regulation voltage 14.40 ~ 14.70 V
STARTER
Voltage 12 V
Output power 2.8 kw
Direction of rotation Clockwise
Battery rated voltage 12 V

SERVICE SPECIFICATIONS - STARTING AND CHARGING 03-21
03
Generator front cover × Stator component 6~8
Generator × Generator bracket 20 ~ 24
Generator adjust bolt 20 ~ 24 03

Generator cable nut 21 ~ 25
Generator belt pulley bolt 20 ~ 24
Starter shell bolt 8 ~ 10
Magnetic switch bolt 8 ~ 10
Magnetic switch × Magnetic coil 14 ~ 16
Starter × Battery cable 18 ~ 20
Starter × Transmission case 68 ~ 72
Battery tray × Body 16 ~ 18
Battery tray bracket × Battery tray 16 ~ 18
Battery hold down 8 ~ 10
Battery cable 8 ~ 10
03-22 SERVICE SPECIFICATIONS - FRONT SUSPENSION
FRONT SUSPENSION
SERVICE DATA
FRONT WHEEL ALIGNMENT
Front toe-in 0.5 ±1 mm
Front wheel camber 0′ ± 30′ (Difference between left and right ≤ 30′)
Kingpin inclination 10°30′ ± 30′ (Difference between left and right ≤ 30′)
Kingpin caster 1°30′ ± 30′ (Difference between left and right ≤ 30′)
Front shock absorber × Body 45 ～ 55
Front shock absorber × Lower control arm 80 ～ 100
Torsion bar × Frame 55 ～ 65
Upper control arm × Frame 130 ～ 160
Upper control arm ball joint × Steering knuckle 130 ～ 160
Lower control arm × Frame 160 ～ 200
Lower control arm ball joint × Steering knuckle 130 ～ 160
Stabilizer bar link × Stabilizer bar 45 ～ 55
Stabilizer bar bracket × Frame 45 ～ 55
Strut rod × Lower control arm 100 ～ 120
Strut rod × Frame 120 ～ 150

SERVICE SPECIFICATIONS - REAR SUSPENSION 03-23
REAR SUSPENSION
SERVICE DATA
03
REAR WHEEL ALIGNMENT
Rear toe-in 2 ± 2 mm (Difference between left and right ≤ 1 mm)
Rear wheel camber 0°15′ ± 45′ (Difference between left and right ≤ 45′) 03
Rear shock absorber × Rear trailing arm 45 ～ 55
Rear shock absorber × Frame 80 ～ 100
Rear trailing arm × Frame

Inside point 120 ～ 150
Outside point 145 ～ 175
Stabilizer bar link × Stabilizer bar 45 ～ 55
Stabilizer bar × Rear trailing arm 45 ～ 55
Stabilizer bar bracket × Frame 22 ～ 25

03-24 SERVICE SPECIFICATIONS - TIRE AND WHEEL
TIRE AND WHEEL

SERVICE DATA
TIRE PRESSURE
205/70R15-95H
Front tire 2.4 bar
Rear tire 2.8 bar
Spare tire 3.0 bar
195/70R15C-104S
Front tire 3.3 bar
Rear tire 4.5 bar
Spare tire 4.8 bar
Wheel nut 90 ～ 120
SERVICE SPECIFICATIONS - AXLE AND PROPELLER SHAFT 03-25
AXLE AND PROPELLER SHAFT

SERVICE DATA
03
PROPELLER ASSY
Propeller tube outer diameter × Thickness φ 65 × 2.3 mm
Operating torque Maximum 1600 N·m 03

Angle without interference Maximum 22°
Dynamic unbalance Maximum 30 g.cm （3200 r/min）
Propeller radial runout

Standard 0.4 mm
Limit 0.5 mm
Clearance between tube yoke and transmission output

shaft spline Standard 0.15 mm
Limit 0.35 mm
U-JOINT
Cross spider journal
Standard 18.440 mm
Limit 18.425 mm
Clearance between needle bearing and yoke 0 mm (Interferencefit)
Clearance between cross spider and needle bearing 0.01 ～ 0.06 mm
Axial clearance of cross spider 0.10 ～ 0.30 mm
AXLE HUB
Back lash
Front ≤ 0.05 mm
Rear ≤ 0.05 mm
Deviation
Front ≤ 0.07 mm
Rear ≤ 0.07 mm
Primal rotating force

Front ≤ 5 N·m
Rear ≤ 5 N·m
TRANSAXLE
Rear wheel track 1540 mm
FINAL DRIVE ASSY

Number of drive pinion teeth 12
Number of crown gear teeth 41
Final ratio 3.417

03-26 SERVICE SPECIFICATIONS - AXLE AND PROPELLER SHAFT
DIFFERENTIAL ASSY
Crown gear deviation ≤ 0.07 mm
Crown gear back lash 0.13 ～ 0.18 mm
Contact area between drive pinion and crown gear Center of the tooth surface. The distance away from
Locate small end ≥ 2mm
Length ≥ 60% tooth length
Width ≥ 60% tooth width
Differential gear and pinion back lash 0.05 ～ 0.20 mm
Differential gear clearance 0 ～ 0.15 mm
Radial clearance between differential pinion and pinion

shaft 0.05 ～ 0.13 mm
Radial clearance between differential gear and

differential case 0.05 ～ 0.11 mm
Thickness of diiferentila gear thrust washer

Standard 0.6 mm
Limit -
Thickness of diiferentila pinion thrust washer

Standard 1.6, 1.7, 1.8 mm
Limit -
DRIVE PINION
Pinion flange back lash ≤ 0.10 mm
Pinion flange deviation ≤ 0.10 mm
Drive pinion primal rotating force 1.3 ～ 2.2 N·m

SERVICE SPECIFICATIONS - AXLE AND PROPELLER SHAFT 03-27
03
Final drive pinion flange × Propeller shaft 70 ～ 78
Center support bearing bracket × Frame 60 ～ 70
End yoke retaining bolt 157 ～ 216 03

Rear brake backing plate × Rear trailing arm 100 ～ 120
Rear brake fluid tube × Rear wheel brake cylinder 30 ～ 40
Rear axle hub nut 230 ～ 240
Steering knuckle × Upper control arm B-joint 135 ～ 145
Lower control arm B-joint × Lower control arm 69 ～ 77
Axle shaft assy × Output flange 65 ～ 80
Final drive drain plug 55 ～ 65
Final drive filler plug 15 ～ 25
Final drive vent plug 15 ～ 20
Longitudinal hanger assy × Final drive assy 205 ～ 215
Transverse hanger assy × Final drive assy 170 ～ 180
Longitudina hanger assy × Frame 116 ～ 120
Stud × Frame 140 ～ 170
Stud × Nut 96 ～ 100
Crown gear × Differential case 63 ～ 77
Differential bearing cap × Differential case 85
Rear cover × Final drive housing 27 ～ 32
Pinion nut
Minimum 196
Increment 13
Maximum 343
03-28 SERVICE SPECIFICATIONS - BRAKE
BRAKE
SERVICE DATA
BRAKE PEDAL
Height Standard 125 ~ 135 mm
Free play Standard 5 ~ 10 mm
Reserve distance Standard ≥ 75 mm
FRONT BRAKE
Thickness of front brake pad
Standard 10.0 mm
Limit 1.6 mm
Thickness of front brake disk

Standard 28.0 mm
Limit 25.5 mm
Front brake disk run out

Standard -
Limint 0.04 mm
REAR BRAKE
Thickness of rear brake shoe
Standard 6.0 mm
Limit 1.0 mm
Brake drum inside diameter 270 mm
Clearance between rear brake drum and brake shoe Standard 0.2 ~ 0.5 mm
Front disk brake caliper vent plug 5.8 ～ 9.8
Rear wheel brake cylinder vent plug 5.8 ～ 9.8
Brake fluid reservoir bolt 3～5
Brake master cylinder bolt 8 ～ 12

Brake master cylinder tube connector 21 ～ 24
Front axle hub nut 150 ～ 180
Front disk brake caliper mounting bolt -
Front disk brake caliper bolt 100 ～ 120
Front disk brake caliper fluid tube connector 21 ～ 24
Rear wheel cylinder brake fluid tube connector 21 ～ 24
Rear axle hub nut 21 ～ 24

SERVICE SPECIFICATIONS - BRAKE 03-29

Front wheel speed sensor bracket retaning nut 9 ～ 11
Rear wheel speed sensor bracket retaning nut

03
9 ～ 11
03
03-30 SERVICE SPECIFICATIONS - PARKING BRAKE
PARKING BRAKE
Parking brake opertation handle bolt 21 ～ 25
Parking brake switch bolt -
Rear parking brake pull cable asy × Rear brake backing plate 9 ～ 11
SERVICE SPECIFICATIONS - TRANSMISSION 03-31
TRANSMISSION
SERVICE DATA
R5M21-Z-GBA5 03
Transimission fluid 2L
1st gear ratio 3.967

03
2nd gear ratio 2.136
3rd gear ratio 1.360
4th gear ratio 1.000
5th gear ratio 0.856
Reverse gear ratio 3.578
Odometer gear ratio (Driven gear / drive gear) 16 / 5
Counter shaft washer axial clearance 0 ～ 0.05 mm

Input shaft gear bearing axial clearance
Standard 0 ～ 0.06 mm
Limit -
Front bearing retainer axial clearance

Limit -
Change shifter axial clearance limit mechanism sub-assy side

Limit -
Change shifter axial clearance washer side

Limit -
Reserve shifter axial clearance

Limit -
Output shaft radial runout

Standard 0.02 mm
Limit -
Output shaft journal

A 34.989 ～ 35 mm
B 42.989 ～ 43 mm
C 35.002 ～ 35.013 mm
D 30.002 ～ 30.011 mm
Axial clearance between od-r synchronizer ring and gear

Standard -
Limit 0.5 mm
Axial clearance between 4th synchronizer ring and gear

Standard -
Limit 0.5 mm
03-32 SERVICE SPECIFICATIONS - TRANSMISSION
Axial clearance between 3rd synchronizer ring and gear

Standard -
Limit 0.5 mm
Axial clearance between 2nd synchronizer ring and gear

Standard -
Limit 0.5 mm
Axial clearance between 1st synchronizer ring and gear

Standard -
Limit 0.5 mm
Radial clearance between od-r synchronizer ring and gear

Standard -
Limit 0.5 mm
Radial clearance between 4th synchronizer ring and gear

Standard -
Limit 0.5 mm
Radial clearance between 3rd synchronizer ring and gear

Standard -
Limit 0.5 mm
Radial clearance between 2nd synchronizer ring and gear

Standard -
Limit 0.5 mm
Radial clearance between 1st synchronizer ring and gear

Standard -
Limit 0.5 mm
Clearance between od-r synchronizer sleeve and gearshift fork

Limit -
Clearance between 3rd-4th synchronizer sleeve and gearshift

fork Standard 0.05 ～ 0.35 mm
Limit -
Clearance between 1st-2nd synchronizer sleeve and gearshift

Limit -
Axial clearance between 3rd-4th synchronizer sleeve and hub

Limit -
ZM001AJ2
Transimission fluid 2L
1st gear ratio 3.99 03
2nd gear ratio 2.15
3rd gear ratio 1.33

03
4th gear ratio 1.00
5th gear ratio 0.85
Reverse gear ratio 4.22
Odometer gear ratio (Driven gear / drive gear) 16/5
Input shaft gear bearing axial clearance

Limit -
Output shaft radial runout

Standard 0.04 mm
Limit -
Output shaft journal

A 34.975 ～ 34.991 mm
B 37.975 ～ 37.991 mm
C 30.385 ～ 30.4 mm
D 30.585 ～ 30.6 mm
Axial clearance between 5th synchronizer ring and

connecting gear Standard 1 ～ 1.6 mm
Limit 0.8 mm
Axial clearance between 4th synchronizer ring and gear

Limit 0.8 mm
Axial clearance between 3rd synchronizer ring and gear

0.8 mm
Limit
Axial clearance between 2nd synchronizer ring and gear

Limit 0.8 mm
Axial clearance between 1st synchronizer ring and gear

Limit 0.8 mm
Radial clearance between 5th synchronizer ring and

connecting gear Standard 1 ～ 1.6 mm
Limit 0.8 mm
Radial clearance between 4th synchronizer ring and gear

Limit 0.8 mm
03-34 SERVICE SPECIFICATIONS - TRANSMISSION
Radial clearance between 3rd synchronizer ring and gear

0.8 mm
Limit
Radial clearance between 2nd synchronizer ring and gear

0.8 mm
Limit
Radial clearance between 1st synchronizer ring and gear

Limit 0.8 mm
Clearance between 5th synchronizer sleeve and gearshift fork

Limit -
Clearance between 3rd-4th synchronizer sleeve

and gearshift fork
Limit -
Clearance between 1st-2nd synchronizer sleeve and gearshift

Limit -
R5M21-Z-GBA5
Drain plug 39 ～ 59
Transmission lifting lug × Frame 41 ～ 51
Gearshift connecting rod × Transmission assy 18 ～ 26
Gear select connecting rod × Transmission assy 18 ～ 26
Filler plug 29.4 ～ 34.3
Front bearing retainer × Transmission assy 29 ～ 41
Reserve idler gear shaft × Transmission assy 17 ～ 22
Output shaft lock nut 245 ～ 265
Reserve idler gear shaft slotted nut 20 ～ 59
Counter shaft lock nut 157 ～ 186
Change shafter adjuster lock nut 29.4 ～ 41.1
Extension Housing × Transmission assy 14.7 ～ 21.5

ZM001AJ2
Drain plug 30 ～ 50 03
Transmission lifting lug × Frame 41 ～ 51
Gearshift connecting rod × Transmission assy 18 ～ 26

03
Gear select connecting rod × Transmission assy 18 ～ 26
Filler plug 30 ～ 50
Output shaft rear bearing baffle × Transmission assy 17 ～ 22
Reserve idler gear shaft pressure plate bolt 17 ～ 22
Control cover × Transmission assy 17 ～ 22
Input shaft front bearing retainer 17 ～ 22
Extension Housing × Transmission assy 30 ～ 45

03-36 SERVICE SPECIFICATIONS - CLUTCH
CLUTCH
SERVICE DATA
CLUTCH PEDAL
Height
Standard 150 mm
Limit -
Free play
Standard 0.8 mm
Limit -
Push rod play

Standard -
Limit -
CLUTCH
Clutch disk thickness
Standard -
Limit 0.3 mm
Height of diaphragm spring

Standard -
Limit 0.5 mm
Flywheel runout
Standard -
Limit 0.2 mm
Drain plug -
Clutch pedal lock nut 15 ~ 26
Clutch pedal pin nut -
Clutch master cylinder nut -
Clutch master cylinder fluid tube connector 25
Clutch slave cylinder fluid tube connector -
Clutch slave cylinder bolt -
Clutch cover bolt 25 ~ 28

SERVICE SPECIFICATIONS - STEERING COLUMN 03-37
STEERING COLUMN
SERVICE DATA
03
VEHICLE
Turn radius Minimum 5.75 m
Off track (30 m， 40 Km/h) 03

Left ＜2m
Right ＜1m
STEERING WHEEL
Diameter 390 mm
Free play ± 10°
Adjustable distance 49 mm
Turning force
Engine stopped ＜ 200 N
Engine idling ＜ 45 N
CLOCK SPRING
Gross rotating turns ≥ 5.3
STEERING PROPELLER SHAFT

Clearance between cross spider and bearing ≤ 0.2 mm
Steering wheel nut 40 ～ 50
Horn switch assy (with airbag) × Steering wheel 10
Steering column assy × Steering column beam welding assy 41 ～ 51
Steering propeller shaft assy × Steering column assy 29 ～ 35
Lower propeller shaft seal housing retaining bolt 21 ～ 25
Steering propeller shaft assy × Steering gear assy 29 ～ 35
Engine lower guard plate retaining bolt 20 ～ 25
Steering column beam welding assy × Clutch pedal 15 ～ 26

03-38 SERVICE SPECIFICATIONS - POWER STEERING
POWER STEERING
SERVICE DATA
VEHICLE
Turn radius Minimum 5.75 m
Off track (30 m， 40 Km/h)

Left ＜2m
Right ＜1m
STEERING WHEEL
Diameter 390 mm
Free play ± 10°
Adjustable distance 49 mm
Turning force
Engine stopped ＜ 200 N
Engine idling ＜ 45 N
STEERING PUMP BELT

Deflection
Gasoline vehicles ≤ 5 mm (98 N)
Diesel vehicles 5.5 ～ 8.5 mm (98 N)
STEERING FLUID
Operating temperature - 40 ～ 120 ℃
Level difference Engine idling → stopped ≤ 5 mm
Pressure
Engine idling, valve closed -
Engine idling, valve open, steering wheel at lock position ≤ 8 MPa
Pressure difference
Vavle open, engine running at 1000 and 3000 r/min -
STEERING GEAR ASSY

Weight 10.6 Kg
Number of rack teeth 30
Number of pinion teeth 8
Module 1.85
Gear ratio 36.7 mm/r
Rotating angle of rack shaft 1220°
Gross rotating turn of pinion 4.2 ± 0.1
Pitch circle of pinion φ 16.33 mm
Radial runout of rack 0.15 mm

SERVICE SPECIFICATIONS - POWER STEERING 03-39
03
Power steering line connector 40 ～ 45
Steering wheel nut 40 ～ 50
Engine lower guard plate retaining bolt 20 ～ 25 03

Steering gear assy × Subframe 118 ± 10
Steering gear assy × Steering propeller shaft assy 29 ～ 35
Steering tie rod × Steering knuckle arm 84 ～ 100

03-40 SERVICE SPECIFICATIONS - HEATER AND AIR CONDITIONING

SERVICE DATA
AMOUNT OF COMPRESSOR OIL
Replace compressor Compressor has 200 ml oil, no need addition
Replace evaporator 10 ml
Replace accumulator 5 ～ 10 ml
Replace condenser
No leakage 5 ml
Leakage 10 ml
Replace pipes
No leakage No addition
Leakage 5 ml
DUAL FUNCTION PRESSURE SWITCH

Low pressure side pressure
ON 0.196 MPa
OFF -
Middle pressure side pressure

ON 1.77 MPa
OFF 1.37 MPa
High pressure side pressure

ON -
OFF 3.14 MPa
Φ9 aluminium tube, M16×1.5 thread 12 ～ 15

SERVICE SPECIFICATIONS - SUPPLEMENTAL RESTRAINT SYSTEM 03-41

SERVICE DATA
03
AIRBAG
Operating temperature - 35 ～ 85 ℃
Operating voltage 12 ± 3 V 03
CLOCK SPRING
Gross rotating turns ≥ 5.3
Horn switch assy (with airbag) × Steering wheel 10
RCM retaining nut 9 ～ 11
RCM bracket retaining bolt 9 ～ 11

03-42 SERVICE SPECIFICATIONS - SEAT BELT
SEAT BELT
Driver / assistant driver seat retractor × Body 50 ～ 55
Driver / assistant driver seat belt upper anchor × Anchor adjuster assy 50 ～ 55
Driver / assistant driver seat belt lower anchor × Body 50 ～ 55
Driver / assistant driver seat belt anchor adjuster assy × Body 50 ～ 55

SERVICE SPECIFICATIONS - LIGHTING 03-43
LIGHTING
03
Front comination switch assy × Frame -
03
03-44 SERVICE SPECIFICATIONS - WIPER AND WASHER
WIPER AND WASHER

SERVICE DATA
WIPER MOTOR
Speed of front wiper motor
LO 40 ～ 50 r / min
HI 60 ～ 80 r / min
Speed of rear wiper motor 33 ～ 43 r / min
Wiper assy retaining bolt 13 ～ 17
Rear wiper nut 8 ～ 12

SERVICE SPECIFICATIONS - SEAT 03-45
SEAT
03
(Electrical) buckle assy × Driver / assistant driver seat bracket 50 ～ 55
Driver / assistant driver seat base welding assy × Body 45 ～ 55 03

Driver / assistant driver seat × Driver / assistant driver seat base
welding assy Front -
Rear 45 ～ 55
03-46 SERVICE SPECIFICATIONS - SLIDING ROOF
SLIDING ROOF
Sliding roof assy × Body -
SERVICE SPECIFICATIONS - ENGINE HOOD AND DOORS 03-47
ENGINE HOOD AND DOORS

SERVICE DATA
03
ENGINE HOOD
Clearance 4.0 +/- 1.0 mm
Flatness 0 + 0.5 / - 1.0 mm 03

FRONT DOOR
Flatness 0 +/- 1.0 mm
SLIDING DOOR
Flatness 0 +/- 1.0 mm (Right and left)

3.0 +/- 1.5 mm (Up and down)
REAR HATCH
Clearance 5.5 +/- 1.5 mm (Side)
8 +/- 2.0 mm (Bottom)
Flatness 0 +/- 1.5 mm
Door hinge bolt 21 ～ 25
03-48 SERVICE SPECIFICATIONS - EXTERIOR AND INTERIOR TRIM
EXTERIOR AND INTERIOR TRIM

Rear hatch handle bolt -
Front bumper assy bolt -
Rear bumper assy bolt -

DIAGNOSTICS
04
GASOLINE ENGINE CONTROL SYSTEM........................................ 04-1
PRECAUTION.............................................................................. 04-1
LOCATION................................................................................... 04-4
HOW TO DIAGNOSTICS ANALYSE ........................................... 04-7
DIAGNOSTIC HELP - INTERMITTENT FAULT ........................ 04-10
BASIC SERVICE PROCEDURE................................................ 04-12
ECM TERMINAL DIAGRAM (ECM SIDE) ................................. 04-13
04
DIAGNOSTIC SYSTEM ............................................................. 04-18
READING AND ERASING DIAGNOSTIC TROUBLE
CODE (DTC) .............................................................................. 04-20
CAPTURING DATA ................................................................... 04-22
FAIL-SAFE CHART.................................................................... 04-23
DATA STREAM LIST/ACTIVE TEST......................................... 04-25
DIAGNOSTIC TROUBLE CODE CHART .................................. 04-29
P0117 - ENGINE COOLING TEMPERATURE
SENSOR CIRCUIT LOW VOLTAGE ......................................... 04-34
P0118 - ENGINE COOLING TEMPERATURE
SENSOR CIRCUIT HIGH VOLTAGE ........................................ 04-34
P0107 - MAP SENSOR CIRCUIT LOW VOLTAGE OR
OPEN ......................................................................................... 04-38
P0108 - MAP SENSOR CIRCUIT HIGH VOLTAGE .................. 04-38
P0112 - IAT SENSOR CIRCUIT LOW VOLTAGE OR
OPEN ......................................................................................... 04-43
P0113 - IAT SENSOR CIRCUIT HIGH VOLTAGE .................... 04-43
P0122 - THROTTLE POSITION LOW VOLTAGE ..................... 04-47
P0123 - THROTTLE POSITION HIGH VOLTAGE .................... 04-47
P0131 - FRONT OXYGEN SENSOR SHORT LOW.................. 04-52
P0132 - FRONT OXYGEN SENSOR SHORT HIGH ................. 04-52
P0134 - FRONT OXYGEN SENSOR OPEN ............................. 04-52
P0336 - CKP SENSOR CIRCUIT NOISY SIGNAL .................... 04-58
P0325 - KNOCK SYSTEM FAULT............................................. 04-63
P0327 - KNOCK SENSOR FAULT ............................................ 04-63
P0480 - FAN 1 FAULT ............................................................... 04-67
P0481 - FAN 2 FAULT ............................................................... 04-67
PROBLEM SYMPTOMS TABLE................................................ 04-74
ENGINE SYMPTOM DIAGNOSTIC........................................... 04-75
DIESEL ENGINE CONTROL SYSTEM.......................................... 04-112
PRECAUTION.......................................................................... 04-112
LOCATION............................................................................... 04-115
HOW TO DIAGNOSTICS ANALYSE ....................................... 04-118
CAUTIONS FOR CIRCUIT TROUBLESHOOTING ................. 04-120
DIAGNOSTIC HELP - INTERMITTENT FAULT ...................... 04-122
BASIC SERVICE PROCEDURE.............................................. 04-124
DIAGNOSTIC SYSTEM ........................................................... 04-130
READING AND ERASING DIAGNOSTIC TROUBLE
CODE (DTC) ............................................................................ 04-132
CAPTURING DATA ................................................................. 04-134
DATA STREAM LIST/ACTIVE TEST....................................... 04-135
DIAGNOSTIC TROUBLE CODE CHART ................................ 04-138
P0100 - AIR MASS SIGNAL CUTOFFOR SHORT CIRCUIT
TO EITHER BATTERY OR GROUND ..................................... 04-153
P0101 - AIR MASS SIGNAL RANGE CHECK ERROR ........... 04-153
P0102 - AIR MASS RATIO IS LOWER THRESHOLD LOW ... 04-153
P0103 - AIR MASS RATIO IS HIGHER THRESHOLD HIGH .. 04-153
P0117 - COOLANT TEMPERATURE SENSOR VOLTAGE
BELOW LOWER LIMIT............................................................ 04-160
P0118 - COOLANT TEMPERATURE SENSOR VOLTAGE
ABOVE UPPER LIMIT ............................................................. 04-160
P0340 - NO CAMSHAFT SIGNAL ........................................... 04-165
P0341 - WRONG CAMSHAFT SIGNAL .................................. 04-165
P0192 - RAIL PRESSURE VOLTAGE BELOW
LOWER LIMIT.......................................................................... 04-170
P0193 - RAIL PRESSURE VOLTAGE ABOVE UPPER
LIMIT ........................................................................................ 04-170
P0201 - INJECTOR 1 OPEN LOAD......................................... 04-175
P0261 - INJECTOR 1 SHORT CIRCUIT LOW SIDE
TO HIGH SIDE......................................................................... 04-175
P0262 - INJECTOR 1 SHORT CIRCUIT ON LOW SIDE
TO BATTERY........................................................................... 04-175
P0401 - EGR NEGATIVE GOVERNOR DEVIATION
BELOW LIMIT .......................................................................... 04-180
P0402 - EGR POSITIVE GOVERNOR DEVIATION
ABOVE LIMIT........................................................................... 04-180
P0122 - ACCELERATOR PEDAL 1 VOLTAGE
P2135 - ACCELERATOR PEDAL 1 PLAUSIBILITY WITH
APP2 VIOLATED ..................................................................... 04-186
LIST OF SYMPTOM OF FAILURE .......................................... 04-195
DIESEL ENGINE SYMPTOM DIAGNOSIS AND TESTS ........ 04-200
ANTI-LOCK BRAKE SYSTEM....................................................... 04-217
PRECAUTION.......................................................................... 04-217
LOCATION............................................................................... 04-218
ABS MODULE CONNECTOR ................................................. 04-219
PROBLEM SYMPTOMS TABLE.............................................. 04-222
PRE - CHECK .......................................................................... 04-223
C0200 - FRONT WHEEL SPEED SENSOR RH
MALFUNCTION ....................................................................... 04-225
C0205 - FRONT WHEEL SPEED SENSOR
LH MALFUCTION ................................................................... 04-230
C0210 - REAR WHEEL SPEED SENSOR RH
MALFUCTION.......................................................................... 04-235
C0215 - REAR WHEEL SPEED SENSOR LH
MALFUCTION.......................................................................... 04-235
C0278 - THE MAIN RELAY ELECTRICAL
RESISTANCE EXCEEDS LIMIT OR FUSE IS
BLOWN IN THE KL30 CIRCUIT .............................................. 04-240
C1249 - OPEN CIRCUIT IN STOP LAMP SWITCH
CIRCUIT(WITH 4G63/4G64 ENGINE)..................................... 04-243
C1249 - OPEN CIRCUIT IN STOP LAMP SWITCH
CIRCUIT(WITH BJ493ZQ3 ENGINE) ...................................... 04-248
C1251 - PUMP MOTOR MALFUNCTION................................ 04-253
ABS WARNING LIGHT IS ALWAYS ON ................................. 04-256 04
ABS WARNING LIGHT IS INOPERATIVE .............................. 04-256
EBD WARNING LIGHT IS ALWAYS ON ................................. 04-258
EBD WARNING LIGHT IS INOPERATIVE .............................. 04-258
SUPPLEMENTAL RESTRAINT SYSTEM ..................................... 04-260
PRECAUTION.......................................................................... 04-260
LOCATION............................................................................... 04-261
RESTRAINT CONTROL MODULE CONNECTOR.................. 04-262 04
PRECHECK ............................................................................. 04-265
$9203 - BATTERY VOLTAGE LOW ........................................ 04-267
$9204 - DRIVER AIRBAG FAULT - LOW RESISTANCE ........ 04-271
$9205 - DRIVER AIRBAG FAULT - HIGH RESISTANCE ....... 04-271
$9206 - DRIVER AIRBAG CIRCUIT SHORT TO GROUND.... 04-274
$9207 - DRIVER AIRBAG CIRCUIT SHORT TO BATTERY ... 04-277
SRS WARNING LIGHT IS ALWAYS ON ................................. 04-280
SRS WARNING LIGHT IS INOPERATIVE .............................. 04-280
REVERSE RADAR SYSTEM ......................................................... 04-283
PRECAUTION.......................................................................... 04-283
LOCATION............................................................................... 04-284
SYSTEM DESCRIPTION......................................................... 04-285
REVERSE RADAR SYSTEM IS INOPERATIVE AT ALL ........ 04-290
SELF-CHECK FUNCTION IS INOPERATIVE ......................... 04-294
REVERSE RADAR SYSTEM IS OPERATIVE WHEN THE
SHIFT LEVER IS OUT OF REVERSE POSITION................... 04-296
REVERSE RADAR SYSTEM IS INOPERATIVE WITHIN
SPECIFIED DISTANCE ........................................................... 04-298
REVERSE RADAR SYSTEM IS OPERATIVE BUT
THERE IS NO OBSTACLE BEHIND VEHICLE ....................... 04-300
BUZZER IS INOPERATIVE OR OPERATIVE INCORRECTLY
WITHIN SPECIFIED DISTANCE ............................................. 04-302
COMBINED DISPLAY IS INOPERATIVE WITHIN SPECIFIED
DISTANCE ............................................................................... 04-304
POWER WINDOWS ....................................................................... 04-306
PRECAUTION.......................................................................... 04-306
LOCATION............................................................................... 04-307
TERMINALS OF MAIN POWER WINDOW AND DOOR
LOCK/UNLOCK SWITCH ........................................................ 04-308
TERMINALS OF CENTRAL DOOR LOCK CONTROLLER..... 04-309
BASIC INSPECTION ............................................................... 04-310
ALL POWER WINDOWS ARE INOPERATIVE ....................... 04-314
FRONT POWER WINDOW LH IS INOPERATIVE .................. 04-328
FRONT POWER WINDOW LH DOES NOT OPEN................. 04-331
FRONT POWER WINDOW LH DOES NOT CLOSE............... 04-334
FRONT POWER WINDOW RH IS INOPERATIVE.................. 04-337
FRONT WINDOW RH IS INOPERATIVE (USING THE FRONT
POWER WINDOW SWITCH RH) ............................................ 04-340
OUTSIDE MIRROR ........................................................................ 04-345
LOCATION............................................................................... 04-345
TERMINALS OF OUTSIDE MIRROR DEFROST SWITCH..... 04-346
MIRRORS ARE INOPERATIVE (BOTH SIDES) ..................... 04-349
A SINGLE MIRROR IS INOPERATIVE ................................... 04-352
MIRROR ADJUSTMENT UP/DOWN IS INOPERATIVE ......... 04-354
MIRROR ADJUSTMENT LEFT/RIGHT IS INOPERATIVE ...... 04-356
POWER FOLDING IS INOPERATIVE ..................................... 04-358
MIRROR HEATING IS INOPERATIVE .................................... 04-360
POWER DOOR LOCKS ................................................................. 04-364
PRECAUTION.......................................................................... 04-364
LOCATION............................................................................... 04-365
TERMINALS OF CENTRAL DOOR LOCK CONTROLLER..... 04-366
THE FUNCTION OF POWER DOOR
LOCKS IS INOPERATIVE ....................................................... 04-369
ONE DOOR IS INOPERATIVE ................................................ 04-379
IGNITION KEY POSITION REMIND
CONTROLLER IS INOPERATIVE ........................................... 04-382
SLIDING ROOF SYSTEM .............................................................. 04-391
LOCATION............................................................................... 04-391
SYSTEM DESCRIPTION ......................................................... 04-392
TERMINALS OF MAIN COMPONENTS.................................. 04-393
SLIDING ROOF SYSTEM IS INOPERATIVE .......................... 04-396
SLIDING ROOF DOES NOT OPEN OR OPEN
INCORRECTLY (CLOSE IS NORMAL) ................................... 04-402
SLIDING ROOF DOES NOT CLOSE OR CLOSE
INCORRECTLY (OPEN IS NORMAL) ..................................... 04-406
SLIDING ROOF STOPS OPERATION HALFWAY.................. 04-410
WIPER AND WASHER .................................................................. 04-412
PRECAUTION.......................................................................... 04-412
LOCATION............................................................................... 04-413
WIPERS ARE INOPERATIVE - WINDSHIELD........................ 04-419
WIPERS ARE INOPERATIVE AT LOW SPEED -
WINDSHIELD........................................................................... 04-424
WIPERS ARE INOPERATIVE AT HIGH SPEED -
WINDSHIELD........................................................................... 04-427
WIPERS ARE INOPERATIVE IN INTERMITTENT
MODE - WINDSHIELD............................................................. 04-430
WASHER PUMP IS INOPERATIVE - WINDSHIELD............... 04-433
WHEN THE WIPER SWITCH IS OFF, THE WIPER BLADE
DOES NOT RETRACT ............................................................ 04-436
WIPER IS INOPERATIVE - REAR WINDOW .......................... 04-439
WIPER IS INOPERATIVE IN INTERMITTENT MODE - REAR
WINDOW ................................................................................. 04-445
WASHER PUMP IS INOPERATIVE - REAR WINDOW .......... 04-449
REAR WINDOW DEFROSTER SYSTEM ...................................... 04-452
LOCATION............................................................................... 04-452
DEFROSTER SYSTEM IS INOPERATIVE.............................. 04-456
HEATER AND AIR CONDITIONING SYSTEM.............................. 04-464 04
PRECAUTION.......................................................................... 04-464
LOCATION............................................................................... 04-466
A/C SYSTEM IS INOPERATIVE.............................................. 04-473
AIR FLOW CONTROL: FRONT BLOWER MOTOR
IS INOPERATIVE ................................................................... 04-479 04
AIR FLOW CONTROL: REAR EVAPORATOR MOTORS
ARE INOPERATIVE................................................................. 04-483
AIR FLOW CONTROL: FRONT AIR FLOW IS
INSUFFICIENT ....................................................................... 04-488
AIR FLOW CONTROL: REAR AIR FLOW IS
INSUFFICIENT ........................................................................ 04-491
TEMPERATURE CONTROL: TEMPERATURE
CONTROL IS INOPERATIVE .................................................. 04-494
WARM AIR FLOW CONTROL: NO WARM AIR
COMES OUT ........................................................................... 04-501
WARM AIR FLOW CONTROL: WARM AIR COMES
OUT RARELY .......................................................................... 04-508
A/C SYSTEM IS INOPERATE ................................................. 04-515
AIR FLOW CONTROL: FRONT BLOWER MOTOR
IS INOPERATIVE ................................................................... 04-518
AIR FLOW CONTROL: REAR EVAPORATOR MOTORS
ARE INOPERATIVE................................................................. 04-523
AIR FLOW CONTROL: FRONT AIR FLOW IS
INSUFFICIENT ....................................................................... 04-528
AIR FLOW CONTROL: REAR AIR FLOW IS
INSUFFICIENT ....................................................................... 04-531
TEMPERATURE CONTROL: TEMPERATURE
CONTROL IS INOPERATIVE .................................................. 04-534
WARM AIR FLOW CONTROL: NO WARM AIR
COMES OUT ........................................................................... 04-539
WARM AIR FLOW CONTROL: WARM AIR COMES
OUT RARELY .......................................................................... 04-546
HORN SYSTEM.............................................................................. 04-550
LOCATION............................................................................... 04-550
HORN IS INOPERATIVE ......................................................... 04-552
HORN IS ALWAYS ON............................................................ 04-558
ALT HORN IS INOPERATIVE ................................................. 04-561
BASS HORN IS INOPERATIVE ............................................. 04-563
AUDIO SYSTEM............................................................................. 04-565
PRECAUTION.......................................................................... 04-565
LOCATION............................................................................... 04-568
TERMINALS OF RADIO UNIT................................................. 04-569
THE AUDIO SYSTEM IS INOPERATIVE ................................ 04-574
NO SOUND IS HEARD FROM SPEAKER IN ALL MODES .... 04-578
SOUND QUALITY IS POOR IN ALL MODES.......................... 04-582
VOLUME IS TOO LOW IN ALL MODES ................................. 04-584
SOUND QUALITY IS POOR ONLY WHEN
PLAYING CD/DVD................................................................... 04-588
RADIO BROADCASTING SIGNAL CAN NOT BE RECEIVED.
(POOR RECEPTION) .............................................................. 04-589
CD/DVD CAN NOT BE INSERTED OR CD/DVD IS EJECTED
RIGHT NOW AFTER BEING INSERTED ................................ 04-598
CD/DVD SOUND SKIPS.......................................................... 04-600
LIGHTING SYSTEM ....................................................................... 04-601
PRECAUTION.......................................................................... 04-601
LOCATION............................................................................... 04-603
LO-BEAM HEADLAMP IS INOPERATIVE (ONE SIDE) .......... 04-611
LO-BEAM HEADLAMPS ARE INOPERATIVE
(BOTH SIDES) ......................................................................... 04-615
HI-BEAM HEADLAMP IS INOPERATIVE
(ONE SIDE)............................................................................. 04-618
HI-BEAM HEADLAMPS ARE INOPERATIVE
(BOTH SIDES) ........................................................................ 04-622
LO-BEAM AND HI-BEAM HEADLAMPS ARE INOPERATIVE
(ONE SIDE).............................................................................. 04-625
LO-BEAM AND HI-BEAM HEADLAMPS ARE INOPERATIVE (BOTH
SIDES) ..................................................................................... 04-628
FRONT FOG LAMP IS INOPERATIVE (ONE SIDE) ............... 04-633
FRONT FOG LAMPS ARE INOPERATIVE (BOTH SIDES) .... 04-635
FRONT FOG LAMPS ARE ALWAYS ON ................................ 04-640
REAR FOG LAMP IS INOPERATIVE (ONE SIDE) ................. 04-643
REAR FOG LAMPS ARE INOPERATIVE (BOTH SIDES) ...... 04-645
REAR FOG LAMPS ARE ALWAYS ON .................................. 04-652
HAZARD WARNING LAMPS ARE INOPERATIVE
(TURN SIGNAL LAMPS ARE NORMAL)................................ 04-654
TURN SIGNAL LAMPS ARE INOPERATIVE
(HAZARD WARNING LAMPS ARE NORMAL)....................... 04-658
HAZARD WARNING AND TURN SIGNAL LAMPS ARE
INOPERATIVE ......................................................................... 04-662
TURN SIGNAL LAMP IS INOPERATIVE (ONE SIDE) ............ 04-668
HAZARD WARNING LAMPS ARE ALWAYS ON .................... 04-670
STOP LAMPS ARE INOPERATIVE (BOTH SIDES) -
WITH 4G63/4G64 ENGINE...................................................... 04-672
STOP LAMP IS INOPERATIVE (ONE SIDE) -
WITH 4G63/ 4G64 ENGINE..................................................... 04-675
HIGH-MOUNTED STOP LAMP IS INOPERATIVE -
WITH 4G63/4G64 ENGINE...................................................... 04-677
STOP LAMPS ARE INOPERATIVE (BOTH SIDES) -
WITH BJ493ZQ3 ENGINE ...................................................... 04-679
STOP LAMP IS INOPERATIVE (ONE SIDE) -
WITH BJ493ZQ3 ENGINE ....................................................... 04-683
HIGH-MOUNTED STOP LAMP IS INOPERATIVE -
WITH BJ493ZQ3 ENGINE ....................................................... 04-685
BACK-UP LAMP IS INOPERATIVE (ONE SIDE) -
WITH 4G63/4G64 ENGINE...................................................... 04-687
BACK-UP LAMPS ARE INOPERATIVE (BOTH SIDES) -
WITH 4G63/4G64 ENGINE..................................................... 04-689
BACK-UP LAMP IS INOPERATIVE (ONE SIDE) -
WITH BJ493ZQ3 ENGINE ...................................................... 04-692
BACK-UP LAMPS ARE INOPERATIVE (BOTH SIDES) -
WITH BJ493ZQ3 ENGINE ....................................................... 04-694 04
FRONT INDOOR LAMP IS INOPERATIVE ............................. 04-697
REAR INDOOR LAMP IS INOPERATIVE ............................... 04-700
SLIDING DOOR STEP LAMPS ARE INOPERATIVE.............. 04-703
CARGO LAMP IS INOPERATIVE............................................ 04-705
INSTRUMENT CLUSTER ILLUMINATION
IS INOPERATIVE ................................................................... 04-707
ELECTRONIC CLOCK ILLUMINATION IS INOPERATIVE..... 04-710 04
HAZARD SWITCH ILLUMINATION IS INOPERATIVE ........... 04-713
12V POWER POINT SOCKET ILLUMINATION IS
INOPERATIVE ......................................................................... 04-716
CIGARETTE LIGHTER ILLUMINATION IS INOPERATIVE .... 04-719
FRONT A/C CONTROLLER ILLUMINATION
IS INOPERATIVE ................................................................... 04-722
AUDIO ILLUMINATION IS INOPERATIVE .............................. 04-725
REAR FOG LAMP SWITCH ILLUMINATION IS
INOPERATIVE ........................................................................ 04-728
OUTSIDE MIRROR DEFROST SWITCH
ILLUMINATION IS INOPERATIVE ......................................... 04-731
COMBINED DISPLAY ILLUMINATION IS INOPERATIVE...... 04-734
REAR WINDOW DEFROST SWITCH ILLUMINATION IS
INOPERATIVE ........................................................................ 04-737
REAR HEATER SWITCH (FRONT CONTROL) ILLUMINATION IS
INOPERATIVE ......................................................................... 04-740
REAR HEATER SWITCH (REAR CONTROL) ILLUMINATION
IS INOPERATIVE ................................................................... 04-743
REAR HEATER CONTROL PANEL ILLUMINATION IS
INOPERATIVE ......................................................................... 04-746
REAR A/C SWITCH (FRONT CONTROL) ILLUMINATION IS INOP-
ERATIVE.................................................................................. 04-749
FRONT PARKING LAMPS ARE INOPERATIVE..................... 04-752
TAIL LAMPS ARE INOPERATIVE........................................... 04-754
LICENSE LAMP IS INOPERATIVE ......................................... 04-756
PARKING LAMPS, TAIL LAMPS AND LICENSE LAMP
ARE INOPERATIVE................................................................. 04-758
INSTRUMENT CLUSTER .............................................................. 04-763
PRECAUTION.......................................................................... 04-763
LOCATION............................................................................... 04-764
INSTRUMENT CLUSTER INFORMATION.............................. 04-765
TERMINALS OF INSTRUMENT CLUSTER ............................ 04-768
THE INSTRUMENT CLUSTER IS INOPERATIVE .................. 04-776
MALFUNCTIN IN SPEEDOMETER......................................... 04-779
MALFUNCTION IN TACHOMETER ........................................ 04-782
MALFUNCTION IN FUEL GAUGE .......................................... 04-785
ENGINE COOLANT TEMPERATURE WARNING
LIGHT NEVER/ALWAYS ON................................................... 04-788
ENGINE COOLANT TEMPERATURE INDICATOR
LIGHT NEVER ON................................................................... 04-793
BRAKE WARNING LIGHT NEVER/ALWAYS ON ................... 04-796
ENGING OIL PRESSURE WARNING LIGHT
NEVER/ALWAYS ON .............................................................. 04-800
SEAT BELT WARNING LIGHT NEVER/ALWAYS ON ............ 04-804
DOOR AJAR WARNING LIGHT NEVER/ALWAYS ON .......... 04-808
COMBINED DISPLAY.................................................................... 04-814
PRECAUTION.......................................................................... 04-814
LOCATION............................................................................... 04-815
TERMINALS OF COMBINED DISPLAY .................................. 04-817
COMBINED DISPLAY IS INOPERATIVE ................................ 04-820
IN-VEHICLE TEMPERATURE DOES NOT DISPLAY OR
DISPLAY INCORRECTLY ....................................................... 04-823
REVERSE DATA DOES NOT DISPLAY OR DISPLAY
INCORRECTLY ....................................................................... 04-826
DIAGNOSTICS - GASOLINE ENGINE CONTROL SYSTEM 04-1
GASOLINE ENGINE CONTROL SYSTEM

DIAGNOSTICS
PRECAUTION
1. POWER OFF. 04
• The battery negative cable must be disconnected first before removing or installing any electric
appliance and when tools or facilities will touch the exposed terminals. It should be connected
eventually. This will prevent person injured and vehicle damaged.
• The ignition switch must be OFF without any special descriptions.
WARNING
The ignition and illuminatioin switches must be OFF before disconnecting or connecting the battery 04
negative cable (the semiconductor maybe damaged without doing that).
CAUTION
Do not leave the key in the vehicle in case the doores are locked before disconnecting the battery negative
cable for the vehicle equipped with remote control central lock.
2. RESET THE ODOMETER AND CLOCK IF DISCONNECTING THE COMBINATION INSTRUMENT
BATTERY NEGATIVE CABLE.
CAUTION
The total course will not be reset.
3. THE SAVING DATA SETTING WILL LOST IF DISCONNECTING THE BATTER NEGATIVE CABLE.
CAUTION
After connecting the battery negative cable, the audio system shoud be reset.
4. EXPRESSIONS OF IGNITION SWITCH.
Switch Type Ignition Switch (position) Ignition Switch (condition)

Ignition switch off LOCK Off
Ignition switch on (ACC) ACC On (ACC)

Expression
Ignition switch on (IG) ON On (IG)
Engine start START Start
5. PRECAUTIONS FOR OVERHAULING THE ENGINE CONTROL SYSTEM FAILURE.

(a) Do not disconnect power circuit while engine is running at high speed in case the instantaneous over-
voltage damage the ECM and sensors.
(b) The ECM should be disconnected when welding on the vehicle body. It is special attention that perform-
ing the repair work beside the ECM or sensors.
(c) The system will resume its normal state temporarily or competely by removing and reinstalling the sus-
picious faulty components when the connector terminals or the installing state of the components go
out of order.
(d) The high impedance type multimeter should be used to the test except the especial description of the
procedure in place of the traditional analogue types multimeter.
(e) Don’t check any electric appliance connecting the ECM with a test light.
(f) Never connect the negative and positive battery cables wrong. The battery negative cable must be
grounded.
(g) ECM and sensors must be kept from moisture. No permission damaging the seal device of ECM and
sensors and washing them more.
(h) Prevent human body static electricity from damaging ECM: The operator body must be grounded when
operator checks ECM or replace chips.
04-2 DIAGNOSTICS - GASOLINE ENGINE CONTROL SYSTEM
(i) In order to identifying the faulty position, we must check the vehicle condition while vehicle goes out of
order. For example, we check the faults through the DTC. We record these faults states before
disconnecting every connector or removing and installing components.
(j) We must remove and install ECM, actuators and independent sensors when the ignition switch is OFF
unless there is additional specification in the checking procedure.
(k) If the removed and installed ECM, actuators and sensors are to be reinstalled, the system should be
checked after completing installation. Using the special diagnosis tool to check DTC.
(l) Check the ECM connector terminals with a multimeter.
• Connect the small probing pin to the probe of a multimeter.
• Check voltage value of terminals referring to the inspection sheet by back probing ECM connectors
terminals.
(m) When diagnosis, the ignition switch turns “ON” and the connectors are disconnected. DTC of the other
system will be set. After diagnosis, confirm DTC in all systems.Turn the ignition switch “LOCK” when
the connectors are connected and disconnected.
(n) The test probe must not be probed in wire harness. This will reduce the waterproofness. And it also
cause corrossion. Using the test wire, wire connector, measure wire harness and so on.
(o) Check the common connectors when they are in connection status by probing terminals in the wire
harness. If the connector is too small to check, do not force inserting.
(p) If check the common connectors when they are not in connection status (check male connectors):
• Do not short terminals circuit by using a probe. This will damage the interior circuit in ECM.
• The system to be checked and other system will store DTC when they aren’t in connecting status.
(q) If check the common connectors when they are not in connection status (check female connectors):
• Use the special tools to check wire harness.
(r) We shall have a short harness or connectors without taking cautions by wrong insertion. This will dam-
age wire harness, sensor, ECM and other components So we must carefully handle when checking.
(s) Do not check with the list order.
• If the check results are different from the standard value, then check related sensors, actuators and
wire harness. Repair or replace if necessary.
• Check with the voltage meter again after repairing or replacing. Confirm if the faults have been
eliminated.
(t) Check resistance and continuity between terminals of ECM with multimeter.
• Ignition switch: OFF
• Disconnect ECM harness connector.
(u) Ground inspection.
• Ground connections are very important to the proper operation of electrical and electronic circuits.
Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion
(rust) can become an unwanted resistance. This unwanted resistance can change the way a circuit
works.
• Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can
drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the
circuit. Even when the ground connection looks clean, there can be a thin film of rust on the surface.
• When inspecting a ground connection follow these rules:
04
04
1 Remove Bolt (Screw) 3 Reinstall Bolt (Screw) Securely
Inspect Mating Surface For Tarnish, Dirt,

2 Rust, Etc. Clear As Required To Assure
Good Contact.
(a) Remove the ground bolt or screw.

(b) Inspect all mating surfaces for tarnish, dirt, rust, etc.
(c) Clean as required to assure good contact.
(d) Reinstall bolt or screw securely.
(e) Inspect for “add-on” accessories which may be interfering with the ground circuit.
(f) If several wires are crimped into one ground eyelet terminal, check for improper crimps. Make sure all
of the wires are clean, securely fastened and providing a good ground path. If multiple wires are cased
in one eyelet, make sure no ground wires have excess wire insulation.
LOCATION
1 ECM 2 MAP/IAT Sensor

04
04
1 Injector 5 ECT Sensor
2 Throttle Body 6 Knock Sensor
3 Plug 7 CKP Sensor
4 Idle Air Control Motor 8 Odemerter Sensor

1 DLC 5 Accelerator Pedal
2 Brake Pedal 6 Ignition Switch
3 Body Junction Box 7 Steering Column
4 Instrument Cluster
HOW TO DIAGNOSTICS ANALYSE

NOTE
Use diagnostic scan tool to diagnose vehicle.
04
1. VEHICLE INTO REPAIR SHOP
YES > Go to next step.

2. COLLECT AND ANALYSE CUSTOMER’S SYMPTOM

04
3. CONNECT THE DIAGNOSTIC SCANNER TO DLC3

4. CHECK DTC AND DATA FREEZE-FRAME DATA

5. ERASE DTC

6. VISUAL CHECK

7. CONFIRM FAULT SYMPTOM
Check result (if engine can not start,check following first)
Result Proceed To
Fault present Step 9
Normal Step 8
8. SIMULATE FAULT SYMPTOM

9. CHECK IF DTC PRESENT
Check result
Result Proceed To
DTC present Next step
Normal Step 11
10. REFER TO DTC TABLE
YES > Go to step 13.

11. BASIC CHECK
Check result
Result Proceed To
Fault can not be confirmed Next step
Fault can be confirmed Step 16
12. REFER TO SYMPTOM TABLE
Check result
Result Proceed To
Fault can be confirmed circuit Next step
Fault can be confirmed part Step 15
13. CHECK ECM POWER SUPPLY CIRCUIT

14. CHECK ELECTRIC CIRCUIT
Check result
Result Proceed To
15. CHECK INTERMITTENT FAULT

16. CHECK PARTS

17. CONFIRM FAULT

18. ADJUST OR REPAIR

19. PERFORM CONFIRMATION TEST
YES > END.

THE MAIN POINTS OF REPAIRING BURNED FUSE OUT

CAUTION
DTC cause by burned fuse.
04
1. Remove the burned fuse. Check the resistance
between the load side and ground where the fuse
burned. Turn off all the switch that connecting to the
fuse. If the resistance is almost zero, the switch and
the load components circuit must be shorted
somewhere. If the resistance is not zero, there is no 04
circuit for short. But the temporaly shorted circuit
also will cause the fuse burning.
2. The shortage caused by following:
• Clipped harness
• Damaged harness
• Water seep into connection
• Operation
1 Battery
2 Fuse
3 Load switch
4 Burned fuse
5 Short position
DIAGNOSTIC HELP - INTERMITTENT FAULT

If an intermittent fault exists, perform diagnosis as follow:
CAUTION
• Intermittent incidents may occur. In many cases, the malfunction resolves itself (the part or
circuit function returns to normal without intervention). It is important to realize that the
symptoms described in the customer's complaint often do not recur on (1st trip) DTC visits.
Realize also that the most frequent cause of intermittent incidents occurrences is poor
electrical connections. Because of this, the conditions under which the incident occurred may
not be clear. Therefore, circuit checks made as part of the standard diagnostic procedure may
not indicate the specific malfunctioning area.
• In this case, the maintenance staff must find out the situation in detail from the customer, ask
the car owner for the details of driving conditions, weather conditions, frequency of occurrence
and symptom of failure, take analysis and simulate the same or similar conditions and
environment, then, determine if the symptom of failure is caused by vibration, temperature or
other factors. No matter how experienced the maintenance staff are, how skilled their technique
is, if analyzing the failure without checking, they would certainly neglect some important factors
during repairing which causes wrong speculation and the repair work will take an indirect route
or can’t go forward. The following checking will help to find out this kind of failure.
1. VIBRATION METHOD.
• Connector: Shake the connector lightly in vertical or

horizontal directions, check if the wiring harness
connector connecting the connector and corresponding
parts is loose, the terminal is dirty, rusty, worn or bended
and if the connection is loose because of the terminal
extension.
• Harness: Shake the harness lightly in vertical or
horizontal directions, thoroughly check the harness
breakaway condition in the connector connecting
vibration section and engine/cab instruments.
• Relay, part and sensor: Pat the sensor, relay and part
considered as the failure cause lightly with hands, check
them for failure, don't hit the relay with force, otherwise
the relay may be open.
2. HEATING METHOD.
If one doubtful region is considered to cause a failure, heat the part which is the most possible cause of failure
with an electric blower or the like to check if the failure occurs.
CAUTION 04
Don’t heat to over 60 ℃ (the heating temperature should be in the limit of touching the part with hands);
don’t heat the control module.
3. SPRAYING METHOD.
If the failure is considered to occur in rainy day or wet weather, spray water to the vehicle to check if the failure
occurs.
04
CAUTION
• Don’t spray water to the engine directly to cool the engine, sprinkle water on the front face of
radiator to change the temperature and humidity indirectly.
• Don’t spray water on electronic parts directly.
• Please take extra care to sprinkle water on vehicle leaking water.
4. ELECTRIC APPLIANCE CONNECTED FULLY METHOD.
If the failure is possible to be caused by electric overload, connect all electrical loads, including the heater
blower, the headlamps and the rear-window defroster, to check if the failure occurs. The trouble location or
failure part must be found out while the symptom is confirmed during the failure symptom simulation test. To do
this, narrow the range of circuit which is possible to failure based on the symptom of failure before starting the
test and the pre-connection of connectors, then carry out the symptom simulation test and judge if the circuit
tested is normal. When a puzzling failure occurs, make full use of troubleshooting and diagnostic code list for
fault analysis and diagnosis to narrow the failure range and find out the trouble location quickly. This method is
very practical and effective.
5. DATA FLOW CAPTURE WITH DIAGNOSTIC SCANNER.
Use the function of data flow capture on the diagnostic scanner. When seeing the data flow on the diagnostic
scanner, make the rated data status to simulate the fault conditions based on the freeze-frame on the
diagnostic scanner.
6. OSCILLOSCOPE METHOD.
• Using the oscilloscope to capture waveform can be more helpful to find intermittent malfunction.
• The oscilloscope analyzer can collect the waveforms of ignition, injection and electrical control system
sensors, diagnose if the sensor fails or not correctly by analyzing the sensor waveforms, and diagnose
the failures of sparking-plug, high voltage wire and ignition coil of ignition system. It can also analyze
the possible fault points of the air intake and exhaust system and the fuel system.
• Generally, there is no method to replace the ones to view the known normal parameters of vehicle. Only
by knowing which parameter is the normal, can it be picked out as problematic or abnormal one.
• If you apply the known injection nozzle waveforms in the waveform testing of other magnetic valves,
their overall waveforms are very similar.
7. OTHER METHODS.
Before replacing ECM of other electronic control modules in part replacing method, take full diagnosis for other
external causes; ECM or other electronic control modules are expensive products with high reliability.
CAUTION
When replacing and testing possible damaged ECM or control modules, install the possible damaged
ECM or control modules on a failure-free vehicle for testing; Don’t install new control modules on a
failed vehicle for testing to avoid damaging the control modules.
BASIC SERVICE PROCEDURE

1. CHECK BATTERY VOLTAGE
CAUTION
Check when engine stops or ignition switch is OFF.
Check result
Result Proceed To
More than 11V Next step
Less than 11V Charge or change battery
2. CHECK IF THE ENGINE STARTS
Is the check result normal?

NO > Go to fault symptom chart.
3. CHECK FILTER

NO > Replace or clean filter.
4. CHECK IDLE SPEED

NO > Go to fault symptom chart.
5. CHECK FUEL PRESSURE

NO > Eliminate fuel pressure fault, and go to next step.
6. CHECK IGNITION

YES > Go to fault symptom chart.
NO > Eliminate ignition system fault.
13.
ECM TERMINAL DIAGRAM (ECM SIDE)
04
04
CHECK ECM TERMINAL WITH MULTIMETER

CAUTION
The normal standard voltage of per terminal as follow “normal condition”. The table also points out the
check condition.
Terminal No. Terminal Description Detection Condition Specified Condition

55 No.1 Injector
70 No.2 Injector
Idle: depress accelerator suddenly Voltage: 11 ～ 14 V
56 No.3 Injector
71 No.4 Injector
54 Idle air control motor loop A
53 Idle air control motor loop B Engine: warm condition, start

engine Voltage: 0 ～ 3 V
33 Idle air control motor loop C
34 Idle air control motor loop D
Ignition switch: ON Battery voltage

47 Pump relay
Engine: idle 0～3V
Ignition switch: ON Battery voltage

63 EVAP solenoid
Engine: warm condition, 3000 RPM 0～3V
32 Ignition control: (1 - 4) Engine: 3000 RPM 0.3 ～ 3.0 V
52 Ignition control: (2 - 3) Engine: 3000 RPM 0.3 ～ 3.0 V


17
Continuity power supply Ignition switch: OFF Battery voltage
18
39 A/C request signal Engine running, depress A/C switch -
46 A/C feed back signal Engine running, depress A/C switch -
31 MIL Ignition switch: OFF → ON 0～3V
Ignition switch: OFF Battery voltage

58 Main relay
Ignition switch: ON 0～3V
Heated upstream oxygen Engine: warm condition, idle 0～3V

61
sensor
Engine: 5000 RPM Battery voltage
Heated downstream oxyge Engine: warm condition, idle 0～3V

64
sensor
Engine: 5000 RPM Battery voltage
IAT: 0 ℃ 3.2 ～ 3.8 V
IAT: 20 ℃ 2.3 ～ 2.9 V

27 IAT sensor Ignition switch: ON
IAT: 40 ℃ 1.5 ～ 2.1 V
IAT: 80 ℃ 0.4 ～ 1.0 V
38 Upstream oxygen sensor Engine: warm condition, 2000 RPM 0.1 ～ 0.9 V
62 Downstream oxygen sensor Engine: warm condition, 2000 RPM About 100 mV
5 V standard sensor power

4 Ignition switch: ON 4.5 ～ 5.5 V
supply

20 Ignition switch: ON 4.5 ～ 5.5 V
supply
1 Ignition signal Ignition switch: ON Battery voltage
ECT: 20 ℃ 2.3 ～ 2.9 V
43 ECT sensor Ignition switch: ON ECT: 40 ℃ 1.3 ～ 1.9 V
ECT: 80 ℃ 0.3 ～ 0.9 V
TPS: idle 0.3 ～ 1.0 V (0 %)

24 TPS Ignition switch: ON
Open widely 4.5 ～ 5.5 V (100 %)
Ignition switch: ON
3 VSS 0 ～ 5 V (repeat)
Move forward slowly
Start motor 0.4 ～ 4.0 V

12 CKP sensor
Idle 1.5 ～ 2.5 V
73 Ground - 0V

5 - 0V
Ground
21 - 0V 04
11 Diagnostic signal K Ignition switch: ON Pulse signal
30 Diagnostic request Ignition switch: ON Pulse signal
ECM TERMINAL DEFINITION

04
Terminal No. Terminal Description Color Terminal No. Terminal Description Color
Downstream oxygen
1 Ignition signal G 38 L-W
sensor (high voltage)
2 - - 39 A/C request signal L-R
3 VSS W-G 40 - -

4 R 41 - -
supply
5 Sensor ground BR 42 MAP signal L-B
6 Oxygen sensor (low voltage) W 43 ECT signal Y-B
7 - - 44 - -
8 - - 45 Revolution signal Y-W
9 A/C press signal L 46 A/C feed back signal Y-L
10 - - 47 Pump control Y-R
11 Diagnostic communication K Y 48 - -
Revolution signal
12 G 49 - -
(high voltage)
13 - - 50 High fan control W-Y
14 - - 51 - -
15 - - 52 Ignition control (2, 3) W-L
Idle air control motor loop

16 - - 53 B-G
B
Continuity power supply (12 Idle air control motor loop

17 R-Y 54 B-Y
V) A
Continuity power supply (12

18 R-Y 55 Injector 1 GR
V)
19 - - 56 Injector 3 GR-W

20 G-B 57 - -
supply
21 Sensor ground BR-B 58 Main relay control LG
22 - - 59 - -
23 Fuel level signal R-B 60 - -

Terminal
Terminal Description Color Terminal No. Terminal Description Color
No.
Heated upstream oxygen
24 TPS signal R-G 61 P
sensor control
Upstream oxygen signal

25 - - 62 P-B
(high voltage)
26 - - 63 EVAP control G-O
Heated downstream
27 IAT signal R-B 64 V
oxygen sensor control
28 Revolution signal (low voltage) L 65 - -
29 Service lamp O 66 - -
30 Diagnostic request R-W 67 Low fan control V-W
31 MIL R-L 68 - -
32 Ignition control (1, 4) G-W 69 Knock signal P-L
33 Idle air control motor loop C G-R 70 Injector 2 GR-R
34 Idle air control motor loop D G-L 71 Injector 4 GR-B
35 Poor accelerator signal L-R 72 - -
36 - - 73 Ground -
37 - - 74 - -
CHECK ECM HARNESS-SIDE TERMINAL WITH A MULTIMETER

Standard normal resistance and continuity as follow:
No. Item Normal Condition (20 ℃ ) 04

1 No.1 injector
2 No.2 injector
13 ～ 16 Ω
3 No.3 injector
4 No.4 injector 04
5 Idle air control motor loop A, B terminal
28 ～ 33 Ω
6 Idle air control motor loop C, D terminal
7 EGR solenoid valve 36 ～ 44 Ω
8 EVAP solenoid valve 36 ～ 44 Ω
9 ECM ground Continuity
10 Heated oxygen sensor About 12 Ω
5.3 ～ 6.7 Ω
2.3 ～ 3.0 Ω
11 IAT sensor
1.0 ～ 1.5 Ω
0.30 ～ 0.42 Ω
5.1 ～ 6.5 Ω
2.1 ～ 2.7 Ω
12 ECT sensor
0.9 ～ 1.3 Ω
0.26 ～ 0.36 Ω
DIAGNOSTIC SYSTEM
(a) The failure of engine electric control system is divided
into 2 classes:
• First is lighting MIL lamp (1); When the instrument MIL
lamp lights, based on relevant requirements of national
rules, it needs to be treated immediately, otherwise the
system will limit the speed of the engine so as to affect the
normal operating of vehicle.
• The other is lighting SVS lamp (2), indicating that the
system fails and needs to be repaired in time.
• The failures of both classes should be checked with
diagnostic scanner or special equipment with
corresponding functions.
NOTE
The following matters should be noted during the engine running and service processes.
1. Turn the ignition switch ON before starting. wait for about 3 seconds. Observe whether the mil
indicates on instrument. If the preheat indicator turns on, start engine in 2 seconds after the
preheat indicator turns OFF.
2. The lighting of SVS lamp and MIL lamp is controlled by ECM; The special lighting of SVS lamp
and MIL lamp after and before starting are described below:
• For system without failure, the ignition switch is turned ON, the MIL lamp lights on, SVS lamp lights and
then goes out (system self-checking). The SVS lamp and MIL lamp are off after engine starting and
stalling.
• For system with failure, the ignition switch is turned ON, the MIL lamp lights on, the SVS lamp is off and
then lights on after self-checked; After engine starting, if the SVS lamp in failure class is defined as
lighting on mode, the SVS lamp will light on after the requirements for SVS lamp lighting are met; if the
MIL lamp in failure class is defined as lighting on mode, the SVS lamp will light on after the
requirements for MIL lamp lighting are met; After engine stalling, the ignition switch is turned OFF and
goes out after process (90s for the longest).
3. If an engine failure that may involve the fuel injection system-electronic controlled is to be
diagnosed and cleared, first determine if the failure is related with the fuel injection system-
electronic controlled. If the engine fails but the malfunction indicator lamp doesn't light, the failure
is unrelated to the electronic control system generally.
(b) The diagnostic trouble codes record and data related

with sensors and actuators in ECM can be read by
KT600 diagnostic scanner. Additional, the actuator can
be positive driven by the scan tool under specified
conditions.
(c) DLC- data link connector.

(d) ECM communicate with DLC.
(e) Terminals in DLC arrange according to standard.
04
Terminal No. Name Check Result
4 Ground Less than 1 Ω
Pulse signal (When

6 Diagnostic signal
commnicate) 04
Diagnostic Pulse signal (When
7
communication K commnicate)
16 Battery positive 9 ～ 14 V
NOTE
• Connect the diagnostic scanner cable to DLC. Turn
the ignition switch ON. Try to open it. If displayed
error communication on screen, then the diagnostic
scanner faults .
• If the diagnostic scanner communicates with other
vehicle normally, then check the DLC on the original
vehicle.
ENGINE CONTROL SYSTEM SELF-DIAGNOTIC ITEM

No. Check Item
1 Injector
2 Main Relay
3 Fuel Pump
4 Ignition Coil
5 Oxygen Sensor
6 EVAP Solenoid
7 Knock Sensor
8 Vehicle Speed Sensor
9 Poor Accelerator Sensor
10 CKP Sensor
11 Throttle Position Sensor
12 ECT Sensor
13 MAP/IAT Sensor
READING AND ERASING DIAGNOSTIC TROUBLE CODE (DTC)

NOTE
The troubles are tested and determined by the engine control system and stored in the Engine Control
Module (ECM); the system troubles can be current or history.
(a) Current troubles: Exist in ECM currently. For example: The circuit of Engine Coolant Temperature
(ECT) sensor is open. The current troubles must be repaired. Otherwise, they can’t be erased from
memory.
(b) History troubles: Have two storage types.
• The trouble has been repaired and actual trouble has disappeared, but the memory hasn’t been erased
from ECM.
• The trouble occurred once and didn’t exist, but it is possible to occur again. For example: Poor contact
of conducting wire. As the stored troubles are not current ones, it’s unnecessary to repair them before
erased from the memory, or it can be processed referring to the trouble-shooting methods for
intermittent malfunction.
CAUTION
• If the battery voltage is too low and the trouble code can’t be output normally from ECM, the
battery voltage must be tested before checking and the voltage should not be less than 11 V.
• When the battery or ECM connectors are disconnected, the trouble code stored in ECM will be
erased.
• Before connecting or disconnecting KT600 scan tool, be sure to confirm the ignition switch is in
OFF (LOCK) position.
CAUTION
• Using the KT600 collective intelligence scan tool, read DTC.
• Using the KT600 scan tool, perform the reading DTC procedure below:
(a) Check and confirm the following conditions:

• The throttle is closed.
• Turn A/C switch OFF.
• Shift transmission in neutral.
(b) Turn the ignition switch OFF.
(c) Connect the KT600 scan tool to the Data Link Connector
(DLC) - use the most current software available.
(d) Turn the ignition switch ON.
(e) Select the item “AUTO DIAGNOSIS\FOTON\LIGHT
BUS\MP-X MP\ENGINE\4G63 GASOLINE ENGINE OR
4G64 GASOLINE ENGINE\ MT20U2\READ DTC”.
(f) Check DTC and data stream. After recording, delete it (If
DTC cannot be deleted, then perform the diagnosis
procedure refering to “Diagnostics trouble code check”.
Repair faults ).
(g) Start engine and warm it to normal operating
temperature.
(h) Under one of the condition, run engine to MIL ON:
• Simulate DTC setting condition.
• Simulate the customer’s description.
• Simulate the scan tool freeze data.
(i) Use the scan tool to read the DTC in ECM.
(j) If there are DTCs, but the data stream is normal or the
function is good, then refer to the diagnostics help. If there
are DTCs, but the stream is abnormal or the function is not
good, then perform diagnosis procedure refering to 04
“Diagnostics trouble code chart”.
NOTE
• Use the scan tool to delete DTCs. As soon as DTC is detected, ECM will record the vehicle and
driving conditions as the type of freeze stream. When eliminating faults, the catching function
will help to confirm the condition of the fault, such as warm condition, stop condition and lean
or rich A/F ration and other data. 04
• DTC setting condition:
(a) Engine speed
(b) VSS
(c) ECT sensor
(d) MAP sensor
(e) Barometric sensor
(f) IAT sensor
(g) TPS
(h) EVAP
(i) Fuel pressure adjustment
(j) A/C switch
THE WAY OF CLEAR DTC

Using the scan tool, clear DTC:
(a) Turn the ignition switch OFF.
(b) Connect the KT600 scan tool to the Data Link Connector (DLC) - use the most current software
available.
(c) Turn the ignition switch ON.
(d) Select the item “AUTO DIAGNOSIS\FOTON\LIGHT BUS\MP-X MP\ENGINE\4G63 GASOLINE
ENGINE OR 4G64 GASOLINE ENGINE\MT20U2\CLEAR DTC”.
CAPTURING DATA
CAUTION
Once DTC is captured and stored, ECM records the vehicle and driving conditions information as a
form of rated data. During troubleshooting, the rated data can help determine if the vehicle was
running or parked, and data of other sensors and actuators has been recorded when the trouble
occurred.
CAUTION
If the DTC is detected but the trouble can’t reappear, confirm the freeze-frame rated data. ECM records
the engine condition in form of freeze-frame data at regular intervals. The diagnostic scanner can be
used to read several sets of freeze-frame data respectively. KT600 diagnostic scanner provides
powerful random data flow help function. Select read data flow function menu in engine system, enter
the data flow testing result display interface, click “?Help” button to eject the following windows:
• Driving Record Playback
• Calculator
• Data Range Reference
• Data Capture
• Data Comparisons
• Data Flow Settings
• Data/Waveform Display
• Driving Recorder Menu
• The data can be used to simulate the vehicle conditions as the failure occurs. It also can help determine
the cause of trouble and judge if it’s temporary fault. When the engine is running with trouble, select the
menu items: Auto Diagnosis\Foton(V03.20)\Light Bus\MP-X MP\Engine\4G63 Gasoline or 4G64
Gasoline\MT20U2\Read Data Flow (Click “?Help”)\Data Capture\Click Record\(Click “?Help”)\Data
Comparisons.
• Enter the data flow testing interface, click “?Help” button and enter the data flow help menu, select
“Data Capture” for data capturing function, the system will record all available data currently.
• After storing files, click “?Help” button, select “Data Comparisons” in help menu and the system calls
stored data files to do data comparisons.
• Enter data flow testing interface, click “Value\Waveform Display” in “?Help” function menu to eject the
“Value\Waveform Graphs”. This function displays the change rule of data flow value intuitively in form of
graphs so as to judge the troubles of automotive electric equipment.
FAIL-SAFE CHART
NOTE
When the DTC listed below is detected, the ECM enters fail-safe mode and the MIL lights up.
04
Number Item Control Contents Period Of Fault
• The MIL light will turn on.

• Unstable idle.
• Lack of engine power.
1 Injector
• Poor acceleration.
• Engine will not start. 04
• Plugged injector.

2 Relay • System is out of work.
• Can not start engine.

• Noisy fuel pump operation.
3 Fuel pump
• Engine will not start.

• Unstable idle.
4 Ignition coil
• Poor fuel economy.
• Excessive exhaust emissions.
• Weak spark.

5 Oxygen sensor • Excessive exhaust emissions.
• Sluggish acceleration.
• Poor driving capability.

• The engine base fuel closed-loop control self-learning will be shut off.
6 EVAP solenoid valve
• The engine idle air control self-learning will be shut off.
• Unstable idle or high idle.

• The engine produces an engine knock.
• Overheated engine.
7 KS • Excessive exhaust emissions.
• Internal engine damage.

• The engine RPM will be limited.
8 VSS
• No VSS diaplay.

9 IAT sensor
• The IAT is equal to ECT.
Number Item Control Contents Period Of Fault

• Misfire.
10 Poor accelerator sensor
• Rough engine operation.

• Engine is hard to start.
• The engine RPM will be limited after the engine starts.
• The highest RPM is less than 3800 RPM.
11 CKP sensor
• Excessive exhaust emissions.
• No ignition signal to the ECM.
• The tachometer does not work.
12 TPS

• Engine hard to start when cold.
• Engine hard to start when hot.
• If the sensor circuit is shorted to power, the engine will run under the
13 ECT sensor default values.
• The temperature gauge indicates too high.
• The temperature gauge indicates too low.
• The cooling fan operates continuously on high speed.
• The high temperature warning lamp will flash when the instrument
panel indicates low temperature.

14 MAP/IAT sensor
• Unstable idle.
DATA STREAM LIST/ACTIVE TEST

1. DATA STREAM LIST.
NOTE
04
• Through reading the data stream displayed on scan tool sreen, we can check the sensor,
actuator and switch data value but not removing any components. As the first step, this way is
the best way to short diagnosis period .
• The following arranged the data stream under the normal condition. It only offers to reference.
Don’t judge a component normal or not only depend on these value.
READ DATA STREAM PROCEDURE 04

(a) Start the engine and warm it to normal operating temperature.
(c) Connect the KT600 scan tool to the Data Link Connector (DLC) - use the most current software
available.
(e) Select the item “AUTO DIAGNOSIS\FOTON\LIGHT BUS\MP-X MP\ENGINE\4G63 GASOLINE ENGINE
OR 4G64 GASOLINE ENGINE\MT20U2\READ DATA STREAM”.
(f) The table below lists the data found in inspection items at different states by the KT600 in “DATA LIST”
items.
• If no concrete specification of idle condition, the shift selector lever is in neutral position. The A/C and
accessories switch are in the OFF position.
• Injector driving time means time is taken by crankshaft at speed of less than 250 RPM and power
supply voltage of 11 V.
• For new vehicle (within operation distance of 500 km), sometimes injector driving time is 10% more
than standard time.
• For new vehicle (within operation distance of 500 km), sometimes step length of stepper motor is more
30 steps than standard step length.
Displayed Item Check Item Specified Condition
• Engine: Warm Engine suddenly decelerate

from 4000 RPM ≤ 0.2 V
• A/F: Mixture is made
leaner when decelerating
• A/F: Mixture is made Engine suddenly accelerate 0.6 ～ 1 V
Oxygen sensor richer when accelerating
• Engine: Warm Engine: Idle ≤ 0.4 V

• Check A/F with oxygen
sensor 2500 RPM 0.6 ～ 1 V
• ECT: 80 ～ 95 ℃ Engine: Idle -
MAP sensor • Lamp and all other 2500 RPM -

accessorie: OFF
• Transmission: Neutral Engine: Idle -
IAT: - 20 ℃ - 20 ℃
IAT: 0 ℃ 0℃
• Ignition switch: ON
IAT sensor IAT: 20 ℃ 20 ℃
• Or engine is running
IAT: 40 ℃ 40 ℃
IAT: 80 ℃ 80 ℃
Engine: Idle 0.3 ～ 1 V (0%)
TPS Ignition switch: ON TP open slowly Increase proportionally
Wide open 4.5 ～ 5.5 V
Power supply Ignition switch: ON System voltage
Engine: Stop OFF

Ignition switch Ignition switch: ON
Engine: Start ON
ECT: - 20 ℃ - 20 ℃
ECT: 0 ℃ 0℃
ECT sensor Ignition switch: ON ECT: 20 ℃ 20 ℃
ECT: 40 ℃ 40 ℃
ECT: 80 ℃ 80 ℃
Altitude: 0 m 101 kPa

Barometric sensor Ignition switch: ON
Engine: Idle A/C switch: OFF OFF

A/C switch (Turn A/C switch ON, A/C
compressor works) A/C switch: ON ON
Displayed Item Check Item Specified Condition
ECT: 0 ℃ 60 ～ 90 ms
Injector Engine: Running ECT: 20 ℃ 30 ～ 5 ms 04
ECT: 80 ℃ 6.7 ～ 10.1 ms
Engine: Idle 2.2 ～ 3.4 ms

• ECT: 80 ～ 95 ℃
Injector 2500 RPM 1.9 ～ 3.1 ms
• Accessorie: OFF
• Transmission: Neutral Engine runs at high speed
04
Increase
suddenly
Engine: Idle 2 ～ 18 BTDC

Ignition coil • Engine: Warm
2500 RPM 27 ～ 47 BTDC
• ECT: 80 ～ 95 ℃ A/C switch: OFF 2 ～ 25 steps

• Accessorie: OFF
Idle air control
motor • Transmission: Neutral
• Engine: Idle A/C switch: OFF → ON A/C switch: OFF → ON
• A/C works
Not activate (Compressor

A/C switch: OFF
clutch does not work)
A/C relay Engine: Warm and idle
Activate (Compressor
A/C switch: ON
clutch works)
Compare the values read

• Engine: Running
from tachometer and KT600 The same
• Tachometer: Connection respectively
ECT: 20 ℃ 1275 ～ 1475 RPM
CKP sensor ECT: 0 ℃ 1225 ～ 1425 RPM
Engine: Idle ECT: 20 ℃ 1100 ～ 1300 RPM
ECT: 40 ℃ 950 ～ 1150 RPM
ECT: 80 ℃ 650 ～ 850 RPM
2. ACTIVE TEST.
CAUTION
The active test function for us to check the sensor, actuator and switch data value but not removing
any components. We can use the scan tool to perform the test. As the first step, this way is the best
way to short diagnosis period.
The displayed data stream when performing the active test.
available.
(d) Select the item “AUTO DIAGNOSIS\FOTON\LIGHT BUS\MP-X MP\ENGINE\4G63 GASOLINE
ENGINE OR 4G64 GASOLINE ENGINE\MT20U2\ACTIVE TEST”.
(e) Refer to the following chart, perform the active test. The following chart is the item which in the
“ACTIVE TEST” of the KT600 scan tool.
(f) When performing the function of the “ACTIVE TEST”, if there is fault phenomenon, check and repair.
(g) After repairing, using the KT600 to perform again.
(h) Clear DTC.
(i) Disconnect KT600 scan tool.
(j) Restart engine to perform test. Confirm the faults has been eliminated.
Displayed Item Test Component Control Area Diagnosis Remark

MIL Control MIL ON/OFF -
EVAP EVAP solenoid valve ON/OFF -
Fuel pump relay Fuel pump relay ON/OFF -
Low fan Control low fan ON/OFF -
High fan Control high fan ON/OFF -
A/C relay Shut off A/C relay ON/OFF -
Idle air control motor Control idle motor steps - -
Idle air control motor Control idle motor speed - -
Idle control motor reset Control Idle motor reset - -
Ignition advance angle Ignition advance angle - -
Gear signal learn 58X learn - -
Injector (A/B/C/D) Shut off fuel injection ON/OFF -
BLM learn - - -
BLM reset - - -
Fuel open control Open control - -
Inspect catalysator at idle Check catalysator at idle - -
Oxygen sensor response Oxygen sensor response - -

DIAGNOSTIC TROUBLE CODE CHART

Note
If a malfunction code is displayed during the DTC check in the check mode, check the harness or con-
nectors for the codes listed in the table below. For details of each code, refer to the DTC chart.
04
DTC No. DTC Definition Trouble Area
• MAP sensor
P0106 MAP/TPS Siganl Rationality • Open or short in MAP sensor harness or connectors
• ECM
04
• MAP sensor
P0107 MAP Sensor Circuit Low Voltage or Open • Short in MAP sensor harness or connectors
• ECM
• MAP sensor
P0108 MAP Sensor Circuit High Voltage • Open or short in MAP sensor harness or connectors
• ECM
• IAT sensor
P0112 IAT Sensor Circuit Low Voltage or Open • Short in IAT sensor harness or connectors
• ECM
• IAT sensor
P0113 IAT Sensor Circuit High Voltage • Open or short in IAT sensor harness or connectors
• ECM
• ECT sensor
P0117 Coolant Circuit Low Voltage • Short in ECT sensor harness or connectors
• ECM
• ECT sensor
P0118 Coolant Circuit High Voltage • Open or short in ECT sensor harness or connectors
• ECM
• Throttle position sensor

P0122 Throttle Position Low Voltage • Open or short in throttle position sensor harness or
connectors
• ECM
• Throttle position sensor

P0123 Throttle Position High Voltage • Short in throttle position sensor harness or
connectors
• ECM
• Upstream oxygen sensor

P0131 Front Oxygen Sensor Short Low • Short in upstream oxygen sensor harness or
connectors
• ECM

P0132 Front Oxygen Sensor Short High • Short in upstream oxygen sensor harness or
connectors
• ECM
• Open or short in upstream oxygen sensor harness

or connectors
• Upstream oxygen sensor heater
P0133 Front Oxygen Sensor slow response • Relay
• Air induction system
• Fuel pressure
• Injector
• ECM

Front Oxygen Sensor Inadequate • Open in upstream oxygensensor harness or
P0134
Activeness Or Open connectors
• ECM
• Upstream oxygen heater

P0135 Front Oxygen Heater Fault • Open or short in upstream oxygen heater harness or
connectors
• ECM

P0137 Rear Oxygen Sensor Short Low • Open or short in downstream oxygen sensor
harness or connectors
• ECM
• Downstream oxygen sensor

P0138 Rear Oxygen Sensor Short High • Open or short in downstream oxygen sensor
• ECM
• Downstream oxygen sensor

Rear Oxygen Sensor Inadequate • Open in downstream oxygen sensor harness or
P0140
Activeness Or Open connectors
• ECM
• Downstream oxygen heater

P0141 Rear Oxygen Heater Fault • Open or short in downstream oxygen heater
• ECM
• Air induction system

• Injector blockage
• MAP sensor
• Engine coolant temperature sensor
• Fuel pressure
• Gas leakage in exhaust system
P0171 Fuel Trim BLM Learn Too Lean • Open or short in oxygen sensor circuit
• Oxygen sensor
• Oxygen sensor heater
• Relay
• PCV valve and hose
• PCV hose connection
• ECM
• Injector leak or blockage

• MAP sensor 04
• Ignition system
• Fuel pressure
P0172 Fuel Trim BLM Learn Too Rich • Gas leakage in exhaust system
• Open or short in oxygen sensor harness or
connectors
• Oxygen sensor 04
• Oxygen sensor heater
• Relay
• ECM
• Injector A
P0201 Injector A Circuit Diagnostic • Injector A harness or connectors
• ECM
• Injector B
P0202 Injector B Circuit Diagnostic • Injector B harness or connectors
• ECM
• Injector C
P0203 Injector C Circuit Diagnostic • Injector C harness or connectors
• ECM
• Injector D
P0204 Injector D Circuit Diagnostic • Injector D harness or connectors
• ECM
• Pump relay
P0230 Fuel Pump Relay Fault • Pump relay harness or connectors
• ECM
• Open or short in engine wire

• Connector connection
• Vacuum hose connection
• Ignition system
• Injector
• Fuel pressure
• MAP sensor
P0300 The Engine Misfire Fault
• Compression pressure
• Valve clearance
• Valve timing
• PCV hose connection
• PCV hose
• ECM
• Knock sensor
P0325 Knock Control System Fault • Knock sensor harness or connectors
• ECM
• Knock sensor
P0327 Knock Sensor Fault • Knock sensor harness or connectors
• ECM
• Open or short in CKP sensor harness or connectors

P0336 CKP Sensor Circuit Noisy Signal
• ECM
• CKP sensor
P0337 CKP Sensor Circuit No Signal • Open or short in CKP sensorharness or connectors
• ECM
• Open or short in purge solenoid harness or

connectors
P0443 Purge Solenoid Diagnostic
• Purge solenoid
• ECM
• Fan1
P0480 Fan 1 Fault • Fan 1 harness or connectors
• ECM
• Fan 2
P0481 Fan 2 Fault • Fan 2 harness or connectors
• ECM
P0601 Fault Of Flash Checksum • ECM
• Malfunction indicator lamp

P0650 Malfunction Indicator Lamp Fault • Malfunction indicator lamp harness or connectors
• ECM
• Main power relay

P0685 Main Power Relay Fault • Main power relay harness or connectors
• ECM
• Open or short in upstream oxygen sensor

P1167 Oxygen Signal Rich In DFCO • Engine hood main relay
• Upstream oxygen heater and main relay harness or
connectors
• ECM
• Open or short in upstream oxygen sensor

P1171 Oxygen Signal Lean In PE • Engine hood main relay
• Upstream oxygen heater and main relay harness or
connectors
• ECM
• CKP sensor is not installed

P1336 TEC Not Learned
• ECM
• Accelarator
P1391 G Sensor Rationality
• ECM
• Accelarator
P1392 G Sensor Short Low • Short in accelarator harness or connectors 04
• ECM
• Accelarator
P1393 G Sensor Short High • Short or open in accelarator harness or connectors
• ECM
04
P0117 - ENGINE COOLING TEMPERATURE SENSOR CIRCUIT LOW

VOLTAGE
P0118 - ENGINE COOLING TEMPERATURE SENSOR CIRCUIT HIGH
VOLTAGE
1 Electric Appliance Connector
2 Cabinet
3 NTC Resistance
DESCRIPTION
1. This sensor is one Negative Temperature Coefficient (NTC) thermistance, of which the
resistance will reduce following the increasing of the temperature in non-linear relation. When
the coolant temperature is low, the resistance in the thermistor increases. When the
temperature is high, theresistance drops. The variations in resistance are reflected in the
voltage output from the sensor.
2. The ECM monitors the sensor voltage and uses this value to calculate the engine coolant
temperature.
WIRING DIAGRAM
DTC No. DTC Definition DTC Detection Condition Trouble Area
• 60 seconds since the ignition switch is 04
• ECT sensor
Engine cooling turned “ON” or after engine starts
P0117 temperature sensor circuit • Short in ECT
• Sensor output voltage has continued to be sensor circuit
low voltage 0.2 V or lower (corresponding to an intake
• ECM
airtemperature of 145 ℃ or higher) for 4
seconds
• Ignition switch: ON 04
• 60 seconds since the ignition switch is • ECT sensor
Engine cooling turned “ON” or after engine starts • Open or short in
P0118 temperature sensor circuit • Sensor output voltage has continued to be ECT sensor
high voltage 4.6 V or higher (corresponding to an circuit
intakeair temperature of -45 ℃ or lower) for • ECM
4 seconds
NOTE
• While performing electrical diagnosis & testing, assure the ECM ground good contact.
• While performing electrical diagnosis & testing, always refer to the electrical schematics for
specific circuitand component information.
• While performing electrical diagnosis & testing, look for broken, bent, pushed out or corroded
terminals.
• If the ECM detects the DTC P0117 or P0118, it operates the fail–safe function in which the
engine coolant temperature is assumed to be a default value. At the same time, with the ignition
switch ON, the cooling fans will operate at high speed. The fail–safe function will not untill the
ECM detects the acceptance condition.
• If any DTC is detected, using the scan tool, select the item “AUTO DIAGNOSIS\ FOTON\LIGHT
BUS\MP-X MP\ENGINE\4G63 GASOLINE ENGINE OR 4G64 GASOLINE ENGINE\MT20U2\READ DATA
STREAM\COOLANT TEMPERATURE”.
Displayed Temperature Malfunction

-40 °C Open circuit
140 °C Short circuit
INSPECTION PROCEDURE
1. READ VALUE AND DTC OF SCAN TOOL (ENGINE COOLANT TEMPERATURE)

(b) With the KT600 scan tool, perform the DTC confirming procedure.
(c) Read sensor value displayed on the KT600 scan tool.
Result
Display DTC And Temperature Proceed To Malfunction
• P0118
Next step Open or short to power
• - 40 °C
Display DTC And Temperature Proceed To Malfunction
• P0117
Step 5 Short to ground
• 140 °C or more
• P0117 or P0118
• OK (Same as present coolant Diagnostic help Check for intermittent problems
temperature)

YES > Go to diagnostic help for checking intermittent problems.
NO > If there is an open circuit, go to next step.
If there is a short circuit, go to step 5.
2. READ VALUE OF KT600 SCAN TOOL (ENGINE COOLANT TEMPERATURE SENSOR TERMINAL
1- 2)

(b) Disconnect the E021 ECT sensor connector.
(c) Connect terminals 1 and 2 of the engine coolant

temperature sensor connector E021 on the wire harness
side.
(e) Select the item “AUTO DIAGNOSIS\FOTON\LIGHT
BUS\MP-X MP\ENGINE\4G63 GASOLINE ENGINE OR
4G64 GASOLINE ENGINE\MT20U2\READ DATA
STREAM\COOLANT TEMP”.
(f) Read ECT value displayed on the KT600 scan tool.
Temperature value: ≥ 140 °C

YES > Confirm good connection at sensor. If OK, replace engine coolant temperature sensor.
NO > Go to next step.
3. CHECK HARNESS AND CONNECTOR (ECT SENSOR - GROUND)
(a) Disconnect terminals 1 and 2 of the engine coolant

temperature sensor connector E021 on the wire harness
side.
(b) Measure the voltage according to the value in the table
below.
Standard voltage
Tester Connection Specified Condition

E021 (1) - Ground 5.0 ± 0.25 V

NO > Repair or replace harness or connector. If OK, replace ECM.
04
4. CHECK HARNESS AND CONNECTOR (ECT SENSOR - ECM)

(b) Disconnect the E023 ECM connector.
(c) Measure the resistance according to the value in the
table below.
04
Standard resistance (check for open)

E021 (2) - E023 (5) ＜2Ω

YES > Go to step 7.
NO > Repair or replace harness or connector.
5. READ VALUE OF KT600 SCAN TOOL (ENGINE COOLANT TEMPERATURE)

(d) Select the item “AUTO DIAGNOSIS\FOTON\LIGHT BUS\MP-X MP\ENGINE\4G63 GASOLINE ENGINE
OR 4G64 GASOLINE ENGINE\MT20U2\READ DATA STREAM\COOLANT TEMP”.
(e) Read ECT value displayed on the KT600 scan tool.
Temperature value: -40 °C
YES > Replace ECT sensor.

table below.
Standard resistance (check for short)

E021 (1) - E021 (2)
≥ 1MΩ
E021 (1) - Ground

YES > Replace ECM. (Refer to “Chapter 11A engine control system - ECM, replacement”)
P0107 - MAP SENSOR CIRCUIT LOW VOLTAGE OR OPEN

P0108 - MAP SENSOR CIRCUIT HIGH VOLTAGE
DESCRIPTION
MT20U2 adopted speed-density air measurement method to check the air intake volume into the
engine so as to control the fuel injection pulse width for the precise control of engine power output.
Meanwhile, this system adopted intake pressure cylinder determination technology and the intake air
sensor is installed near the inlet opening of cylinder 4 intake manifold. At the moment when the throttle
is opened, there will be one instantaneous pressure drop at the sensor, of which the value is about 1
kPa. When the ECM detected and received this instantaneous pressure drop, the ECM will determine
the compression upper dead center signal after software diagnosis treatment (its functions is similar
with the camshaft position sensor of traditional electric injection system, also referred as phase
sensor).
WIRING DIAGRAM
• MAP sensor
• MAP sensor loose connector 04
• Open or short in MAP sensor
• Ignition switch: ON signal circuit
MAP sensor circuit low • No TPS faults • Short circuit in MAP sensor
P0107 voltage or open • ECM detects that the MAP signal circuit
input signal is less than • Open circuit in MAP sensor
acceptable value 5V circuit
• Open in MAP sensor ground 04
circuit
• ECM
• MAP sensor
• Engine: Running
• Short in MAP sensor signal
MAP sensor circuit high • No TPS faults circuit
P0108 • ECM detects that the MAP
voltage • Short in MAP sensor 5V
input signal is higher than power circuit
acceptable value
• ECM
NOTE
terminals.
BUS\MP-X MP\ENGINE\4G63 GASOLINE ENGINE OR 4G64 GASOLINE ENGINE\MT20U2\READ
DATA STREAM”.
1. READ VALUE SCAN TOOL (MAP)

(c) Read MAP value displayed on the the KT600 scan tool.
Result
Displayed DTC And Pressure Proceed To Malfunction
• P0108
Next step Short to voltage
• About 45 kPa (or 4 V)
• P0107
Next step Open or short to ground
• About 45 kPa (or 4 V)
• P0107 or P0108
Diagnostic help Check for intermittent problems
• Pressure normal

NO > If there an open or short circuit, go to next step.
2. CHECK MAP SENSOR REFERENCE VOLTAGE

(b) Disconnect the E010 MAP sensor connector.
(d) Measure the voltage according to the value in the table

below.
Standard voltage

E010 (1) - Ground 5.0 ± 0.25 V

3. CHECK HARNESS AND CONNECTOR (MAP SENSOR GROUND CIRCUIT)
(a) Jump wire at terminals 1 and 3 of the E021 MAP sensor

connector.
(b) Read MAP value displayed on the KT600 scan tool.
Standard voltage: 5.0 ± 0.25 V

YES > Go to step 5.
4. CHECK HARNESS AND CONNECTOR (MAP SENSOR - ECM)

(c) Disconnect the E023 ECM connector.
(d) Measure the resistance according to the value in the
table below.

E010 (3) - E023 (4) ＜2Ω

04
5. CHECK MAP SIGNAL
(a) Connect the E010 MAP sensor connector.

(b) Connect the E023 ECM connector.
(c) Start engine.

(d) Measure the voltage according to the value in the table 04
below.
Standard voltage

E010 (1) - Ground 5V
• Idle: 1.3 V
• No load condition, opening
E010 (4) - Ground throttle slowly: 1.3 V
• Open quickly: 4 V, then return
back to 1.5 V

6. CHECK HARNESS AND CONNECTOR (MAP SENSOR - GROUND)

(e) Measure the voltage according to the value in the table
below.
Standard voltage


7. READ MAP SIGNAL VOLTAGE

(c) Jump wire at terminals 1 and 4 of the E010 MAP sensor
connector.
(e) Using scan tool, select the item “AUTO DIAGNOSIS\

FOTON\LIGHT BUS\MP-X MP\ENGINE\4G63 GASOLINE
ENGINE OR 4G64 GASOLINE ENGINE\ MT20U2\READ
DATA STREAM\MAP SENSOR VOLTAGE VALUE”.
Standard: 4 V

NO > Repair or replace harness or connector for short or open.
8. REPLACE ECM
(a) Replace ECM. (Refer to “Chapter 11A engine control system - ECM, replacement”)
(c) Perform reading sensor data stream procedure.
(d) Confirm no DTC and data normal.
P0112 - IAT SENSOR CIRCUIT LOW VOLTAGE OR OPEN

P0113 - IAT SENSOR CIRCUIT HIGH VOLTAGE
04
04
DESCRIPTION
The IAT sensor has a thermistor that varies its resistance depending on the temperature of the intake
air. When the air temperature is low, the resistance in the thermistor increases. When the temperature
is high, the resistance drops. The variations in resistance are reflected as voltage changes to the ECM
terminal.
WIRING DIAGRAM
• Ignition switch: ON.

• 60 seconds since the ignition switch is • IAT sensor
turned “ON”, or after engine starts.
IAT sensor circuit low • Short in IAT sensor 5
P0112 voltage or open • Sensor output voltage has continued to V reference circuit
be 0.2 V or lower (corresponding to an
• ECM
intake air temperature of 125 ℃ or lower)
for 4 seconds.
• Ignition switch: ON.

• 60 seconds since the ignition switch is • IAT sensor
turned “ON”, or after engine starts.
IAT sensor circuit • Open in IAT sensor 5
P0113 • Sensor output voltage has continued to
high voltage V reference circuit
be 4.6 V or higher (corresponding to an
• ECM
intake air temperature of -45 ℃ or lower)
for 4 seconds.
NOTE
terminals.
• If any DTC is detected, using the scan tool, select the item “AUTO DIAGNOSIS\FOTON\LIGHT
DATA STREAM”.
1. READ VALUE OF KT600 SCAN TOOL (IAT)

(b) Using the KT600 scan tool, perform the DTC confirming procedure.
(c) Read IAT value displayed on the KT600 scan tool
Temperature: Same value as the actual intake air temperature.
Result
Displayed DTC And Temperature Proceed To Malfunction
• P0113
Step 4 Short to voltage
• About 45 ℃
• P0112
Next step Open or short to ground
• About 45 ℃
• P0112 or P0113
• IAT is normal

NO > If there is an open or short circuit, go to next step.

(b) Disconnect the E010 IAT sensor connector. 04
(c) Jump wire at terminal 2 and 3 of the E010 connector IAT
sensor.
(e) Using scan tool, select the item “AUTO DIAGNOSIS\FOTON\LIGHT
BUS\MP-X MP\ENGINE\4G63 GASOLINE ENGINE OR 4G64
04
GASOLINE ENGINE\ MT20U2\ READ DATA STREAM\IAT SENSOR
VALUE”.
(f) Read IAT value.
Temperature value: About 140 °C

YES > Confirm good connectionat sensor. If OK, replace IAT sensor.
3. CHECK HARNESS AND CONNCCTOR (IAT SENSOR - GROUND)
(a) Disconnect the jump wire at terminal 2 and 3 of the

E010.
below.
Standard voltage
E010 (2) - Ground 4.5 ～ 5.0 V

NO > Confirm good connectionat sensor. If OK, replace ECM.
4. CHECK HARNESS AND CONNECTOR (IAT SENSOR - ECM)

(b) Disconnect the ECM connector.
table below.

E010 (3) - E023 (4) ＜2Ω

YES > Go to step 7.

(b) Disconnect ECT sensor connector.
(d) Using scan tool, select the item “AUTO DIAGNOSIS\FOTON\LIGHT BUS\MP-X MP\ENGINE\4G63
GASOLINE ENGINE OR 4G64 GASOLINE ENGINE\MT20U2\ READ DATA STREAM\IAT SENSOR
VALUE”.
(e) Read IAT value.
Temperature value: About -40 ℃
YES > Repalce IAT sensor.
6. CHECK HARNESS AND CONNECTOR (IAT SENSOR - GROUND)


table below.

E010 (2) - E010 (3)
≥ 1MΩ
E010 (2) - Ground

7. REPLACE ECM
P0122 - THROTTLE POSITION LOW VOLTAGE

P0123 - THROTTLE POSITION HIGH VOLTAGE
04
04
DESCRIPTION
MT20U2 Throttle Position Sensor (TPS) is used to provide throttle angle, angle speed and engine idle
position information to the ECM, based on which the ECM can obtain the engine load information,
operating mode (such as start, idle, reverse towing, partial load, full load) and acceleration &
deceleration information. This sensor is of three-line type and the ECM will check the throttle open
extent by monitoring the voltage variation.
WIRING DIAGRAM
• 60 seconds since the ignition switch • TPS failed or maladjusted
Throttle position low
P0122 voltage is turned “ON”, or after engine starts • Open or short in TPS circuit
• Sensor output voltage has continued • ECM
to be 0.2V or lower for 4 seconds
• 60 seconds since the ignition switch
is turned “ON”, or after engine starts • TPS failed or maladjusted
Throttle position
P0123 • Setting the closed throttle position • Short in TPS circuit
high voltage
switch ON, the sensor output • ECM
voltage has continued to be 2 V or
higher for 4 seconds
NOTE
terminals.
DATA STREAM”.
1. READ VALUE OF SCAN TOOL (TPS)

(c) Read TPS value displayed on the KT600 scan tool.
Result
Displayed DTC And Voltage Proceed To Malfunction
• P0122 ( ＜ 0.2 V) Step 4 Short to voltage
• P0123 ( ＞ 2 V) Next step Open or short to ground
• P0122 or P0123
• TPS signal is normal

NO > If there is an open or short circuit, go to next step.
2. CHECK HARNESS AND CONNECTOR (TPS - GROUND)

(b) Disconnect the E007 TPS connector.

below.
Standard voltage
E007 (2) - Ground 4.5 ～ 5.0 V

NO > Repair or replace TPS reference voltage harness or connector for open or short. If OK, replace ECM.
3. READ TPS SIGNAL
(a) Jump wire at terminals 2 and 3 of the E007 TPS

connector. 04
(b) Perform reading sensor data stream procedure with scan
tool.
Voltage value: 4 V
04

YES > Go to step 5.
4. CHECK HARNESS AND CONNECTOR (TPS - ECM)

table below.

E007 (1) - E023 (5) ＜2Ω

(a) Connect the E007 TPS connector.


below.

E007 (2) - Ground Ignition switch ON: 5.0 V
• Ignition switch ON (TP close

completely): 0.5 V (scan tool: 0%)
E007 (3) - Ground
• Ignition switch ON(TPis full
opening): 4.5 V (scan tool: 100%)


NO > Repair or replace TPS, harness or connector.

below.
Standard voltage


NO > Repair or replace harness or connector for short.
7. READ TPS SIGNAL

(b) Connect the E007 TPS connector.
(c) Jump wire at terminals 2 and 3 of the E007 TPS
connector.
(e) Using scan tool, select the item “AUTO DIAGNOSIS\FOTON\LIGHT

BUS\MP-X MP\ENGINE\4G63 GASOLINE ENGINE OR 4G64
GASOLINE ENGINE\MT20U2\READ DATA STREAM\TPS VALUE”.
Voltage: 4 V

NO > Repair or replace TPS harness or connector.
8. REPLACE ECM
(b) Using the KT600 scan tool, perform the DTC confirming procedure. 04
04
P0131 - FRONT OXYGEN SENSOR SHORT LOW

P0132 - FRONT OXYGEN SENSOR SHORT HIGH
P0134 - FRONT OXYGEN SENSOR OPEN
1 Air
2 Case
3 Solid electrolyte
4 Platinum electrode
5 Heater
6 Lining
7 Exhaust gas
8 Rich
9 Air/fuel ratio
10 Lean
DESCRIPTION
The Engine Control Module (ECM) supplies a voltage of about 450 mV between the ECM terminals 62 and 6.
The oxygen sensor varies the voltage within a range of about 1V if the exhaust is rich, down to about 0.1 V
if the exhaust is lean. The oxygen sensor is like an open circuit and produces no voltage when it is below
360 ℃ . An open oxygen sensor circuit or a cold oxygen sensor causes open-loop operation.
WIRING DIAGRAM
04
04
• The engine controls system is in closed

loop
• The engine speed is below 6000 RPM
Front oxygen • Upstream oxygen sensor feedback
• Short in upstream oxygen
P0131 sensor short low voltage has continued to be 0.07 V or
sensor circuit
lower at least 40 seconds
• ECM
• DTC P0107、 P0108、 P0117、
P0118、 P0122、 P0123、 P0335 are
not set
• Upstream oxygen sensor feedback

voltage has continued to be 4.8 V or • Upstream oxygen sensor
Front oxygen higher for at least 0.2 seconds • Short in upstream oxygen
P0132
sensor short high • DTC P0107、 P0108、 P0117、 sensor circuit
P0118、 P0122、 P0123、 P0335 are • ECM
not set
• Upstream oxygen sensor feedback

voltage has continued to be between • Upstream oxygen sensor
Front oxygen 0.42 ～ 0.48 V • Open in upstream oxygen
P0134
sensor open • DTC P0107、 P0108、 P0117、 sensor circuit
P0118、 P0122、 P0123、 P0335 are • ECM
not set
NOTE
terminals.
If any DTC is detected, using the scan tool, select the item “AUTO DIAGNOSIS\ FOTON\LIGHT BUS\MP-
X MP\ENGINE\4G63 GASOLINE ENGINE OR 4G64 GASOLINE ENGINE\MT20U2\READ DATA STREAM”.
DIAGNOSIC HELP
• Normal scan tool voltage varies between 0.1 to 1.0 V while in closed-loop.
• Check oxygen sensor harness, maybe the oxygen sensor is not well installed. It touch the exhaust pipe.
• Check if there is intermittent ground existent between ECM and oxygen sensor.
• Perform an injector balance test. Check if the lean mixture was caused by injector blocking.
• The vacuum leaking of crankcase cause lean mixture.
• The out air enter into exhaust pipe and through the oxygen sensor by the leaking of exhaust manifold
wsaher.
1. READ VALUE AND DTC OF SCAN TOOL (OXYGEN SENSOR)

(c) Read oxygen sensor value displayed on the KT600 scan tool.
(d) Engine runs at idle.
Result

• P0131 ( ＜ 0.21 V) Step 6 Short to ground
• P0132 ( ＞ 4.8 V) Step 7 Short to power
• P0134 (0.42 V ～ 0.48 V) Next step Open

• If there is an open circuit, go to next step.
• If there is an short to groung circuit, go to step 6.
• If there is an short to power circuit, go to step 7.
2. CHECK HARNESS AND CONNECTOR (OXYGEN SENSOR)
(b) Disconnect the E017 oxygen sensor connector. 04

below.
Standard voltage
Tester Connection Specified Condition 04

E017 (1) - E017 (2) 0.45 V

YES > Replace oxygen sensor.
3. CHECK HARNESS AND CONNECTOR (OXYGEN SENSOR - GROUND)

(b) Disconnect the E017 oxygen sensor connector.
below.
Standard voltage

E017 (2) - Ground 0.45 V

YES > Go to step 5.
4. CHECK HARNESS AND CONNECTOR (OXYGEN SENSOR - ECM)

table below.

E017 (2) - E023 (62) ＜2Ω

5. CHECK HARNESS AND CONNECTOR (OXYGEN SENSOR - ECM)
(a) Disconnect the E017 oxygen sensor connector.

(b) Measure the resistance according to the value in the
table below.

E017 (1) - E023 (6) ＜2Ω

(a) Measure the resistance according to the value in the

table below.
E017 (2) - Ground ≥ 1 MΩ


below.
Standard voltage (check for short)


(a) Turn the ignition switch ON.

(b) Measure the voltage according to the value in the table 04
below.
Standard voltage

04

9. REPLACE ECM
P0336 - CKP SENSOR CIRCUIT NOISY SIGNAL

1 Shielded cable
2 Permanent magnet
3 Sensor case
4 Mounting bracket
5 Soft magnet iron core
6 Coil
7 Air clearance
DESCRIPTION
The 58X reference signal is produced by the Crankshaft Position (CKP) sensor. The Engine Control
Module (ECM) uses the 58X reference signal to calculate engine RPM and CKP. The ECM constantly
monitors the number of pulses on the 58X reference circuit and compares them to the number of MAP
signal being received. If the ECM receives and incorrect number of pulses on the 58X reference
circuit, DTC P0336 will be set.
WIRING DIAGRAM
• CKP sensor
• CKP loose connector
P0336 CKP sensor circuit noisy signal • Open or short in CKP
• ECM received no or error signal
sensor circuit
• ECM
NOTE
specific circuitand component information. 04
terminals.
DATA STREAM”.
04
1. READ VALUE AND DTC USING SCAN TOOL (CKP SENSOR)

(c) Read CKP sensor value displayed on the KT600 scan tool.
(e) Using scan tool, perform the CKP sensor waveform confirming procedure.
2. CHECK CKP SIGNAL USING THE OSCILLOSCOPE
(a) Raise vehicle.

(b) Remove engine lower guarde plate.
(c) Start engine and runs at idle speed.

(d) Using the oscilloscope, check the CKP sensor waveform.

YES > Go to step 5.
3. CHECK CKP SENSOR

(b) Disconnect the E013 CKP sensor connecrtor.
(c) Check the resistance according to the value in the table
below.
Standard resistance

E013 (2) - E013 (3) 560 Ω ± 10% (25 ± 5 ℃ )

NO > Replace CKP sensor.
4. CHECK CKP SENSOR WAVEFORM
(a) Replace the CKP sensor with a known good one.

(b) Start engine and runs at idle speed.
(c) Using the oscilloscope, check the CKP sensor waveform.

NO > Go to step 7.
5. CHECK CKP SENSOR HARNESS AND CONNECTOR (CKP SENSOR - ECM)

table below.

E013 (2) - E023 (28)
＜2Ω
E013 (3) - E023 (12)

table below.
04
E013 (2) - Ground
≥ 1MΩ
E013 (3) - Ground
04
6. CHECK CKP SENSOR HARNES AND CONNECTOR (CKP SENSOR - GROUND)

below.

E013 (2) - Ground
0V
E013 (3) - Ground

7. CHECK CKP SENSOR SIGNAL PLATE

(b) Check for a problem such as scrap, dirt, foreign body
and loose with the 58X CKP signal plate and signal
tooth.
(c) Check the mounting clearance of the CKP sensor.
Clearance: 0.3 ～ 1.5 mm

NO > Remove any foreign obstacles, clean 58X signal tooth. If there is fault present, replace 58X signal
plate.
8. CHECK DTC
(a) Using the KT600 scan tool, perform the DTC confirming procedure.
Is DTC still present?
YES > Replace ECM. (Refer to “Chapter 11A engine control system - ECM, replacement”)
NO > System is normal.
P0325 - KNOCK SYSTEM FAULT

P0327 - KNOCK SENSOR FAULT
04
No. Item
1 1 ms/div
04
DESCRIPTION
The Knock Sensor (KS) system is used to detect engine detonation, allowing the Engine Control
Module (ECM) to retard ignition control spark timing based on the KS signal being received. The KS
produces an AC signal. The KS signal’s amplitude and frequency depend upon the amount of knock
being experienced. The ECM contains a non-replaceable knock filter module called a Signal-to-noise
Enhancement Filter (SNEF) module. This filter module in the ECM determines whether knock is
occurring by comparing the signal level on the KS circuit with the voltage level on the noise channel.
The noise channel allows the ECM to reject any false knock signal by knowing the amount of normal
engine mechanical noise present. Normal engine noise varies depending on engine speed and load.
When the ECM determines that an abnormally low noise channel voltage level is being experienced,
DTC P0325 & P0327 will be set.
WIRING DIAGRAM
• Knock sensor
• ECT is higher than 80 ℃
• KS loose connector
• Engine RPM is higher than 2,500 RPM
P0325 Knock system fault • Open or short in KS
• ECM detect that the KS signal is out of circuit
the range
• ECM
• Knock sensor
• ECT is higher than 80 ℃
• KS loose connector
P0327 Knock sensor fault • Engine RPM is higher than 2,500 RPM
• Short in KS circuit
• The knock sensor voltage is below 0.2 V
• ECM
NOTE
terminals.
DATA STREAM”.
1. READ VALUE OF KT600 SCAN TOOL (KS)
(a) Start the engine and warm it to normal operating

temperature.
(b) Using the KT600 scan tool, perform the DTC confirming
procedure.
(c) Driving vehicle, read knock sensor value displayed on
the KT600 scan tool.
Result
Normal (Check intermittent problems) Feed back value change
Feed back value no

Appear fault (Go to next step)
change
2. CHECK KNOCK SENSOR

(b) Disconnect the E006 KS connector. 04
table below.
Standard resistance (check resistance)

04
E006 (1) - E006 (2)
E006 (1) - Ground ＞ 1 MΩ (20 ℃ )

E006 (2) - Ground

NO > Replace KS.
3. CHECK HARNESS AND CONNECTOR (KS - ECM)

table below.

E006 (1) - E023 (69)
＜ 2 Ω (20 ℃ )
E006 (2) - E023 (5)

NO > Replace KS harness or connector.
4. CHECK HARNESS AND CONNECTOR (KS - ECM)

table below.

E006 (1) - Ground
≥ 1 MΩ (20 ℃ )
E006 (2) - Ground

NO > Replace KS harness.
5. CHECK HARNESS AND CONNECTOR (KS - GROUND)

below.
Standard voltage (check for short):

E006 (1) - Ground
0V
E006 (2) - Ground

6. REPLACE ECM
P0480 - FAN 1 FAULT

P0481 - FAN 2 FAULT
04
04
DESCRIPTION
The coolant fans are used to rduce heat in the engine system. And the condensator after the A/C is
turned on.
WIRING DIAGRAM
• Main fan relay (low)

• Main fan B001: running
• Short or open in main fan B001
P0480 Fan 1 fault • ECM detects that faults has contin- control harness
ued to be present in R13 harness for
• Short or open in R13 drive harness
3 seconds
• ECM
• Secondary fan relay R12

• Secondary fan: running
• Short or open in secondary fan
P0481 Fan 2 fault • ECM detects that faults has contin- B002 control harness
ued to be present in R12 harness for
• Short or open in R12 drive harness
3 seconds
• ECM
NOTE
terminals.
DATA STREAM”.
1. PERFORM ACTIVE TEST BY SCAN TOOL (OPERATE FAN)
(a) Connect the KT600 scan tool to the DLC.

(b) Start the engine and warm it to normal operating
temperature.
(c) Using the KT600 scan tool, perform the DTC confirming
procedure.
(e) Using scan tool, select the item “AUTO DIAGNOSIS\FOTON\
LIGHT BUS\MP-X MP\ ENGINE\4G63 GASOLINE ENGINE
OR 4G64 GASOLINE ENGINE\MT20U2\ACTIVE TEST\
SECONDARY FAN”.
Standard
Scan Tool Operation Specified Condition

Secondary fan: ON Main fan B001: Active
Secondary fan: OFF Main fan B001: Not active
• Main fan B001: Active

Main fan: ON
• Secondary fan B002: not active
• Main fan B001: Not active

Main fan: OFF
• Secondary fan B002: Not active


NO > If secondary fan is not normal, go to next step.
If main fan is not normal, go to step 7.
2. INSPECT FUSE 04

(b) Disconnect F29 (30A).
(c) Inspect fuse.
04
Is the inspection normal?

NO > Replace F29 (30A). Go to step 5.
3. CHECK MAIN FAN RELAY (LOW SPEED)
(a) Remove the main fan relay R13 from fan junction box in
engine room.
table below.
≥ 10 kΩ (Not apply battery

voltage between terminal 85 - 86)
R13 (30) - R13 (87)
＜ 1 Ω (Apply battery voltage
between terminal 85 - 86)

NO > Replace main fan relay (low speed).
4. CHECK HARNESS AND CONNECTOR (MAIN FAN RELAY R13 - ECM)
(a) Disconnect the E023 ECM connector.

table below.

R13 (86) - E023 (67) ＜2Ω

5. CHECK HARNESS AND CONNECTOR (MAIN FAN RELAY R13 - GROUND)

table below.

R13 (86) - Ground ≥ 1 MΩ

04
6. CHECK HARNESS AND CONNECTOR (MAIN FAN RELAY R13 - GROUND)

below.
Standard voltage 04
R13 (86) - Ground 0V

7. INSPECT FUSE

(b) Disconnect F28 (30A).
(c) Inspect fuse.

NO > Replace F28 (30A). Go to step 9.
8. CHECK SECONDARY RELAY R12 AND MAIN FAN RELAY (HIHG SPEED) R14
(a) Disconnect the main fan relay R12 and R14 from fan
junction box in engine room.
table below.

R12 (30) - R12 (87) ≥ 10 kΩ (Not apply battery voltage
between terminal 85-86)
R14 (30) - R14 (87) ＜ 1 Ω (Apply battery voltage
between terminal 85-86)

NO > Repalce relay R12 or R14.
9. PERFORM ACTIVE TEST BY SCAN TOOL (OPERATE FAN)
(a) Remove main fan relay (high speed) R14 and secondary
fan relay R12.
(b) Using scan tool, select the item “AUTO DIAGNOSIS\
FOTON\LIGHT BUS\MP-X MP\ENGINE\4G63 GASOLINE
ENGINE OR 4G64 GASOLINE ENGINE\MT20U2\ACTIVE
TEST\MAIN FAN”.
(c) Measure the voltage according to the value in the table
below.
Standard voltage
Scan Tool Operation Specified Condition

High speed fan: ON Battery voltage
High speed fan: OFF 0V

10. REPLACE ECM
(b) Using the KT600 scan tool, perform the DTC confirming procedure. 04
04

Use the table below to help you find the cause of the problem. The numbers indicate thepriority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
GASLINE ENGINE CONTROL SYSTEM SYMPTOM

Symptom Check Order
Communication with KT600 is impossible KT600 failed to communicate with ECM. 1
Engine cranks, but will not start. 2

Starting
When engine is cold, it starts difficultly, body shock. 3
Unstable idle (Rough idle, hunting). 4

Idling stability (Improper idling)
Idle speed is high (Improper idle speed). 5
When the engine is cold, it stalls (At idle). 6

Idling stability (Engine stalls)
The engine stalls when accelerating. 7
Accelerated reaction is slow, acceleraton

8
Driving disturbance.
Poor acceleration capability. 9
ENGINE CONTROL SYSTEM SYMPTOM DESCRIPTION

Item Symptom
The starter is used to crank the engine, but there is
Failed to start no combustion within the cylinders, and the engine
Starting does not start.
Hard starting Engine starts after cranking a while.
Idling stability Hunting Engine speed does not remain constant.

(Improper idling) Incorrect idle speed The engine does not idle at the usual correct speed.
Engine stall easily when ECT is low after it start for

Engine will stall when it is cold (Idle)
Idling stability a while.
(Engine stalls) The engine stalls when the accelerator pedal is
Engine stalls when moving
depressed.
Hesitation is the delay in response of the vehicle

speed that occurs when the accelerator is
Accelerated reaction is slow, depressed in order to accelerate from the speed at
acceleraton disturbance which the vehicle is now traveling or a temporary
drop in vehicle speed during such acceleration.
Driving Serious hesitation is called “sag”.
Poor acceleration is the inability to obtain an

acceleration corresponding to the degree of throttle
Poor acceleration capability
opening (Even though acceleration is smooth) or
the inability to reach maximum speed.
ENGINE SYMPTOM DIAGNOSTIC

CAUTION
• Some symptom diagnostics require visual and outer inspection. Perform these inspections
04
first. These inspection can select a problem that needn’t check deeply. And it can save the
expensive time.
• Inquiry customer about the fault after taking over vehicle:
(a) The first time when the faults appear.
(b) The engine temperature when the faults appear.
(c) The vehicle roadhaul. 04
(d) The road which the customer usually drives.
(e) The vehicle maintenace log.
(f) The vehicle maintenace record.
(g) Is there any aftermarket retrofit device on vehicle? After the inspection, the checking time will be
shorted.
• Perform the primary inspection.
(a) Confirm the engine MIL is normal. If it is not good, repair it first.
(b) Confirm that no DTC exists in the ECM. If DTC exists, refer to the DTC chart to eliminate it.
(c) With the scan tool to inspect the engine control system hot data stream. And confirm them in the nor-
mal range.
(d) Confirm the fault and the reason.
(e) When repairing the vehicle, confirm the repair record.
• Visual inspection.
(a) Check the fuel system for any fuel leakage.
(b) Check the vacuum system for any broken, kinked or incorrectly linked vacuum pipes or hoses.
(c) Check the intake air pipe for being jammed, leaking, or damaged.
(d) Check the ignition system for any broken or aging spark plug wires and verify the engine firing order is
correct.
(e) Check the engine ground cable and verify a clean and tight connection.
(f) Check the sensors and actuators electrical connectors and verify good contact and tight connection.
CAUTION
• The carbon deposits in the back of the valve will cause the poor engine acceration, unsteady
idling, starting difficulty in cold temperature, ect.
• Valve, carbon deposits in the combustion chamber.
Determined by the ECI (Electronic Controlled Injection) engine control features, the cylinder carries out
the fuel injection first and then the ignition at each running. The ignition is cut off immediately the engine
is shut off, but the petrol injected in this running cycle can’t be recovered and is attached on the intake
valve and the combustion chamber wall. The petrol is volatile, but the waxes and colloids in the petrol
remain. In the long term, the waxes and colloids become thick and hard after repeatedly heated, so the
carbon deposits are formed. If the engine burns oil or the filled petrol quality is poor and with many
impurities, the valve carbon deposits are more severe and the formation rate is faster. As the carbon
deposit structure is similar to the sponge, after the valve carbon deposits are formed, part of fuel
injected into the cylinder every time will be attached, making the air-fuel mixture strength actually into
the cylinder thin, which causes poor engine running, difficult starting, rough idling, poor accelerating,
backfire during emergency fueling, exhaust exceeding the standards, consumption increasing and
other abnormal symptoms. If the carbon deposits are more severe, they may lead to improperly sealed
valve, and the cylinder can't work without cylinder pressure, or even the valve is adhered and can’t
return. Now the motion interference occurs between the valve and the piston which would damage the
engine finally.
• Carbon deposits in the intake manifold.

As the running of each piston in the whole engine is not synchronous, when the engine is shut off,
some intake valves in some cylinders can’t be fully closed, the unburned fuel evaporates and is
oxidized continuously thus to form some softer black carbon deposits in the intake pipe, especially at
the rear of the throttle valve. On the one hand, the carbon deposits make the intake pipe wall coarse;
the air forms a spiral vortex at the coarse section, affecting the air intake effect and the quality of air-fuel
mixture. On the other hand, the carbon deposits block the idling aisle, making the idling speed control
device clamped or exceeding its regulation range, leading to low idling speed and rough idling.
• If the carbon deposit in the cylinder is too much, usually it will cause the high pressure. But the
vehicle has more mileage, there is much more carbon deposit in the cylinder. Because of the
wear, the cylinder pressure will decline. So it is not the good way to judge if there is the carbon
deposit in the cylinder . The good way is:
(a) With the electronic endoscopy.
(b) Inspect the feedback voltage.
(c) Disassembly way.
• It’s a gradual process from the carbon deposit formation to aggregation and to affecting engine
normal running. When the engine cold starting is hard and the idling is rough, it shows that the
carbon deposits are quite serious, if further it will cause misfire and cylinder fuel cut, until the
engine unable to start. When the cold starting is hard, check the engine at once, clean the valve
carbon deposits in time after removing other factors to avoid damage caused by removing the
cylinder cover.
• Should pay attention to the following for the danger of the carbon deposit：
(a) Fill with the high quality gasoline.
(b) Don’t idle long.
(c) Run at high speed usually.
Symptom Diagnosic Logic Suspect Area
• No power supply • ECM power supply

Communication with KT600 is • Open in the harness of ECMand • Open in the harness of ECM and
impossible scan tool KT600 scan tool KT600
• ECM • ECM
1. READ VALUE OF SCAN TOOL

(b) Connect the KT600 scan tool to the Diagnostic Link Connector (DLC) - use the most current software
available, press the POWER key to start the KT600.
(d) Using scan tool, select the item “AUTO DIAGNOSIS\FOTON\LIGHT BUS\MP-X MP\ ENGINE\4G63
GASOLINE ENGINE OR 4G64 GASOLINE ENGINE\MT20U2\ READ DATA STREAM”.
(e) Using the KT600 scan tool, read data stream displayed on the screen.
Whether the ECM data stream can be read?
2. CHECK OTHER MODULE DATA STREAM
(a) Using scan tool, select the item “AUTO DIAGNOSIS\FOTON\LIGHT BUS\MP-X MP\ENGINE\4G63
GASOLINE ENGINE OR 4G64 GASOLINE ENGINE\MT20U2\ READ DATA STREAM”. 04
(b) Read the data stream on the scan tool.
Whether the SRS or ABS data stream can be read?
YES > Go to step 4.
3. CHECK HARNESS OR CONNECTOR (DLC COMMUNICATION K - ECM)
04
(b) Disconnect ECM connector.
(c) Check the continuity between the connector C401 terminal 7 - ECM connector terminal 11.
Resistance：＜ 2 Ω
(d) Using the multimeter, check the continuity between the connector C401 terminal 7 and ground.
Resistance：≥ 1 MΩ
(e) Turn the ignition switch ON, using the multimeter, check the voltage between diagnostic box C401 ter-
minal 7 and ground.
Voltage: 0 V
NO > Repair or replace ECM harness or connector.
4. CHECK ECM POWER AND GROUND
(a) Check ECM power.

(b) Check ECM ground.
NO > Repair or replace ECM harness or connector.
5. REPLACE ECM
(a) Replace ECM. (Refer to “ Chapter 11A engine control system - ECM, replacement”)
(b) Read value displayed on the KT600 scan tool.
(c) Confirm the comminication between ECM and scan tool.
.
Symptom Condition Diagnosic Logic Suspect Area
• Malfunction of the ignition

• Engine run normally system
The cause is probably that a • Malfunction of the fuel
• Battery is normal
spark plugs are fouled pump system
Engine cranks, • MIL is normal defective, or that the supply of
but will not start • No phenomenon of • Malfunction of the injector
fuel to the combustion chamber
burning when cranking is defective • Leakage or malfunction of
the engine intake air system
• ECM
NOTE
If the engine can’t be started with starting symptom, it shows the ignition system, fuel system and
control system don’t fully lose the functions even though work normally. The cause of this starting
failure is nothing but may be that the high tension sparks are too weak, the ignition is improper, the air/
fuel mixture is too thin or thick, or the cylinder pressure is too low. In general, first check the ignition
system, then the air intake system, the fuel system, the control system, the engine cylinder pressure at
last.
1. INSPECTION MIL AND DTC
(a) Using the KT600 scan tool, perform the reading DTC procedure. (Refer to ”Chapter 04A engine control
system - read and clear DTC”)
Is the DTC present?
2. VISUAL INSPECTION
(a) Perform the visual inspection.

Is the inspection result normal?
NO > Eliminate the exterior problems.
3. CHECK THE SECONDARY IGNITION SYSTEM
(a) Perform the following to test the secondary ignition system:

• Disconnect the injector fuse.
• Remove any of the 4 spark plugs.
• Connect the spark plug to spark plug wire.
• Ground the spark plug on the cylinder block.
• Crank the engine to test the secondary ignition system with the spark plugs removed.
Normal result: A strong blue spark visible is at each spark plug while cranking the engine
YES > Go to step 6.
(a) Check ignitioin coil resistance, and clear connector terminals.

(b) Check whether there is carbon deposit in plug, carbon tracking, residual current in insulating ceramics 04
cause of crack, clearance, burned in the positive and negative. And clear the plug.
NO > Clear, replace the faulty components.
5. CHECK IGNITION SPARK PLUG WIRE
04
(a) Using multimeter, check resistance of the ignition spark wire.
Resistance: ≥ 4 kΩ
NO > Replace the ignition spark wire.
6. CHECK CKP SENSOR
(b) Read the displayed CKP sensor value. It should be within the specified value.
NO > Check whether the sensor installion is correct. (Refer to “Chapter 04 engine control system - CKP sen-
sor”)
7. CHECK THE THROTTLE BODY
(a) Depress the accelerator slightly. Check whether the engine can start.
Can the engine start?
YES > Check throttle body and idle air path. Clear the carbon deposit. Disconnect the idle air control motor
connector, Check whether there is 12 V. And the resistance value is 28 ～ 33Ω when the temperature is
20 ℃ . Check whether the idle air control motor is clip. If necesasary, repair or replace it.
CAUTION
The carbon and grease beside the throttle and air path change the cross section of the idle air path. It
makes the ECM control the idle air impossilly. And it will cause the A/F too lean or too rich. The
borning will not be normal. And the usual reasons of unnormal borning are: carbon and grease, grease
beside the throttle air path, carbon and grease with the idle air control motor.
8. CHECK ECT SENSOR AND MAP/IAT SENSOR
(a) Check whether the installation of the MAP/IAT is normal.

(b) Check whether the MAP/IAT sensor is dirty.
(c) Using scan tool, select the item “AUTO DIAGNOSIS\FOTON\LIGHT BUS\MP-X MP\ENGINE\4G63
(d) Turn the ignition switch ON. Read the displayed ECT and MAP/IAT sensor value. It should reach the
specified value.
NO > Clear,repair or replace the harness or connector. If the MAP value is not still normal , go to step 15.
9. CHECK THE FUEL SYSTEM CIRCUIT

(b) Check whether the pump relay and pump operate normally.
NO > Repair or replace the fuel pump harness or connector.
10. CHECK THE FUEL SYSTEM PRESSURE
(a) Release the fuel system pressure. (Refer to “Chapter 12A fuel system - precaution”)
(b) Check the fuel system pressure. (Refer to “Chapter 12A fuel system - precaution”)
NO > Repair or replace the fuel system parts and harness:
• If the pressure is higher than 350 kPa, check the return pipe:
(1) If the return pipe is bent or twisted, repair or replace it.
(2) If the return pipe is normal, replace the pressure regulator.
• If the pressure is less than 350 kPa, turn the ignition switch ON, make the pump operate, check
the pressure again:
(1) If the pressure can be established, go to step 12.
(2) If the pressure cannot be established, go to step 13.
11. CHECK INJECTOR
(a) Disconnect the injector connector.

(b) Remove the injector and fuel rail assy.
(c) Apply 12 V battery voltage to the injector directly.
(d) Check whether every injector can spray even and standard quantity gasline.
CAUTION
If the spraying condition is not normal just as the “cylindrical growth”, or the spraying quantity is not
equal much more under the same condition (more than 5 ml), then replace the injector.
WARNING
When check the fuel system:
• Place a “Caution - No inflammable” symbol inside the operation area.
• Release fuel system pressure before servicing fuel system components. Service vehicles in well-
ventilated areas and avoid ignition sources.
• Never Never smoke while servicing the vehicle.
YES > Go to step14.
NO > Clear the injector. Check the injector operation condition again. If not OK, replace it. Confirm the fault is
not present. If not OK, go to next step.
12. CHECK FUEL SYSTEM RETURN
(a) Using the fuel return blocker, clamping the return pipe, make the system fuel can not return. Check
whether the system pressure can establish again quickly.
YES > Replace the fuel pressure regulation.
NO > Repair or replace the fuel supply pipe, pump or injector.
13. CHEKC FUEL SYSTEM SUPPLY
(a) Check whether the input pipe leakage or block.

CAUTION 04
Running the engine, Check connectors for fuel leaks as following:
(b) Turn the ignition switch ON (not crank the engine). Apply pressure on the fuel pipe. Check whether fuel
leaks at fuel pipe connection.
YES > Repair or replace the inlet fuel pipe.
NO > Replace fuel pump. 04
14. CHECK CYLINDER PRESSURE
(a) Perform the cylinder compression pressure test. The standard as following:
• Per cylinder pressure: 1270 kPa
• Per cylinder limit: 880 kPa
• Per cylinder difference limit: less than 25%
YES > Go to step16.
15. CHECK ENGINE VALVE-TIMING
(a) Check whether the engine valve-timing gear mark is aligned, damaged. And the belt is loose. Whether
the jumping over teeth exists.
NO > Perform the valve timing align operation. (Refer to “Chapter 15A engine mechanism- timing belt”)
16. CHECK ENGINE MECHANISM
(a) Perform the engine mechanism inspection:

• Check the cylinder with the endoscopy.
• Inspect the feedback voltage.
• Disassembly the engine inner faults.
• Clear the carbon deposit or remove and check the engine cylinder head. Check valves, carbon deposit
of manifold. For example: The clearance between the cylinder and the piston ring. The leakage of the
cylinder gasket, and loose of the valve guides, carbon deposit of the valve.
NO > Repair the engine inner mechanism faults.
17. REPLACE ECM
(c) Confirm the comminication between ECM and scan tool.
1. A/F is not correct • Ignition system

2. Carbon deposit at • Supply fuel system
valve • Injector
• Engine runs normally 3. Operation condition is • Leakage of the inlet
• MIL is normal not equal between system
Engine starts difficultily • It needs several times every cylinder
when it is cold (idle) • Cylinder compression
for engine starts 4. ECT sensor is fault pressure
successfully when it is 5. Others:
cold • Engine management
• MAP/IAT sensor system
• Idle step motor • Battery
• Fuel quality • ECM
NOTE
Hard engine starting refers to that the starter is able to drive the engine to run in normal speed with
clear starting symptom, but the engine only run after continuous starting or the starter driving for a
long time. For the failure of hard starting, determine whether the occurrence is in cold starting or hot
starting, or both of them. The cause of this failure is from the fuel injection system generally. Check it
in the following method.
1. CHECK ENGINE MIL AND DTC
(a) Using the KT600 scan tool, perform the reading DTC procedure. (Refer to ”Chapter 04A engine control
Is the DTC present?
YES > Refer to DTC chart. Perform the diagnostic procedure.
2. CHECK THE VISUAL INSPECTION

(b) Check following after opening the engine hood:
(c) Filter
(d) Leakage of the intake manifold
3. CHECK BATTERY
(a) Check the battery voltage when cranking the engine.

Battery voltage: ≥ 9.6 V
NO > Battery charge or replace it.
4. CHECK STARTER
(a) Check whether the starter or the starter circuit exist fault.
Is the check result normal? 04
5. CHECK CKP SENSOR
(a) Using scan tool, select the item “AUTO DIAGNOSIS\FOTON\LIGHT BUS\MP-X MP\ ENGINE\4G63
GASOLINE ENGINE OR 4G64 GASOLINE ENGINE\MT20U2\ READ DATA STREAM”. 04
(b) Read the displayed CKP sensor value. It should reach the specified value.
NO > Check whether the sensor installion is correct. (Refer to “Chapter 04 engine control system - CKP sen-
sor”)
6. CHECK ECT SENSOR
(b) Or with the multimeter to check the ECT sensor or feedback voltage. (or with a 1.5 kΩ resistance,
replace the ECT sensor. Start engine. If OK, it means that the ECT sensor isnot normal).
NO > Repair or replace the ECT sensor.
7. CHECK MAP SENSOR
(a) Check MAP sensor after starting engine successfully.

Pressure value: 35 ～ 55 kPa
NO > Eliminate the leakage of intake system.
8. CHECK THROTTLE BODY
(a) Depress the accelerator slightly. Start egnine. Check whether the engine can start.
Can the engine start?
YES > Check throttle body and idle air path. Clear the carbon deposit. Go to next step.
CAUTION
makes the ECM control the idle air impossilly. And it will cause the A\F too lean or too rich. The born-
ing will not be normal. And the usual reasons are: carbon and grease, grease beside the throttle air
path, carbon and grease with the idle air controlmotor.
NO > Go to step 10.
9. CHECK IDLE AIR CONTROL MOTOR
(a) Disconnect the idle air control motor connector. Check whether there is 12 V. And the resistance value
is 28 ～ 33 Ω when the temperature is 20 ℃ .
(b) Remove the idle air control motor to test:
(c) Check expansion of the idle air control motor when turning the ignition switch ON.
(d) Check whether the idle air control motor can move when turning the ignition switch OFF.
NO > Repair or replace harness or connector or the idle air control motor.

(c) Using scan tool, select the item “DIAGNOSIS\FOTON\LIGHT BUS\MPX\ENGINE\4G63 GASOLINE
ENGINE OR 4G64 GASOLINE ENGINE\MT20U2\READ DATA STREAM”.
(d) Turn the ignition switch ON. Read the displayed ECT and MAP/IAT sensor value. It should be within the
specified value.
NO > Clear, repair or replace the harness or connector. If the MAP value is not still normal, go to step 15.
the pressure again:
12. CHECK INJECTOR
(a) Remove the injector connector.

CAUTION
If the spraying condition isnot normal just as the “cylindrical growth”, or the spraying quantity is not
WARNING
ventilated areas and avoid ignition sources.
• Never smoke while servicing the vehicle.
YES > Go to step15.
NO > Clean the injector. Check the injector operation condition again. If not OK, replace it. Confirm the fault
isnot present. If not OK, go to next step.
04
(a) Using the fuel return blocker, and clamping the return pipe, make the system fuel not return. Check
NO > Repair or replace the fuel supply pipe, pump,injector.
04
(a) Check whether the input pipe leaks or block.
CAUTION
Running the engine, Check connectors for fuel leaks as following:
(b) Turn the ignition switch ON (not crank the engine).
(c) Apply pressure on the fuel pipe.
(d) Check whether fuel leakage at fuel pipe connection.
NO > Replace fuel pump.

YES > Go to step18.
(a) Check ignitioin coil resistance, and clear connector terminals.

(b) Check whether there is carbon deposit in plug, carbon tracking，residual current in insulating ceramics
NO > Clear, replace the faulty components.
(a) With multimeter, check resistance of the ignition spark wire.

Resistance：≥ 4 kΩ
(a) Check whether the engine valve-timing gear mark is aligned, damaged and the belt is loose.

• Disassembly the engine.
of manifold. For example: the clearance between the cylinder and the piston ring. The leakage of the
21. REPLACE ECM
.

The cause is probably • Malfunction of the
that the ignition system, ignition system 04
air-fuel. • Malfunction of air-fuel
ratio, IAC motor or ratio control system
Unstable idle (Rough idle, The engine cannot keep compression pressure is • Malfunction of the IAC
hunting) stability defective. Because the system
range of possible causes
• Poor compression
is broad,
inspection is narrowed • Drawing air into intake
down to simple items. air system 04
• ECM
NOTE
The unstable idle is the usually faulty. It has many kinds of types. It includes unstable, misfire, etc.
When performing the diagnosis and elimination, should analyse according to the specific symptom.
(a) Using the KT600 scan tool, perform the reading DTC procedure. (Refer to “Chapter 04A engine control
Is the DTC present?
YES > Refer to DTC chart. Perform the diagnosis procedure.

(b) Check after opening the engine hood:
(c) Inspect the engine operating condition.
(d) Inspect the tachometer if the pointer deviates the idle target value.
(e) Inspect if the idle trembles is normal or load reasons, such as: A/C, lighting, push the lever into gear,
turn the steering wheel, etc.
(f) Check the vacuum system for any broken, kinked or incorrectly linked vacuum pipes or hoses.
(g) Check whether the exhaust pipe emit black smoke. Check whether there is unburned petrol fumes.
(h) Check whether the throttle cable is adjusted to be appropriate.
3. CHECK THE THROTTLE AND IDLE AIR CONTROL MOTOR
(a) Check throttle body and idle air path. Clear the carbon deposit and greasy dirt.
(b) Start engine and runs at idle.
(c) Using scan tool, select the item “AUTO DIAGNOSIS\FOTON\LIGHT BUS\MP-X MP\ ENGINE\4G63
GASOLINE ENGINE OR 4G64 GASOLINE ENGINE\MT20U2\ ACTIVE TEST”.
(d) Perform the idle air control motor test.
• When the scan tool control the rotation of expansion of the idle air control motor, the engine RPM
changes from high to low in synchronism (touching the idle air control motor, can feel vibration).
(e) Disconnect the idle air control motor connector, Check whether there is 12 V. And the resistance value is
28 ～ 33 Ω when the temperature is 20 ℃ . Check whether the idle air control motor is clip. If necesasary,
repair or replace it.
(f) Remove the idle air control motor . Connect the connector:
• Check whether the idle air control motor can extend-retract when turning the switch off.
• Check whether the idle air control motor can move when turning the ignition switch on.
NO > Clear, repair or replace harness or connector.
4. CHECK THE IGNITION SYSTEM
(a) Engine runs at idle speed. brennschluss one by one. Inspect if the idle speed changes.
CAUTION
It is better that use the active test function of the scan tool to perform the brennschluss test. If without
the scan tool or the scan tool wirhout the function, the brennschluss period shoul not be too long, if
not, the Three Way Catalytic Converter (TWC) will be damaged.
(b) When brennschluss every cylinder, the same RPM should decline obviously or the same vibration.
YES > Go to step12.

normal result: A strong blue spark visible is at each spark plug while cranking the engine
YES > Go to step 8.
(a) Check secondary ignition wire resistance. And clear the connector terminals.
(b) Check whether there is carbon deposit in plug, carbon tracking, residual current in insulating ceramics
NO > Replace the faulty components.


8. CHECK THE INJECTOR
(a) Using scan tool, select the item “AUTO DIAGNOSIS\FOTON\LIGHT BUS\MP-X MP\ENGINE\4G63 04
(b) Perform the injector active test.
(c) Check whether the same engine RPM decline obviously and shortly in synchronism (touching the injec-
tor, can feel vibration, or with the voice-tool, touch the injector, the action voice should be hearded).
04
NO > Repair, clear or replace harness or connectors. Every injector can spray even and standard quantity
gasoline. If not OK, replace it.
CAUTION
If the spraying condition isnot normal just as the “cylindrical growth”, or the 4 injectors spraying quan-
tity is not equal much more under the same condition (more than 5 ml), then replace the injector.
WARNING
ventilated areas and avoid open flame sources.
• If the pressure is higher than 350 kPa， check the return pipe:
the pressure again:
(a) Using the fuel return blocker and clamping the return pipe, make the system fuel not return. Check

CAUTION
Check connectors for fuel leakage as following:
(d) Check whether fuel leaks at fuel pipe connection.
NO > Replace fuel pump.
12. CHECK INTAKE AND EXHAUST SYSTEM
(a) Check the fuel system for any fuel leakage.

(b) Check the vacuum system for any broken, kinked or incorrectly linked vacuum pipes or hoses.
(c) Check the intake air pipe for being jammed, leaking, or damaged.
(d) Check the engine ground cable and verify a clean and tight connection.
(e) Check the sensors and actuators electrical connectors and verify good contact and tight connection.
(f) Check the PCV valve.
(g) Check whether the EVAP system leakage.
(h) Checkif the fuel pressure regulator vacuum pipe broken, kinked or crack.
(i) Check whether the Three-Way Catalytic Converter (TWC) is blocked.
(j) Check whether the throttle body gasket leakage.
(k) Check whether the intake manifold gasket leakage.
NO > Repair or replace the faulty components.
13. CHECK MAP/IAT SENSOR
(a) Check whether the installation of the MAP/IAT is normal?

(b) Remove the MAP/IAT sensor.
(c) Check whether the MAP/IAT sensor is dirty.
(d) Using scan tool, select the item “AUTO DIAGNOSIS\FOTON\LIGHT BUS\MP-X MP\ENGINE\4G63
GASOLINE ENGINE OR 4G64 GASOLINE ENGINE\MT20U2\READ DATA STREAM”.
(e) Read the scan tool displaied MAP/IAT sensor data stream value.
(f) With the 3 kinds of the basic types: idle tets, accerlerate suddenlly test and blocked test in exhaust
system. Test the vaccum rate in the intake manifold.
NO > Clear and reinstall or repair. If not OK, go to step 15.
14. CHECK OXYGEN SENSOR
(a) Engine idle.

(b) Inspect the displayed scan tool data stream.
(c) When the temperature is normal after the engine enter into the closed-loop control, inspect if the
oxygen sensor operate normally.
Oxygen Sensor Normal Value: 0 ～ 1 V. Change 5 ～ 8 times in 10 seconds periodically.

NO > Replace xoygen sensor harness or connector.
04
• Per cylinder pressure: 1270 kPa.
• Per cylinder limit: 880 kPa.
• Per cylinder difference limit: less than 25%. 04
YES > Go to step17.

(b) Check the cylinder with the endoscopy.
(c) Inspect the feedback voltage.
(d) Disassembly the engine inner faults.
(e) Clear the carbon deposit or remove and check the engine cylinder head.
(f) Check valves, carbon deposit of manifold. For example: the clearance between the cylinder and the
piston ring. The leakage of the cylinder gasket, and loose of the valve guides, carbon deposit of the
valve.
18. REPLACE ECM
• Malfunction of the Idle

Idle is too high (The The cause is probably that the air control motor
Engine idle speed too
engine does not idle at the intake air volume during idle • Malfunction of the
high
usual correct speed) is too great throttle body
• ECM
(a) Using the KT600 scan tool, perform the reading DTC procedure. (Refer to ”Chapter 04 engine control
Is the DTC present?

• Inspect the engine operating condition.
• Inspect the tachometer if the pointer deviates the idle target value.
• Inspect if the idle trembles is normal or load reasons, such as: A/C, lighting, push the lever into gear,
• Check the vacuum system for any broken, kinked or incorrectly linked vacuum pipes or hoses.
• Check whether the exhaust pipe emit black smoke. Check whether there is unburned petrol fumes.
• Check whether the throttle cable is adjusted to be appropriate.
3. CHECK THE ACCELERATOR PEDAL
(a) Check whether the accelerator pedal cable blocked.

NO > Adjust or replace the accelerator cable.
4. CHECK THE RELATED ACCESSORIES
(a) Check EVAP.

(b) Check the fuel pressure vacuum regualtor.
(c) Check whether the PCV vacuum pipe installation is reliable.
(d) Check whether the braking system vacuum booster pipe installation is reliable.
NO > Adjust or replace.
5. CHECK IDLE
(a) Engine runs at idle speed.

(b) Gear in N position. 04
(c) Depress brake pedal.
(d) Inspect if the idle speed is too high.
NO > Go to step 7.
04
6. CHECK THE VACUUM BOOSTER
(a) Blocking the vacuum pipe, inspect if the idle become normal.
NO > Repair or replace the vacuum booster.
7. CHECK PCV VALVE
(a) Clipping the PCV vacuum pipe, inspect if the idle become normal.
(b) Check whether the PCV valve clip. If the opening degree is normal.
NO > Replace PCV valve.
8. CHECK IDLE AIR CONTROL MOTOR
(a) Start engine and runs at idle.

(b) Using scan tool, select the item “AUTO DIAGNOSIS\FOTON\LIGHT BUS\MP-X MP\ENGINE\4G63
GASOLINE ENGINE OR 4G64 GASOLINE ENGINE\MT20U2\ACTIVE TEST”.
(c) Perform the idle air control motor test:
• Disconnect the idle air control motor connector, Check whether there is 12 V. And the resistance value is
28 - 33 Ω when the temperature is 20 ℃ .
• Remove the idle air control motor to test:
(d) Check expansion of the idle air control motor when turning the ignition switch ON.
(e) Check whether the idle air control motor can move when turning the ignition switch OFF.
NO > Repair or replace harness or connector or the idle air control motor.
9. CHECK THE INTAKE SYSTEM
(a) Check the vacuum system for any broken, kinked or incorrectly linked vacuum pipes or hoses.
(b) Check the intake air pipe for being jammed, leaking, or damaged.
NO > Repair or replace.
(a) Check whether the installation of the MAP/IAT sensor is normal?

(d) Turn the ignition switch ON. Read the displayed ECT and MAP/IAT value. It should be within the speci-
fied value.
NO > Clear, repair or replace the harness or connector. If the MAP value is not still normal, go to step 12.
YES > Go to step13.
NO > Repair or replace:
• If the pressure is less than 350 kPa.
(c) Go to next step.
12. CHECK INJECTOR

CAUTION
WARNING
YES > Replace the injector washer.
NO > Clean the injectpor and recheck it. Every injector can spray even and standard quantity gasline. If not
OK, replace it.
13. REPLACE ECM
.
• Malfunction of the IAC

motor 04
The cause is probably • Malfunction of the
that the air/fuel mixture is throttle body
The cause is probably
When the engine is cold, inappropriate when the
that the intake air volume • Malfunction of the
it stalls (At idle) engine is cold, or that the
during idle is too great injector
intake air
volume is insufficient. • Malfunction of the
ignition system
• ECM 04
(a) Using the KT600 scan tool, perform the reading DTC procedure. (Refer to “Chapter 04 engine control
Is the DTC present?

CAUTION
makes the ECM control the idle air impossilly. And it will cause the A/F too lean or too rich. The born-
ing will not be normal. And the usual reasons are: carbon and grease, grease beside the throttle air
path, carbon and grease with the idle air controlmotor.
(b) Start engine and run at idle.
(d) Perform the idle air control motor test:
(e) Disconnect the idle air control motor connector, Check whether there is 12 V. And the resistance value is
28 - 33 Ω when the temperature is 20 ℃ . Check whether the idle air control motor is clip. If necesasary,
NO > Clean, repair or replace harness or connectors.
4. CHECK THE ECT SENSOR
(a) Check the resistance accord with the standard:

• 20 ℃ : 2.1 ～ 2.7 kΩ
• 80 ℃ : 0.26 ～ 0.36 kΩ
(b) Using scan tool, select the item “AUTO DIAGNOSIS\FOTON\LIGHT BUS\MP-X MP\ ENGINE\4G63
GASOLINE ENGINE OR 4G64 GASOLINE ENGINE\MT20U2\ READ THE DATA STREAM”.
NO > Replace the ECT sensor.
5. CHECK THE IAT SENSOR
(a) Check the resistance accord with the standard:

• 20 ℃ : 2.3 ～ 3.0 kΩ
• 80 ℃ : 0.3 ～ 0.42 kΩ
(b) Using scan tool, select the item “AUTO DIAGNOSIS\FOTON\LIGHT BUS\MP-X MP\ ENGINE\4G63
GASOLINE ENGINE OR 4G64 GASOLINE ENGINE\MT20U2\ READ THE DATA STREAM”.
NO > Replace the IAT sensor.
GASOLINE ENGINE OR 4G64 GASOLINE ENGINE\MT20U2\ACTIVE TEST”.
gasline. If not OK, replace it.
CAUTION
WARNING
(b) Check the fuel system pressure. (Refer to “Chapter 12A fuel system - precaution”) 04
(2) If the return pipe is normal, replace the pressure regulator. 04
the pressure again:
NO > Repair or replace the fuel supply pipe, pump, injector.

CAUTION
Check connectors for fuel leaks as following:
• Turn the ignition switch ON (not crank the engine). Apply pressure on the fuel pipe. Check whether fuel
YES > Repair or replace the intake fuel pipe.
NO > Replace the fuel pump.

NO > Repair the engine mechanism faults.
13. REPLACE ECM
.
• Malfunction of the Idle air

control motor 04
• Malfunction of the throttle
body
• Defective ignition system, • Malfunction of the ignition
The engine stalls when abnormal air-fuel ratio, system
The engine stalls when
the accelerator pedal is poor • Malfunction of air-fuel ratio
accelerating
depressed • compression, etc are control system
suspected • Malfunction of the fuel 04
supply system
• Poor acceleration
• Clogged exhaust system
• ECM
NOTE
Start in idling mode: Put into gear without pressing the accelerator pedal, disengage the clutch and
start the engine. This moment, as the throttle valve is closed and the idling electric shock is closed,
ECM considers it as the idling mode. The control of idling mode is a cruise control without any load
signal, namely a steady speed control that the engine is controlled in target speed range. Speed-
raising control is done if with load signal. During starting, the load signal is input into ECM, the later
raises the engine speed, enhances the dynamic property and keeps the idling from the effect of load.
This moment the starting is smoothly and hard to be shut off generally. If the starting is wobbled and
easy to be shut off and the speed falls in idling mode, find the causes from the idling control.
Is the DTC present?

• Inspect if the idle trembles is normal or load reasons, such as: A\C, lighting, push the lever into gear,
(b) Start engine and run at idle.
(d) Perform the idle air control motor test:
(e) Disconnect the idle air control motor connector, Check whether there 12 V exists. And the resistance value
is 28 - 33 Ω when the temperature is 20 ℃ . Check whether the idle air control motor is clip. If necesasary,
(f) Remove the idle air control motor. Connect the connector:
• Check whether the idle air control motor can extend-retract when turning the switch off.
• Check whether the idle air control motor can move when turning the ignition switch on.
NO > Clear, repair or replace harness or connector.
4. CHECK THROTTLE POSITION
(a) With the scan tool, check whether the throttle is normal.
(b) Check whether the throttle open degree is normal when depressing the accelerator pedal.
NO > Adjust the throttle position.
5. CHECK THE LOAD SIGNAL
(a) Check whether the gear signal is sent to ECM.

(b) Check whether the A/C signal is sent to ECM.
(c) Check whether the load signal is sent to ECM.
NO > Repair the load signal harness.
6. CHECK THE IGNITION SYSTEM
(a) Engine runs at idle speed.

(b) Cut off one by one.
(c) Inspect if the idle speed changes.
CAUTION
It is better that use the active test function of the scan tool to perform the cutoff test. If without the
scan tool or the scan tool wirhout the function, the brennschluss period shoul not be too long, if not,
the TWC will be damaged.
(d) When brennschluss every cylinder, the same RPM should decline obviously or the same vibration.
YES > Go to step14.

(b) Disconnect the injector fuse. 04
(c) Remove any of the 4 spark plugs.
(d) Connect the spark plug to spark plug wire.
(e) Ground the spark plug on the cylinder block.
(f) Crank the engine to test the secondary ignition system with the spark plugs removed.
(a) Check secondary ignition wire resistance. And clean the connector terminals.
(a) Using multimeter, check resistance of the ignition spark wire.

Resistance：≥ 4 kΩ
gasline. If it is not OK, replace it.
CAUTION
If the spraying condition is not normal just as the “cylindrical growth”, or the 4 injectors spraying
quantity is not equal much more under the same condition (more than 5 ml), then replace the injector.
WARNING
the pressure again:
NO > Repair or replace the fuel supply pipe, pump,injector.

CAUTION
(b) Turn the ignition switch ON (not crank the engine). Apply pressure on the fuel pipe. Check whether fuel
• Per cylinder difference limit: less than 25%.

• Check the cylinder with the endoscopy. 04
17. REPLACE ECM
(b) Read value displayed on the the KT600 scan tool.
.
• Malfunction of the Idle

air control motor
• Malfunction of the
when the accelerator is throttle body
depressed in order to The cause is probably • Malfunction of the
Accelerated reaction is accelerate from the that ignition system, air- ignition system
slow, acceleraton speed, the vehicle is now fuel mixture or
disturbance traveling or a temporary compression pressure is • Malfunction of air-fuel
drop in vehicle speed defective ratio control system
during such acceleration. • Malfunction of fuel
supply system
• Poor compression
• ECM
(a) Using the KT600 scan tool, perform the reading DTC procedure. (Refer to “Chapter engine control sys-
tem - read and clear DTC”)
Is the DTC present?

3. CHECK THE AIR FILTER
(a) Check whether the air filter dirty, grease and blocked.
NO > Clean or replace the filter. If not OK, go to next step.
4. CHECK IDLE
(a) Start engine and runs at idle.

(b) Check whether the idle speed is normal. 04
NO > Refer to the symptom chart - idle, eliminate the problems.
(a) Check whether the installation of the MAP/IAT is normal?

04
(e) Read the scan tool displayed MAP/IAT sensor data stream value.
NO > Clear and reinstall or repair.
6. CHECK TPS
(b) With the analogue mulitimeter to check TPS resistance (resistance should be continuity).
(c) Refer to engine DTC chart.
7. CHECK FUEL SYSTEM PRESSURE
the pressure again:
8. CHECK INJECTOR

CAUTION
If the spraying condition isnot normal just as the “cylindrical growth”, or the spraying quantity is not
WARNING
YES > Go to step11.
NO > Clean the injector. Check the injector operation condition again. If not OK, replace it. Confirm the fault is
not present. If still not OK, go to next step.
NO > Repair or replace the fuel supply pipe, pump and injector.

CAUTION
(d) Check whether fuel leakage at fuel pipe connection.
11. CHECK EXHAUST SYSTEM
(a) Check the exhaust system and Three-Way Catalytic Converter (TWC).
(b) Check whether the exhaust pipe blocked with the exhaust pressure meter.
NO > Replace or clean the exhaust system.
(a) Check whether the engine valve-timing gear mark is aligned, damaged. And the belt is loose.

04
• Disassembly the engine faults.
15. REPLACE ECM
• Malfunction of the
Poor acceleration is the ignition system
inability to obtain an • Malfunction of air-fuel
acceleration corresponding Defective ignition system, ratio control system
to the degree of throttle abnormal air-fuel ratio, poor • Malfunction of the fuel
Poor Acceleration
opening (even though compression, etc are supply system
acceleration is smooth) or suspected. • Poor acceleration
the inability to reach • Clogged exhaust
maximum speed system
• ECM
Is the DTC present?
2. CHECK VISUAL INSPECTION

3. CHECK TPS
GASOLINE ENGINE OR 4G64 GASOLINE ENGINE\MT20U2\READ DATA STREAM”.
(b) With the analogue mulitimeter to check TPS resistance (resistance should be continuity).
(c) Refer to engine DTC chart.


(e) Read the scan tool displaied MAP/IAT sensor data stream value. 04
NO > Clear and reinstall or repair.
04
the pressure again:
6. CHECK INJECTOR

CAUTION
If the spraying condition is not normal just as the “cylindrical growth”, or the spraying quantity is not
WARNING
YES > Go to step 9.
NO > Clean the injector. Check the injector operation condition again. If not OK, replace it. Confirm the fault is
not present. If not OK, go to step 12.

CAUTION
• Turn the ignition switch ON (not crank the engine).
• Apply pressure on the fuel pipe.
• Check whether fuel leakage at fuel pipe connection.

(a) Check secondary ignition wire resistance. And clear the connector terminals.

• Per cylinder pressure: 1270 kPa. 04
04

15. REPLACE ECM
04-112 DIAGNOSTICS - DIESEL ENGINE CONTROL SYSTEM
DIESEL ENGINE CONTROL SYSTEM

PRECAUTION
1. POWER OFF.
• The battery negative cable must be disconnected first before removing or installing any electric
appliance on when tools or facilities will touch the exposed terminals. It should be connected
eventually. This will prevent person injured and vehicle damaged.
• The ignition switch must be off without any special descriptions.
WARNING
The ignition and illuminatioin switches must be off before before removing or installing the battery
negative cable (the semiconductor maybe damaged without doing that).
2. RESET THE ODOMETER AND CLOCK IF DISCONNECTING THE COMBINATION INSTRUMENT
BATTERY NEGATIVE CABLE.
CAUTION
The total course will not be reset.


Expression
4. OVERHAUL THE DIESEL ENGINE CONTROL SYSTEM FAILURE PRECAUTIONS.

(a) No disconnecting battery from electric circuit while engine is running at high speed in case the instanta-
neous overvoltage damage the ECM and sensors.
(b) The ECM should be disconnected at the time for electric welding on the car body. It is special attention
that performing the repair work beside the ECM or sensors.
(c) The system will resumes its normal state temporarily or competely by removing and reinstalling the sus-
picious faulty components when the connector terminals or the installing state of the components go
out of order.
(d) The high impedance type multimeter should be used to the test except the especial description of the
procedure in place of the traditional analogue types multimeter.
(e) Don’t check any electric apparatus connecting the ECM with a test light.
(f) Never connect the negative and positive battery cables wrong. The battery negative cable must be
grounded.
(g) ECM and sensors must be kept from moisture. No permission damaging the seal device of ECM and
sensors and washing them more.
(h) Prevent human body static electricity from damaging ECM: The operator body must be grounded when
operator checks ECM or replace chips.
(i) In order to identifying the faulty position, we must check the vehicle condition while vehicle goes out of
order. For example, we check the faults through the DTC. And we record these faults states before
disconnecting every connector or removing and installing components.
(j) We must remove and install ECM, actuators and independent sensors when the ignition switch is off
unless there is additional specification in the checking procedure.
(k) If the removed and installed ECM, actuators and sensors are to be reinstalled, the system should be
checked after completing installation. Using the special diagnosis tool to check DTC.
DIAGNOSTICS - DIESEL ENGINE CONTROL SYSTEM 04-113
(l) When diagnosis, the ignition switch turns “ON” position and the connectors are dissociated. Other
system will store DTC. After diagnossis, confirm DTC in all systems. Turn the ignition switch “LOCK”
position when the connectors are connected and disconnected.
(m) The test probe must not be probed in wire harness. This will reduce the waterproofness. And it also 04
cause corrossion. Use the test wire, wire connector and measure wire harness and so on.
(n) Check the common connectors when they are in connection status by probing terminals in the wire
harness. If the connector is too small to check, should not force insertion.
(o) If check the common connectors when they are not in connection status (check male connectors):
• Be careful and not short terminals circuit by using a probe. This will damage the interior circuit in ECM.
• The system to be checked and other system will store DTC when they aren’t in connecting status. 04
(p) If check the common connectors when they are not in connection status (check formale connectors):
• Using the special tools, check wire harness.
(q) We shall have a short harness or connectors without taking cautions by wrong insertion. This will dam-
age wire harness, sensor, ECM and other components So we must carefully handle when checking.
(r) Don’t check with the list order.
• If the check results are different from the standard value, then check related sensors ,actuators and
wire harness. Repair or replace as necessary.
• Check with the voltage meter again after repairing or replacing. Confirm if the faults have been com-
pleted.
(s) Ground inspection.
• Ground connections are very important to the proper operation of electrical and electronic circuits.
Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion
(rust) can become an unwanted resistance. This unwanted resistance can change the way a circuit
works.
• Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can
drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the
circuit. Even when the ground connection looks clean, there can be a thin film of rust on the surface.
• When inspecting a ground connection follow these rules:
1 Remove Bolt (Screw) 3 Reinstall Bolt (Screw) Securely
Inspect Mating Surface For Tarnish, Dirt,

2 Rust, Etc. Clear As Required To Assure
Good Contact
(a) Remove the ground bolt or screw.

(b) Inspect all mating surfaces for tarnish, dirt, rust, etc.
(c) Clean as required to assure good contact.
(d) Reinstall bolt or screw securely.
(e) Inspect for “add-on” accessories which may be interfering with the ground circuit.
(f) If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of
the wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in
one eyelet make sure no ground wires have excess wire insulation.
LOCATION
04
04
1 ECM 2 Fuel Tank

1 Injector 9 Timing Belt Cover
2 Intake Manifold Assy Engine Coolant Temperature (ECT)

10
Sensor
3 Common Rail Pressure Sensor
11 Coolant Fan Temperature Sensor
4 Crankshaft Position (CKP) Sensor
12 Turbocharge
5 High Pressure Common Rail
13 High Pressure Pipe
6 Left Mount
14 EGR Valve
7 High Pressure Pump
8 Camshaft Position (CMP) Sensor

04
04
1 DLC 5 Accelerator Pedal
2 Brake Pedal 6 Ignition Switch
3 Body Junction Box 7 ECM
.
HOW TO DIAGNOSTICS ANALYSE

NOTE
Use diagnostic scan tool to diagnose vehicle.
1. VEHICLE SENT INTO REPAIR SHOP
YES > Go to the next step.

2. GET INFORMATION ABOUT SYMPTOM FROM THE CUSTOMER

3. CONNECT THE DIAGNOSTIC SCANNER TO DLC3

4. CHECK DTC AND DATA FREEZE-FRAME

5. ERASE DTC

6. VISUAL CHECK

7. CONFIRM FAULT SYMPTOM
Check result (if engine can not start,check following first)
Result Proceed To
Fault present Next step
Normal Step 8
8. SIMULATE FAULT SYMPTOM

9. CHECK IF DTC PRESENT
Check result
Result Proceed To
DTC present Next step
Normal Step 11
10. REFER TO DTC TABLE

11. Basic check
Check result
Result Proceed To 04
12. REFER TO SYMPTOM TABLE

04
Check result
Result Proceed To
Faulty circuit can be confirmed Next step
Faulty part can be confirmed Step 15
13. CHECK ECM POWER SUPPLY CIRCUIT

14. CHECK ELECTRIC CIRCUIT
Check result
Result Proceed To
15. CHECK INTERMITTENT FAULT

16. CHECK PARTS

17. CONFIRM FAULT

18. ADJUST OR REPAIR

19. PERFORM CONFIRMATION TEST
YES > END.

CAUTIONS FOR CIRCUIT TROUBLESHOOTING

1. CAUTIONS FOR CIRCUIT TROUBLESHOOTING ARE AS FOLLOWS.
(a) Be sure to use the high-impedance multimeter; be sure to original conducting wire service tool kit,
including various kinds of connectors, contact probes, sealing elements, terminals, testing leads and
other tools for service connectors.
(b) Conduction testing. Select the conduction testing mode on the multimeter, which is marked with a diode
symbol. Disconnect both ends of the circuit or part to be tested during the testing. Contact one test pen
with one end of circuit or one terminal of part and contact the other test pen with the other end of circuit
or the other terminal of part. Read the measured value; if the resistance is less than 2 Ω, the multimeter
sounds a buzzer to indicate the conduction; if the circuit is open, the multimeter doesn’t sound a buzzer.
(c) Test for short-circuit grounding. The short-circuit grounding is a case in which it can’t be grounding
(ground) but actually is grounding. The testing sequences for short-circuit grounding are:
• Turn the ignition switch OFF.
• Unplug the connector to be tested. Remove the sensor from the harness connector if to test it; remove
the harness connector from the sensor if to test the harness connector on ECM.
• Contact one test pen of the multimeter with the contact probe to be tested and the other test pen with
the ground.
• The read of multimeter must be larger than 1MΩ, indicating the circuit is open rather than short.
• If the circuit isn’t open and the resistance value is less than 2 Ω, it shows that the conducting wire
tested must be shorted to ground.
• Repair or replace the part or harness.
(d) Testing for short between contact probes. Short between contact probes means the case in which there
should be no conduction between two contact probes but conduction exists. Testing sequences are:
• Turn the ignition switch OFF, remove the connector to be tested; if the contact probe and other sensors
form a circuit, remove the sensor.
• Contact one test pen of the multimeter with the proper contact probe to be tested at the connector
harness side, and the other test pen with the other contact probes at the connector harness side.
• The read of multimeter must be larger than 1MΩ, indicating the circuit is open; if the circuit isn’t open
and the resistance value is less than 2 Ω, it shows there must be short circuit between contact probes
tested.
• Check the inside of harness connector for wet vapor which may cause short circuit.
• Repair or replace the harness.
(e) Conduction testing. Conduction means that the resistance between two contact probes is less than a
definite value, namely the resistance should be less than 2 Ω.Testing sequences are:
• Turn the key switch OFF.
• Remove the harness connector to be tested.
• Contact both test pens with contact probes of harness to be tested separately.
• For the conducted harness, the resistance should be less than 2 Ω.
• If the resistance is larger than 2 Ω, repair or replace the harness.
CAUTION
DTC stored caused by burned fuse.
2. Remove the burned fuse. Check the resistance

between the load side and ground where the fuse
burned there. Shut off all the switch that connecting
to the fuse. If the resistance is almost zero, the 04
switch and the load components circuit must be
shorted somewhere. If the resistance is not zero,
there is no circuit for short. But the temporaly short
circuit also will cause the burning of the fuse.
3. The shortage caused by following:
• Harness was clipped 04
• Harness was damaged
• Water enter into connector or harness
• Misoperation
1 Battery
2 Fuse
3 Load switch
4 Burned fuse
5 Short position
DIAGNOSTIC HELP - INTERMITTENT FAULT

If an intermittent fault exists, perform diagnosis as follow:
CAUTION
• Intermittent incidents may occur. In many cases, the malfunction resolves itself (the part or
circuit function returns to normal without intervention). It is important to realize that the
symptoms described in the customer's complaint often do not recur on (1st trip) DTC visits.
Realize also that the most frequent cause of intermittent incidents occurrences is poor
electrical connections. Because of this, the conditions under which the incident occurred may
not be clear. Therefore, circuit checks made as part of the standard diagnostic procedure may
not indicate the specific malfunctioning area.
• In this case, the maintenance staff must find out the situation in detail from the customer, ask
the car owner for the details of driving conditions, weather conditions, frequency of occurrence
and symptom of failure, take analysis and simulate the same or similar conditions and
environment, then, determine if the symptom of failure is caused by vibration, temperature or
other factors. No matter how experienced the maintenance staff are, how skilled their technique
is, if analyzing the failure without checking, they would certainly neglect some important factors
during repairing which causes wrong speculation and the repair work will take an indirect route
or can’t go forward. The following checking will help to find out this kind of failure.
1. VIBRATION METHOD.
• Connector: Shake the connector lightly in vertical or

horizontal directions, check if the wiring harness
connector connecting the connector and corresponding
parts is loose, the terminal is dirty, rusty, worn or bended
and if the connection is loose because of the terminal
extension.
• Harness: Shake the harness lightly in vertical or
horizontal directions, thoroughly check the harness
breakaway condition in the connector connecting
vibration section and engine/cab instruments.
• Relay, part and sensor: pat the sensor, relay and part
considered as the failure cause lightly with hands, check
them for failure, don't hit the relay with force, otherwise
the relay may be open.
2. HEATING METHOD.
If one doubtful region is considered to cause a failure, heat the part which is the most possible cause of failure
with an electric blower or the like to check if the failure occurs.
04
CAUTION
Don’t heat to over 60 ℃ (the heating temperature should be in the limit of touching the part with hands);
don’t heat the control module.
3. SPRAYING METHOD.
If the failure is considered to occur in rainy day or wet weather, spray water to the vehicle to check if the failure
occurs. 04
CAUTION
• Don’t spray water to the diesel engine directly to cool the engine, sprinkle water on the front
face of radiator to change the temperature and humidity indirectly.
• Don’t spray water on electronic parts directly.
• Please take extra care to sprinkle water on vehicle leaking water, as the water leaked into
vehicle may damage ECM.
4. ELECTRIC APPLIANCE CONNECTED FULLY METHOD.
If the failure is possible to be caused by electric overload, connect all electrical loads, including the heater
blower, the headlamps and the rear-window defroster, to check if the failure occurs. The trouble location or
failure part must be found out while the symptom is confirmed during the failure symptom simulation test. To do
this, narrow the range of circuit which is possible to failure based on the symptom of failure before starting the
test and the pre-connection of connectors, then carry out the symptom simulation test and judge if the circuit
tested is normal. When a puzzling failure occurs, make full use of troubleshooting and diagnostic code list for
fault analysis and diagnosis to narrow the failure range and find out the trouble location quickly; this method is
very practical and effective.
5. DATA FLOW CAPTURE WITH DIAGNOSTIC SCANNER.
Use the function of data flow capture on the diagnostic scanner. When seeing the data flow on the diagnostic
scanner, make the rated data status to simulate the fault conditions based on the freeze-frame on the
diagnostic scanner.
6. OSCILLOSCOPE METHOD.
• Using the oscilloscope to capture waveform can be more helpful to find intermittent malfunction.
• The oscilloscope analyzer can collect the waveforms of ignition, injection and electrical control system
sensors, diagnose if the sensor fails or not correctly by analyzing the sensor waveforms, and diagnose
the failures of sparking-plug, high voltage wire and ignition coil of ignition system. It can also analyze
the possible fault points of the air intake and outtake system and the diesel fuel system.
• Generally, there is no method to replace the ones to view the known normal parameters of vehicle. Only
by knowing which parameter is the normal, can it be picked out as problematic or abnormal one.
• • If you apply the known injection nozzle waveforms in the waveform testing of other magnetic valves,
their overall waveforms are very similar.
7. OTHER METHODS.
Before replacing ECM of other electronic control modules in part replacing method, take full diagnosis for other
external causes. ECM or other electronic control modules are expensive products with high reliability.
CAUTION
When replacing and testing possible damaged ECM or control modules, install the possible damaged
ECM or control modules on a failure-free vehicle for testing; don’t install new control modules on a
failed vehicle for testing to avoid damaging the control modules.
BASIC SERVICE PROCEDURE

If the failure can't be confirmed through DTC testing, do the troubleshooting analysis for all circuits that are
possible to cause failures. In many cases, carrying out the following preparation works can find out the location
causing failure effectively. So, it’s necessary to take this method during engine troubleshooting.
CAUTION
• Troubleshooting working is a systematical project, so the diesel engine should be taken as a
whole (a system) rather than a set of components. To grasp the whole situation of failure
occurrence, make a complete understanding from the operators and observe the diesel engine,
take necessary checking and make analysis to finger the cause of the failure.
• Some failures of diesel engine, such as gas in diesel system, filter blocking, loose driving belt
and so on, can be cleared through necessary technical maintenance and adjustment. But some
failures, such as cylinder gasket damage, piston ring severe wear and valve face wear, can’t be
cleared with general methods of maintenance and adjustment as the mechanism defect. There
failures only can be cleared by removing and repairing the diesel engine or replacing parts.
(a) The diesel using condition:
No. Item
1 Is there any unnormal sound.
2 Load or not.
3 Accelerate or decelerate.
4 Does the oil pressure or ECT change.
6 The resume of the oil, diesel, coolant.
7 Check whether the exhaust thickness is normal.
8 Check whether the electric accelerator pedal is sensitive.
9 Check whether the deceleration is normal.
10 Check whether the shut down is satisfaction.
11 Check whether the cold starting is satisfaction.
12 Check whether there is any misfire or stall.
13 What kind of diesel is used, what the degree is, and where from.
14 During idle or full speed running, there would be a surge or not.
15 Check whether the long period idle can last.
(b) The maintenance history should be known. Including as following:
No. Item
1 Recently, Whether diesel engine has been repaired.
2 Ever, Whether this trouble happen.
3 Recently, When the oil and diesel has changed.
4 How long or far the diesel engine run.
5 Is there any metallic impurity, when change oil filter.
6 Any repaired items.

(c) Inspect the checking result finally, as following:
No. Item
1 Whether the diesel engines is clean. 04
2 What the degree of tightness of belt is.
3 There is external seepage of oil, diesel and water or not.
4 Whether there had been hot phenomenon.
5 Whether there is any temporary maintenance on diesel engine. 04

6 What the sounding of the diesel engine is. And any surge of the belt pulley.
Whether there component which does not belong to the diesel engine or nonstandard
7
component exist.
Oil level, coolant level and diesel level (if relate to the bearing, pay attention to the oil
8
condition).
9 When removeing, pay attention to the carbon deposit, abnormal taste, etc.
13.
ECM CONNECTOR TERMINAL DIAGRAM
ECM TERMINAL DEFINITION

Fuel Injector 3 high
A1 W K18 - -
voltage

A2 W K19 - -
voltage
A3 - - K20 - -
A4 - - K21 - -
A5 - - K22 - -
A6 - - K23 - -
A7 CKP signal ground B K24 - -
Diagnostic
Common rail pressure
A8 W K25 communication （K- L-B
sensor ground
line）
Coolant temperature
A9 - - K26 -
indication output signal
A10 - - K27 - -
CMP sensor 5 V power

A11 Ye K28 Ignition signal B-G
supply
A12 CKP speed signal L K29 - -
A13 - - K30 APP1 sensor ground BR
A14 - - K31 APP2 sensor signal L
A15 - - K32 - -

A16 W K33 - -
voltage

A17 W K34 - -
voltage
A18 - - K35 - -
High pressure pump

A19 R-L K36 - -
power supply
A20 CMP sensor ground V K37 - -
A21 - - K38 - -
A22 - - K39 - -
A23 - - K40 Oil-water separator signal Y-L
A24 - - K41 - -
A25 - - K42 Start request signal R-W
A26 - - K43 - -
A27 CKP sensor speed signal GR K44 - -
Common rail pressure Electric accelerator power

A28 G K45 L-Y
sensor 5 V power supply supply
Electric accelerator power

A29 - - K46 L-B
supply
A30 - - K47 -
Fuel Injector 2 low Engine speed output

A31 R K48 Y-W
voltage signal
A32 - - K49 - -
Fuel Injector 4 low
A33 G K50 - -
voltage
04
A34 - - K51 - -
A35 - - K52 Pre-heat control intput Y-G
A36 - - K53 - -
A37 IAT sensor GR K54 A/C request signal W-R

04
A38 - - K55 - -
A39 - - K56 - -
A40 - - K57 - -
A41 ECT sensor ground B K58 Clutch signal Y
A42 MAF sensor W-L K59 - -
A43 Common pressure signal Y-B K60 - -
A44 MAF sensor ground G-R K61 - -
A45 - - K62 - -
Fuel Injector 3 low

A46 L K63 - -
voltage
Fuel Injector 1 low

A47 L K64 - -
voltage
A48 - - K65 - -
A49 Pump control W-L K66 - -
A50 CMP signal Y-R K67 - -
A51 - - K68 A/C relay signal W
Start enabling output

A52 - - K69 R-W
signal
A53 - - K70 - -
A54 - - K71 - -
A55 - - K72 Main relay L-G
A56 - - K73 - -
A57 - - K74 - -
Vehicle speed sensor

A58 ECT signal BR-W K75 B
onput signal
A59 - R-B K76 - -
A60 EGR control Wh K77 - -
K01 Power supply R-B K78 - -
K02 Ground W-B K79 - -

K03 Power supply R K80 Redundant brake signal GR
K05 Power R K82 - -
K07 - - K84 - -
K08 APP2 sensor ground V-O K85 - -
K09 APP1 sensor signal V-W K86 - -
K10 - - K87 - -
K11 - - K88 - -
K12 - - K89 - -
K13 - - K90 - -
K14 - - K91 SVS indicator R-Y
K15 - - K92 Pre-heat indicator L-W
K16 - - K93 Pre-heat relay G-Y
K17 Brake signal B-Y K94 - -

CHECK ECM HARNESS-SIDE TERMINAL WITH A MULTIMETER

Standard normal resistance and continuity as follow:
No. Item Normal Condition 04

1 No.1 injector
2 No.2 injector
0.255 ± 0.040 Ω (20 ～ 70 ℃ )
3 No.3 injector
4 No.4 injector
04
5 EGR solenoid valve 14 Ω (20 ℃ )
7 CKP sensor 860 ± 86 Ω (20 ℃ )
14785 ～ 16443 Ω (-20 ℃ )
5605 ～ 6168 Ω (0 ℃ )
9 IAT sensor
2401.9 ～ 2619.3 Ω (20 ℃ )
318.68 ～ 340.27 Ω (80 ℃ )
15.462 Ω (-20 ℃ )
5.986 Ω (0 ℃ )
10 ECT sensor
2.500 Ω (20 ℃ )
0.323 Ω (80 ℃ )
DIAGNOSTIC SYSTEM
1. The failure of engine electric control system is
divided into 2 classes:
(a) First is lighting MIL lamp; when the instrument MIL lamp
lights, based on relevant requirements of national rules, it
needs to be treated immediately, otherwise the system
will limit the speed of the engine so as to affect the
normal operating of vehicle.
(b) The other is lighting SVS lamp, indicating that the system
fails and needs to be repaired in time.
(c) The failures of both classes should be checked with
diagnostic scanner or special equipment with
corresponding functions.
2. The following matters should be noted during the engine running and service processes.
(a) Turn the ignition switch on before starting. Wait for about 3 seconds. Observe whether the mil indicates
on instrument. If the preheat indicator turns on, start engine in 2 seconds after the preheat indicator
turns off.
(b) The lighting of SVS lamp and MIL lamp is controlled by ECM; the special lighting of svs lamp and MIL
lamp after and before starting are described below:
• For system without failure, the ignition switch is turned ON, the MIL lamp lights on, SVS lamp lights and
then goes out (system self-checking). The SVS lamp and MIL lamp are off after engine starting and
stalling.
• For system with failure, the ignition switch is turned ON, the MIL lamp lights on, the SVS lamp is off and
then lights on after self-checked. After engine starting, if the SVS lamp in failure class is defined as
lighting on mode, the SVS lamp will light on after the requirements for SVS lamp lighting are met. If the
MIL lamp in failure class is defined as lighting on mode, the SVS lamp will light on after the
requirements for MIL lamp lighting are met. After engine stalling, the ignition switch is turned OFF and
goes out after AFTRRUN process (90S for the longest).
(c) If an engine failure that may involve the fuel injection system-electronic controlled is to be diagnosed
and cleared, first determine if the failure is related with the fuel injection system-electronic controlled. If
the engine fails but the malfunction indicator lamp doesn't light, the failure is unrelated to the electronic
control system generally.
(d) The diagnostic trouble codes record and data related

with sensors and actuators in ECM can be read by
KT600 diagnostic scanner. Additional, the actuator can
be positive driven by the diagnostic scanner under
specified conditions.
(e) DLC- data link connector.

(f) ECM communicate with DLC.
(g) Terminals in DLC arrange accord with standard.
04
Terminal No. Name Check Result
Diagnostic Pulse signal (When

7
communication K commnicate) 04
16 Battery positive 9 ～ 14 V
NOTE
• Connect the diagnostic scanner cable to DLC. Turn the
ignition switch ON. Try to open it. If displayed error
communication on screen, then the diagnostic scanner
fault .
• If the diagnostic scanner communicate with other
vehicle normally, then check the DLC on the original
vehicle.
ENGINE CONTROL SYSTEM SELF-DIAGNOTIC ITEM

No. Check Item
1 Injector
2 Pre-heat Controller
3 High Pump
4 MAF Sensor
5 EGR Vacuum Solenoid Valve
6 Common Rail Pressure Sensor
7 CKP Sensor
8 CMP Sensor
9 Accelerator Pedal Position Sensor
10 ECT Sensor
READING AND ERASING DIAGNOSTIC TROUBLE CODE (DTC)

NOTE
The troubles are tested and determined by the diesel engine control system and stored in the diesel
Engine Control Module (ECM); the system troubles can be current or history.
(a) Current troubles: Exist in ECM currently. For example: The circuit of Engine Coolant Temperature
(ECT) sensor is open. The current troubles must be repaired, otherwise, they can’t be erased from
memory.
(b) History troubles: Have two storage types.
• The trouble has been repaired and actual trouble has disappeared, but the memory hasn’t been erased
from ECM.
• The trouble occurred once and didn’t exist, but is possible to occur again. For example: Poor contact of
conducting wire. As the stored troubles are not current ones, it’s unnecessary to repair them before
erased from the memory, or it can be processed referring to the trouble-shooting methods for
intermittent malfunction.
CAUTION
• If the battery voltage is too low and the trouble code can’t be output normally from ECM, the
battery voltage must be tested before checking and the voltage should not be less than 11 V.
• When the battery or ECM connectors are disconnected, the trouble code stored in ECM will be
erased.
• Before connecting or disconnecting KT600 scan tool, be sure to confirm the ignition switch is in
OFF (LOCK) position.
CAUTION
Using the KT600 collective intelligence scan tool, read DTC.
Using the KT600 scan tool, perform the reading DTC procedure:
(a) Check and confirm the following conditions:

• Release the accelerator pedal.
• Turn A/C switch OFF.
• Shift transmission to neutral.
(c) Connect the KT600 scan tool to the Data Link Connector
(DLC) - use the most current software available.
(e) Select the item “AUTO DIAGNOSIS\FOTON (V03.20)\
LIGHT BUS\MP-X MP\ENGINE\ DIESEL ENGINE\
BOSHE DIESEL COMMON RAIL SYSTEM\EDC16C39
OR EDC17C55\ READ DTC”.
(f) Check DTC and data stream. After recording, delete it (if
DTC cannot be deleted, then perform the diagnosis
procedure refer to “Diagnostics trouble code check”.
Repair faults ).
(g) Start diesel engine and warm it to normal operating
temperature.
(h) Under one of the condition, run engine to MIL ON:
• Simulate DTC set condition.
• Simulate the customer’s description.
• Simulate the scan tool freeze-frame data.
(i) Using the scan tool, read the DTC in ECM.
(j) If there are DTCs but the stream is normal or the function
is good, then refer to the diagnostics help. If there are DTC
but the stream isnot normal or the function is not good,
then perform diagnosis procedure refer to “Diagnostics 04
trouble code chart”.
NOTE
Using the scan tool to catch data. As soon as DTC was saved, ECM recorded the vehicle and driving
conditions as the type of freeze-frame data stream. When eliminate faults, the capture function will
help to confirm the conditionof the fault, such as warm condition,stop condition and other data.
Using the scan tool, clear DTC: 04
available.
(d) Select the item “AUTO DIAGNOSIS\FOTON(V03.20)\LIGHT BUS\MP-X MP\ ENGINE\ DIESEL
ENGINE\ BOSCH DIESEL COMMON RAIL SYSTEM\EDC16C39 OR EDC17C55\CLEAR DTC”.
CAPTURING DATA
CAUTION
Once DTC is captured and stored, ECM records the vehicle and driving conditions information as a
form of rated data. During troubleshooting, the rated data can help determine if the vehicle was
running or parked, and data of other sensors and actuators has been recorded when the trouble
occurred.
CAUTION
• If the DTC is detected but the trouble can’t reappear, confirm the freeze-frame rated data. ECM
records the diesel engine condition in form of freeze-frame data at regular intervals. The scan
tool can be used to read several sets of freeze-frame data respectively. The KT600 scan tool
provides powerful random data flow help function. Select read data flow function menu in diesel
engine system, enter the data flow testing result display interface, click “?Help” button to eject
the following windows:
• Driving Record Playback
• Calculator
• Data Range Reference
• Data Capture
• Data Comparisons
• Data Flow Settings
• Data/Waveform Display
• Driving Recorder Menu
• The data can be used to simulate the vehicle conditions as the failure occurs. It also can help determine
the cause of trouble and judge if it’s temporary fault. When the diesel engine is running with trouble,
select the menu items: Auto Diagnosis\Foton(V03.20)\Light Bus\MP-X MP\Engine\Bosch Diesel Com-
mon Rail System\EDC16C39 OR EDC17C55\Read Data Flow (Click “?Help”)\Data Capture\ Click
Record\(Click “?Help”)\Data Comparisons.
• Enter the data flow testing interface, click “?Help” button and enter the data flow help menu, select
“Data Capture” for data capturing function, the system will record all available data currently.
• After storing files, click “?Help” button, select “Data Comparisons” in Help” menu and the system calls
stored data files to do data comparisons.
• Enter data flow testing interface, click “Value/Wave form Display” in “?Help” function menu to eject the
“Value/Waveform Graphs”. This function displays the change rule of data flow value intuitively in form of
graphs so as to judge the troubles of automotive electric equipment.
DATA STREAM LIST/ACTIVE TEST

1. DATA STREAM LIST.
NOTE
04
• Through reading the data stream displayed on scan tool sreen, we can check the sensor,
actuator and switch data value but not removing any components. As first step, this way is the
best way to short diagnosis period.
• The following arranged the data stream under the normal condition. It only offer to reference.
Don’t judge a component normal or not only depend on these values.
READ DATA STREAM PROCEDURE: 04

(c) Connect the KT600 scan tool to the Data Link Connector (DLC) - use the most current software
available.
(e) Select the item “AUTO DIAGNOSIS\FOTON (V03.20)\LIGHT BUS\MP-X MP\ENGINE\DIESEL
ENGINE\BOSCH DIESEL COMMON RAILSYSTEM\EDC16C39 OR EDC17C55\READ DTC”.
(f) The table below lists the data found in inspection items at different states by KT600 within “DATA LIST”
items.
CAUTION
If no concrete specification of idle condition, the lever is in neutral position. The A/C and accessories switch are
in the OFF position.
Specified
Display Item Check Item
Condition
Battery voltage Ignition switch: ON System voltage
RPM Idle 0 ～ 2200 RPM
• Engine: running
ECT Actually measure -40 ～ 120 ℃
IAT: 0 ℃ 0℃
IAT: 20 ℃ 20 ℃
• Engine: running
IAT
• Ignition switch: ON IAT: 40 ℃ 40 ℃
IAT: 80 ℃ 80 ℃
Accelerator pedal: release

fully 0.72 ～ 0.74 V
Accelerator pedal 1 • Ignition switch: ON
voltage • Engine: running Accelerator pedal:
3.95 V
depress fully
Accelerator pedal: release

fully 0.36 ～ 0.37 V
Accelerator pedal 2 • Ignition switch: ON
voltage • Engine: Not running Accelerator pedal:
1.97 V
depress fully
Accelerator pedal:
Open
Clutch pedal condition Ignition switch: ON depress
Accelerator pedal: release Close

Specified
Display Item Check Item
Condition
Engine: idle A/C switch: OFF Close
A/C control condition (A/C turns ON, A/C
compressor works) A/C switch: ON Open
Main relay condition Ignition switch: ON Open
CKP - CMP sensor Engine: running Open

Ignition switch: ON
synchronization state Engine: not running Close
Pre-heat switch: open Open

Pre-heat indicator output Ignition switch: ON
Pre-heat switch: close Close
Start motor: start Open

Start motor condition
Start motor: not start Close
2. ACTIVE TEST.
CAUTION
The active test function for us to check the sensor, actuator and switch data value but not removing
any components. We can use the scan tool to perform the test. As the first step, this way is the best
way to short diagnosis period.
available.
(d) Select the item “AUTO DIAGNOSIS\FOTON (V03.20)\LIGHT BUS\MP-X MP\ ENGINE\DIESEL
ENGINE\BOSCH DIESEL COMMON RAILSYSTEM\ EDC16C39 OR EDC17C55\ACTIVE TEST”.
(e) Refer to the following chart, perform the active test. The following chart is the item which in the
“ACTIVE TEST” of the KT600 scan tool.
(f) When performing the function of the “ACTIVE TEST”, if there is fault phenomenon, check and repair.
(g) After repairing, using the KT600 scan tool, perform again.
(h) Clear DTC.
(i) Disconnect the KT600 scan tool.
(j) Restart engine to perform test. Confirm the faults has been deleted.
When performing the active test, the displayed data stream table will be shown as below.
Scanner Display Test Component Control Area Diagnosis Remark

Diesel engine RPM test Diesel engine RPM - - 04
Front supply pump test Front supply pump - -
Pressure wave revise

Pressure wave - -
remove
Exterior detector test Exterior detector - -

04
Common rail pressure
Common rail pressure - -
test
Cylinder stop test Cylinder - -
EGR cooler output test EGR cooler - -
Exhaust brake test Exhaust valve - -
3. FUNCTION TESTS.
CAUTION
Function tests can test the engine functions including high-pressure, acceleration, cylinder
compression, cylinder cut, starting capacity and so on.
The function testing includes the following items:
• High pressure testing
Test the leak of high pressure system, leak of high pressure pump, fuel return and efficiency of delivery in low
pressure in different rail pressures and speeds.
• Acceleration testing
Close the injectors in cylinder one by one, increase the fuel injection, test the speed, record abnormal cylinder
values and compare the test values with the min value.
• Cylinder cut testing
Close the injectors in cylinder one by one, test the speed and record abnormal cylinder values.
• Compression testing
ECM software limits the fuel injection function of diesel engine, the starter drives the diesel engine to run, ECM
tests and records the speeds of cylinders at particular stages.
• Starting troubles information testing
During diesel engine starting, incorrect signals of diesel engine speed, rail pressure and camshaft position may
result in the diesel engine unable to start. The causes of the diesel engine unable to start can be found out
through this test.

Note
If a malfunction code is displayed during the DTC check in the check mode, check the circuit for the
codes listed in the table below. For details of each code, refer to the DTC chart.
• A/C harness
Fault Path Of Air Condition Relay Power Stage Short
P0647 • A/C switch
Circuit Battery
• A/C relay
• A/C harness
Fault Path Of Air Condition Relay Power Stage Short
Circuit Ground
• A/C relay
• A/C harness
Fault Path Of Air Condition Power Stage No Load,
Excess Temperature
• A/C relay
Air Condition Pressure Sensor Period Max Error = Src- • A/C pressure sensor
P0531
high,period Min Error = Src-low • A/C pressure senhsor harness
• A/C pressure sensor

P0533 Air Condition Pressure Sensor Duty Cycle Min Error
• A/C pressure senhsor harness

P0532 Air Condition Pressure Sensor Duty Cycle Max Error
• A/C pressure switch

P0530 Air Condition Pressure Pressure Dsmdeb1type
• A/C pressure switch harness

P2518 Air Condition Pressure Voltage Above Upper Limit

P2517 Air Condition Pressure Voltage Below Lower Limit
P060B Ecusrc-high Error Of ADC Reference Voltage • ECM
• MAF sensor
Checking The Drift Factors Out Of The Range In The
P1100 • Short or open in MAF sensor harness
Low-idle Mode
• ECM
• IAT sensor
Intake Air Temperature Sensor Voltage Above Upper
P1101 • IAT sensorharness or connectors
Limit Or Below Lower Limit
• ECM
• MAF sensor
Error Path For Signal Range Check Of Duty Cycle Of
Air Temparature Signal
• ECM
• MAF sensor
Error Path For Plausibility Check Of Offset Drift Of
Airmass
• ECM
• Air temparature sensor

P0113 Air Temparature Above Upper Limit • Air temparature sensor harness
• ECM
• Air temparature sensor

P0112 Air Temparature Below Lower Limit • Air temparature sensor harness 04
• ECM
• MAF sensor
P0101 Air Mass Signal Signal Range Check Error • MAF sensor harness
• ECM
• MAF sensor
P0103 Airmass Ratio Is Higher Threshold High • MAF sensor harness 04
• ECM
• MAF sensor
P0102 Airmass Ratio Is Lower Threshold Low • MAF sensor harness
• ECM
• Generator
P0563 Voltage Above Upper Limit
• ECM
• Positive battery cable

P0562 Voltage Below Lower Limit • Open in generator ground harness
• ECM
• MAF sensor
Air Mass Signal Cutoff Or Short Circuit To Either
P0100 • MAF sensor harness
Battery Or Ground
• ECM
• IAT sensor
P1106 IAT Max Error For The Time Period • IAT sensor harness
• ECM
• IAT sensor
P1107 IAT Min Error For The Time Period • IAT sensor harness
• ECM
• IAT sensor
P0110 IAT Signal Error For The Time Period • IAT sensor harness
• ECM
• Acclerator pedal position sensor 1

P0123 Acclerator Pedal 1 Voltage Above Upper Limit • Acclerator pedal position sensor 1
harness
• ECM
• Acclerator pedal 1 sensor

P0122 Acclerator Pedal 1 Voltage Below Lower Limit • Acclerator pedal 1 sensor harness
• ECM

• Acclerator pedal position sensor
1harness
P2135 Acclerator Pedal 1 Plausibility With App2 Violated • Acclerator pedal position sensor 2
harness
• ECM

P0223 Acclerator Pedal 2 Voltage Above Upper Limit • Acclerator pedal position sensor 2
harness
• ECM

P0222 Acclerator Pedal 2 Voltage Below Lower Limit • Acclerator pedal position sensor 2
harness
• ECM
• Atmospheric pressure sensor

Atmospheric Pressure Sensor Voltage Above Upper
P2229 • Atmospheric pressure sensor harness
Limit
• ECM

Atmospheric Pressure Sensor Voltage Below Lower
Limit
• ECM

Atmospheric Pressure Sensor Voltage Above Upper
Physical Range
• ECM

Atmospheric Pressure Sensor Voltage Below Lower
Physical Range
• ECM
• Acclerator pedal sensor and harness

P2299 Offset Between Of Acclerator Pedal And Brake Switch • Brake switch and harness
• ECM
• EGR solenoid valve

P0402 EGR Positive Governor Deviation Above Limit • EGR solenoid valve harness
• ECM

P0401 EGR negative Governor Deviation Below Limit • EGR solenoid valve harness
• ECM
• Battery
• Generator
P0563 Battery Voltage Fault -voltage Above Upper Limit
• Generator and battery harness
• ECM
• Battery
• Generator
P0562 Battery Voltage Fault -voltage Below Lower Limit
• Generator and battery harness
• ECM
• Brake switch
P0571 Brake Signal Is Defective
• Brake switch harness
• Brake switch
P0504 Brake Signals Not Plausible
• Brake switch harness
Coolant Temperature Sensor Voltage Above Upper • Coolant temperature sensor

P0118
Limit • Coolant temperature sensor harness
Coolant Temperature Sensor Voltage Below Lower • Coolant temperature sensor

P0117
Limit • Coolant temperature sensor harness 04
• Coolant
Coolant Temperature Minimum Temperature Raise • Thermostat
P0116
Not Reached Within Time Limit • Coolant temperature sensor
• Coolant temperature sensor harness
• Coolant temperature sensor

P1601 Coolant Temperature Output Short Circuit To Battery
• Coolant temperature sensor harness 04

P1602 Coolant Temperature Output Short Circuit To Ground

P1603 Coolant Temperature Output No Load

P1604 Coolant Temperature Output Excess Temp.
Coolant Temperature Output Voltage Above Upper • Coolant temperature sensor

P110D
Physical Range • Coolant temperature sensor harness
Coolant Temperature Output Voltage Below Lower • Coolant temperature sensor

P110E
Physical Range • Coolant temperature sensor harness
• Coolant
Coolant Temperature Minimum Temperature Not
P0128 • Thermostat
Reached Within Time Limit
• Diesel
Misfire Cylinder 1 Number Of Recognized Misfire • Injector 1
P0301
Events Above Limit • Injector 1 harness
• No. 1 cylinder mechanism fult
• Diesel
P0302
• Diesel
P0303
• Diesel
P0304
• Diesel
Misfire In Multiple Cylinders Number Of Recognized • Injector
P0300
Misfire Events Above Limit • Injector harness
• Cylinder mechanism fult
P0856 Physical Unplausibility Of DCS-demand • ECM


Error Path/status For Performance Limitation Logic
P1109 • ECM
Degradation Level 0

P110A • ECM
Degradation Level 1

P110B • ECM
Degradation Level 2

P110C • ECM
Degradation Level 3
P161F Faultpath For Compression Test • ECM
• CKP sensor
• CKP sensor harness
P1515 Clutch Signal Error
• VSS
• VSS harness
• CKP sensor
P1605 CKP Sensor Short Circuit Battery • CKP sensor harness
• ECM
• CKP sensor
P1606 CKP Sensorl Short Circuit Ground • CKP sensor harness
• ECM
• CKP sensor
P1607 CKP Sensor No Load • CKP sensor harness
• ECM
• Environment air temperature sensor

Environment Air Temperature Sensor Voltage Above
P0073 • Environment air temperature sensor
Upper Limit
harness

Environment Air Temperature Sensor Voltage Below
Lower Limit
harness

Intake Air Sensor Voltage Above Upper Physical
Range
harness

Intake Air Sensor Voltage Below Lower Physical
Range
harness
• Stop button
P2530 Engine Compartment Stop Button
• Stop button harness
P062F Incompatible Data Value In EPROM • ECM

P0490 EGR Power Stage Short Circuit Battery • EGR solenoid valve harness
• ECM

P0489 EGR Power Stage Short Circuit Ground • EGR solenoid valve harness
• ECM

P0404 EGR Power Stage No Load • EGR solenoid valve harness 04
• ECM

P0403 EGR Power Stage Excess Temperature • EGR solenoid valve harness
• ECM

• EGR solenoid valve harness 04
P245D EGR CD-Cooling Bypass Valve Short Circuit Battery • EGRvalve
• Cooling system
• ECM

• EGR solenoid valve harness
P245C EGR CD-Cooling Bypass Valve Short Circuit Ground • EGR valve
• Cooling system
• ECM

P245A EGR CD-Cooling Bypass Valve No Load • EGR valve
• Cooling system
• ECM

P245B EGR CD-Cooling Bypass Valve Excess Temperature • EGR valve
• Cooling system
• ECM
• EGR valve position sensor

EGR Valve Position Sensor Voltage Above Upper
P0406 • EGR valve position sensor harness
Limit
• ECM
• EGR valve position sensor

P0405 EGR Valve Position Sensor Voltage Below Lower Limit • EGR valve position sensor harness
• ECM
• Cylinder 1 injector
Cylinder 1 Injector Above Upper Limit Of Filtered
P1200 • Cylinder 1 injector harness
Energizing Time
• ECM
Cylinder 1 Injector Below Lower Limit Of Filtered
Energizing Time
• ECM
Energizing Time
• ECM
Energizing Time
• ECM
Energizing Time
• ECM
Energizing Time
• ECM
Energizing Time
• ECM
Energizing Time
• ECM
Energizing Time Calibration Injection Of Cylinder 1

P120C • ECM
Above Upper Limit Of Energizing Time

P120D • ECM
Below Lower Limit Of Energizing Time

P120E • ECM

P120F • ECM

P1210 • ECM

P1211 • ECM

P1212 • ECM

P1213 • ECM
• Oil level sensor

P1621 Eng Power Stage Short Circuit Battery
• Oil level sensor harness

P1622 Eng Power Stage Short Circuit Ground

P1623 Eng Power Stage No Load

P1624 Eng Power Stage Excess Temperature
• Coolant and temperature sensor

Difference Between Coolant And Second
P1112 • Coolant and temperature sensor
Temperatures Exceeds A Max. Value
harness
• CMP sensor
P0340 No Camshaft Signal • CMP sensor harness
• ECM
• CMP sensor
P0341 Wrong Camshaft Signal • CMP sensor harness 04
• ECM
• Crankshaft
• Crankshaft sensor
P0335 No Crankshaft Signal
• Crankshaft sensor harness
• ECM
• Crankshaft 04
P0336 Wrong Crankshaft Signal • Crankshaft position sensor
• Crankshaft position sensor harness
• Camshaft
P0016 Offset Between Camshaft And Crankshaft • Crankshaft
• Timing belt
Map Containes Non Strictly Monotonus Q Curves Not

P1007 • ECM
Plausible Fault
• Fuel temperature sensor

P0183 Fuel Temperature Sensor Voltage Above Upper Limit
• Fuel temperature sensor harness
• Fuel temperature sensor

P0182 Fuel Temperature Sensor Voltage Below Lower Limit
• Fuel temperature sensor harness
Fuel Temperature Sensor Voltage Above Upper • Fuel temperature sensor

P1110
Physical Range • Fuel temperature sensor harness
Fuel Temperature Sensor Voltage Below Lower Upper • Fuel temperature sensor
P1111
Physical Range • Fuel temperature sensor harness
• Fan control relay

P0692 Fan Control For Pwm Type Relay Short Circuit Battery • Fan control relay harness
• ECM

Fan Control For PWM Type Relay Short Circuit
P0691 • Fan control relay harness
Ground
• ECM

P0480 Fan Control For PWM Type Relay No Load • Fan control relay harness
• ECM

Fan Control For PWM Type Relay Excess
Temperature
• ECM

Fan Control For Digital Power Stage 2 Short Circuit To
Battery
• ECM

Fan Control For Digital Power Stage 2 Short Circuit
Ground
• ECM

P0481 Fan Control For Digital Power Stage 2 No Load • Fan control relay harness
• ECM

Fan Control For Digital Power Stage 2 Excess
Temperature
• ECM
• Water level in fuel sensor

P2267 Water Level In Fuel Sensor Error Incase Of Water
• Water level in fuel sensor harness
• Water level in fuel sensor

P2264 Water Level In Fuel Sensor Not Working Normally
• Water level in fuel sensor harness
• The glow control relay

P0384 The Glow Control Relay Actuator Short Circuit Battery
• The glow control relay harness
The Glow Control Relay Actuator Short Circuit • The glow control relay
P0383
Ground • The glow control relay harness
• The glow control relay

P0670 The Glow Control Relay Actuator No Load
• The glow control relay harness
The Glow Control Relay Actuator Excess • The glow control relay
P0670
Temperature • The glow control relay harness
• The glow display lamp

P1608 The Glow Display Lamp Short Circuit Battery • The glow display lamp harness
• Illumination

P1609 The Glow Display Lamp Short Circuit Ground • The glow display lamp harness
• Illumination

P160A The Glow Display Lamp No Load • The glow display lamp harness
• Illumination

P160B The Glow Display Lamp Excess Temperature • The glow display lamp harness
• Illumination
Failure Of A Glow Plug, Relay Failure, Short Circuit In • Glow plug

P0380 Glow Plug, • Glow plug harness
Over-current • The glow control relay actuator
• Glow plug
Short Circuit In Glow Plug, Over-current, Relay Got
P0382 • Glow plug harness
Stuck
• The glow control relay actuator
P060A Communication Error Of Cj940 • ECM
P062F Error State Of EEPROM, ECM Inner Error • ECM
P160C Hptst Deactivates Rail Pressure Monitoring • ECM

• Air temperature sensor

P0098 Air Temperature Sensor Voltage Above Upper Limit • Air temperature sensor harness 04
• ECM

P0097 Air Temperature Sensor Voltage Below Lower Limit • Air temperature sensor harness
• ECM

P1005
Air Temperature Sensor Voltage Above Upper
• Air temperature sensor harness 04
Physical Range
• ECM

Air Temperature Sensor Voltage Below Lower Upper
P1006 • Air temperature sensor harness
Physical Range
• ECM
• Injector
P0611 Number Of Injections Limited By Charge Balance • Injector harness
• ECM
• Injector
P062B Chip-specific Errors -> Stop Engine • Injector harness
• ECM
• Injector 1
P0262 Injector 1 Short Circuit On Low Side To Battery • Injector 1 harness
• ECM
• Injector 1
Injector 1 Not-classifyable Error (Depending On Appli-
P0263 • Injector 1 harness
cation)
• ECM
• Injector 1
P0261 Injector 1 Short Circuit Low Side To High Side • Injector 1 harness
• ECM
• Injector 1
P0201 Injector 1 Open Load • Injector 1 harness
• ECM
• Injector 2
• ECM
• Injector 2
cation)
• ECM
• Injector 2
• ECM
• Injector 2
• ECM
• Injector 3
• ECM
• Injector 3
cation)
• ECM
• Injector 3
• ECM
• Injector 3
• ECM
• Injector 4
• ECM
• Injector 4
cation)
• ECM
• Injector 4
• ECM
• Injector 4
• ECM
• Injector
Bank1-specific Errors-injector Short Circuit On High
P1223 • Injector harness
Side To Ground Or Voltage
• ECM
• Injector
Bank1-specific Errors-injector Short Circuit On Low
P1224 • Injector harness
Side To Ground
• ECM
Power Stage Fault Status For Mil Short Circuit Bat-

• MIL
P0650 tery,short Circuit Ground,no Load Or Excess Tempera-
ture • MIL harness
• Main relay
P0687 Main Relay Does Not Open In Time
• Main relay harness
• Main relay
P0686 Main Relay Opens Too Early
• Main relay harness
• Metering unit
P0251 Open Load Of Metering Unit Output
• Metering unit harness
• Metering unit
P0252 Excess Temperature Of Metering Unit Powerstage
• Metering unit
P0254 Short Circuit To Battery Of Metering Unit Output
• Metering unit
P0253 Short Circuit To Ground Of Metering Unit Output
• Metering unit harness 04
Signal Range Check High Error Of Metering Unit Ad-
P025D • ECM
channel
Signal Range Check Low Error Of Metering Unit Ad-

P025C • ECM
channel
Set, If Error-counter Of Watchdog Or Controller Are

P060C Not Plausible
04
• ECM
Or The System Must Shut Down
• Oil temperature sensor

P0523 Oil Pressure Sensor Voltage Above Upper Limit • Oil temperature sensor harness
• ECM

P0520 Oil Pressure Sensor Hardware Signal Error • Oil temperature sensor harness
• ECM

Oil Pressure Sensor Plausibility Check - Oil Pressure
P0521 • Oil temperature sensor harness
Too High
• ECM

P0524 Plausibility Check - Oil Pressure Too Low • Oil temperature sensor harness
• ECM

P0198 Oil Temperature Sensor Voltage Above Upper Limit • Oil temperature sensor harness
• ECM

P0197 Oil Temperature Sensor Voltage Below Lower Limit • Oil temperature sensor harness
• ECM

P0195 Oil Temperature Sensor Signal Error For CAN • Oil temperature sensor harness
• CAN signal harness
• Oil temperature sensor and harness

P100D Plausibility Error Between OTS And CTS • ECT sensor and harness
• ECM
P1613 Energising Time Exceeds Limit Of Overrun Monitoring • ECM
• Clutch
• CKP sensor
P1614 Plausibility Error In Engine Speed Check • CKP sensor harness
• Backup switch
• ECM
• Pump
P0629 Power Stage Pre-supply Pump Short Circuit Battery • Pump harness
• ECM
• Pump
P0628 Power Stage Pre-supply Pump Short Circuit Ground • Pump harness
• ECM
• Pump
P0627 Power Stage Pre-supply Pump No Load • Pump harness
• ECM
• Pump
P062A Power Stage Pre-supply Pump Excess Temperature • Pump harness
• ECM
• Common rail pressure sensor

P0193 Rail Pressure Voltage Above Upper Limit • Common rail pressure sensor harness
• ECM

P0192 Rail Pressure Voltage Below Lower Limit • Common rail pressure sensor harness
• ECM

Rail Pressure Sensor (RPS) Raw Value Is Above
P0191 • Common rail pressure sensor harness
Maximum Offset
• ECM

Rail Pressure Sensor (RPS) Raw Value Is Below
Minimum Offset
• ECM

Maximum Positive Deviation Of Rail Pressure
Exceeded
• ECM

Maximum Positive Deviation Of Rail Pressure
Exceeded Concerning Set Flow Of Fuel
• ECM

Maximum Negative Rail Pressure Deviation With
Metering Unit On Lower Limit Is Exceeded
• ECM

P0087 Minimum Rail Pressure Exceeded • Common rail pressure sensor harness
• ECM

P0088 Maximum Rail Pressure Exceeded • Common rail pressure sensor harness
• ECM
Setpoint Of Metering Unit In Overrun Mode Not

P1014 • ECM
Plausible
Is Set To Deaktivate Misfire Detection During Runup

P1615 • ECM
Test
P1616 ECM Watch Dog Switch Off Path Defect • ECM
• Injector harness
P1618 Voltage Monitoring Lower Limit Shut Off Path Defect
• ECM
• Injector harness
P1617 Voltage Monitoring Upper Limit Shut Off Path Defect
• ECM 04
• Sensor supply harness
P0643 Sensor Supply Voltage 1 Voltage Above Upper Limit
• ECM

P0642 Sensor Supply Voltage 1 Voltage Below Lower Limit
• ECM
• Sensor supply harness 04

• ECM
Sensor Supply Voltage 2 Voltage Voltage Below Lower • Sensor supply harness
P0652
Limit • ECM

• ECM

P0698 Sensor Supply Voltage 3 Voltage Below Lower Limit
• ECM
P1621 Eng Power Stage Short Circuit Battery • ECM
• Starter
P0617 Starter Power Stage Short Circuit Battery
• Starter harness
• Starter
P0616 Starter Power Stage Short Circuit Ground
• Starter harness
• Starter
P0615 Starter Power Stage Excess Temperature, No Load
• Starter harness
• System lamp (SVS) harness

P1619 System Lamp (SVS) Short Circuit Battery
• System lamp (SVS)

P161A System Lamp (SVS) Short Circuit Ground

P161B System Lamp (SVS) No Load

P161C System Lamp (SVS) Excess Temperature
• Ignition switch
P2533 No Terminal 15 Signals Detected • Ignition switch harness
• ECM
P0607 Deviation Between Tpu And System Time • ECM
P0503 Exceeding Of The Maximum Vehicle Speed • ECM
• VSS
P0500 HW Signal For Vehicle Speed Not Valid • VSS harness
• ECM
Vehicle Speed Not Plausible With Injection Mass And

P0501 • ECM
Engine Speed
• CAN signal harness

P2157 CAN Signal For Vehicle Speed Not Valid
• ECM
Errorpath For Dataset Variant Coding, Npl=requested

• Signal harness
P161D Variant Could Not Be Set,
Sig=variant Dataset Defect - Signal Fault • ECM
Errorpath For Dataset Variant Coding, NPI=requested

P161E Variant Could Not Be Set, SIG=variant Dataset Defect • ECM
- Not Plausible Fault
• Signal harness
P0607 Set, If SPI-communication Failed
• ECM
P0100 - AIR MASS SIGNAL CUTOFFOR SHORT CIRCUIT TO

EITHER BATTERY OR GROUND
P0101 - AIR MASS SIGNAL RANGE CHECK ERROR 04
P0102 - AIR MASS RATIO IS LOWER THRESHOLD LOW
P0103 - AIR MASS RATIO IS HIGHER THRESHOLD HIGH
04
DESCRIPTION
Mass Air Flow (MAF) sensor tests the air input. MAF sensor fixed in the whole vehicle air intake pipe, is
featured by no moving part, more reliable work and with the function of Intake Air Temperature (IAT)
sensor. MAF sensor uses the current heating method to test the air flow inhaled into the engine. The
electric heating element is first heated to a fixed temperature value larger than the air intake
temperature. When the intake air is passing through, the temperature of the electric heating element
falls. In order to keep the temperature difference, the current must be increased to keep a fixed
temperature difference between the electric heating element and the air intake temperature. The
current proportionally reflects the air flow inhaled into engine. MAF monitors the intake flow rate and
feeds it back to ECM which completes the close loop control of EGR rate together with EGR magnetic
valve. MAF sensor consists of air intake temperature and MAF sensor.
WIRING DIAGRAM
• Engine: running • MAF sensor

Air Mass Signal Cutoff
P0100 Or Short Circuit To • ECM detect that the MAF • Open or short in MAF sensor
Either Battery Or Ground voltage signal is out of the harness or connctor
range • ECM
• MAF sensor
• Open in 12 V power harness
• Short to 12 V power in MAF
• Engine: running sensor harness
Air Mass Signal Signal • ECM detect that the MAF • Open in MAF sensor signal
P0101 Range Check Error voltage signal is out of the harness
range • Open in MAF sensor ground
• Short in MAF sensor signal
harness
• ECM
• MAF sensor
• Engine: running
Air Mass Ratio Is Lower • Open or short in MAF sensor
P0102 • MAF voltage is less than 0.2 V
Threshold Low harness or connctor
for 3 seconds
• ECM
• MAF sensor
• Engine: running
Air Mass Ratio Is Higher • Open or short in MAF sensor
P0103 • MAF voltage is more than 4.9
Threshold High harness or connctor
V for 3 seconds
• ECM
NOTE
specific circuit and component information. 04
terminals.
• If any DTC is detected, using the scan tool, select the item “AUTO DIAGNOSIS\FOTON(V03.20)\LIGHT
BUS\MP-X MP\ENGINE\DIESEL ENGINE\BOSCH DIESEL COMMON RAIL SYSTEM\EDC16C39 OR
EDC17C55\READ DATA STREAM”.
04
1. READ DTC AND DATA STREAM DISPLAYED OF KT600 SCAN TOOL (MAF SENSOR)
(a) Start the engine and warm it to normal operating

temperature (80 ± 5 ℃ ).
(b) Using the KT600 scan tool, perform the DTC confirming
procedure.
(c) Using the KT600 scan tool, perform the data stream
reading procedure.
(d) Engine: running.
(e) Using the KT600 scan tool, select the item "AUTO
DIAGNOSIS\FOTON(V03.20)\LIGHT BUS\MP-X MP\
ENGINE\ DIESEL ENGINE\ BOSCH DIESEL COMMON
RAILSYSTEM\ EDC16C39 OR EDC17C55\READ DATA
STREAM\CURRENT FUEL QUANTITY”.
(f) The value must be changed when the accelerator pedal
is opened or closed.
Result
P0100 • Go to next step
P0103 • Go to step 4
2. CHECK MAF SENSOR POWER SUPPLY
(b) Disconnect the E035 MAF sensor connector.

(d) Measure the voltage according to the value(s) in the
table below.
Standard voltage

E035 (4) - Ground 12 V

NO > Go to step 7.
3. CHECK MAF SENSOR
(a) Apply battery voltage between terminal 3 - 4 the E035

MAF sensor connector.
(b) Connect multimeter (+) to terminal 3, multimeter (-) to
terminal 2.
(c) Measure the voltage according to the value(s) in the
table below.
Standard voltage

The signal output should even
E035 (2) - E035 (3) change when blowing air into
MAF sensor with mouth or fan

NO > Replace MAF sensor.
4. CHECK HARNESS AND CONNECTOR (MAF SENSOR - ECM)

(c) Measure the resistance according to the value(s) in the
table below.

E035 (2) - E050 (A37)
＜2Ω
E035 (3) - E050 (A44)
(d) Measure the resistance according to the value(s) in the

table below.

E035 (2) - Ground ≥ 1 MΩ

04
5. CHECK HARNESS AND CONNECTOR (SENSOR - GROUND)
(a) Connect the E050 ECM connector.

(b) Disconnect the E035 MAF sensor connector.
table below. 04

E035 (3) - Ground ＜2Ω

NO > Repair or replace MAF sensor harness or connector.
6. CHECK HARNESS AND CONNECTOR (MAF SENSOR - ECM)

(b) Measure the voltage according to the value(s) in the
table below.
Standard voltage

E035 (2) - Ground
0V
E035 (3) - Ground

7. CHECK FUSE

(b) Check body junction box.
• Remove fuse F17 (10A) from the C301 body junction
box.
• Check fuse.
• Reinstall the fuse.

NO > Replace fuse 17 (10A). Go to next step. Check harness for short to ground.
8. CHECK HARNESS AND CONNECTOR (MAF SENSOR)
(a) Disconnect the body junction box C301 connector.

table below.

E035 (4) - F17 ＜2Ω

table below.
E035 (4) - Ground ≥ 1 MΩ


04
9. REPLACE ECM
(a) Replace ECM. (Refer to “Chapter 11B engine control system - ECM, replacement”)
(c) Using the KT600 scan tool, perform the data stream reading procedure.
(d) When engine running, the value must be changed when the accelerator pedal is opened or closed.
04
(e) Confirm no DTC and data stream normal.
P0117 - COOLANT TEMPERATURE SENSOR VOLTAGE BELOW

LOWER LIMIT
P0118 - COOLANT TEMPERATURE SENSOR VOLTAGE ABOVE
UPPER LIMIT
DESCRIPTION
• This sensor is one Negative Temperature Coefficient (NTC) thermistance, of which the
resistance will reduce following the increasing of the temperature in non-linear relation. when
the coolant temperature is low, the resistance in the thermistor increases. when the temperature
is high, the resistance drops. the variations in resistance are reflected in the voltage output from
the sensor.
• The ECM monitors the sensor voltage and uses this value to calculate the engine coolant
temperature.
WIRING DIAGRAM
• ECT sensor 04
Coolant Temperature • 60 seconds since the ignition switch
P0117 Sensor Voltage Below • Short in ECT sensor
is turned ON or after engine starts
Lower Limit harness
• Short in ECT sensor harness for 0.5
• ECM
seconds
• ECT sensor
Coolant Temperature • 60 seconds since the ignition switch
P0118 Sensor Voltage Above is turned ON or after engine starts
• Short or open in ECT 04
Upper Limit sensor harness
• Open in ECT sensor harness for 0.5
• ECM
seconds
NOTE
specific circuit and component information.
terminals.
• If the ECM detects the DTC P0117 or P0118, it operates the fail–safe function in which the
engine coolant temperature is assumed to be - 40 ℃ . At the same time, with the ignition switch
on, the cooling fans will operate at high speed. The fail–safe function will not stop untill the
ECM detects the acceptance condition.
• If any DTC is detected, using the scan tool, select the item “AUTO DIAGNOSIS\
FOTON(V03.20)\LIGHT BUS\MP-X MP\ENGINE\DIESEL ENGINE\ BOSCH DIESEL COMMON RAIL
SYSTEM\EDC16C39 OR EDC17C55\READ DATA STREAM\ECT(ECT VOLYAGE)”.
Displayed Temperature Malfunction

- 40 °C Open circuit
140 °C Short circuit
1. READ VALUE AND DTC OFKT600 SCAN TOOL (ENGINE COOLANT TEMPERATURE)
(a) Start the engine and warm it to normal operating temperature (80 ± 5 ℃ ).
(c) Read sensor value displayed on the KT600 scan tool.
Displayed DTC And Temperature Proceed To Malfunction
• P0118
Next step Open or short to power
• -40 °C
• P0117
Step 5 Short to ground
• 140 °C or more
• P0117 or P0118
• OK (Same as present ECT)


NO > If there is an open circuit, go to next step. If there is a short circuit, go to step 5.
2. READ VALUE OF KT600 SCAN TOOL (ENGINE COOLANT TEMPERATURE SENSOR TERMINAL 1- 2)

(c) Jump wire at terminal 1 and 2 of the E038 engine coolant

temperature sensor connector on the wire harness side.
(e) Using the KT600 scan tool, select the item “AUTO
DIAGNOSIS \FOTON (V03.20)\ LIGHT BUS\MP-X
MP\ENGINE\ DIESEL ENGINE\BOSCH DIESEL COMMON
RAILSYSTEM\EDC16C39 OR EDC17C55\READ DATA
STREAM\COOLANT TEMPERATURE”.
(f) Read ECT value displayed on the KT600 scan tool.
Temperature value: ≥ 140 ℃

YES > Confirm good connection at sensor. If OK, replace engine coolant temp. sensor.
(a) Disconnect the E038 engine coolant temperature sensor connector on the wire harness side.

below.
Standard voltage
E038 (1) - Ground 4.5 ～ 5.0 V

4. CHECK HARNESS AND CONNECTOR (ECT SENSOR - ECM)

(b) Disconnect the E050 ECM connector. 04
table below.

04
E038 (2) - E050 (A41) ＜2Ω

YES > Go to step 7.
5. READ VALUE OF KT600 SCAN TOOL (ENGINE COOLANT TEMPERATURE)

(d) Using the KT600 scan tool, select the item “AUTO DIAGNOSIS\FOTON(V03.20)\ LIGHT BUS\MP-X
MP\ENGINE\DIESEL ENGINE\BOSCH DIESEL COMMON RAILSYSTEM\EDC16C39 OR
EDC17C55\READ DATA STREAM\COOLANT TEMPERATURE”.
(e) Read ECT value displayed on the KT600 scan tool.
Temperature value: -40 °C
YES > Replace ECT sensor.


table below.

E038 (1) - E038 (2)
≥ 1MΩ
E038 (1) - Ground

7. REPLACE ECM
(c) Using the KT600 scan tool, perform the data stream reading procedure.
(d) Confirm no DTC and data stream normal.
P0340 - NO CAMSHAFT SIGNAL

P0341 - WRONG CAMSHAFT SIGNAL
04
1 CMP sensor signal
2 CKP sensor signal
04
DESCRIPTION
The Camshaft Position (CMP) sensor is used to detect camshaft position and to have correlation with
crankshaft position so that the ECM can determine which cylinder is ready to be fueled by the injector.
WIRING DIAGRAM
• Camshaft
• Engine: running
• CMP sensor
• No CMP sensor signal was sent
• Open or short in CMP
to ECM during running
P0340 No camshaft signal sensor harness
• With engine speed 600 RPM or
• Timing chain has jumped a
more, ECM check the CMP and
tooth
CKP deviation
• ECM
• Camshaft
• CMP sensor
• Engine: running • Open or short in CMP
P0341 Wrong camshaft signal • CMP signal is less than specific sensor harness
value • Timing chain has jumped a
tooth
• ECM
NOTE
terminals.
• If any DTC is detected, using the scan tool, select the item “AUTO DIAGNOSIS\ FOTON(V03.20)\LIGHT
BUS\MP-X MP\ENGINE\DIESEL ENGINE\BOSCH DIESEL COMMON RAIL SYSTEM\EDC16C39 OR
EDC17C55\READ DATA STREAM”.
1. CHECK VALUE OF KT600 SCAN TOOL (CMP SENSOR)

(b) Disconnect the E034 CMP sensor connector.
(d) Check the voltage according to the value in the table

below.
Standard voltage

E034 (1) - Ground 4.5 ～ 5.0 V

2. CHECK HARNESS OR CONNECTOR (CMP SENSOR - GROUND)

(b) Check the resistance according to the value in the table
below.

E034 (3) - Ground ＜2Ω

3. CHECK HARNESS OR CONNECTOR (CMP SENSOR - ECM)

(b) Check the resistance according to the value in the table 04
below.

E034 (2) - E050 (A50) ＜2Ω
04
E034 (2) - Ground ≥ 1MΩ

4. CHECK HARNESS AND CONNECTOR (CMP SENSOR - GROUND)

(b) Check the voltage according to the value in the table
below.


5. CHECK HARNESS AND CONNECTOR (CMP SENSOR TERMINAL 2 - 3)

below.
E034 (2) - E034 (3) ≥ 1MΩ

6. CHECK CMP SENSOR SIGNAL

(c) Connect the E034 CMP sensor connector.
(d) Start engine.
(e) Using the oscilloscope, check CMP sensor signalwave.

7. CHECK CMP SENSOR

(b) Disconnect the E034 CMP sensor connector.
below.

E034 (2) - E034 (3)
E034 (1) - E034 (2) Except 0 or ∞

E034 (1) - E034 (3)

NO > Replace CMP sensor.
8. REPLACE CMP SENSOR AND CHECK CMP SENSOR
(a) Replace the CMP sensor on the vehicle with a known good one.
(b) Using the oscilloscope, check CMP sensor signal wave.
YES > System is OK.
9. CHECK CMP AND CMP SIGNAL PLATE
(a) Remove the cylinder head cover and timing belt cover. (Refer to “Chapter 15B engine mechanism -
timing belt overhaul”) 04
(b) Check the mounting clearance.
Clearance: 0.2 ～ 1.8 mm
(c) Check if the timing belt was damaged.
(d) Check the camshaft and camshaft signal plate for any condition that would result in an incorrect signal,
such as damage, loose mounting or foreign material when rotating the camshaft.
NO > Remove any debris and clean the crankshaft signal plate or replace the crankshaft. Reinstall the CKP
sensor.
10. CHECK THE ENGINE BASE TIMING
(a) Check if the timing is correct.

NO > Align the engine timing belt
11. REPLACE ECM
P0192 - RAIL PRESSURE VOLTAGE BELOW LOWER LIMIT

P0193 - RAIL PRESSURE VOLTAGE ABOVE UPPER LIMIT
DESCRIPTION
Common rail pressure sensor is used to measure the diesel pressure of the common rail. The sensor
feed back the signal to ECM. ECM utilize the signal to perform the closed-loop control on the common
rail diesel system.
WIRING DIAGRAM
• Engine: running • Common rail pressure sensor 04

Rail pressure voltage • ECM detects that the common rail • Open or short in common rail
P0192 below lower limit pressure sensor input signal is pressure sensor harness
less than acceptable value • ECM
• Engine: running • Common rail pressure sensor

Rail pressure voltage • ECM detects that the common rail • Short in common rail pres-
P0193
above upper limit pressure sensor input signal is sure sensor harness 04
higher than acceptable value • ECM
NOTE
terminals.
• If any DTC is detected, using the scan tool, select the item “AUTO DIAGNOSIS\
FOTON(V03.20)\LIGHT BUS\MP-X MP\ENGINE\DIESEL ENGINE\BOSCH DIESEL COMMON RAIL
SYSTEM\EDC16C39 OR EDC17C55\READ DATA STREAM”.
• When ECM detect DTC P0193 and P0192，we should adopt the following control strategy:
(a) ECM will increase the diesel quantity of the high pump.
(b) Diesel pressure will be ultrahigh. The pressure limiting valve will be bursted.
(c) The actual rail pressure will kept at level from 70 ～ 76 MPa (displayed on scan tool : 72 MPa or so).
(d) Limit the RPM (less than 1700 RPM or so, realise through control injection). The accelerator will still
take effect within the limits.
(e) After turnning the ignition switch OFF, the pressure limiting valve will be shut off. The system will return
to normal.
(f) If the system has entered into the strategy during cranking, the engine can strat and without any appar-
ent sensation.
1. READ VALUE OF KT600 SCAN TOOL (COMMON RAIL PRESSURE VALUE AND VOLTAGE
VOLTAGE)
(c) Read common rail pressure and voltage value displayed on the KT600 scan tool.
Displayed DTC And Pressure Proceed To Malfunction
• P0192 Next step Open or short to ground
• P0193 Next step Short to voltage
• P0192 or P0193
• Pressure is normal (0 ~ 1450 MPa) Diagnostic help Check for intermittent problems
• Voltage is normal (0.49 ~ 3.83 V)

NO > If there an open or short circuit, go to next step.
2. CHECK HARNESS AND CONNECTOR (COMMON RAIL PRESSURE SENSOR - GROUND)

(b) Disconnect the E041 common rail pressure sensor connector.

below.
Standard voltage

E041 (3) - Ground 5.0 ± 0.25 V

NO > Repair or replace common rail pressure sensor harness or connector for open or short. If OK, replace
ECM.
3. CHECK COMMON RAIL PRESSURE SENSOR
(a) Jump wire terminal 1 and 3 of the E041 common rail

pressure sensor connector on the wire harness side.
(b) Perform reading sensor data stream procedure with scan
tool.
Standard voltage: 4.5 ～ 5.0 V

YES > Go to step 5.

(b) Disconnect the E041 common rail pressure sensor 04
connector on the wire harness side.
table below.
Standard resistance

E041 (1) - Ground ＜2Ω

(a) Connect the E041 common rail pressure sensor connector.
(b) Turn the ignition switch ON.

(c) Set multimeter to voltage range, black terminal to
ground, red terminal to common rail pressure sensor
terminal 2.
below.
Standard voltage

E041 (2) - Ground Ignition switch: about 0.5 V
(e) Start engine.

(f) While depressing the accelerator, confirm that the volt-
age changed.
(g) Measure the voltage according to the value in the table
below.
Standard voltage

E050 (A43) - Ground 0.49 ~ 3.83 V

YES > Go to step 7.

(b) Disconnect the E041 common rail pressure sensor con-
nector.
below.
Standard voltage


7. CHECK COMMON RAIL PRESSURE SENSOR SIGNAL

(c) Connect the E041 terminals 1 - 2 of common rail pres-
sure sensor connector on the wire harness side.
ENGINE\ DIESEL ENGINE\ BOSCH DIESEL COMMON
RAILSYSTEM\EDC16C39 OR EDC17C55\READ DATA
STREAM\COMMON RAIL PRESSURE SENSOR VOLT-
AGE”.
Standard voltage: 4 V

NO > Repair or replace harness or connector for short or open.
8. REPLACE ECM
P0201 - INJECTOR 1 OPEN LOAD

P0261 - INJECTOR 1 SHORT CIRCUIT LOW SIDE TO HIGH SIDE
04
P0262 - INJECTOR 1 SHORT CIRCUIT ON LOW SIDE TO BATTERY
04
DESCRIPTION
The Engine Control Module (ECM) has 4 individual injector driver circuits, each of which controls an
injector. The ECM monitors the current in each driver circuit. The ECM measures a voltage drop
through a fixed resistor and controls it. The voltage on each driver is monitored to detect a fault. If the
voltage is not what the ECM expects to monitor on the circuit, a Diagnostic Trouble Code (DTC) is set.
The DTCs detect a low voltage and/or an open circuit and high voltage conditions for low-side drive
injector outputs.
WIRING DIAGRAM
• Injector1
• Short in injector1 high side to
Injector 1 Open Load battery
P0201
• Short in injector1 low side to
battery
• Engine: running • Short in injector1 high side to
• The pump operate normally ground
• Ignition voltage: ＞ 10 V • Short in injector1 low side to
• ECM detectes that open or ground
Injector 1 Short Circuit
P0261 short in injector1harness or • Short in injector1 low side to
Low Side To High Side
connector high side
• Open or high resistance in
injector1 high side
Injector 1 Short Circuit On • Open or high resistance in
P0262 injector1 low side
Low Side To Battery
• ECM
NOTE
terminals.
• If any DTC is detected, using the scan tool, select the item “AUTO DIAGNOSIS\ FOTON
(V03.20)\LIGHT BUS\MP-X MP\ENGINE\DIESEL ENGINE\BOSCH DIESEL COMMON RAIL SYSTEM\
EDC16C39 OR EDC17C55\READ DATA STREAM\ CURRENT INJECTION QUANTITY”.
1. READ VALUE OF KT600 SCAN TOOL (INJECTOR)
(c) Using the KT600 scan tool, select the item “AUTO DIAGNOSIS\FOTON(V03.20) \LIGHT BUS\MP-X
EDC17C55\READ DATA STREAM\INJECTOR DATA”.
Is DTC present?
NO > System is normal.
2. PERFORM ACTIVE TEST ON SCAN TOOL
(a) Using the KT600 scan tool, select the item “AUTO DIAGNOSIS\FOTON(V03.20)\ LIGHT BUS\MP-X
EDC17C55\ACTIVE TEST OR FUNCTION TEST\ MISFIRE TEST”.
(b) Perform active test - misfire test.
3. CHECK DTC
Result 04
Displayed DTC Proceed To Malfunction
• P0201 Next step Open
• P0261 Go to step 8 Short to battery
• P0262 Go to step 6 Short to Ground 04
4. CHECK HARNESS AND CONNECTOR (INJECTOR TERMINAL 1 - 2)

(b) Disconnect the E025 injector connector.
table below.

E025 (1) - E025 (2) 0.255 ± 0.040 Ω (20 ～ 70 ℃ )

NO > Replace injector.
5. CHECK HARNESS AND CONNECTOR (INJECTOR - ECM)

table below.

E025 (1) - E050 (A16)
＜2Ω
E025 (2) - E050 (A47)

6. CHECK HARNESS AND CONNECTOR (INJECTOR - GROUND)

table below.

E025 (1) - Ground
≥ 1MΩ
E025 (2) - Ground

7. CHECK HARNESS AND CONNECTOR (INJECTOR HARNESS CONNECTOR TERMINAL 1 - 2)

table below.
E025 (1) - E025 (2) ≥ 1MΩ

8. CHECK HARNESS AND CONNECTOR (INJECTOR - GROUND)
(a) Remove main relay R2 in engine room fusejunction box

A301.
(b) Jump wire at terminal 2 and 5 in the engine room fuse
junction box A301 corresponding main relay R2.

below.
Standard voltage
04
E025 (1) - Ground
0V
E025 (2) - Ground
04
9. REPLACE ECM
P0401 - EGR NEGATIVE GOVERNOR DEVIATION BELOW LIMIT

P0402 - EGR POSITIVE GOVERNOR DEVIATION ABOVE LIMIT
DESCRIPTION
An Exhaust Gas Recirculation (EGR) system is used to lower Oxides of Nitrogen (NOX) emission levels
caused by high combustion temperatures. It a accomplishes this by feeding small amounts of exhaust
gases back into the combustion chamber. When the air/fuel mixture is diluted with the exhaust gases,
combustion temperatures are reduced.
WIRING DIAGRAM

EGR Negative Governor • Ignition switch: ON • EGR solenoid valve
P0401 04
Deviation Below Limit
• ECM detects that the EGR valve • Open or short in EGR
EGR Positive Governor input signal is out of the solenoid valve harness
P0402 acceptable value. • ECM
Deviation Above Limit
NOTE
• While performing electrical diagnosis & testing, assure the ECM ground good contact. 04
terminals.
1. READ VALUE OF KT600 SCAN TOOL (EGR VALVE)
Is DTC present？
NO > The system is OK.
2. PERFORM ACTIVE TEST BY KT600 SCAN TOOL (OPERATE EGR COOLER)
(a) Using the KT600 scan tool, select the item “AUTO DIAGNOSIS\FOTON(V03.20) \ LIGHT BUS\MP-X MP\ENGINE\
DIESEL ENGINE\ BOSCH DIESEL COMMON RAILSYSTEM\EDC16C39 OR EDC17C55\ACTIVE TEST OR
FUNCTION TEST”.
(b) Perform active test or function test - EGR cooler test.
3. CONFIRM DTC
Result
Displayed DTC Proceed To Malfunction
• P0401 Next step Open or short to ground
• P0402 Step 10 Short to battery

4. CHECK EGR

(b) Disconnect the E053 EGR connector.
table below.
Standard resistance

C053 (1) - C053 (2) 14 Ω (20 ℃ )

NO > Replace EGR solenoid valve.
5. CHECK HARNESS AND CONNECTOR (EGR - GROUND)

below.

C053 (1) - Ground 12 V

YES > Go to step 8.
6. CHECK FUSE

(b) Remove F20 (20A) in body fuse junction box C301.
(c) Remove FL6 (50A) in engine room fuse junction box
A301.
(d) Check fuse.

NO > Replace fuse F20 (20A), FL6 (50A). Go to step 9, check harness or connector.
04
7. CHECK MAIN RELAY R2
(a) Remove main relay R2 in engine room fuse junction box

A301.
table below.
04

10 kΩ or more (Not apply bat-
tery voltage between terminal
1-2)
R2 (3) - R2 (5)
Less than 1 Ω
(Apply battery voltage between
terminal 1-2)

NO > Replace main relay R2.
8. CHECK HARNESS AND CONNECTOR (EGR - ECM)

table below.

C053 (2) - E050 (A60) ＜2Ω

9. CHECK HARNESS AND CONNECTOR (EGR - GOUND)

table below.

C053 (2) - Ground ≥ 1MΩ

10. CHECK HARNESS AND CONNECTOR (EGR - GROUND)
(a) Disconnect main relay R2 in engine room fuse junction

box A301.
(b) Jump wire at terminal 3 - 5 in the engine room fuse junc-
tion box A301 corresponding main relay R2.

below.
Standard voltage

C053 (2) - Ground 0V

11. TEST EGR COOLER
(a) Using the KT600 scan tool, select the item “AUTO DIAGNOSIS\FOTON(V03.20)\LIGHT BUS\MP-X
MP\ENGINE\DIESEL ENGINE\BOSCH DIESEL COMMON RAIL SYSTEM\EDC16C39 OR 04
EDC17C55\ACTIVE TEST OR FUNCTION TEST”.
(b) Perform active test or function test - EGR cooler test.
NO > Replace the EGR cooler.
04
12. REPLACE ECM
P0122 - ACCELERATOR PEDAL 1 VOLTAGE BELOW LOWER LIMIT

P0123 - ACCELERATOR PEDAL 1 VOLTAGE ABOVE UPPER LIMIT
P0222 - ACCELERATOR PEDAL 2 VOLTAGE BELOW LOWER LIMIT
P0223 - ACCELERATOR PEDAL 2 VOLTAGE ABOVE UPPER LIMIT
P2135 - ACCELERATOR PEDAL 1 PLAUSIBILITY WITH APP2 VIO-
LATED
DESCRIPTION
The Accelerator Pedal Position Sensor (APPS) is mounted on the pedal bracket. It has 2 three-line
types of potentiometer sensor. The ECM applies a 5 V reference voltage to the sensor. The sensor slide
indicator connects with the accelerator and rotates following the shaft. When the accelerator pedal
changes, the position of the slide indicator will also change on the carbon film resistance, at such
moment the resistance output will also change, which reflects the open extent of the accelerator indi-
rectly.
WIRING DIAGRAM
04
04
• APPS1
• Ignition switch: ON • APPS1 loose connector
Acclerator pedal 1 voltage
P0122 • ECM detect that the APPS1 signal • Open or short in APPS1
below lower limit
is lower than acceptable value harness or connector
• ECM
• APPS1
Acclerator pedal 1 voltage • Short in APPS1 har-
P0123 • ECM detect that the APPS1 signal
above upper limit ness or connector
is higher than acceptable value
• ECM
• APPS2
• Ignition switch: ON • APPS2 loose connector
Acclerator pedal 2 voltage
P0222 • ECM detect that the APPS2 signal • Open or short in APPS2
below lower limit
is lower than acceptable value harness or connector
• ECM
• APPS2
Acclerator pedal 2 voltage • Short in APPS2 har-
P0223 • ECM detect that the APPS2 signal
above upper limit ness or connector
is higher than acceptable value
• ECM
• APPS1
• APPS2
Acclerator pedal 1 • No sensor referece voltage DTC
P2135 plausibility with app2 exist • Open or short in APPS1
violated or APPS2 harness or
• The signal of APPS1 and APPS2 is connector
inconsistent
• ECM
NOTE
terminals.
• If any DTC is detected, using the scan tool, select the item “AUTO DIAGNOSIS\ FOTON
(V03.20)\LIGHT BUS\MP-X MP\ENGINE\DIESEL ENGINE\BOSCH DIESEL COMMON RAIL
SYSTEM\EDC16C39 OR EDC17C55\READ DATA STREAM\APPS1 VOLTAGE AND APPS2 VOLT-
AGE”.
• If exist APPS DTC P0122、 P0123、 P0222、 P0223and P2135 simultaneously， then check DTC
P2135 finally.
1. READ VALUE AND DTC OF KT600 SCAN TOOL (OXYGEN SENSOR)
(c) Read APPS value displayed on the KT600 scan tool.
(d) Perform reading sensor data stream procedure.
• P0122 ( ＜ 0.899 V) Next step Short to ground
• P0123 ( ＞ 0.899 V) Next step Short to battery
• P0222 ( ＜ 0.572 V) Step 8 Short to ground
• P0223 ( ＞ 0.572 V) Step 8 Short to battery
• P2135 Next step Short to ground or battery
• P0122 、 P0123 (0.899 V)

• P0222、 P0223 (0.572 V)
• P2135
• The oxygen signal is normal
2. CHECK HARNESS AND CONNECTOR (APPS)

(b) Disconnect the C050 APP connector.

below.
Standard voltage
C050 (2 ) - Ground 4.5 ～ 5.0 V


04
(a) Measure the voltage according to the value in the table

below.
Standard voltage

04
C050 (2) - C050 (3) 4.5 ～ 5.0 V

YES > Go to step 5.
4. CHECK HARNESS AND CONNECTOR (APPS - GROUND)

table below.

C050 (3) - Ground ＜2Ω

(a) Connect the C050 APP connector.


below.
Standard voltage

C050 (2) - Ground Ignition switch ON: 5.0 V
• Ignition switch ON (accelerator

pedal full release): 0.899 V
C050 (4) - Ground
• Ignition switch ON (accelerator
pedal full depress): 3.548 V

NO > Repair or replace APPS1, harness or connector.

(b) Disconnect the C050 APP connector.
(c) Disconnect the Q010 ECM connector.
(d) Remove main relay.
(e) Jump wire at terminal 3 and 5 in the engine room fuse
(f) Turn the ignition switch ON.

below.
Standard voltage


NO > Repair or replace APP1, harness or connector.
7. READ VALUE OF KT600 SCAN TOOL (APPS)

(b) Connect the Q010 ECM connector. 04
(c) Connect the C050 APP connector terminal 2 ～ 4.
ENGINE\DIESEL ENGINE\BOSCH DIESEL COMMON
04
STREAM\ACCELERATOR PEDAL VOLTAGE”.
Voltage: 4.5 ~ 5.0 V


(b) Disconnect the C050 APPS connector.

below.
Standard voltage
C050 (1) - Ground 4.5 ～ 5.0 V

NO > Repair or replace APP2, harness or connector. If harness and connector OK, replace ECM.
(a) Measure the voltage according to the value in the table

below.
Standard voltage
C050 (1) - C050 (5) 4.5 ～ 5.0 V



(b) Check the resistance according to the value in the table
below.

C050 (5) - Ground ＜2Ω

NO > Repair or replace APPS, harness or connector.
(a) Connect the C050 APPS connector.

below.
Standard voltage

C050 (1) - Ground • Ignition switch ON: 5.0 V
• Ignition switch ON (accelerator full

release): 0.572 V
C050 (6) - Ground
• Ignition switch ON (depress
accelerator to wide open): 1.608 V


(b) Disconnect the C050 APPS connector. 04
(c) Disconnect the Q010 ECM connector.
(d) Remove main relay.
(e) Jump wire at terminal 3 and 5 in the engine room fuse
(f) Turn the ignition switch ON. 04

below.


13. READ VALUE OF KT600 SCAN TOOL (APPS)

(b) Connect the Q010 ECM connector.
(c) Jump wire at terminal 1 and 6 of the C050 APP2
connector
DIAGNOSIS\FOTON(V03.20)\LIGHT BUS\ MP-X MP\
ENGINE\DIESELENGINE\ BOSCH DIESEL COMMON
STREAM\ACCELERATOR PEDAL VOLTAGE”.
Voltage: 4.5 ~ 5.0 V

14. REPLACE ECM
(d) Confirm no DTC and data stream normal.
LIST OF SYMPTOM OF FAILURE

CAUTION
• If the trouble isn’t confirmed in DTC checking and the cause of trouble can’t be confirmed in
04
basic checking, please take the troubleshooting in the sequence listed in the following list, then
go to related page for troubleshooting.
• Thorough analysis on the customer’s complaint is the key for successful troubleshooting. The
more information from the complaint, the quicker and easier the problem can be solved. The
failure symptom diagnosis list is organized in the thought of determining the failure location
and solving the problem by doing the easiest and most logical things. Complete all steps in
sequence from top to down. The list is impossible to contain all possible problems. But the 04
failure symptom diagnosis can be used to develop thoughts so as to find out the cause of
trouble and remove it.
DIESEL ENGINE PROBLEM SYMPTOMS TABLE

Symptom Suspect Area
• Battery.
• Main relay.
• Harness or connector.
• CKP sensor.
• Diesel quality.
Failed to start • Blocking or leakage in low pressure lines.
• Preheat system.
• High pressure or common rail pressure
controller.
• Injector or injector control system.
• Diesel engine mechanism system.
• ECM.
Engine start • Battery.
• Starter.
• Relay and strater switch.
• Diesel quality.
• Air in diesel system.
• Preheat system.
Hard starting • ECT sensor.
• Blocking or low in low pressure lines.
• Too low in high pressure lines.
• Common rail pressure controller.
• Injector or inject control system.
• ECM.
• Blocking in the air filter.

• Diesel quality.
• Failure turbocharger.
• APPS is error or poor signal.
Power Poor power • EGR control system.
• Blocking or leakage in turbocharger.
• ECT sensor.
• Injector, common rail pressure sensor, high
pressure pump.
• Diesel quality.
• Air in diesel system.
• Injector.
Idling stability (Improper • Injector control system.
Idle shaking
idling) • Common rail pressure sensor, common rail
pressure controller.
• High pressure pump.
• ECM.
• Air filter block.

• ECT sensor.
• Diesel quality.
• Turbocharger (Poor pressure).
• EGR valve and control system.
Black smoke
• Injector or injector control system.
• MAF sensor.
• Diesel engine overloaded.
• ECM.
• Water in diesel cylinder or diesel.

• Preheat system.
• Diesel quality.
• Inject pressure and spraying condition is not
normal.
White smoke
• Oil level is too high.
• Breather.
• Supercharger.
• ECM.
Smoking
That the exhaust pipe gives off blue smoke
shows there is a lot of engine oil getting into the
combustion chamber and burnt. Meanwhile the
engine oil consumption of diesel engine also
rises sharply. The causes of trouble may be:
• The engine oil level inside the diesel engine
pan is too high.
• The piston chamfer is installed in opposite
direction during installation to let engine oil
into the combustion chamber.
• The cylinder and piston ring is severe worn or
Blue smoke the piston ring gap is not aligned or the
elasticity is decreased.
• The piston ring is severe worn or broken
causing the ring seized.
• The diesel engine lubrication oil is inhaled
into the combustion chamber through the
valve guide.
• Diesel quality.
• The valve oil seal is damaged.
• The valve oil seal seat and the valve guide
aren’t aligned or the gap is too large.
• The match between piston pin and

connecting rod small end bushing hole is too
loose. There is slight but sharp sound during
04
idling running.
• The gap between piston and cylinder is too

large; an impact sound can be heard at
engine body outer wall and it increase with
the speed increasing.
04
There is abnormal knocking • The wear of connecting rod bearing shell and
Abnormal noise when main bearing shell makes the fit clearance
or impact sound during
running too large; the body impact sound can be
running.
heard at the crank case during running; the
heavy and power impact sound can be heard
if the speed reduces suddenly.
• The valve hits the piston; the clear, even and

rhythmic knocking sound can be heard at the
cylinder head.
• The gap between intake/exhaust valves is too

large. The loud and rhythmic sound can be
heard at the cylinder head.
• Too low coolant.

• Fan belt loose or brake.
• Thermoster valve is stuck.
Over heat
• Coolant pump fault.
• Blocking in radiator core.
• Poor oil is quality.
Abnormal temperature • Thermoster valve cannot close completely.

Too cold
• Coolant temperature indicator.
• Raditor leakage.
• Raditor hose connector loose or hose
damaged.
Lack of coolant
• Coolant pump leakage.
• Heater hose connector loose or hose
damaged.
• Foreign substances in engine oil are piled at

the turbo side seal.
• The engine oil temperature is too high. Oil
supply isn't enough. The floating bearing is
burnt out.
• The supercharger return tube is blocked,
deformed leading to engine oil leaks at the
turbo, compressor shaft end.
• The supercharger seal is damaged and fails.
Under-power • The turbine shaft rotor loses balance.
• The turbo blades and compressor blades are
rubbed and damaged.
• The air filter is blocked.
• The induction tunnel of the supercharging
compensator is cracked.
• There is much dirt in air intake and exhaust
pipes.
• The supercharger works abnormally or is
damaged.
• Leakage at the junction part or dirt in inlet and

outlet pipe.
Pressure charging system High diesel wastage
• Poor performance of turbocharge.
• Piston ring wear out.
• Turbocharge seal ring wear out, damaged.

• Leakage at the side of impeller blades of
compressor of turbocharger.
High oil wastage
• The screw at the junction of inlet and outlet
oilpipe loose, the washer damaged.
• Poor oil quality.
• There is much oil dirt in the turbo end and the

gas passage becomes narrow evidently.
• There is much oil dirt in the compressor end
Abnormal knocking and the gas passage becomes narrow
evidently.
• The floating bearing wears severely. The
turbo and blade wheel have friction with the
case.
• Foreign matter enter into inner.

Vibration produced by
friction between turbine , • Floating bearing severe wearing, cause up
rotor and case and down.
• Poor turboshaft dynamic balancing.
• The mount of diesel engine is loose or the

inner is broken and damaged; check the
diesel engine bracket, mount and/or
04
insulation for damage.
Attaching parts • The transmission flying wheel or flexible

connecting bolt is loose.
Body serious vibration
• Accessories resonant vibration.
04
• The diesel engine bottom guard plate impacts
the oil pan because of deformation.
• The dynamic balance of rotating parts such

Diesel engine as crankshaft and crankshaft pulley is
disqualified.
DIESEL ENGINE SYMPTOM DIAGNOSIS AND TESTS

CAUTION
• Some symptom diagnosis steps require visual and observational check. First carry out the
visual and observational check every time. The check can solve one problem without further
test and can save valuable time.
• Ask the vehicle owner for the followings as receiving the vehicle:
(a) The time as the trouble first occurred.
(b) The diesel engine temperature as the trouble occurred.
(c) The vehicle miles of travel.
(d) The owner’s driving road and manner.
(e) The vehicle maintenance condition.
(f) The vehicle maintenance history.
(g) If the vehicle is equipped with optional device. Initial assessment can be done through the
understanding above to reduce the checking time.
• Original inspection should be done at first before the carrying out the fault diagnosis based on
the diesel engine symptom.
(a) Be sure the diesel engine malfunction indicator lamp works normal. If it's abnormal, first troubleshoot
the malfunction indicator lamp.
(b) Be sure there is no diesel engine Diagnostic Trouble Code (DTC) stored in the diesel engine Electronic
Control Module (ECM). If it exists, check through corresponding DTC list for troubleshooting. Read
DTC (all current and history DCT should be recorded) - Clear DTC - Run (the conditions of trouble
occurrence should be represented this moment) - Read DTC again Read DTC List in service manual
and refer to the cause, effect and erasing method of DTC. Don’t neglect the intermittent malfunction
codes.
(c) Check the hot engine idling speed data of electronic control system with a diagnostic scanner and
confirm they are all within the normal range.
(d) Be sure the customer’s complaint is current and the causes of failure exist.
(e) Confirm the maintenance record, the diesel engine compression pressure and the diesel fuel condition
during the vehicle maintenance.
• Observational visual check.
(a) Check the connection status of ECM ground wire.
(b) Check if the diesel engine vacuum system connecting pipe is cracked, twisted, squashed or damaged
and if the connection is correct.
(c) Check if the diesel engine oil dipstick and the engine oil filler port are installed properly.
(d) Check if the diesel engine grounding (ground) is clean and the connection is firm.
(e) Check if the engine intake pipes leak gas at the joint faces.
(f) Check if the engine diesel fuel system high/low pressure oil pipes leak at the joints.
(g) Check if the engine diesel fuel goes bad and the water and diesel fuel are proper.
(h) Check if the connectors of engine sensors and actuators are in good contact and firm connection.
CAUTION
• There are many causes of trouble that the diesel engine gives off black smoke; the problems
with oil supply system, diesel qulity, combustion system, air intake and exhaust system may
cause the trouble of diesel engine giving off black smoke.
• Although the problems with the oil supply system problem, the combustion system problem,
the air intake system and the exhaust system and other factors may be the cause of trouble that
the diesel engine gives off black smoke, for a diesel engine, the cause of trouble of giving off
black smoke may be only one factor among them.
• For the diesel engine equipped with turbocharger, one air leak source is the turbocharger intake
pipe, which is easy to neglect. The diesel engine intake pipe supplies the turbocharger with air.
• If one system fails, it may lead to many trouble symptoms of diesel engine.
(a) For example, either blocked intake system or too long pipe may increase the intake resistance. The 04
intake resistance is too large and the intake system is blocked (for example, the air cleaner element is
blocked, the intake pipe makes the inhale resistance of supercharger increase because of settled dust),
thus leading to that the supercharging pressure of diesel engine falls and waves, further resulting in that
the diesel engine power falls, the engine runs unbalance and generates black smoke. Too high intake
temperature is also possible to cause the diesel engine to give off black smoke. Besides causing the
diesel engine to give off black smoke, the trouble of intake system also has the following symptoms: 04
• The diesel engine is short of power.
• The diesel engine consumption increases.
(b) If the intake system is installed improperly, for example, the exhaust pipe is too long or thin, the muffler
is improper, it may increase the exhaust resistance, cause restricted exhaust of diesel engine thus
leading to giving off black smoke. If the exhaust system has a problem, besides giving off black smoke,
the diesel engine also has the following symptoms:
• The diesel engine is short of power.
• The diesel engine exhaust temperature increases.
• The diesel consumption increases.
(c) If the turbocharger fails, it arises many symptoms:
• The supercharger creates powerful vibrations and makes noise during running.
• The diesel engine is short of power and its forces drop.
• The diesel consumption increases.
• Oil discharging at turbo end or pump impeller end leads to increasing engine oil consumption of diesel
engine. The turbocharger adopts full floating type slide bearing on the rotor shaft. If the rotor shaft is
worn and the rotor axial clearance especially the radial clearance is too large, the seal ring fails. Severe
wear can bring much oil-fouled and carbon-residue deposits in the exhaust pipe and the muffler, not
only increasing the exhaust resistance, lowering the supercharger speed and the diesel engine forces,
but also increasing the engine oil consumption of the diesel engine.
(d) Troubles with cylinder head parts: this moment the diesel engine is short of power and the performance
drops, and also there are symptoms such as air leak, giving off black smoke and abnormal knocking.
DIESEL ENGINE TROUBLESHOOTING LIST

DIESEL ENGINE CAN’T START
CAUTION
For successful start of diesel engine, it must be ensured with high enough speed, good cylinder
compression effort and good atomized diesel fuel injected in time. In addition, the temperature should
be high enough to make the atomized diesel reach the ignition status. In general, the possible causes
of engine unable to start are related to the electric system, the diesel system and the mechanical
system of the diesel engine.
Suspect Area Trouble-Shooting
1. Poor connection, bad

• Check harness and connector. Repair or replace.
harness or connector
2. Low battery • Check charging system. Charging battery or replace.
3. CKP sensor, CMP • Using the scan tool to read the CKP sensor, CMP sensor
sensor faults, poor fixed data stream and DTC. If no signal , then check harness.
or harness fault Reinstall or replace the sensor.
Electrical system
4. Starter • Repair or replace.
5. Main relay • Replace.
6. Common rail pressure • Using the scan tool to read the common rail pressure
control system sensor data stream, repair or replace.
7. ECM • Replace.
• Check whether the diesel supply line connector loose. If

1. Air in diesel system
loose. (Refer to “Chapter 13B diesel - replace filter”)
2. Diesel system lines

blocking. The pressure
• Check whether the diesel system is clear, leakage.
are too low in high and
low pressure system
Diesel system
3. Blocking in diesel filter • Check diesel filter or replace.
4. High pressure pump

• Check and replace (Internal leakage or no diesel).
fault
• Check whether the spray of the injector is normal,

5. Injector fault dropping or clamping. Check whether the washer is
damaged .
• Check the timing belt tension. Reinstall or replace it.

1. Timing system (Refer to “Chapter 15B diesel engine mechanism - engine
timing belt overhaul”)
Mechanism • Check valve clearance, spring. Check the sealing

system 2. Valve is unable to close performance of the valve guides and valve seats. Check
properly whether the valve seat is too deep. If the sealing ing is not
good, repair it.
• Replace the piston ring. Depending on actual need,

3. Wear-out of piston
replace it.
DIESEL ENGINE IS DIFFICULT TO START

CAUTION
In case that the battery power is sufficient, there is fuel in diesel fuel tank and the starter motor is
good, if the diesel engine is difficult to start or can’t start, please put emphasis on checking the 04
following parts: the electric system, the preheating system, the diesel system and the mechanical
system of the diesel engine.
1. Poor connection, 04
bad harness or • Check harness and connector. Repair or replace.
connector
2. Low battery • Check charging system. Charging battery or replace.
• Using the scan tool to read the sensor data stream. Check
3. ECT sensor
harness, repair or replace.
Electrical system
4. Starter • Repair or replace.
5. Injector control • Using the scan tool to read the sensor data stream. Check
system harness, repair or replace.
6. CKP sensor, CMP • Using the scan tool to read the sensor data stream and DTC.
sensor faults, poor If no signal , then check harness. Reinstall or replace the
fixed or harness fault sensor.
1. The preheat system

is out of work caused
Preheat system by electrical
• Check fuse, harness and preheat controller.
components.
preheat plug is out
of work
• Check whether the diesel supply line connector loose. If loose.

(Refer to “Chapter 13B diesel - replace filter”)

blocking. The
pressure are too low • Check whether the diesel system is clear, leakage.
in high and low
pressure system
Diesel system
3. Blocking in diesel
• Check diesel filter or replace.
filter

• Check and replace (Internal leakage or no diesel).
fault
• Check whether the spray of the injector is normal, dropping

5. Injector fault
or clamping. Check whether the washer is damaged .
• Check whether the filter is dirty, ash and blocking of the intake
1. Air filter (Usually when the intake is blocked. the exhaust will emmit
smoke when starting).
• Check the timing belt tension. Reinstall or replace it. (Refer to

2. Timing system “Chapter 15B diesel engine mechanism - engine timing belt
overhaul”)
Mechanism
system • Check valve clearance, spring. Check the sealing
3. Valve is unable to performance of the valve guides and valve seats. Check
close properly whether the valve seat is too deep. If the seal ing is not good,
repair it.
4. Wear-out of piston • Replace the piston ring. Depending on actual need, replace it.
5. Camshaft and • Check whether the installation of the camshaft gear is

camshaft gear alignned.
DIESEL ENGINE IS SHORT OF POWER

CAUTION
• For diesel engine short of power, the main features are: uneven running in low speed, exhaust
pipe giving off black smoke in high speed, abnormal sound. In case that the diesel engine
hasn’t reached the major repair, the short of power is mainly caused by the trouble of diesel
supply system and poor compression of cylinder.
1. Poor connection,
connector
• Using the scan tool to perform the active test. Repair or

2. EGR control system
replace.
3. ECT sensor
4. Common rail • Using the scan tool to read the sensor data stream. Check
pressure system harness, repair or replace.
5. Electric accelerator • Check the installation position. Using the scan tool to read the
Electrical system pedal position sensor data stream and DTC. Check harness, repair or
sensor replace.
6. Injector control • Using the scan tool to read the sensor data stream. Check
system harness, repair or replace.
• Check the installation position. Using the scan tool to read the
7. synchronous signals
sensor data stream and DTC. Check harness, repair or
error
replace.
8. MAF sensor
9. Main relay • Check main relay and related harness.
10. ECM • Replace.

1. Diesel • Diesel quality.
• Check whether the diesel supply line connector loose. If loose. 04

(Refer to “Chapter 13B diesel - replace filter”)

blocking. The
pressure are too low • Check whether the diesel system is clear.
in high and low
Diesel system pressure system 04
4. Blocking in diesel
• Check diesel filter or replace.
filter

• Check and replace.
fault

6. Injector fault
or clamping. Check whether the washer is damaged.
• Check whether the air filter dirty, deposition. The inlet

1. Inlet system (filter)
blocking.
2. EGR valve • Check whether EGR valve clamping.
• Check the intake and exhaust system. Check if there is leak or

block between the air cleaner and the turbocharger, the
turbocharger and the cylinder head, the turbocharger and the
exhaust pipe.
• Check the pressure of turbocharger with the turbocharger
pressure meter; the pressure should meet specified value.
• Check of replace the turbocharger bearing, clean the intake
pipes, the case and the impeller; tighten the nuts and clamps
at the joints.
• Check the radial clearance of the turbocharger rotor: press
Mechanism down the compressor impeller in radial direction with hands,
system 3. Turbocharger system measure the minimum clearance between the compressor
impeller and the compressor case with a feeler gauge; the
measured value should not be less than 0.10mm.Replace the
floating bearing if the measured value is less than 0.10 mm.
• Check the axial clearance of the turbocharger rotor: fix a
magnet base on the turbo case outlet flange face, contact the
dial gauge with the turbo rotor axis end face, push or pull the
turbo rotor axially, the measured value is the axial clearance
value. The axial clearance of rotor on the new supercharger
should be ≤ 0.1mm, the operating limit ≤ 0.25 mm.
Disassemble the assembly and replace the worn parts if the
axial clearance of the supercharger rotor is greater than the
operating limit value.

overhaul”)
• Check valve clearance (when cold):

Intake valve: 0.4 ± 0.05 mm
Exhaust valve: 0.4 ± 0.05 mm
• The free length of valve spring: 48 mm, if out of the range ,
replace it.
• Check the clearance between valve leveler and valve Guide:
Inlet valve: 0.039 ～ 0.071 mm
5. Valve is unable to
close properly Outlet valve: 0.064 ～ 0.096 mm
• Check limit clearance between valve leveler and valve Guide:
Inlet valve: 0.20 mm
Outlet valve: 0.25 mm
• Check the gas tightness of the valve seat, check if the valve
retainer sinks too deeply or is burnt to wear; if the tightness is
poor, repair and grind the matching surface of valve seat to
recover the tightness.
• Replace piston ring. Replace cylinder depending on wear

6. Piston wear
condition.
Mechanism
system • Check cylinder head bolts. Tighten them according to the
7. Cylinder gasket
specified torque. Or replace cylinder head gasket.
8. Exhaust pipe • Check the carbon deposition. Clear it.
9. Leakage at the
juncted surface • Tighten the cylinder head bolts according to the specified
between the cylinder torque.
head and body. The
cylinder head bolts • Overhaul cylinder head. Check whether the gasket is
loose. The cylinder damaged. If not OK, replace it.
gasket damaged
10. Crank link

mechanism
(Unsmooth • Remove oil pan. Check whether the lower end of the
stagnation between connecting rod axial runout . If not, remove piston linkage.
the piston pin in the Overhaul it.
connecting-rod bush
and piston pin)
1. The coolant
• Check dirty on the radiator or cooling surface. Clear the
temperature is too
internal scale.
high
• Check the oil quantity. Depending on actual need, add it. if the
Diesel engine is 2. The oil temperature shaft bearing or related components are worn-out caused by
overheat is too high heat, overhaul diesel engine after finding out the causes of
fever of components.
3. The exhaust
temperature is too • Check injector.
high
DIESEL ENGINE IDLE IS UNSTABLE

CAUTION
The problem is mostly intake system and diesel control system.
04
1. Poor connection,
connector
2. Common rail 04
• Using the scan tool to read the sensor data stream and DTC.
pressure control
Check harness, repair or replace.
system
Electrical system
3. Injector control • Using the scan tool, read the sensor data stream and DTC.
system Check harness, repair or replace.
4. CKP sensor, CMP

• Using the scan tool to read the sensor data stream. If no
sensor faults, poor
signal there, check harness, reinstall or replace sensor.
fixed or harness fault
5. ECM • Check whether the ECM connector swamped.
1. Check whether the • Check whether the diesel supply line connector loose. If loose.
air in diesel (Refer to “Chapter 13B diesel - replace filter”)

blocking. The
pressure are too low • Check whether the diesel system is clear.
in high and low
Diesel system pressure system
3. Diesel filter blocking • Check diesel filter or replace.
4. High pump fault • Check and replace.

5. Injector fault
or clamping. Check whether the washer is damaged.
1. Filter • Check whether the filter is dirty, ash and blocking of the intake.

overhaul”)
Mechanism
system • Check valve clearance, spring. Check the sealing
3. Valve is unable to performance of the valve guides and valve seats. Check
close properly whether the valve seat is too deep. If the sealing is not good,
repair it.
4. Piston abrasion • Replace the piston ring. Depending on actual need, replace it.
DIESEL ENGINE GIVES OFF BLACK SMOKE

CAUTION
It indicates that the air fuel ratio is incorrect if the electric control diesel engine gives off black smoke,
mainly because of insufficient air input and large quantity of fuel injected. For insufficient air input, it’s
reflected in air leak or blocking of intake system pipe, insufficient supercharging pressure, air flow
sensor trouble and so on. In addition, poor atomizing of injector also can lead to giving off black
smoke because of insufficient combustion. It shows that the diesel fuel isn’t burnt sufficiently if the
diesel engine gives off black smoke; the diesel fuel that isn’t burnt is exhausted in uncombined type
and forms the black smoke. The diesel engine giving off black smoke also goes with powerless
accelerating and short of power usually.
1. Poor
connection, bad
• Check harness and connector condition. Repair or replace.
harness or
connector
2. Common rail
• Using the scan tool to read the sensor data stream. check , repair or
pressure control
replace.
system
Electrical
system 3. Injector and
• Using the scan tool to read the data stream and DTC. Check harness,
EGR control
repair or replace.
system
4. MAF fault or
• Using the scan tool to read the sensor data stream. if signal is not
poor fixed or
correct, check harness. Reinstall or replace sensor.
harness fault
5. ECM • Replace ECM.
1. High pressure is
• Overhaul.
too high
Diesel
system 2. High pump fault • Check and replace.
• Check whether the spray of the injector is normal, dropping or

3. Injector fault
clamping. Check whether the washer is damaged.
• Check whether the filter is dirty, ash and blocking of the intake (Usually
1. Filter when the intake is blocked. the exhaust will emmit smoke when
starting).
04
• Check the intake and exhaust system. Check if there is leak or block
between the air cleaner and the turbocharger, the turbocharger and the
cylinder head, the turbocharger and the exhaust pipe.
• Check the pressure of turbocharger with the turbocharger pressure
meter; the pressure should meet specified value.
• Check of replace the turbocharger bearing, clean the intake pipes, the 04
case and the impeller; tighten the nuts and clamps at the joints.
• Check of rotor’s radial clearance: Press the compressor blades with a
Mechanism 2. Check the hand in radial direction and measure the minimum clearance between
system turbocharge the compressor blade and compressor casing with thickness gauge.
system The measured value should not be less than 0.10 mm, if not, replace the
turbocharger.
• Check of rotor’s axial clearance: Fix a magnetic base on outlet flange
facing of turbocharger, let the dial indicator touch the rotor spindle, and
then push or pull the turbocharger rotor in axial direction to get a
clearance value, the measured value is the clearance value. The rotor’s
axial clearance value of new turbocharger should not be more than 0.1
mm and operating limit value should not be more than 0.25 mm. If the
axial clearance value of turbocharger rotor exceeds the operating limit
value, replace the turbocharger.
• Check the timing belt tension. Reinstall or replace it. (Refer to “Chapter
3. Timing system
15B diesel engine mechanism - engine timing belt overhaul”)
• Check the valve clearance (Measure the valve clearance value with a
plug gauge, adjust the valve clearance again to specified value if it’s
abnormal); the clearance values of intake and exhaust valves in cold
condition are:
Intake valve: 0.4 ± 0.05 mm
Exhaust valve: 0.4 ± 0.05 mm
• The free length of valve spring: 48 mm, if out of the range, replace it.
1. Valve is unable • Check the clearance between valve leveler and valve Guide:
to close properly Inlet valve: 0.039 ～ 0.071 mm
Outlet valve: 0.064 ～ 0.096 mm
Mechanism • Check limit clearance between valve leveler and valve Guide:
system Inlet valve: 0.20 mm
Outlet valve: 0.25 mm
• Check valve clearance, spring. Check the sealing performance of the
valve guides and valve seats. Check whether the valve seat is too deep.
If the sealing is not good, repair it.
1. Check of clearance between piston and cylinder bush: 0.042 ～ 0.060

mm.
2. The limit clearance between piston and cylinder bush: 0.20 mm.
2. Piston abrasion
3. If the clearance of the piston and the cylinder bush are large, the pres-
sure will be low. The diesel combustion is not full. then the black smoke
will emit.
DIESEL ENGINE RUNS WITH ABNORMAL NOISE

CAUTION
• First, identify the type of the abnormal noise, find out whether it is the knocking caused by
abnormal explosion or the clashing caused by abnormal motion. Then, checkout and diagnose
the noise source based on the noise characteristics and combining the construction principle.
• The diesel engine is strictly forbidden to continue running with abnormal noise; when an
abnormal noise is found, park the vehicle urgently, do the checking and troubleshooting, then
run the engine again.
Possible Cause Troubleshooting
• The clearance between the piston-pin seat and the

piston-pin is within 0.002 ～ 0.015 mm, the maximum
wear limit is 0.03 mm; the clearance between the
small end of connecting rod and the piston-pin is
1. The match between piston pin within 0.008 ～ 0.020 mm, the maximum wear limit is
and connecting rod small end 0.05 mm.
bushing hole is too loose; there • If the clearance value is out of the specified range,
is slight but sharp sound during replace the connecting rod small end bushing to make
idling running the value within the range. When installing the stop
Mechanism ring of the piston pin, check the external of the stop
system ring for crack or scar. The stop ring opening should be
out of alignment with the mounting notch on the piston
during installation.
• The fit clearance between the piston and the cylinder

2. The gap between piston and
cylinder is too large; an impact bush is within 0.042 ～ 0.060 mm, the clearance wear
sound can be heard at engine limit is 0.20 mm. Measure the fit clearance between
body outer wall and it increase the piston and the cylinder bush during maintenance;
with the speed increasing replace both the piston and the cylinder bush if the
clearance exceeds the wear limit.
Possible Cause Troubleshooting
• Install the piston connecting rod assembly and crank

3. The wear of connecting rod assembly on the cylinder block, rotate the crankshaft,
watch carefully if the crankshaft compensator and
04
bearing shell and main bearing
shell makes the fit clearance bottom of connecting rod crash to the cylinder block.
too large; the body impact The radial clearance between the connecting rod
sound can be heard at the bearing shell and the journal is within 0.029 ～ 0.075
crank case during running; the mm, the maximum wear limit is 0.03 mm; the axial
heavy and power impact sound clearance between the connecting rod and the
can be heard if the speed crankshaft is within 0.175 ～ 0.29 mm, the maximum
reduces suddenly wear limit is 0.35 mm; replace it if damaged and install 04
it upon specified clearance.
4. The valve hits the piston; the

Mechanism clear, even and rhythmic • Find out the cause of hitting, check the valve timing
system knocking sound can be heard and adjust the valve clearance.
at the cylinder head
1. Check the valve clearance (measure the valve

clearance value with a plug gauge, adjust the valve
clearance again to specified value if it’s abnormal).
The clearance values of intake and exhaust valves in
5. The gap between intake/ cold condition are:
exhaust valves is too large; the • Intake valve: 0.4 ± 0.05 mm
loud and rhythmic sound can
be heard at the cylinder head • Exhaust valve: 0.4 ± 0.05 mm
2. Check the gas tightness of the valve seat, check if the
valve retainer sinks too deeply or is burnt to wear. If
the tightness is poor, repair and grind the matching
surface of valve seat to recover the tightness.
TEMPERATURE OF COOLING-LIQUID IN DIESEL ENGINE COOLING SYSTEM

IS ABNORMAL, COOLING-LIQUID IS INSUFFICIENT
CAUTION
• If the diesel engine is overheating, don’t stop the running of diesel engine immediately or fill it
with cooling liquid suddenly. Reduce the throttle, run the engine with no-load, shut off the
engine and check it after the temperature of cooling-liquid in the cooling system drops.
• Excessive high temperature of cooling-liquid may cause damage to the cylinder gasket; the causes
are:
(a) The diesel engine temperature is too high (Over the critical line of engine temperature).
(b) The vehicle runs with the cooling-liquid temperature over 100 ℃ till the diesel engine goes out by itself.
(c) After the diesel engine goes out by itself as the temperature is too high, open the diesel engine hood, fill
the engine with water after natural cooling (At this moment, never open the expansion valve cap to
avoid being burnt); generally, the cylinder gasket has been damaged and needs to be replaced.
• Excessive high temperature of cooling-liquid may cause deformation to the cylinder head; the
causes are:
(a) When the temperature is too high and the vehicle continues running till the diesel engine goes out by
itself, if open the expansion water tank cover (Avoid being burnt by fleeing steam with a washcloth or
other things) and fill it with water immediately, the cylinder head will be deformed.
• If the diesel engine is overheating, don’t open the expansion water tank cover to avoid being
burnt. Do take good care of safety when adding cooling liquid. Remove the overheating trouble
immediately, otherwise it may cause damage to other parts.
• Add coolant. Check whether the coolant

1. Coolant is too low leakage. Depending on actual need,
repair it.
04
2. Coolant level is out of range • Check coolant concentration.
• Check the keeping pressure condition. If

3. Radiator cap fault
not OK, replace it.
4. Thermostat will not open

• Check the thermostat open degree. If not 04
OK, replace assy.
• Check whether the gasket damaged to be

leakage. The poor ability of pump was
5. Water pump fault
caused rotor clipping or corrosion, if not
OK, replace it.
6. Radiator core block or the adherent sub-

• Clear radiator and lines.
stance and the rust chokes channel
• Add or replace oil which meet

7. Oil level is too low or poor quality
requirements.
8. Thermostat will not close completely • Check the thermostat open degree. If not
(Coolant temperature too low) OK, replace assy.
Cooling system
• Check coolant temperature. Repair
9. Coolant temperature indicator
indicator harness or replace it.
10.Cooling fan system • Check or replace harness, relay or fan.
11. Radiator leakage • Repair or replace radiator.
12.Radiator hose connector loose or

• Tighten up clamp or replace hose.
damage
13.Heating water tank hose connector loose

• Tighten up clamp or replace hose.
or damaged
14.Radiator heat sink distortion or there is

• Check , clear and repair radiator blades.
foreign bodies blocked inside
15.Engine cylinder head bolts loose • Check and replace.
• Overhaul engine cylinder head, replace

16.Engine cylinder gasket damaged
cylinder gasket.
• Overhaul engine. Replace cylinder block

17.Cylinder block or cylinder head cracks
or cylinder head.
18.ECM (BTDC is nor correct) • Replace.

TROUBLE WITH DIESEL ENGINE SUPERCHARGER SYSTEM

CAUTION
• Actually, the turbocharger unit is a kind of air compressor, increasing the air input of diesel
engine by compressing air; generally, the turbocharger drives the turbo in the turbo chamber by
use of the inertia force of gas exhausted by the diesel engine, then the turbo drives the coaxial
impeller which compresses the air from the air cleaner pipe, supercharges it and delivers it into
the cylinder. With the diesel engine speed increasing, the gas exhausting speed and the turbo
speed increase and the impeller compresses more air into the cylinder. The air with increased
pressure and density can burn more fuel, so increasing the fuel quantity and adjusting the
diesel engine speed will improve the diesel engine output.
• The turbocharger unit mainly consists of the turbo chamber and the supercharger. First, the air
intake port of the turbo chamber is connected with the exhaust manifold of diesel engine, while
the exhaust port with the exhaust pipe. Then, the intake port of supercharger is connected with
the pipe of air cleaner, the exhaust port with the intake manifold. At last, the turbo and the
impeller are installed in the turbo chamber and the supercharger respectively, the both are
coaxial and rigid coupled.
• Foreign matters are strictly prohibited into the intake and exhaust system during the diesel
engine troubleshooting, installing and removing processes. As the supercharger rotor rotates
with very high speed and the clearance between the rotor and the case is small, foreign matters
of whatever material and size will affect the running of rotor and cause damage to the blades. If
the blades are damaged, the supercharger produces abnormal vibration and noise. This
moment, stop the vehicle immediately for supercharger troubleshooting.
• If the supercharger leaks oil, as long as the impeller of rotating shaft doesn’t scrape the inner
shell and rotates freely, don’t replace the supercharger which can continue to be used after the
trouble oil leak is removed.

1. Foreign substances in engine oil are
• Replace oil, repair booster compressor.
piled at the turbo side seal 04
2. The engine oil temperature is too high;
oil supply isn't enough; the floating • Check oil supply system.
bearing is burnt out
3. The supercharger return tube is
blocked, deformed leading to engine
• Repair or replace return tube.
oil leaks at the turbo, compressor shaft 04
end
4. The supercharger seal is damaged
• Replace seal.
and fails
5. The turbine shaft rotor loses balance • Repair, replace turbine shaft rotor.
• Check the radial clearance of the
turbocharger rotor: press down the
compressor impeller in radial direction with
hands, measure the minimum clearance
between the compressor impeller and the
compressor case with a feeler gauge; the
measured value should not be less than
Under-power 0.10 mm. Replace the floating bearing if the
measured value is less than 0.10 mm.
• Check the axial clearance of the
6. The turbo blades and compressor turbocharger rotor: fix a magnet base on the
blades are rubbed and damaged turbo case outlet flange face, contact the dial
gauge with the turbo rotor axis end face,
push or pull the turbo rotor axially, the
measured value is the axial clearance value.
The axial clearance of rotor on the new
supercharger should be ≤ 0.1 mm, the
operating limit ≤ 0.25 mm. Disassemble the
assembly and replace the worn parts if the
axial clearance of the supercharger rotor is
greater than the operating limit value.
7. The air filter is blocked • Clear or replace filter.
8. The induction tunnel of the
• Check or replace induction tunnel.
supercharging compensator is cracked
9. There is much dirt in air intake and
• Clear, repair intake and exhaust pipes.
exhaust pipes
10.The supercharger works abnormally or • Check booster pressure.

is damaged • Check or replace booster.
1. Leakage at the junction of the air
High diesel • Check or replace components.
intake and exhaust pipes
wastage
2. Booster compressor poor performance • Clear, adjust or replace booster compressor.

1. Turbocharge seal ring wear out,
• Replace seal ring.
damaged
• Check whether there is leakage or block
2. Leakage at the side of impeller blades
between filter and booster compressor,
of compressor of turbocharger
High oil wastage booster and cylinder head.
3. The screw at the junction of inlet and
outlet oilpipe loose, the washer • Check or replace washer.
damaged
4. Poor oil quality • Replace oil.
1. There is much oil dirt in the turbo end
and the gas passage becomes narrow • Clear or replace.
evidently
There is
abnormal 2. There is much oil dirt in the
knocking or compressor end and the gas passage • Clear or replace.
impact sound becomes narrow evidently
3. The floating bearing wears severely;
the turbo and blade wheel have friction • Repalce floating bearing.
with the case
1. Foreign matter enter into inner • Clear or replace.
Vibration 2. Floating bearing severe wearing • Replace floating bearing.
3. Poor turboshaft dynamic balancing • Check or replace.
DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM 04-217

PRECAUTION
1. ELECTRONIC CONTROL. 04
(a) Before removing or installing any electrical device, please disconnect the negative cable to prevent
damage to the device or personal injury.
(b) Make sure ignition switch is OFF if no specific instructions.
NOTE
If equipped with central locking, before disconnecting the battery negative cable, do not leave keys in
the car, so as to lock the door. 04
2. REMOVE INSTRUMENT CLUSTER OR DISCONNECT THE NEGATIVE CABLE WILL RESULT IN
LOSS OF DATA.
NOTE
Total odometer will not be cleared.
3. WHEN THE BATTERY TERMINAL IS REMOVED, ALL THE MEMORIES OF THE CLOCK, RADIO,
DTCS, ETC. WILL BE ERASED. SO BEFORE REMOVING IT, CHECK THEM AND NOTE THEM
DOWN.
NOTE
When service is finished, reset the clock and audio systems.

Ignition switch on (ACC) ACC On(ACC)

Expression
Ignition switch on (IG) ON On(IG)
Engine s47tart START Start
5. NOTICES ABOUT ANTI-LOCK BRAKE SYSTEM RECONDITION.

(a) Malfunction symptoms of the anti-lock brake system are difficult to confirm, so the diagnostic trouble
codes(DTC) become the most important source of information when troubleshooting. When
troubleshooting the supplemental restraint system, always check the diagnostic trouble codes(DTC)
before disconnecting the battery.
(b) When the ignition switch must be in OFF position, the sensor and ABS module can be removed or
installed.
(c) After repairing on the anti-lock brake system is completed, check the ABS warning light.
(d) Never use the multimeter to measure the pin-out of ABS module.
04-218 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM
LOCATION
1 ABS Module 4 Rear Wheel Speed Sensor LH
2 Front Wheel Speed Sensor LH 5 Rear Wheel Speed Sensor RH
3 Front Wheel Speed Sensor RH
6 Stop Lamp Switch 8 Body Junction Box
ABS MODULE CONNECTOR
04
04
Pin Definition Color Pin Definition Color
1 Wheel Signal FL － R 14 EBD Warning Light Y-R
2 Wheel Signal FL ＋ G 15 ABS Warning Light Y-G
3 －－ 16 －－
4 Ignition B-R 17 －－
5 Wheel Signal RL ＋ Y 18 Brake Signal G-W
6 Wheel Signal RL － L 19 Wheel Signal FR ＋ W
7 Diagnosis K P-B 20 Wheel Signal FR － B
8 Ground W-B 21 －－
9 Motor Power Supply R 22 Wheel Signal RR － LG
10 －－ 23 Wheel Signal RR ＋ P
11 －－ 24 Ground W-B
12 －－ 25 Solenoid Power Supply B-R
13 －－

NOTE
If a malfunction code is displayed during the DTC checking, check the circuit listed. For details of each
code, turn to the relevant troubleshooting page in the DTC chart.
DTC No. Detection Item (DTC Definition) Trouble Area
• Front wheel speed sensor RH

C0200 Front Wheel Speed Sensor RH Malfunction • Front wheel speed sensor RH circuit
• Front wheel speed sensor RH rotor
• Front wheel speed sensor LH

C0205 Front Wheel Speed Sensor LH Malfunction • Front wheel speed sensor LH circuit
• Front wheel speed sensor LH rotor
• Rear wheel speed sensor RH

C0210 Rear Wheel Speed Sensor RH Malfunction • Rear wheel speed sensor RH circuit
• Rear wheel speed sensor RH rotor
• Rear wheel speed sensor LH

C0215 Rear Wheel Speed Sensor LH Malfunction • Rear wheel speed sensor LH circuit
• Rear wheel speed sensor LH rotor
C0226 Coil Malfunction • ABS module
The Main Relay Electrical Resistance Exceeds • Fuse

C0278
Limit Or Fuse Is Blown In The KL30 Circuit. • Power source circuit
• Battery
C1241 Malfunction In ABS Module • Charging system
• Power source circuit
C1244 Deceleration Sensor Malfunction • (Not equipped)
• Stop lamp switch

C1249 Open circuit in stop lamp switch circuit
• Stop lamp switch circuit
• ABS pump motor

C1251 Pump Motor Malfunction
• ABS pump circuit

Front Wheel Speed Sensor RH Output Voltage
C1271 • Front wheel speed sensor RH circuit
Malfunction
• Front wheel speed sensor RH rotor

Front Wheel Speed Sensor LH Output Voltage Mal-
C1272 • Front wheel speed sensor LH circuit
function
• Front wheel speed sensor LH rotor
• Rear wheel speed sensor RH

Rear Wheel Speed Sensor RH Output Voltage Mal-
C1273 • Rear wheel speed sensor RH circuit
function
• Rear wheel speed sensor RH rotor
• Rear wheel speed sensor LH

C1274 • Rear wheel speed sensor LH circuit
function
• Rear wheel speed sensor LH rotor
Front Wheel Speed Sensor RH Output Voltage

C1275 • Front wheel speed sensor RH rotor
Malfunction

Front Wheel Speed Sensor LH Output Voltage Mal-
C1276 • Front wheel speed sensor LH rotor
function
04
C1277 • Rear wheel speed sensor RH rotor
function

C1278 • Rear wheel speed sensor LH rotor
function
C1279 Deceleration Sensor Output Voltage Malfunction • (Not equipped)

04

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
Symptom Suspect Area Reference
1. Check the DTC reconfirming Chapter 35 brake - brake master

that the normal code is output. cylinder assy, overhaul
2. Brake line leakage, breakage Chapter 35 brake - front brake,

ABS is inoperative.
deformation, etc. overhaul
Chapter 35 brake - front brake,

3. ABS module overhaul
1. Check the DTC reconfirming Chapter 35 brake - brake master

that the normal code is output. cylinder assy, overhaul
2. Brake line leakage, breakage Chapter 35 brake - front brake,

ABS does not operate correctly.
deformation, etc. overhaul
Chapter 35 brake - front brake,

3. ABS module overhaul
Chapter 04 diagnostics - anti-lock

1. ABS warning light circuit. brake system, ABS warning light is
always on
ABS warning light is always on.
2. ABS module brake system, ABS warning light is
always on

1. ABS warning light circuit. brake system, ABS warning light is
inoperative
ABS warning light is inoperative.
2. ABS module brake system, ABS warning light is
inoperative

1. EBD warning light circuit. brake system, EBD warning light is
always on
EBD warning light is always on.
2. ABS module brake system, EBD warning light is
always on

1. EBD warning light circuit. brake system, EBD warning light is
inoperative
EBD warning light is inoperative.
2. ABS module brake system, EBD warning light is
inoperative
PRE - CHECK
1. DIAGNOSIS SYSTEM
(a) Turn the ignition switch ON, check the ABS warning light 04
and EBD warning light.
Standard：When turn the ignition switch ON, check that
the ABS warning light and EBD warning light go on for
3~4 seconds.
If the system check result is not normal, the ABS warning light
and EBD warning light are lighted. Read the DTC code from 04
KT600 scan tool.
NOTE
When turn the ignition switch ON, anti-lock brake system
components will be tested.
2. DIAGNOSTIC TROUBLE CODE (DTC) CHECK AND

CLEAN.
(a) Check the DTC from KT600 scan tool.
• Make sure to connect the KT600 scan tool and data link
connector.(DLC)
• Click the icon “FOTON”.
• Click the icon “LIGHT BUS”.

• Click the icon “MP-X MP”.
• Click the icon “ABS”.
• Click the icon “SHANGHAI SABS”.
• Click the icon “READ DTC”.

Read the DTC by following the prompts on the scan tool
screen.
(b) Clean the DTC from KT600 scan tool.

• Click the icon “CLEAN DTC”.
Operate the KT600 scan tool to erase the codes.
C0200 - FRONT WHEEL SPEED SENSOR RH MALFUNCTION

The wheel speed sensor detects wheel speed and transmits the
appropriate signals to the ABS module. These signal are used
04
for controlling of the ABS control system.
When the rotors rotate, magnetic field generated by the perma-
nent magnet in the wheel speed sensor generates AC voltage.
Since the frequency of this AC voltage changes in direct propor-
tion to the speed of the rotor, the frequency is used by the ABS
module to detect the speed of each wheel.
04
CIRCUIT DESCRIPTION
DTC No. DTC Detecting Condition Trouble Area
• Vehicle at the speed of 20km/h or more,

pulses are not input for 15 second.
• Momentary interruption of the speed sen-
C0200 sor signal occurs when shift the ignition
• Front wheel speed sensor RH circuit
switch OFF to ON. • Front wheel speed sensor RH rotor
• Wheel speed sensor circuit open.
WIRING DIAGRAM
1. READ VALUE(DTC) OF KT600 SCAN TOOL
(a) Select the DATA STREAM mode on the KT600 scan tool.
(b) Check that there is no difference between the speed value output from the wheel speed sensor dis-
played by KT600 scan tool and the speed value displayed by the speedometer when driving the vehi-
cle.
NOTE
If speedmeter display shows the speed value and the diagnostic value of error within ± 10%, it belongs
to the normal range.
Is the inspection result normal？
YES > Same data, go to step 5.
NO > Difference data, go to next step.
2. INSPECT FRONT WHEEL SPEED SENSOR RH
(b) Disconnect the C015 front wheel speed sensor connec-

tor RH.

table below.
Standard resistance(check for open)
C015 (1) - C015 (2) 0.9 - 1.8 KΩ

table below.
Standard resistance(check for short)

C015 (1) - Ground
≥ 1 MΩ
C015 (2) - Ground

NO > Repair or replace front wheel speed sensor RH.
04
3. INSPECT FRONT WHEEL SPEED SENSOR RH OUTPUT SIGNAL
(a) When the wheel is rotating, measure the front wheel

speed sensor RH output voltage.
Standard
C015 (1) - C015 (2) 120 mV
NOTE
The multimeter should be in the millivolt position. When the
wheel is rotating with 2 laps per second, measure the front
wheel speed sensor RH output voltage.

NO > Go to step 5.
4. CHECK HARNESS AND CONNECTOR (ABS MODULE - FRONT WHEEL SPEED SENSOR RH)
(a) Disconnect the C038 ABS module connector.

(b) Measure the resistance according to the value(s) in the

table below.

C038 (19) - C015 (2)
＜2Ω
C038 (20) - C015 (1)

table below.

C038 (19) - Ground
≥ 1 MΩ
C038 (20) - Ground
Is the check result normal？

YES > Repair or replace ABS module.
5. INSPECT FRONT WHEEL SPEED SENSOR RH INSTALLATION
(a) Position the front wheel speed sensor RH properly.

NOTE
Installation bolts are tightened properly, the sensor
installation position should be flat.

NO > Repair or replace front wheel speed sensor RH.
6. INSPECT FRONT WHEEL SPEED SENSOR RH TIP
(a) Remove the front wheel speed sensor RH.

04
(b) Check the sensor tip.
NOTE
No scratches or foreign objects on the sensor tip.
04

NO > Clean or repair front wheel speed sensor RH.
7. INSPECT FRONT WHEEL SPEED SENSOR RH ROTOR
(a) Check the sensor serrations.

NOTE
No scratches, missing teeth or foreign objects.
If foreign object is attached, remove it. After reassembling,
check the output voltage.

NO > Clean or repair front wheel speed sensor RH rotor.
C0205 - FRONT WHEEL SPEED SENSOR LH MALFUCTION

tion to the speed of the rotor, the frequency is used by the ABS
CIRCUIT DESCRIPTION
• Vehicle at the speed of 20km/h or more,

pulses are not input for 15 seconds.
• Momentary interruption of the speed sen-
C0205 sor signal occurs when shifting the
• Front wheel speed sensor LH circuit
ignition switch OFF to ON. • Front wheel speed sensor LH rotor
• Wheel speed sensor circuit open.
WIRING DIAGRAM
(a) Select the DATA STREAM mode on the KT600 scan tool. 04
cle.
NOTE
04

2. INSPECT FRONT WHEEL SPEED SENSOR LH

(b) Disconnect battery negative and positive terminal and remove the battery.
(c) Disconnect the A002 front wheel speed sensor LH con-

nector.
NOTE
Front wheel speed sensor LH is located next to the battery.

table below.
A002 (1) - A002 (2) 0.9 - 1.8 KΩ

(e) Measure the resistance according to the value(s) in the

table below.

A002 (1) - Ground
≥ 1 MΩ
A002 (2) - Ground

NO > Repair or replace front wheel speed sensor LH.
3. INSPECT FRONT WHEEL SPEED SENSOR LH OUTPUT SIGNAL
(a) When the wheel is rotating, measure the front wheel

speed sensor LH output voltage.
Standard
A002 (1) - A002 (2) 0.12 V
NOTE
wheel is rotating with 2 laps per second, measure the front
wheel speed sensor LH output voltage.
NO > Go to step 5.
4. CHECK HARNESS AND CONNECTOR (ABS MODULE - FRONT WHEEL SPEED SENSOR LH)


table below.
04
C038 (1) - A002 (2)
＜2Ω
C038 (2) - A002 (1)
04

table below.

C038 (1) - Ground
≥ 1 MΩ
C038 (2) - Ground

5. INSPECT FRONT WHEEL SPEED SENSOR LH INSTALLATION
(a) Check the front wheel speed sensor LH installation.

NOTE

NO > Repair or replace front wheel speed sensor LH.
6. INSPECT FRONT WHEEL SPEED SENSOR LH TIP
(a) Remove the front wheel speed sensor LH.

NOTE

NO > Clean or repair front wheel speed sensor LH.
7. INSPECT FRONT WHEEL SPEED SENSOR LH ROTOR

NOTE

NO > Clean or repair front wheel speed sensor LH rotor.
C0210 - REAR WHEEL SPEED SENSOR RH MALFUCTION

C0215 - REAR WHEEL SPEED SENSOR LH MALFUCTION
04
tion to the speed of the rotor, the frequency is used by the ABS 04
CIRCUIT DESCRIPTION
• At vehicle speed of 20km/h or more, • Rear wheel speed sensor RH

pulses are not input for 15 sec. • Rear wheel speed sensor RH circuit
C0210 • Momentary interruption of the speed sen- • Rear wheel speed sensor RH rotor
C0215 sor signal occurs when shifting the • Rear wheel speed sensor LH
ignition switch OFF to ON. • Rear wheel speed sensor LH circuit
• Wheel speed sensor circuit open. • Rear wheel speed sensor LH rotor
WIRING DIAGRAM
(a) Select the DATA STREAM mode on the KT600 scan tool.
cle.
NOTE

2. INSPECT REAR WHEEL SPEED SENSOR
(b) Disconnect the L006/L007 rear wheel speed sensor con-

nector.

table below.

L006 (1) - L006 (2)
≤ 2.2 KΩ
L007 (1) - L007 (2)

table below.

L006 (1) - Ground
L006 (2) - Ground

≥ 1 MΩ
L007 (1) - Ground
L007 (2) - Ground


NO > Repair or replace rear wheel speed sensor. 04
3. INSPECT REAR WHEEL SPEED SENSOR OUTPUT SIGNAL
(a) When the wheel is rotating, measure the rear wheel

speed sensor output voltage.
Standard
04
L006 (1) - L006 (2)
0.120 V
L007 (1) - L007 (2)
NOTE
wheel is rotating with 2 laps per second, measure the rear
wheel speed sensor output voltage.
NO > Go to step 5.
4. CHECK HARNESS AND CONNECTOR (ABS MODULE - REAR WHEEL SPEED SENSOR)


table below.

C038 (5) - L007 (2)
C038 (6) - L007 (1)

＜2Ω
C038 (22) - L006 (1)
C038 (23) - L006 (2)

table below.

C038 (5) - Ground
C038 (6) - Ground

≥ 1 MΩ
C038 (22) - Ground
C038 (23) - Ground

5. INSPECT REAR WHEEL SPEED SENSOR INSTALLATION
(a) Check the rear wheel speed sensor installation.

NOTE

NO > Repair or replace rear wheel speed sensor.
04
6. INSPECT REAR WHEEL SPEED SENSOR TIP
(a) Remove the rear wheel speed sensor.

NOTE
04

NO > Clean or repair rear wheel speed sensor.
7. INSPECT REAR WHEEL SPEED SENSOR ROTOR

NOTE

NO > Clean or repair rear wheel speed sensor rotor.
C0278 - THE MAIN RELAY ELECTRICAL RESISTANCE EXCEEDS

LIMIT OR FUSE IS BLOWN IN THE KL30 CIRCUIT
CIRCUIT DESCRIPTION
• When turn the ignition switch ON, power • Fuse

C0278 source circuit is open or short. • Power source circuit
WIRING DIAGRAM
1. INSPECT FUSE(BODY JUNCTION BOX)
(a) Inspect the ABS actuator fuse in body junction box:

F10(30A).
Standard

F10 (30A) - Ground
Battery voltage
F10 (30A) - Ground

NO > Fuse ends have difference voltage, go to step 3.
2. INSPECT ABS MODULE CONNECTOR

04
04

table below.
Standard

C038 (25) - C038 (8)
Battery voltage
C038 (25) - C038 (24)

3. CHECK HARNESS AND CONNECTOR (ABS MODULE - BODY JUNCTION BOX)
(a) Disconnect fuse F10.

table below.

C038 (25) - F10 ＜2Ω

table below.

C038 (25) - Ground ≥ 1 MΩ

YES > Replace the fuse.
C1249 - OPEN CIRCUIT IN STOP LAMP SWITCH CIRCUIT(WITH

4G63/4G64 ENGINE)
CIRCUIT DESCRIPTION 04
• When the wheel speed shows down • Stop lamp switch

instantly, module did not receive brake
C1249 signal. • Stop lamp switch circuit
• Stop lamp switch circuit is open. • ABS module
04
WIRING DIAGRAM
1. INSPECT FUSE (ENGINE ROOM JUNCTION BOX)
(a) Inspect the stop lamp fuse in engine room junction box:
F27(15A).
Standard

F27 (15A) - Ground
Battery voltage
F27 (15A) - Ground

2. CHECK HARNESS AND CONNECTOR (ENGINE ROOM JUNCTION BOX - STOP LAMP SWITCH)
(a) Disconnect the C004 stop lamp switch connector.

table below.
Standard voltage

C004 (2) - Ground Battery voltage

NO > Go to step 4.
3. CHECK HARNESS AND CONNECTOR (ENGINE ROOM JUNCTION BOX - ABS MODULE)
(a) Connect the C004 stop lamp switch connector.
(b) Disconnect the C038 ABS module connector.

(c) Depress the brake pedal, measure the voltage according

to the value(s) in the table below.
Standard voltage
04
04
NO > Go to step 5.
4. CHECK HARNESS AND CONNECTOR (ENGINE ROOM JUNCTION BOX - STOP LAMP SWITCH)
(a) Disconnect fuse F27,

table below.
C004 (2) - F27 ＜2Ω

table below.
C004 (2) - Ground ≥ 1 MΩ

5. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - ABS MODULE)
(a) Measure the resistance according to the value(s) in the

table below.
C038 (18) - C004 (1) ＜2Ω

table below.
C038 (18) - Ground ≥ 1 MΩ

6. INSPECT STOP LAMP SWITCH CONNECTOR
(a) Depress the brake pedal,

table below.
C004 (1) - C004 (2) ＜2Ω

(c) Depress the brake pedal, measure the resistance

according to the value(s) in the table below.
04
C004 (1) - Ground ≥ 1 MΩ
04
YES > Replace the fuse in engine room junction box.
NO > Repair or replace stop lamp switch.
C1249 - OPEN CIRCUIT IN STOP LAMP SWITCH CIRCUIT(WITH

BJ493ZQ3 ENGINE)
CIRCUIT DESCRIPTION
• When the wheel speed shows down • Stop lamp switch

instantly, module did not receive brake
C1249 signal. • Stop lamp switch circuit
• Stop lamp switch circuit is open. • ABS module
WIRING DIAGRAM
1. INSPECT FUSE (BODY JUNCTION BOX)
04
(a) Inspect the oil water separator fuse in body junction box:
F20(20A).
Standard voltage

F20 (20A) - Ground 04
Battery voltage
F20 (20A) - Ground

2. CHECK HARNESS AND CONNECTOR (BODY JUNCTION BOX - STOP LAMP SWITCH)
(a) Disconnect the C051 stop lamp switch connector.

table below.
Standard voltage


NO > Go to step 4.
3. CHECK HARNESS AND CONNECTOR (BODY JUNCTION BOX - ABS MODULE)
(a) Connect the C051 stop lamp switch connector.
(b) Disconnect the C038 ABS module connector.
(c) Depress the brake pedal, measure the voltage accord-

ing to the value(s) in the table below.
Standard voltage


NO > Go to step 5.
4. CHECK HARNESS AND CONNECTOR (BODY JUNCTION BOX - STOP LAMP SWITCH)
(a) Disconnect fuse F20.

04
table below.
C051 (3) - F20 ＜2Ω 04

table below.
C051 (3) - Ground ≥ 1 MΩ

5. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - ABS MODULE)

table below.
C038 (18) -C051 (2) ＜2Ω


table below.

C038 (18) - Ground ≥ 1 MΩ

6. INSPECT STOP LAMP SWITCH CONNECTOR
(a) Depress the brake pedal, measure the resistance


C051 (2) -C051 (3) ＜2Ω
(b) Depress the brake pedal, measure the resistance


C051 (2) - Ground ≥ 1 MΩ

YES > Replace the fuse in body junction box.
NO > Repair or replace stop lamp switch.
C1251 - PUMP MOTOR MALFUNCTION

CIRCUIT DESCRIPTION
DTC No. DTC Detecting Condition Trouble Area 04
• Pump motor does not operate normally • ABS pump motor

C1251 during initial check. • ABS pump circuit
WIRING DIAGRAM
04
1. INSPECT FUSE (BODY JUNCTION BOX)
(a) Inspect the ABS solenoid valve in body junction box:

F9(30A).
Standard voltage

F9 (30A) - Ground
Battery voltage
F9 (30A) - Ground


table below.
Standard voltage

C038 (9) - C038 (8)
Battery voltage
C038 (9) - C038 (24)

3. CHECK HARNESS AND CONNECTOR (ABS MODULE - BODY JUNCTION BOX)
(a) Disconnect fuse F9, measure the resistance according to

the value(s) in the table below.

C038 (9) - F9 ＜2Ω

table below.
04
C038 (9) - Ground ≥ 1 MΩ
04
ABS WARNING LIGHT IS ALWAYS ON

ABS WARNING LIGHT IS INOPERATIVE
WIRING DIAGRAM

table below.
Standard voltage

C038 (15) - C038 (8)
Battery voltage
C038 (15) - C038 (24)

04
2. CHECK HARNESS AND CONNECTOR (ABS MODULE - INSTRUMENT CLUSTER)

(b) Disconnect the C045 instrument cluster connector.
04

table below.

C038 (15) - C045 (14) ＜2Ω

table below.

C038 (15) - Ground ≥ 1 MΩ

YES > Repair or replace instrument cluster.
EBD WARNING LIGHT IS ALWAYS ON

EBD WARNING LIGHT IS INOPERATIVE
WIRING DIAGRAM
(b) Turn ignition switch ON.

table below.
Standard voltage

C038 (14) - C038 (8)
Battery voltage
C038 (14) - C038 (24)

04
2. CHECK HARNESS AND CONNECTOR (ABS MODULE - INSTRUMENT CLUSTER)

04

table below.

C038 (14) - C045 (28) ＜2Ω

table below.

C038 (14) - Ground ≥ 1 MΩ

04-260 DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM

PRECAUTION
WARNING
• Some vehicles are equipped with an SRS (Supplemental Restraint System). Fail to carry out the
service operations in the correct sequence could cause the supplemental restraint system to
unexpectedly deploy during servicing. It may lead to a serious accident. Furthermore, if a mis-
take is made in servicing the supplemental restraint system, it is possible that the SRS will fail
to operate when requiring. Before servicing (including removal or installation of parts, inspec-
tion or replacement), be sure to read the following items carefully. Then follow the correct pro-
cedure described in this manual.
• Work must be started after 90 seconds from the time that the ignition switch is turned to the
”LOCK” position and the negative (–) terminal cable is removed from the battery. (The
supplemental restraint system is equipped with a back–up power source, so if work is started
within 90 seconds after disconnecting the negative (–) terminal cable from the battery, the SRS
may deploy.
• Do not directly expose the horn switch assy to hot air or flames.
NOTE
• Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the
diagnostic trouble codes (DTC) become the most important source of information when
troubleshooting. When repair the supplemental restraint system, always check the diagnostic
trouble codes (DTC) before disconnecting the battery.
• Even in case of a minor collision where the SRS does not deploy, the horn switch assy and
restraint control module should be inspected.
• Before repairing, remove the driver airbag and restraint control module if shocks are likely to be
applied to the airbag and module during repairing.
• Never use SRS related parts from another vehicle. If necessary, replace with new parts.
• Never disassemble and repair the horn switch assy.
• If the horn switch assy has been dropped, or if there are cracks, dents or other defects in the
case, bracket or connector, replace them with new ones.
• Use the multimeter with high impedance (10 kW/V minimum) for troubleshooting of an electrical
circuit.
• Information labels are attached to the SRS components. Follow the instructions on the notices.
• After working on the supplemental restraint system is completed, check the SRS warning light.
• When the negative (–) terminal cable is disconnected from the battery, memory of the clock and
audio systems will lost. So, before starting work, make a record of the memorized contents in
each memory system. Then, when work is finished, reset the clock and audio systems as
before. To avoid erasing the memory in each memory system, never use a back–up power
supply from another battery.
DIAGNOSTICS - SUPPLEMENTAL RESTRAINT SYSTEM 04-261
LOCATION
04
04
1 Restraint Control Module (RCM) 4 Clock Spring
2 Instrument Cluster 5 Body Junction Box
3 Driver Airbag 6 Ignition Switch

RESTRAINT CONTROL MODULE CONNECTOR
Pin Definition Color Pin Definition Color

1 －－ 16 －－
2 －－ 17 －－
3 －－ 18 －－
4 －－ 19 －－
5 Power Supply B-O 20 －－
6 Ground BR 21 －－
7 SRS Warning Light B-Y 22 －－
8 －－ 23 －－
9 Diagnosis K P-B 24 －－
10 Airbag ＋ Y 25 －－
11 Airbag － Y-B 26 －－
12 －－ 27 Collision Output Interface Y
13 －－ 28 －－
14 －－ 29 －－
15 －－ 30 －－

NOTE
If a malfunction code is displayed during the DTC check, check the circuit listed. For details of each
code, turn to the relevant troubleshooting page in the DTC chart.
04

$9201 RCM is Faulted • Restraint control module
• Battery
$9202 Battery Voltage High • Charging system 04
• Restraint control module
• Fuse
$9203 Battery Voltage Low • Power source circuit
• Driver airbag
• Driver airbag circuit
$9204 Driver Airbag Fault - High Resistance
• Clock spring
• Driver airbag
$9205 Driver Airbag Fault - Low Resistance
• Clock spring
• Driver airbag
$9206 Driver Airbag Circuit Short to Ground
• Clock spring
• Driver airbag
$9207 Driver Airbag Circuit Short to Battery
• Clock spring
$9215 Collision Output Interface 1 is Faulted • Restraint control module



Chapter 04 diagnostics - supplemental
1. SRS warning light circuit restraint system, SRS warning light is always
on
SRS warning light is always on
2. Restraint control module restraint system, SRS warning light is always
on

1. SRS warning light circuit restraint system, SRS warning light is inoper-
ative
SRS warning light is inoperative
2. Restraint control module restraint system, SRS warning light is inoper-
ative
PRECHECK
1. DIAGNOSIS SYSTEM
(a) Turn the ignition switch ON, check the SRS warning light. 04
Standard：When turn the ignition switch ON, check
that the SRS warning light goes on for 5~6 seconds.
If the system check result is abnormal, the SRS warning light is
lighted. Read the DTC code from KT600 scan tool.
NOTE
When the ignition switch turns on, supplemental restraint 04
system components will be tested.
2. DIAGNOSTIC TROUBLE CODE (DTC) CHECK AND

CLEAN
(a) Check the DTC from KT600 scan tool.
• Make sure to connect the KT600 scan tool and data link
connector. (DLC)
• Click the icon “FOTON”
• Click the icon “LIGHT BUS”

• Click the icon “MP-X MP”
• Click the icon “SRS”
• Click the icon “JIULE”
• Click the icon “READ DTC”

Read the DTC by following the prompts on the scan tool
screen.
(b) Clean the DTC from KT600 scan tool.

• Click the icon “CLEAN DTC”
Operate the KT600 scan tool to erase the codes.
$9203 - BATTERY VOLTAGE LOW

CIRCUIT DESCRIPTION
• With vehicle speed at 3 km/h or more, • Fuse

$9203 ignition switch terminal voltage is 10V or • Power source circuit
below for 10 sec or longer. • Restraint control module
WIRING DIAGRAM 04
1. CHECK HARNESS AND CONNECTOR (RESTRAINT CONTROL MODULE - CLOCK SPRING)
(a) Disconnect the negative cable from the battery, and wait at least for 90 seconds.
(b) Disconnect the C061 driver airbag connector.
(c) Disconnect the C027 restraint control module connector.

(d) Connect the negative cable to the battery and turn the ignition switch ON.
(e) Measure the voltage according to the value(s) in the

table below.
Standard voltage


YES > Replace restraint control module.
2. INSPECT FUSE (BODY JUNCTION BOX - GROUND)
(a) Turn the ignition switch ON,

table below.
Standard voltage

F17 (7.5A) - Ground
Battery voltage
F17 (7.5A) - Ground

NO > Go to step 4.
3. CHECK HARNESS AND CONNECTOR (BODY JUNCTION BOX - RESTRAINT CONTROL MOD-
ULE)
(a) Turn the ignition switch OFF and disconnect fuse 17. 04
table below.

04
C027 (5) - F17 ＜2Ω

table below.
C027 (5) - Ground ≥ 1 MΩ

4. CHECK HARNESS AND CONNECTOR (BODY JUNCTION BOX - IGNITION SWTICH)
(a) Disconnect the fuse 17.

table below.
C033 (IG2) - F17 ＜2Ω


table below.
C033 (IG2) - Ground ≥ 1 MΩ

YES > Repair or replace ignition switch.
$9204 - DRIVER AIRBAG FAULT - LOW RESISTANCE

$9205 - DRIVER AIRBAG FAULT - HIGH RESISTANCE
CIRCUIT DESCRIPTION 04
• Short circuit between airbag plus wire harness and airbag

negative wire harness.
• Driver airbag
• Open circuit between airbag plus wire harness and airbag
$9204 negative wire harness. • Driver airbag circuit 04
$9205 • Driver airbag malfunction • Clock spring
• Clock spring malfunction • Restraint control module
• Restraint control module malfunction
WIRING DIAGRAM
1. INSPECT CLOCK SPRING CONNECTOR

(c) Disconnect the C030 clock spring connector.

table below.

C030 (1) - C061 (1)
＜2Ω
C030 (2) - C061 (2)

NO > Replace clock spring.
(a) Disconnect the C027 restraint control module connector.


table below.
04
C027 (10) - C030 (1)
＜2Ω
C027 (11) - C030 (2)
04
YES > Replace driver airbag and operate the KT600 scan tool to erase the codes. If the system check result is
not normal, replace restraint control module.
$9206 - DRIVER AIRBAG CIRCUIT SHORT TO GROUND

CIRCUIT DESCRIPTION
• Short circuit in airbag wire harness (to ground) • Driver airbag

• Driver airbag malfunction • Driver airbag circuit
$9206
• Clock spring malfunction • Clock spring
• Restraint control module malfunction • Restraint control module
WIRING DIAGRAM

(c) Disconnect the C030 clock spring connector.
04
04

table below.

C030 (1) - C061 (1)
＜2Ω
C030 (2) - C061 (2)

table below.

C061 (1) - Ground
≥ 1 MΩ
C061 (2) - Ground

(a) Disconnect the C027 restraint control module connector.

table below.

C027 (10) - C030 (1)
＜2Ω
C027 (11) - C030 (2)

YES > Replace driver airbag and operate the KT600 scan tool to erase the codes. If the system check result is
not normal, replace restraint control module.
$9207 - DRIVER AIRBAG CIRCUIT SHORT TO BATTERY

CIRCUIT DESCRIPTION
• Short circuit in airbag wire harness (to battery) • Driver airbag

• Driver airbag malfunction • Driver airbag circuit
$9206
• Clock spring malfunction • Clock spring
• Restraint control module malfunction • Restraint control module
04
WIRING DIAGRAM

(c) Disconnect the C027 restraint control module connector.
(d) Disconnect the C030 clock spring connector.
(e) Connect the negative cable to the battery and turn the ignition switch ON.
(f) Measure the voltage according to the value(s) in the

table below.
Standard voltage

C030 (1) - Ground
0V
C030 (2) - Ground

(a) Turn the ignition switch OFF and connect the C030 clock spring.
04
(b) Turn the ignition switch ON, measure the voltage accord-
ing to the value(s) in the table below.
Standard voltage

C061 (1) - Ground
0V 04
C061 (2) - Ground

SRS WARNING LIGHT IS ALWAYS ON

SRS WARNING LIGHT IS INOPERATIVE
WIRING DIAGRAM
(c) Disconnect the C030 driver clock spring connector.

(d) Disconnect the C027 restraint control module connector.
04
04
(e) Turn the ignition switch ON.
table below.
Standard voltage

C027 (7) - C027 (6) Battery voltage

2. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - RESTRAINT CONTROL
MODULE)


table below.

C027 (7) - C045 (17) ＜2Ω

table below.

C027 (7) - Ground ≥ 1 MΩ

DIAGNOSTICS - REVERSE RADAR SYSTEM 04-283
REVERSE RADAR SYSTEM

PRECAUTION
1. UNDER THE FOLLOWING CONDITIONS, THE DETECTION FUNCTION MAY NOT FUNCTION 04
PROPERLY:
(a) The sensor is covered with foreign matter, such as mud or snow (detection function returns to normal
when the sensor is cleaned).
(b) The sensor is frozen (detection function returns to normal when the temperature of the sensor rises).
(c) The sensor is covered with a hand.
(d) In very cold weather where a malfunction display appears, the sensor may not be able to detect 04
obstacles.
2. THE DETECTION RANGE MAY BE AFFECTED BY THE FOLLOWING CONDITIONS:
(a) The sensor is covered with foreign matter, such as mud or snow.
(b) The vehicle is in an excessively hot or cold area.
3. UNDER THE FOLLOWING CONDITIONS, A DETECTION ERROR MAY OCCUR:
(a) Driving on a bumpy road, an unpaved road, or in tall grass.
(b) Ultrasonic waves from items such as another vehicle's horn, motorcycle engine sounds, a large
vehicle's air brake sound, or another vehicle's sonar are transmitted near the vehicle.
(c) It is raining heavily or the sensor comes into contact with water (sprayed).
(d) The vehicle is tilted at a large angle.
(e) The vehicle is equipped with a commercial fender pole or a wireless mechanism antenna.
(f) The sensor is covered with foreign matter, such as mud or snow.
(g) The vehicle is moving toward a high curb or the corner of a pointed object.
4. THE SENSOR CANNOT DETECT SOME OBJECTS SUCH AS THE FOLLOWING:
(a) Thin objects, such as wires and ropes.
(b) Materials that absorb ultrasonic waves, such as cotton, snow, etc.
(c) Objects with sharp edges.
(d) Short objects.
(e) Tall, overhanging objects.
5. OTHER NOTICES:
(a) The sensor cannot detect objects directly under the bumper. (The sensor may detect low objects and
thin poles, and then lose track of the objects.)
(b) The sensor may not be able to detect obstacles that are too close to the sensor.
(c) The sensor may not be able to detect obstacles if it is dropped or subjected to a strong impact.
04-284 DIAGNOSTICS - REVERSE RADAR SYSTEM
LOCATION
1 Reverse Radar Sensor LH 4 Combined Display
2 Reverse Radar Sensor MID 5 Reverse Radar Controller
3 Reverse Radar Sensor RH

SYSTEM DESCRIPTION
1. GENERAL
This system uses ultrasonic sensors to send ultrasonic waves. The reverse radar sensors receive the
echo. The reverse radar controller then informs the driver of the distance between the sensors and the 04
obstacles as well as their positions by indicating them on the combined display and by clearance warn-
ing buzzer.
2. FUNCTION OF COMPONENTS
Components Function
Detects the distance between the vehicle and an
04
Reverse radar sensor
obstacle.
Sounds the buzzer to inform the driver according to the

Clearance warning buzzer
distance to the obstacle.
1. Displays the location of the obstacle and the

approximate distance between the vehicle and the
Combined display obstacle.
2. Informs the driver if the reverse radar sensors
malfunction, or if they are frozen or dirty.
1. Judges the approximate distance between the

vehicle and the obstacle based on the signals from
Reverse radar controller the reverse radar sensor and sends it to the
combined display.
2. Sounds the clearance warning buzzer.
Sends the back-up signal to the reverse radar

Back-up lamp switch
controller.
3. INITIALIZATION FUNCTION OF REVERSE RADAR CONTROLLER

(b) Set shift lever in reverse position.
• If all the reverse radar sensors work correctly, the clearance warning buzzer sounds once for 0.5 sec-
ond. The interval time is 0.5 second.
• If one reverse radar sensor works incorrectly, the clearance warning buzzer sounds twice for 0.5 sec-
ond. The interval time is 0.5 second.
• If two reverse radar sensors work incorrectly, the clearance warning buzzer sounds three times for 0.5
second. The interval time is 0.5 second.
• If three reverse radar sensors work incorrectly, the clearance warning buzzer sounds four times for 0.5
second. The interval time is 0.5 second.
4. DETECTION RANGE OF REVERSE RADAR SENSOR
(a) Detection range of reverse radar sensor (both sides).
(b) Detection range of reverse radar sensor (middle).
5. DISTANCE TO AN OBSTACLE, FREQUENCY AND MODE OF CLEARANCE WARNING BUZZER
NO. DISTANCE MODE FREQUENCY

A 90 - 150 cm Long & Intermittent 1 Hz
B 60 - 90 cm Short & Intermittent 2 Hz
C 40 - 60 cm Rapid & Intermittent 4 Hz
D 40 ± 5 cm Continual Continual
6. TERMINALS OF REVERSE RADAR CONTROLLER
Terminal No. Wiring Color Terminal Description

1 B-R Voltage
2 - -
3 - -
4 - -
5 W-L Combined display (Clock)
6 - -
7 P Reverse radar sensor LH
8 L Reverse radar sensor Mid


9 - -
10 - - 04
11 - -
12 - -
13 Y Combined display (Data)
14 - - 04
15 LG Reverse radar sensor RH
16 W-B Ground

1. Fuse -
Chapter 81 communication system

2. Reverse radar controller - reverse radar, replacement
Reverse radar system is inoperative
at all Chapter 81 communication system
3. Combined display - combined display, replacement
4. Wire harness -

1. Reverse radar sensor - reverse radar, replacement
Self-check function is inoperative Chapter 81 communication system

3. Wire harness -


Reverse radar system is operative 2. Reverse radar controller - reverse radar, replacement
when the shift lever is out of reverse
position Chapter 41 transmission - input
3. Back-up Lamp switch shaft and reverse idler gear shaft,
replacement
4. Wire harness -

Reverse radar system is inoperative
within specified distance (Back-up Chapter 81 communication system
lamp is normal)
3. Wire harness -

Reverse radar system is operative but
there is no obstacle behind the Chapter 81 communication system
vehicle (Back-up lamp is normal)
3. Wire harness -

Buzzer is inoperative or operative
incorrectly within specified distance Chapter 81 communication system
(Combined display is normal)
3. Wire harness -

1. Combined display - combined display, replacement
Combined display is inoperative 04
within specified distance (Back-up Chapter 81 communication system
lamp is normal)
3. Wire harness -
04
REVERSE RADAR SYSTEM IS INOPERATIVE AT ALL

WIRING DIAGRAM
1. INSPECT FUSE
(b) Inspect the reverse radar fuse in body junction box: F1 (15
A).

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP SWITCH - GROUND)

(b) Disconnect the E011 back-up lamp switch connector. 04
table below.

04
E011 (2) - Ground ≥ 1 ΜΩ

3. CHECK HARNESS AND CONNECTOR (REVERSE RADAR CONTROLLER - GROUND)

(b) Disconnect the C041 reverse radar controller connector.

table below.

C041 (16) - Ground ＜2Ω

4. INSPECT BACK-UP LAMP SWITCH

(b) Disconnect the E011 back-up lamp switch connector.
(c) Inspect the back-up lamp switch.

Standard resistance
Tester Specified
Condition
Connection Condition
Set shift lever in reverse
1-2 ＜2Ω
position
Set shift lever out of

1-2 ≥ 1 ΜΩ
reverse position

NO > Replace the back-up lamp switch.
5. CHECK HARNESS AND CONNECTOR (FUSE - BACK-UP LAMP SWITCH)


table below.

F1 (15 A) - E011 (2) ＜2Ω

6. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP SWITCH - REVERSE RADAR

CONTROLLER)
(a) Turn the ignition switch OFF. 04

(c) Disconnect the C041 reverse radar controller connector.

table below.
04
E011 (1) - C041 (1) ＜2Ω



table below.

E041 (1) - Ground ≥ 1 ΜΩ

YES > Replace the reverse radar controller.
SELF-CHECK FUNCTION IS INOPERATIVE

WIRING DIAGRAM
1. INSPECT REVERSE RADAR SENSOR

(b) Disconnect the D001 reverse radar sensor LH connector.
(c) Disconnect the D003 reverse radar sensor MID connector.
(d) Disconnect the D004 reverse radar sensor RH connector.
(e) Replace the reverse radar sensor with a new one. (Refer to “Chapter 81 communication system -
reverse radar, replacement”)
(g) Set the shift lever in reverse position.
Does the reverse radar work correctly?
YES > Replace the reverse radar sensor.
2. CHECK HARNESS AND CONNECTOR (REVERSE RADAR SENSOR - GROUND)

(b) Disconnect the D001 reverse radar sensor LH connector. 04

table below.
04
D001 (1) - Ground
D003 (1) - Ground ＜2Ω

D004 (1) - Ground

3. CHECK HARNESS AND CONNECTOR (REVERSE RADAR CONTROLLER - REVERSE RADAR
SENSOR)

(e) Disconnect the C041 reverse radar controller connector.
(f) Measure the resistance according to the value(s) in the

table below.

C041 (7) - D001 (2)
C041 (8) - D003 (2) ＜2Ω

C041 (15) - D004 (2)

REVERSE RADAR SYSTEM IS OPERATIVE WHEN THE SHIFT

LEVER IS OUT OF REVERSE POSITION
WIRING DIAGRAM

Specified
Condition Tester Connection
Condition
04
Set shift lever in
1-2 ＜2Ω
reverse position
Set shift lever out of

1-2 ≥ 1 ΜΩ
reverse position
04


table below.
Standard voltage



NO > Replace the reverse radar sensor.
REVERSE RADAR SYSTEM IS INOPERATIVE WITHIN SPECIFIED

DISTANCE
WIRING DIAGRAM



table below.
04
D001 (1) - Ground
D003 (1) - Ground ＜2Ω

D004 (1) - Ground

SENSOR)


table below.

C041 (7) - D001 (2)
C041 (8) - D003 (2) ＜2Ω

C041 (15) - D004 (2)

REVERSE RADAR SYSTEM IS OPERATIVE BUT THERE IS NO

OBSTACLE BEHIND VEHICLE
WIRING DIAGRAM


SENSOR)


table below.
04

C041 (7) - D001 (2)
C041 (8) - D003 (2) ＜2Ω

C041 (15) - D004 (2)

BUZZER IS INOPERATIVE OR OPERATIVE INCORRECTLY WITHIN

SPECIFIED DISTANCE
WIRING DIAGRAM



table below.
04
D001 (1) - Ground
D003 (1) - Ground ＜2Ω

D004 (1) - Ground

SENSOR)


table below.

C041 (7) - D001 (2)
C041 (8) - D003 (2) ＜2Ω

C041 (15) - D004 (2)

COMBINED DISPLAY IS INOPERATIVE WITHIN SPECIFIED DIS-

TANCE
WIRING DIAGRAM
1. INSPECT COMBINED DISPLAY

(b) Disconnect the C401 combined display connector.
(d) Set the shift lever in reverse position.
Does the combined display work correctly?
YES > Replace the combined display.
2. CHECK HARNESS AND CONNECTOR (REVERSE RADAR CONTROLLER - COMBINED DISPLAY )

(b) Disconnect the C401 combined display connector. 04

table below.

C401 (5) - C041 (13)
＜2Ω
C401 (6) - C041 (5)

04-306 DIAGNOSTICS - POWER WINDOWS
POWER WINDOWS
PRECAUTION
Switch Type81 Ignition Switch (position) Ignition Switch (condition)

Ignition switch off LOCK OFF
Ignition switch on (ACC) ACC ON (ACC)

Expression
Ignition switch on (IG) ON ON (IG)
Engine start START START
2. POWER OFF.
(a) Before removing or installing any electrical device, please disconnect the negative cable from battery
to prevent damage to the device or personal injury.
NOTE
To prevent locking the key in the vehicle, do not leave the key in the vehicle when disconnecting the
negative battery cable.
(b) Ignition switch must be off if no specific instructions.
3. DISCONNECTING THE NEGATIVE BATTERY CABLE WILL RESET BOTH THE TRIP ODOMETER
AND THE CLOCK TO ‘0’.
NOTE
The total odometer can not be reset to ‘0’.
4. THE AUDIO SYSTEM WILL LOSE STORED MEMORY DATA IF THE NEGATIVE BATTERY CABLE
IS DISCONNECTED.
NOTE
After reconnecting the negative battery cable, the audio system will need to be reset (Refer to “Audio
instructions”).
DIAGNOSTICS - POWER WINDOWS 04-307
LOCATION
04
04
1 Front Power Window Motor LH Assy 4 Front Power Window Motor RH Assy
Main Power Window And Door Lock/ 5 Front Power Window Switch RH Assy
2
Unlock Switch Assy
3 Central Door Lock Controller Assy

TERMINALS OF MAIN POWER WINDOW AND DOOR LOCK/

UNLOCK SWITCH
Terminal No Wiring Color Description

1 LG To the front power window switch RH
2 P To the front power window switch RH
3 L-Y To the front power window switch RH
4 L To the central door lock controller
5 L-B To the central door lock controller
6 L-Y Power
7 - -
8 - -
9 L-Y Switch illumination
10 - -
11 - -
12 W-B Ground
TERMINALS OF CENTRAL DOOR LOCK CONTROLLER
04
04

1 L-Y To fuse FL4 (20A)
2 G-R To front power window motor RH
3 R-L To front power window motor RH
4 R To front power window motor LH
5 G To front power window motor LH
6 R To door lock actuator (UNLOCK)
7 G To door lock actuator (LOCK)
8 W-B Ground
9 R-B To fuse F1 (15A)
10 R-B Odometer sensor signal input
11 L To main power window and door lock/unlock switch
12 L-B To main power window and door lock/unlock switch
13 W-R To door ajar switch
14 G-Y To turn signal lamp RH
15 G-B To turn signal lamp LH
16 Y To RCM
17 L-R To door lock actuator LH (UNLOCK)
18 L-O To door lock actuator LH (LOCK)

BASIC INSPECTION
Step Condition Action
Check the battery voltage. Yes Go to step 2.

1 • The battery voltage should above 12 V. Charge or replace the battery. Refer to
Is the check result normal？ No
“Chapter 20A starting and charging - battery”.
Check the front power window motor LH. Yes Go to step 3.

• Turn the ignition switch ON.
• Push or pull the front window switch LH of
2 the main power window and door lock/
unlock switch to the first detent and No Go to the problem symptoms table.
continue to hold until the desired window
position is reached.
Check the front window LH auto opera- Yes Go to step 4.

tion.
3 • Press the main power window and door
lock/unlock switch down to the second No Go to the problem symptoms table.
detent and release it. The window auto-
matically opens all the way.
Check the front power window motor RH. Yes Go to step 5.

• Push or pull the front window switch RH
of the main power window and door lock/
4 unlock switch to the first detent and
continue to hold until the desired window No Go to the problem symptoms table.
position is reached.
Check the front power window motor RH. Yes Go to step 6.

• Push or pull the front power window
5 switch RH and continue to hold until the
desired window position is reached. No Go to the problem symptoms table.
Check power window auto close opera- Yes Go to step 7.

tion.
• Turn the ignition switch OFF.
• Close all doors.
6
• About 2 seconds later LH and RH power No Go to the problem symptoms table.
windows will close in order when doors
are locked.
Check the window lock switch. Replace the main power window and door
• Push the power window lock button of the lock/unlock switch. Refer to “Chapter 88 inte-
Yes
main power window and door lock/unlock rior / exterior trim - vehicle door inner guard
switch. board, replacement”.
7 • Push or pull the front power window
switch RH and continue to hold until the
desired window position is reached. No Go to step 8.
Does the front power window motor RH
operate?

Check the power window lock switch. Yes Go to the problem symptoms table.
• Push the power window lock button of the
main power window and door lock/unlock
04
switch again. Replace the front power window switch RH.
8 • Push or pull the front power window Refer to “Chapter 88 interior / exterior trim -
switch RH and continue to hold until the No
vehicle door inner guard board, replace-
desired window position is reached. ment”.
Does the front power window motor RH
operate?
04

Use the table below to help you to find the cause of the problem. The numbers indicate the priority of the likely

Chapter 04 diagnostics - power
1. Power, ground circuits windows, all power windows are
inoperative

2. The main power window and windows, all power windows are
door lock/unlock switch inoperative
All power windows are inoperative Chapter 04 diagnostics - power

3. The central door lock controller windows, all power windows are
inoperative

4. Front power window motor LH/ windows, all power windows are
RH inoperative
5. Harness Repair harness
1. The main power window and Repair the manin power window
door lock/unlock switch and door luck/unlock switch

2. The central door lock controller windows, front power window LH
is inoperative
Front power window LH is inoperative
3. The front power window motor windows, front power window LH
LH is inoperative

4. Harness windows, front power window LH
is inoperative

1. The main power window and windows, front power window LH
door lock/unlock switch does not open

Front power window LH does not open 2. The central door lock controller windows, front power window LH
does not open

3. Harness windows, front power window LH
does not open

1. The main power window and windows, front power window LH
door lock/unlock switch does not close
Front power window LH does not close Chapter 04 diagnostics - power

2. The central door lock controller windows, front power window LH
does not close


1. Power, ground circuits windows, front power window
RH is inoperative 04
2. The main power window and windows, front power window
door lock/unlock switch RH is inoperative

Front power window RH is inoperative 3. The central door lock controller windows, front power window
RH is inoperative 04

4. The front power window motor windows, front power window
RH RH is inoperative

5. Harness windows, front power window
RH is inoperative

1. The front power window switch windows, front power window
Front power window RH is inoperative
RH RH is inoperative (Using the front
(Using the front power window switch
power window switch RH)
RH)
1. The main power window and Replace the main power window
Front power window RH is inoperative
door lock/unlock switch and door lock/unlock switch
(Using the main power window and
door lock/unlock switch) Repair harness
2. Harness
Auto close window is inoperative (other Replace the central door lock
features are normally) 1. The central door lock controller controller
Auto close window is inoperative Chapter 04 diagnostics - power

(power door locks operates abnor- 1. Power door locks door locks, problem symptoms
mally) table

Auto close window is inoperative
1. Power windows windows, problem symptoms
(power windows is operate abnormally)
table
1. Foreign body Clear foreign body
Replace the door glass

Power window open \ close is slow 2. The door glass weather-strip weatherstrip
3. The power window motor Replace the power window motor
1. The main power window and Replace the main power window
door lock/unlock switch and door lock/unlock switch
Front window LH auto open features is
inoperative (other features are normal)
Replace the central door lock
2. The central door lock controller controller
ALL POWER WINDOWS ARE INOPERATIVE

WIRING DIAGRAM
Does the power door lock operate normally?
NO > Go to step 1.
1. CHECK FUSE
(b) Verify the fuses in the body junction box: F1 (15A). 04

(c) Verify the fuse in the engine room junction box: FL4 (20A).
04

NO > If fuse FL4 (20A) is blown, go to step 4.
If fuse F1 (15A) is blown, go to step 2.
2. CHECK HARNESS AND CONNECTOR (CENTRAL DOOR LOCK CONTROLLER - FUSE)

table below.

C043 (9) - Ground ＞ 1 MΩ

YES > Replace the fuse F1 (15A), go to step 8.
NO > Go to step 3.
(a) Disconnect the central door lock controller connector

C043.

table below.

C043 (9) - Ground ＞ 1 MΩ

YES > Replace the fuse F1(15A) and the central door lock controller.
NO > Replace the fuse F1 (15A). Repair the circuit for a short from the fuse F1 (15A) to the central door lock
controller connector C043, pin 9.
4. CHECK HARNESS AND CONNECTOR (MAIN POWER WINDOW AND DOOR LOCK/UNLOCK
SWITCH - FUSE)
(a) Disconnect the main power window and door lock/unlock

switch connector N002.
(b) Disconnect the C043 central door lock controller

connector.
04
04

table below.

N002 (6) - Ground ＞ 1 MΩ

YES > Go to step 5.
NO > Repair the circuit for a short from the fuse FL4 (20A) to the main power window and door lock/unlock
switch connector N002, pin 6.

table below.

C043 (1) - Ground ＞ 1 MΩ

YES > Go to step 6.
NO > Replace the fuse FL4 (20A). Repair the circuit for a short from the fuse FL4 (20A) to the central door
lock controller connector C043, pin 1.
6. INSPECT CENTRAL DOOR LOCK CONTROLLER

table below.

C043 (1) - C043 (8) ＞ 1 MΩ

YES > Replace the fuse FL4 (20A), Go to step 7.
NO > Replace the fuse FL4 (20A) and the central door lock controller.
7. INSPECT MAIN POWER WINDOW AND DOOR LOCK/UNLOCK SWITCH
(a) Connect the N002 main power window and door lock/
unlock switch connector.

Inspect if the fuse FL4 (20A) is not blown.
YES > Go to step 8.
NO > Replace the main power window and door lock/unlock switch.
8. CHECK HARNESS AND CONNECTOR (CENTRAL DOOR LOCK CONTROLLER - POWER

WINDOW MOTOR)

table below.

C043 (2) - Ground ＞ 1 MΩ
04
C043 (3) - Ground ＞ 1 MΩ
C043 (4) - Ground ＞ 1 MΩ
C043 (5) - Ground ＞ 1 MΩ

YES > Go to step 9.
9. INSPECT FRONT POWER WINDOW MOTOR LH
(a) Disconnect the N004 front power window motor LH con-

nector.
(b) Measure the resistance between the front power window

motor LH pin 1 and pin 2.
Standard resistance

N004 (1) - N004 (2) Approx. 11 Ω

NO > Replace the front power window motor LH.
10. CHECK HARNESS AND CONNECTOR (CENTRAL DOOR LOCK CONTROLLER - FRONT POWER
WINDOW MOTOR LH)

table below.

N004 (1) - N004 (2) ＞ 1 MΩ

11. INSPECT FRONT POWER WINDOW MOTOR RH
(a) Disconnect the M004 front power window motor RH

connector .

motor RH pin 1 and pin 2.
Standard resistance

M004 (1) -M004 (2) Approx. 11 Ω


NO > Replace the front power window motor RH.
04
table below.

M004 (1) - M004 (2) ＞ 1 MΩ
04

(a) Connect the C043 central door lock controller connector.

(c) Operate front window LH and front window RH to open/
close.
Inspect if fuses F1 (15A), FL4 (20A) are not blown.
NO > Replace the central door lock controller.

table below.
Standard voltage

C043 (1) - Ground Battery Voltage

NO > Repair the circuit for an open from the fuse FL4 (20A) to the central door lock controller connector
C043, pin 1.
Repair the circuit for an open from the fuse F1 (15A) to the central door lock controller connector
C043, pin 9.
15. CHECK HARNESS AND CONNECTOR (CENTRAL DOOR LOCK CONTROLLER - GROUND)

table below.

C043 (8) - Ground ≤2Ω

YES > Replace the central door lock controller.
SWITCH - FUSE)
(a) Measure the voltage according to the value(s) in the 04

table below.
Standard voltage

N002 (6) - Ground Battery Voltage
04

NO > Repair the circuit for an open from the fuse FL4 (20A) to the main power window and door lock/unlock
switch connector N002, pin 6.
SWITCH - GROUND)
(b) Disconnect the N002 main power window and door lock/
unlock switch connector.

table below.

N002 (12) - Ground ≤2Ω

SWITCH - CENTRAL DOOR LOCK CONTROLLER)
(a) Disconnect the C043 central door lock controller

connector.

table below.

N002 (4) - N002 (5) ＞ 1 MΩ


table below.

N002 (4) - C043 (11) ≤2Ω

table below.
04
N002 (5) - C043 (12) ≤2Ω
04


table below.
N002 (4) - Ground ＞ 1 MΩ
N002 (5) - Ground ＞ 1 MΩ

(a) Connect the C043 central door lock controller connector.


table below.
Standard voltage

N002 (4) - Ground Approx. 0.36 V
N002 (5) - Ground Approx. 6 V

(a) Connect the N002 main power window and door lock/
unlock switch connector .
(b) Operate front window LH open and close, front window RH.

table below.
Standard voltage
Tester Specified
Condition
Open / close the Approx. 0.6 V
N002 (4) - Ground
window (moment)
Open / close the Approx. 5 ～ 6 V

N002 (5) - Ground
window (undulate)

23. CHECK HARNESS AND CONNECTOR (POWER WINDOW MOTOR - CENTRAL DOOR LOCK
CONTROLLER)
(a) Operate window open and close for front window LH. 04
table below.
Standard voltage
Specified
Tester Connection Switch State
Condition 04
Close the
C043 (4) - C043 (5) Battery Voltage
window
C043 (4) - C043 (5) Stop 0V
Open the
window
(c) Operate window open and close for front window RH.

table below.
Standard voltage
Specified
Condition
Close the
window
C043 (2) - C043 (3) Stop 0V
Open the
window

YES > Repair or replace harness or connector.
FRONT POWER WINDOW LH IS INOPERATIVE

WIRING DIAGRAM
(a) Operate window open and close for front window LH.

table below.
Standard voltage
Tester Specified
Condition
N002 (4) - Ground
window (moment)

N002 (5) - Ground
window (undulate)

YES > Go to step 2.
(b) Disconnect the front power window motor LH connector 04

N004.
04
(c) Measure the resistance between the front power window

motor LH pin 1 and pin 2.
Standard resistance

N004 (1) - N004 (2) Approx. 11 Ω

YES > Go to step 3.
NO > Replace the front power window motor LH.
(a) Measure the voltage according to the value(s) in the

table below.
(b) Operate window open and close for front window LH.
Standard voltage
Specified
Condition
N004 (2) - N004 (1) Close the window Battery Voltage
N004 (1) - N004 (2) Stop 0V
N004 (1) - N004 (2) Open the window Battery Voltage

YES > Replace the front power window motor LH.
NO > Go to step 4.
4. CHECK HARNESS AND CONNECTOR (POWER WINDOW MOTOR - CENTRAL DOOR LOCK
CONTROLLER)

table below.
(b) Operate window open and close for front window LH.
Standard voltage
Specified
Condition
C043 (4) - C043 (5) Close the window Battery Voltage
C043 (4) - C043 (5) Stop 0V
C043 (5) - C043 (4) Open the window Battery Voltage

FRONT POWER WINDOW LH DOES NOT OPEN

WIRING DIAGRAM
04
04
(a) Open the front window LH.

table below.
Standard voltage
Tester Specified
Condition
Approx. 0.6 V
N002 (4) - Ground Open the window
(moment)
N002 (5) - Ground Open the window Approx. 5 ～ 6 V

(undulate)

YES > Go to step 2.
2. CHECK HARNESS AND CONNECTOR (FRONT POWER WINDOW MOTOR LH - CENTRAL DOOR
LOCK CONTROLLER)
(b) Disconnect the front power window motor LH connector

N004.

table below.
(e) Operate window open and close for front window LH.
Standard voltage
Specified
Condition
N004 (2) - N004 (1) Close Battery Voltage
N004 (1) - N004 (2) Stop 0V
N004 (1) - N004 (2) Open Battery Voltage

NO > Go to step 3.
LOCK CONTROLLER)

(b) Disconnect the central door lock controller connector
C043.
04

table below.
N004 (2) - Ground ＞ 1 MΩ

FRONT POWER WINDOW LH DOES NOT CLOSE

WIRING DIAGRAM
(a) Close the front window LH.

table below.
Standard voltage
Tester Specified
Condition
Approx. 0.6 V
N002 (4) - Ground Close the window
(moment)
N002 (5) - Ground Close the window Approx. 5 ～ 6 V

(undulate)

YES > Go to step 2.
LOCK CONTROLLER)

(b) Disconnect the front power window motor LH connector
N004.
04

table below.
(e) Operation window open, close for front window LH.
Standard voltage
Specified
Condition
N004 (2) - N004 (1) Close Battery Voltage
N004 (1) - N004 (2) Stop 0V
N004 (1) - N004 (2) Open Battery Voltage

NO > Go to step 3.
LOCK CONTROLLER)

(b) Disconnect the central door lock controller connector
C043.

table below.
N004 (1) - Ground ＞ 1 MΩ

FRONT POWER WINDOW RH IS INOPERATIVE

WIRING DIAGRAM
04
04
(a) Operate the main power window and door lock/unlock switch to open, close the front window RH.

table below.
Standard voltage
Tester Specified
Condition
N002 (4) - Ground
window (moment)

N002 (5) - Ground
window (undulate)

YES > Go to step 2.
(a) Disconnect the front power window motor RH connector

M004.

motor RH pin 1 and pin 2.
Standard resistance

M004 (1) - M004 (2) Approx. 11 Ω

YES > Go to step 3.
NO > Replace the front power window motor RH.
3. CHECK HARNESS AND CONNECTOR (FRONT POWER WINDOW MOTOR RH - CENTRAL DOOR
LOCK CONTROLLER)

table below.
(b) Open, close the front window RH.
Standard voltage
Specified
Condition
Close the
M004 (2) - M004 (1) Battery Voltage
window
M004 (1) - M004 (2) Stop 0V
Open the
M004 (1) - M004 (2) Battery Voltage
window

YES > Replace the front power window motor RH.

NO > Go to step 4.
4. CHECK HARNESS AND CONNECTOR (FRONT POWER WINDOW MOTOR RH - CENTRAL DOOR
LOCK CONTROLLER) 04

table below.
(b) Open, close the front window RH.
Standard voltage
04
Specified
Condition
Close the
window
C043 (2) - C043 (3) Stop 0V
Open the
window

FRONT WINDOW RH IS INOPERATIVE (USING THE FRONT POWER

WINDOW SWITCH RH)
WIRING DIAGRAM
1. CHECK HARNESS AND CONNECTOR (FRONT POWER WINDOW SWITCH RH - MAIN POWER
WINDOW AND DOOR LOCK/UNLOCK SWITCH)

table below.
Standard voltage

M002 (4) - Ground Approx. 12 V

YES > Go to step 3.
NO > Go to step 2.

table below.
Standard voltage

04

3. INSPECT FRONT POWER WINDOW SWITCH RH
(b) Disconnect the front power window switch RH connector

M002.
(c) Disconnect the main power window and door lock/unlock


table below.
M002 (1) - M002 (3) ＞ 1 MΩ

YES > Go to step 4.
(a) Connect the main power window and door lock/unlock

(b) Connect the front power window switch RH connector

M002.
04
04

table below.
(e) Using the front power window switch RH open, close the
front window RH.
Standard voltage
Specified
Condition
Close the
window
N002 (1) - Ground Stop 0V
N002 (2) - Ground Stop 0V
Open the
window

YES > Replace the main power window and door lock/unlock switch.
NO > Go to step 5.

table below.
(b) Using the front power window switch RH open, close the
front window RH.
Standard voltage
Specified
Condition
Open the
window
M002 (1) - Ground Stop 0V
M002 (3) - Ground Stop 0V
Close the
window

NO > Replace the front power window switch RH.
DIAGNOSTICS - OUTSIDE MIRROR 04-345
OUTSIDE MIRROR
LOCATION
04
04
1 Outside Mirror Assy LH 3 Outside Mirror Remote Control Switch
2 Outside Mirror Assy RH 4 Outside Mirror Defrost Switch Assy

04-346 DIAGNOSTICS - OUTSIDE MIRROR
TERMINALS OF OUTSIDE MIRROR DEFROST SWITCH

OUTSIDE MIRROR DEFROST SWITCH
Terminal No. Wiring Colors Terminal Description

1 LG - R Outside mirror motor RH
2 GR - R Outside mirror motor LH
3 W-B Ground
4 P-B Outside mirror motor LH & RH
5 GR Outside mirror motor fuse
6 LG - B Outside mirror motor LH
7 Y Outside mirror motor RH
8 GR - L Outside mirror motor LH

BASIC INSPECTION
Yes Go to next step 04
Check the battery voltage.
1 • The voltage should be above 12 V. Charge or replace battery. Refer to “Chapter
Is the check result normal? No 20A/20B starting and charging - battery,
replacement”
Check the outside mirror. Yes Go to next step

• Turn the ignition switch ON. 04
2 • Adjust the outside mirror LH and the out-
side mirror RH. No Go to problem symptoms table
Does the outside mirror work correctly?
Check the outside mirror. Yes Go to problem symptoms table

3 Replace the outside mirror. Refer to “Chapter
• Fold the outside mirrors. No
Does the outside mirror work correctly? 82 windshield - outside mirror, replacement”

Use the table below to help you find the cause of the problem. The numbers indicate the probability of the
1. Fuse -
Chapter 82 windshield - power win-

Mirrors are inoperative (Both sides) 2. Outside mirror defrost switch dow, replacement
3. Wire harness -

1. Outside mirror defrost switch dow, replacement
A single mirror is inoperative Chapter 82 windshield - outside

2. Outside mirror mirror, replacement
3. Wire harness -

Mirror adjustment UP/DOWN is Chapter 82 windshield - outside
inoperative 2. Outside mirror motor mirror, replacement
3. Wire harness -

Mirror adjustment LEFT/RIGHT is Chapter 82 windshield - outside
inoperative 2. Outside mirror motor mirror, replacement
3. Wire harness -

Power folding is inoperative Chapter 82 windshield - outside

2. Outside mirror motor mirror, replacement
3. Wire harness -

Mirror heating is inoperative Chapter 82 windshield - outside

2. Outside mirror defrost grid mirror, replacement
3. Wire harness -
MIRRORS ARE INOPERATIVE (BOTH SIDES)

WIRING DIAGRAM
04
04
1. INSPECT FUSE
(b) Inspect the outside fuse in body junction box: F14 (10A).

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR REMOTE CONTROL SWITCH -
GROUND)

(b) Disconnect the N001 outside mirror remote control switch connector.

table below.

N001 (6) - Ground ≥ 1 ΜΩ

3. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR REMOTE CONTROL SWITCH -

GROUND)


table below.

N001 (4) - Ground ＜2Ω

YES > Replace the outside mirror remote control switch.
4. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR REMOTE CONTROL SWITCH - OUT-
SIDE MIRROR FUSE)


table below.

F14 (10A) - N001 (6) ＜2Ω

YES > Replace the outside mirror remote control switch.
A SINGLE MIRROR IS INOPERATIVE

WIRING DIAGRAM
1. INSPECT OUTSIDE MIRROR REMOTE CONTROL SWITCH

(c) Inspect outside mirror remote control switch.

Standard resistance
Item Condition Tester Specified 04

3-6
Left
2-5
3-2
Right
Outside 6-5
Mirror LH ＜2Ω
3-8
Up
6-5
3-6
Down
8-5

NO > Replace the outside mirror remote control switch.
2. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR LH - OUTSIDE MIRROR REMOTE
CONTROL SWITCH)

(b) Disconnect the N003 outside mirror LH connector.
(c) Disconnect the N001 outside mirror remote control switch connector.

table below.

N001 (3) - N003 (3)
N001 (3) - N003 (10)

＜2Ω
N001 (1) - N003 (4)
N001 (7) - N003 (2)

YES > Replace the outside mirror LH.
MIRROR ADJUSTMENT UP/DOWN IS INOPERATIVE

WIRING DIAGRAM


Standard resistance
Item Condition Tester Specified 04

3-6
Up
Outside 2-5
Mirror LH ＜2Ω
3-2
Down
6-5

CONTROL SWITCH)


table below.

N001 (3) - N003 (3)
＜2Ω
N001 (1) - N003 (4)

MIRROR ADJUSTMENT LEFT/RIGHT IS INOPERATIVE

WIRING DIAGRAM


Standard resistance
Tester Specified 04
Item Condition
3-6
Left
Outside 2-5
Mirror LH ＜2Ω
3-2
Right
6-5

CONTROL SWITCH)


table below.

N001 (7) - N003 (2)
＜2Ω
N001 (3) - N003 (3)

POWER FOLDING IS INOPERATIVE

WIRING DIAGRAM


Standard resistance
Item Condition
Tester Specified 04
3-6
Fold
Outside 2-5
Mirror LH ＜2Ω
3-2
Extend
6-5

NO > Replace the outside mirror LH.
CONTROL SWITCH)


table below.

N001 (8) - N003 (1)
＜2Ω
N001 (3) - N003 (10)

MIRROR HEATING IS INOPERATIVE

WIRING DIAGRAM
1. INSPECT FUSE
(b) Inspect the fuse in body junction box: F1 (15A).
04

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR DEFROST SWITCH - GROUND)

table below.

C019 (4) - Ground ≥ 1 ΜΩ

3. INSPECT OUTSIDE MIRROR DEFROST SWITCH

(b) Disconnect the C019 outside mirror defrost switch connector.
(c) Inspect outside mirror defrost switch.

Standard resistance
Specified
Condition
Release outside
mirror defrost 3-6 ≥ 1 ΜΩ
switch
Press outside
mirror defrost 3-6 ＜2Ω
switch

NO > Replace the outside mirror defrost switch.
4. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR FUSE - OUTSIDE MIRROR DEFROST
SWITCH)


table below.

F1 (15 A) - C019 (4) ＜2Ω

5. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR - OUTSIDE MIRROR DEFROST

SWITCH)

(c) Disconnect the M005 outside mirror RH connector.
(d) Disconnect the C019 outside mirror defrost switch connector.
table below.
Standard resistance (check for open) 04
C019 (3) - N003 (8)
＜2Ω
C019 (3) - M005 (8)

6. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR DEFROST SWITCH - OUTSIDE
MIRROR)
(f) Disconnect the N003 outside mirror LH connector.

(g) Disconnect the M005 outside mirror RH connector.
(h) Measure the resistance according to the value(s) in the
table below.

F1 (15 A) - N003 (9)
＜2Ω
F1 (15 A) - M005 (9)

YES > Replace the outside mirror.
04-364 DIAGNOSTICS - POWER DOOR LOCKS
POWER DOOR LOCKS

PRECAUTION


Expression85
2. IT DEPENDS ON OPTIONAL PART THAT THERE ARE DIFFERENT FUNCTIONS AND FEATURES
FOR CENTRAL DOOR LOCK CONTROLLER ASSY.
Central Door Lock Controller Function Description
1. Lock/Unlock doors using the remote controller; 2. Lock/Unlock

Multi - function door lock controller (4-in-1) doors using the key; 3. Control window up/down; 4. Lock doors
at 10 Km/h; 5. Close window
Multi - function door lock controller (3-in-1) 1. Lock/Unlock doors using the key; 2. Control window up/down; 3.
Lock doors at 10 Km/h; 4. Close window
Multi - function door lock controller (2-in-1) 1. Lock/Unlock doors using the key; 2. Control window up/down; 3.
Lock doors at 10 Km/h
NOTE
Multi - function door lock controller (3-in-1) assy and 3-in-1 controller assy are two parts.
3. DOOR LOCK REMOTE CONTROL TRANSMITTER BUTTON CELL: CR2016 × 2.
4. POWER OFF.
(a) Before removing or installing any electrical device,please disconnect the negative battery cable to pre-
vent damage to the device or personal injury.
NOTE
To prevent locking the key in the vehicle, do not leave the key in the vehicle when disconnecting the
negative battery cable.
(b) If no specific instructions, the ignition switch must be off.
AND THE CLOCK TO ‘ 0 ’.
NOTE
The total odometer can not be reset to ‘ 0 ’.
IS DISCONNECTED.
NOTE
instructions”).
DIAGNOSTICS - POWER DOOR LOCKS 04-365
LOCATION
04
04
Door Lock Remote Control Transmitter 5 Front Door Lock Actuator RH

1
Assy
6 Rear Door Lock Actuator RH
Main Power Window And Door Lock/
2 7 Rear Hatch Lock Actuator
Unlock Switch Assy
3 Central Door Lock Controller Assy 8 Rear Door Lock Actuator LH
Ignition Key Position Remind Controller 9 Front Door Lock Actuator LH

4
Assy
TERMINALS OF CENTRAL DOOR LOCK CONTROLLER

1 L-Y To fuse FL4 (20A)
2 G-R To front power window motor RH
3 R-L To front power window motor RH
4 R To front power window motor LH
5 G To front power window motor LH
6 R To door lock actuator (UNLOCK)
7 G To door lock actuator (LOCK)
8 W-B Ground
9 R-B To fuse F1 (15A)
10 R-B Odometer sensor signal input
11 L To main power window and door lock/unlock switch
12 L-B To main power window and door lock/unlock switch
13 W-R To door lamp switch
14 G-Y To turn signal lamp RH
15 G-B To turn signal lamp LH
16 Y To RCM
17 L-R To door lock actuator (UNLOCK)
18 L-O To door lock actuator (LOCK)

BASIC INSPECTION
Check the battery voltage. Yes Go to step 2. 04
• The battery voltage should be above 12
1 Charge or replace the battery. Refer to
V. No
Is the check result normal？ “Chapter 20A starting and charging - battery”.
Check basic function. Yes Go to step 3.

• Use the main power window and door
lock/unlock switch to lock and unlock. 04
• Use the key in driver’s door lock cylinder
2
to lock, all door should be locked. No Go to the problem symptoms table.
• Use the key in driver’s door lock cylinder
to unlock , all door should be unlocked.
Check lockout protection function. Yes Go to step 4.

• Inset the key into ignition switch.
• When the driver’s inside door lock knob is
moved to the lock position with the key in
the ignition switch and any door open, all
doors will lock and then unlock automati-
3 cally.
• When the main power window and door No Go to the problem symptoms table.
lock/unlock switch is moved to the lock
position with the key in the ignition switch
and any door open, all doors will lock and
then unlock automatically.
Check safety function. Yes Go to the problem symptoms table.

• When the main power window and door
lock/unlock switch are moved to the
unlock position with all doors closed and
using the main power window and door
lock/unlock switch locked, all doors can
not unlock.
• When the main power window and door
lock/unlock switch are moved to the
using the key to lock, all doors can not
unlock.
4 • When the main power window and door
lock/unlock switch are moved to the No Replace the center door lock controller assy.
using the door lock remote control
transmitter to lock, all doors can not
unlock.
• Any one of following operations is per-
formed, safety function will be cancelled.
Turn the ignition switch ON.
Use the key to unlock in driver’s door lock
cylinder.
Use the door lock remote control
transmitter to unlock.

Use the table below to help you to find the cause of the problem. The numbers indicate the
priority of the likely cause of the problem. Check each part in order. If necessary, replace
these parts.

Chapter 04 diagnostics - power door lock control
1. Power, ground circuits system, the function of power door locks is
inoperative
Chapter 04 diagnostics - power door lock con-

2. Door lock actuator trol system, the function of power door locks is
The function of power door inoperative
locks is inoperative Chapter 04 diagnostics - power door lock control
3. Central door lock system, the function of power door locks is
controller inoperative

4. Harness system, the function of power door locks is
inoperative
1. Central door lock Chapter 04 diagnostics - power door lock con-

controller trol system, one door is inoperative
One door is inoperative
2. Harness system, one door is inoperative
Chapter 04 diagnostics - power door lock control-

1. Key state switch system, ignition key position remind controller is
inoperative

Ignition key position remind 2. Ignition key position system, ignition key position remind controller is
controller is inoperative remind controller inoperative

3. Harness system, ignition key position remind controller is
inoperative
THE FUNCTION OF POWER DOOR LOCKS IS INOPERATIVE

WIRING DIAGRAM
04
04
• Before operating this inspection procedure, make sure the door ajar warning light is operating nor-
mally.
• If the door ajar warning light is inoperative, repair it. Refer to “Chapter 04 diagnostics - instrument clus-
ter, problem symptoms table”
1. CHECK FUSES
(b) Verify fuses in the body junction box: FL4 (20 A), the fuse in
the engine room junction box: F1 (15 A).

YES > Go to step 8.
NO > If fuse FL4 (20 A) is not OK, Go to step 4.
If fuse F1 (15 A) is not OK, Go to step 2.

table below.
C043 (9) - Ground ＞ 1 MΩ

YES > Replace the fuse F1 (15A).
NO > Go to step 3.
(a) Disconnect central door lock controller connector C043.

04
04

table below.
C043 (9) - Ground ＞ 1 MΩ

YES > Replace the fuse F1 (15A) and the central door lock controller.
NO > Replace the fuse F1 (15A). Repair or replace harness or connector.

C043.

table below.
C043 (1) - Ground ＞ 1 MΩ

YES > Go to step 5.
NO > Replace the fuse FL4 (20 A). Repair or replace harness or connector.
(a) Measure the resistance between the central door lock

controller pin 1 and pin 8.

C043 (1) - C043 (8) ＞ 1 MΩ

YES > Go to step 6.
NO > Replace the fuse FL4 (20 A) and the central door lock controller.
6. CHECK HARNESS AND CONNECTOR (CENTRAL DOOR LOCK CONTROLLER - DOOR LOCK
ACTUATOR)

table below.
C043 (6) - Ground ＞ 1 MΩ
C043 (7) - Ground ＞ 1 MΩ

YES > Go to step 7.
7. CHECK HARNESS AND CONNECTOR (CENTRAL DOOR LOCK CONTROLLER - TURN SIGNAL
LAMP)
(a) Measure the resistance according to the value(s) in the 04

table below.
C043 (14) - Ground ＞3Ω
C043 (15) - Ground ＞3Ω

04

YES > Replace the fuse FL4 (20 A), Go to step 8.
8. CHECK HARNESS AND CONNECTOR (CENTRAL DOOR LOCK CONTROLLER - FUSES)

C043.

table below.
Standard voltage

YES > Go to step 9.
9. CHECK HARNESS AND CONNECTOR (CENTRAL DOOR LOCK CONTROLLER - GROUND)

table below.
C043 (8) - Ground ≤2Ω

10. CHECK HARNESS AND CONNECTOR (CENTRAL DOOR LOCK CONTROLLER - DOOR AJAR
SWITCH)
(a) Close all doors.

table below.
Standard voltage

11. INSPECT FRONT DOOR LOCK ACTUATOR LH
(a) Remove the front vehicle door inner guard plate assy LH. (Refer to “Chapter 88 interior / exterior trim -
vehicle door inner guard board, replacement”)
(b) Remove the front door water-proof film LH.
NOTE
Only raise portion of the front door water-proof film LH.
(c) Disconnect the front door lock actuator LH connector

N006.
04
04
(d) Measure the resistance between the front door lock

actuator LH pin 4, 6 and pin 2.
Tester Specified
Conditions
N006(4) - N006(2) ≤2Ω
Use the key to
unlock
N006(6) - N006(2) ＞ 1 MΩ
N006(4) - N006(2) ＞ 1 MΩ
Use the key to lock
N006(6) - N006(2) ≤2Ω

NO > Replace the front door lock actuator assy LH. (Refer to “Chapter 85 door locks - front door locks,
replacement”)
12. CHECK HARNESS AND CONNECTOR (FRONT DOOR LOCK ACTUATOR LH - GROUND)

table below.
N006 (2) - Ground ≤2Ω

13. CHECK HARNESS AND CONNECTOR (CENTRAL DOOR LOCK CONTROLLER - FRONT DOOR
LOCK ACTUATOR LH)

table below.
N006 (4) - Ground ＞ 1 MΩ
N006 (6) - Ground ＞ 1 MΩ

LOCK ACTUATOR LH)

table below.
Standard voltage
N006 (4) - Ground 0V
N006 (6) - Ground 0V

LOCK ACTUATOR LH

table below.
C043 (17) - N006 (4) ≤2Ω


table below.
04
C043 (18) - N006 (6) ≤2Ω
04

LOCK ACTUATOR LH)
(a) Connect the central door lock controller connector C043.

table below.
Standard voltage


ACTUATOR)
(a) Disconnect all connectors of door lock actuator.

table below.

C043 (6) - Ground ≤2Ω
C043 (7) - Ground ≤2Ω

ACTUATOR)

(b) While using the key to lock and then unlock the door,
measure the voltage according to the value(s) in the
table below.
Standard voltage

C043 (6) - C043 (7) Battery Voltage (Hold-on 0.3 ～ 1.1 s)

ONE DOOR IS INOPERATIVE

WIRING DIAGRAM
04
04
• This inspection procedure is an example of front door RH, other doors inspection procedure are similar.
1. INSPECT FRONT DOOR LOCK ASSY RH
(a) Use the key to lock and unlock in passenger’s door lock cylinder, the passenger’s door should lock and
unlock.
YES > Go to step 2.
NO > Repair or replace the front door lock assy RH.
LOCK ACTUATOR RH)
(a) Disconnect the front door lock actuator RH connector

M001.
(b) While using the main power window and door lock/
unlock switch to lock, measure the voltage according to
Standard voltage

M001 (2) - Ground Battery Voltage (Hold-on 0.3 ～ 1.1 s)

YES > Go to step 3.
LOCK ACTUATOR RH)
(a) While using the main power window and door lock/ 04
unlock switch to unlock, measure the voltage according
to the value(s) in the table below.
Standard voltage

M001 (4) - Ground Battery Voltage (Hold-on 0.3 ～ 1.1 s) 04

YES > Replace the front door lock actuator RH.
IGNITION KEY POSITION REMIND CONTROLLER IS INOPERATIVE

WIRING DIAGRAM
• Make sure the door ajar warning light is operating normally before operating this inspection procedure.
• If the door ajar warning light is inoperative, repair it. Refer to “Chapter 04 diagnostics - instrument clus-
ter, problem symptoms table”
• Do not insert the key into the ignition switch, if no specific description.
1. INSPECT THE KEY STATE HINT FUNCTION
(a) Following the table to inspect..
Function Conditions State
• Turn on the headlamp. Hint chime sounds and turns off

The lamp turns on hint • Pull out the key from the ignition after 5 minutes
switch.
Function Conditions State
• Insert the key into the ignition Hint chime sounds and turns off
Door opens hint switch. after 5 minutes
04
• Only open the front door LH.
• Pull out the key from the ignition The ignition switch lamp will
switch and hold-on more than 2 illuminate and turns off after 15
Delay illumination minutes. seconds.
• Only open the front door LH,
then close.
04
YES > Reconnect all connectors.
NO > Go to step 2.
2. CHECK FUSE
(a) Verify the fuse box engine compartment fuses: F26 (7.5 A) is
OK.

YES > Go to step 4.
NO > Go to step 3.
3. CHECK HARNESS AND CONNECTOR (IGNITION KEY POSITION REMIND CONTROLLER -
FUSES)

(b) Disconnect the ignition key position remind controller

connector C042.
(c) Disconnect the key state switch connector C029.

table below.
C042 (6) - Ground ＞ 1 MΩ

YES > Replace ignition key position remind controller.
FUSES)

table below.
Standard voltage


YES > Go to step 5.
5. CHECK HARNESS AND CONNECTOR (KEY STATE SWITCH - FUSES)
(a) Disconnect the key state switch connector C029.

(b) Measure the voltage according to the value(s) in the 04
table below.
Standard voltage

04

YES > Go to step 6.
6. INSPECT KEY STATE SWTICH
(a) Insert the key into the ignition switch.

(b) Measure the resistance between the key state switch pin
1 and pin 2.

C029 (1) - C029 (2) ≤2Ω
(c) Pull out the key from the ignition switch.

(d) Measure the resistance between the key state switch pin
1 and pin 2.

C029 (1) - C029 (2) ＞ 1 MΩ

YES > Go to step 7.
NO > Replace the key state switch.
7. CHECK HARNESS AND CONNECTOR (IGNITION KEY POSITION REMIND CONTROLLER - KEY
STATE SWITCH)
(a) Connect the key state switch connector C029.

(b) Insert the key into the ignition switch.

table below.
Standard voltage


YES > Go to step 8.
No > Repair or replace harness or connector.
GROUND)

table below.

C042 (1) - Ground ≤2Ω

YES > Go to step 9.
No > Repair or replace harness or connector.
9. CHECK HARNESS AND CONNECTOR (IGNITION KEY POSITION REMIND CONTROLLER - TAIL
RELAY)
(a) Turn off all electronic devices. 04

table below.
Standard voltage

C042 (3) - Ground 0V 04

10. CHECK HARNESS AND CONNECTOR (IGNITION KEY POSITION REMIND CONTROLLER - TAIL
RELAY)
(a) Turn on the headlamp.

table below.
Standard voltage


FRONT DOOR AJAR SWITCH LH)

table below.
Specified
Tester Connection Condition
Condition
C042 (2) - Ground Front door LH open ＞ 1 MΩ
C042 (2) - Ground Front door LH close ≤2Ω

NO > Repair the circuit from the ignition key position remind controller connector C042, pin 2 to the front door
ajar switch LH connector L001, pin 1.
12. CHECK HARNESS AND CONNECTOR (IGNITION KEY POSITION REMIND CONTROLLER - IGNI-
TION SWITCH LAMP)
(a) Disconnect the ignition switch lamp connector C028.
(b) Disconnect the ignition key position remind controller

connector C042.

table below.

C042 (5) - Ground ＞ 1 MΩ

table below.
Standard voltage
04
04
table below.

C042 (5) - C028 (1) ≤2Ω

13. INSPECT IGNITION SWITCH LAMP
(a) Measure the resistance between the ignition switch lamp

pin 1 and pin 2.

C028 (1) - C028 (2) ≤ 100 Ω

NO > Replace the ignition switch lamp.
14. CHECK HARNESS AND CONNECTOR (IGNITION SWITCH LAMP - GROUND)

table below.

C028 (2) - Ground ≤2Ω

YES > Replace ignition key position remind controller.
DIAGNOSTICS - SLIDING ROOF SYSTEM 04-391
SLIDING ROOF SYSTEM

LOCATION
04
04
1 Front Roof Assy 3 Sliding Roof Control Switch
2 Rear Sliding Roof Assy

04-392 DIAGNOSTICS - SLIDING ROOF SYSTEM
SYSTEM DESCRIPTION
1. GENERAL
(a) This system has the following functions:
• Manual slide open and close.
• Auto slide open and close.
2. FUNCTION OF MAIN COMPONENTS
Component Function
Sliding roof control motor Sliding roof control module sends the signal to sliding roof control motor. The sliding
and sliding roof drive roof control motor is then actived. Sliding roof control module controls sliding roof
gear sub-assembly motor to rotate forward and backward.
Sliding roof control Sliding roof control switch sends the signal to sliding roof control module. The sliding
module roof control module analyses the signal and sends it to sliding roof control motor.
3. SYSTEM OPERATION
The sliding roof has the following features:
Function Description
Manual slide open This function enables sliding roof to open (or close) when OPEN/CLOSE switch is pressed
and close without release. Sliding roof stops as soon as the switch is released.
Auto slide open and This function enables sliding roof to fully open (or close) when OPEN/CLOSE switch is
close pressed and immediately released.
TERMINALS OF MAIN COMPONENTS

SLIDING ROOF CONTROL MODULE
04
04

1 R Fuse F6
2 R-Y Sliding roof control switch (Close fully)
3 B-L Sliding roof control switch (Open fully)
4 R-B Ground
5 P Sliding roof control motor (A)
6 L Sliding roof position switch (Close fully)
7 Y Sliding roof position switch (Open fully)
8 LG Sliding roof control motor (B)
SLIDING ROOF CONTROL MOTOR

1 LG Sliding roof control motor (B)
2 W-B Ground
3 Y Sliding roof position switch (Open fully)
4 P Sliding roof control motor (A)
5 W-B Ground
6 L Sliding roof position switch (Close fully)

BASIC INSPECTION
Yes Go to next step
replacement”
Check the sliding roof opening operation. Yes Go to next step

2
• Press the “OPEN” button. No Go to problem symptoms table
Does the sliding roof work correctly?
Check the sliding roof closing operation. Yes Go to problem symptoms table
3 Replace the sliding roof. Refer to “Chapter 86
• Press the “CLOSE” button. No
Does the sliding roof work correctly? sliding roof - sliding roof assy, replacement”

04
1. Fuse -
2. Relay -
Chapter 86 sliding roof - sliding roof

3. Sliding roof control switch assy, replacement 04
Sliding roof system is inoperative 4. Sliding roof control module assy, replacement

5. Sliding rail assy, replacement

6. Sliding roof control motor assy, replacement
7. Wire harness -

1. Sliding roof control switch assy, replacement

Sliding roof does not open or open Chapter 86 sliding roof - sliding roof
incorrectly (close is normal) 3. Sliding rail assy, replacement

4. Sliding roof control module assy, replacement
5. Wire harness -


Sliding roof does not close or close Chapter 86 sliding roof - sliding roof
incorrectly (open is normal) 3. Sliding rail assy, replacement

4. Sliding roof control module assy, replacement
5. Wire harness -


Sliding roof stops operation halfway 2. Sliding roof control module assy, replacement

SLIDING ROOF SYSTEM IS INOPERATIVE

WIRING DIAGRAM
1. INSPECT FUSE
(b) Inspect the sliding roof fuse in body junction box: F6 (20 A).
04

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (SLIDING ROOF CONTROL MODULE - GROUND)

(b) Disconnect the F007 sliding roof control module connector.

table below.

F007 (1) - Ground ≥ 1 ΜΩ

3. CHECK HARNESS AND CONNECTOR (SLIDING ROOF FUSE - SLIDING ROOF CONTROL
MODULE)


table below.

F6 (20 A) - F007 (1) ＜2Ω

4. CHECK HARNESS AND CONNECTOR (SLIDING ROOF CONTROL MODULE - GROUND)


table below.

F007 (4) - Ground ＜2Ω

5. INSPECT SLIDING ROOF CONTROL SWITCH

(b) Remove the sliding roof control switch. (Refer to ”Chapter 86 sliding roof - sliding roof assy, 04
replacement”)
(c) Disconnect the F005 sliding roof control switch connector.
(d) Inspect the sliding roof control switch.
Standard resistance
Specified 04
Condition
2-1
Normal ≥ 1 ΜΩ
2-3
Press “OPEN” 2-3

＜ 2Ω
Press “CLOSE” 2-1

NO > Replace the sliding roof control switch.
6. CHECK HARNESS AND CONNECTOR (SLIDING ROOF CONTROL SWITCH - GROUND)

(b) Remove the sliding roof control switch. (Refer to ”Chapter 86 sliding roof - sliding roof assy,
replacement”)
table below.

F005 (2) - Ground ＜2Ω

7. CHECK HARNESS AND CONNECTOR (SLIDING ROOF CONTROL MOTOR - GROUND)

(b) Disconnect the F003 sliding roof control motor connector.

table below.

F003 (2) - Ground
＜2Ω
F003 (5) - Ground

8. CHECK HARNESS AND CONNECTOR (SLIDING ROOF CONTROL MODULE - SLIDING ROOF
CONTROL MOTOR)

(c) Disconnect the F007 sliding roof control module connector.

table below.

F007 (5) - F003 (4)
＜2Ω
F007 (8) - F003 (1)


(b) Disconnect the F007 sliding roof control module connector. 04
(c) Disconnect the F003 sliding roof control motor connector.

table below.

F003 (1) - Ground
≥ 1 ΜΩ
F003 (4) - Ground

YES > Replace the sliding roof control module.
SLIDING ROOF DOES NOT OPEN OR OPEN INCORRECTLY

(CLOSE IS NORMAL)
WIRING DIAGRAM

(b) Remove the sliding roof control switch. (Refer to “Chapter 86 sliding roof - sliding roof assy, replace-
ment”)

04
Specified
Condition
2-1
Normal ≥ 1 ΜΩ
2-3

＜ 2Ω

NO > Replace the sliding roof switch.
2. INSPECT SLIDING ROOF CONTROL MOTOR

(c) Remove the sliding roof motor. (Refer to ”Chapter 86 sliding roof - sliding roof assy, replacement”)
(d) Replace the sliding roof motor with a new one. (Refer to ”Chapter 86 sliding roof - sliding roof assy,
replacement”)
YES > Replace or repair the sliding roof motor.
CONTROL SWITCH)

replacement”)
(d) Disconnect the F007 sliding roof control module connector.

table below.

F007 (3) - F005 (3) ＜2Ω


replacement”)

table below.

F007 (3) - Ground ≥ 1 ΜΩ

CONTROL MOTOR)


table below.
04
F007 (8) - F003 (1)
＜2Ω
F007 (5) - F003 (4)
04


table below.

F003 (1) - Ground
≥ 1 ΜΩ
F003 (4) - Ground

SLIDING ROOF DOES NOT CLOSE OR CLOSE INCORRECTLY

(OPEN IS NORMAL)
WIRING DIAGRAM

replacement”)

Standard resistance 04
Specified
Condition
2-1
Normal ≥ 1 ΜΩ
2-3

＜ 2Ω

2. INSPECT SLIDING ROOF CONTROL MOTOR

(c) Remove the sliding roof motor. (Refer to ”Chapter 86 sliding roof - sliding roof assy, replacement”)
(d) Replace the sliding roof motor with a new one. (Refer to ”Chapter 86 sliding roof - sliding roof assy,
replacement”)
YES > Replace or repair the sliding roof motor.
3. CHECK HARNESS AND CONNECTOR (SLIDING ROOF CONTROL SWITCH - SLIDING ROOF
CONTROL MODULE)

replacement”)

table below.

F007 (2) - F005 (1) ＜2Ω


replacement”)

table below.

F007 (2) - Ground ≥ 1 ΜΩ

CONTROL MOTOR)


table below.
04
F007 (8) - F003 (1)
＜2Ω
F007 (5) - F003 (4)
04


table below.

F003 (1) - Ground
≥ 1 ΜΩ
F003 (4) - Ground

SLIDING ROOF STOPS OPERATION HALFWAY

WIRING DIAGRAM

replacement”)

Standard resistance
Specified 04
Condition
2-1
Normal ≥ 1 ΜΩ
2-3

＜ 2Ω 04



table below.

F003 (3) - Ground
≥ 1 ΜΩ
F003 (6) - Ground

04-412 DIAGNOSTICS - WIPER AND WASHER
WIPER AND WASHER

PRECAUTION


Expression
2. POWER OFF.
(a) Before removing or installing any electrical device, please disconnect the nagative battery cable to pre-
DIAGNOSTICS - WIPER AND WASHER 04-413
LOCATION
04
04
1 Front Wiper Arm Assy LH 4 Front Wiper Blade Assy RH
2 Front Wiper Blade Assy LH 5 Washer Pipe Assy
3 Front Wiper Arm Assy RH 6 Windshield Washer Bottle And Pump Assy
1 Rear Wiper Arm Assy 3 Wiper And Washer Switch Assy
2 Rear Wiper Blade Assy

SYSTEM DESCRIPTION
1. GENERAL
When ignition switch is ON/ST, the current flows through fuse F4 (20 A) in body junction box, to pin 17
of combination switch, pin 1 of windshield wiper motor, pin 1 of rear wiper motor and pin 10 of 3-in-1 04
multi-function controller C002. System is then powered.
2. WINDSHIELD WIPER AND WASHER SWITCH HI
When the wiper and washer switch is set to the HIGH position, the current flows from the fuse F4 (20 A)
to pin17, pin 8 of the wiper and washer switch, then the front wiper motor is activated. Ground is pro-
vided to the windshield wiper though pin 5 of the windshield wiper motor.
3. WINDSHIELD WIPER AND WASHER SWITCH INT
04
When the wiper and washer combination switch is set INT, the current flows from pin 17 of combination
switch, and pass through wiper intermittent mechanism to pin 7 of combination switch to pin 1 of
windshield wiper motor. The power is ground at pin 5 of windshield wiper motor. This enables wiper and
washer to operate in intermittent mode.
4. REAR WIPER AND WASHER SWITCH INT
When the wiper and washer combination switch is set INT, the current flows from pin 5 of 3-in-1 multi-
function controller, to pin 13 and pin 2 of the combination switch. Power is ground at pin 2 of combina-
tion switch. The 3-in-1 multi-function controller is then activated. then the current passes through pin
13 of 3-in-1 multi-function controller to pin 4 of rear wiper motor. Power is ground at pin 3 of rear wiper
motor. This enables rear wiper to operate in intermittent mode.
BASIC INSPECTION
Yes Go to next step
replacement”
Check the wiper motor in HIGH position. Yes Go to next step

• Set the wiper and washer switch in HIGH
2 position.
Does the wiper motor operate in high No Go to problem symptoms table
mode?
Check the wiper motor in LOW position. Yes Go to next step

• Set the wiper and washer switch in LOW
3 position.
Does the wiper motor operate in low No Go to problem symptoms table
mode?
Check the wiper motor in INT position. Yes Check wiper and washer switch
• Set the wiper and washer switch in INT
4 position.
Does the wiper motor operate in No Go to problem symptoms table
intermittent mode?

04
1. Fuse -
Chapter 51 steering column -

2. Wiper and washer switch combination switch, replacement
Wipers are inoperative - windshield
3. Windshield wiper motor
Chapter 65 wiper and washer - 04
wiper motor, replacement
4. Wire harness -
Chapter 65 wiper and washer -

1. Windshield wiper motor wiper motor, replacement
Wipers are inoperative at low speed Chapter 51 steering column -
- windshield 2. Wiper and washer switch combination switch, replacement
3. Wire harness -

Wipers are inoperative at high Chapter 51 steering column -
speed - windshield 2. Wiper and washer switch combination switch, replacement
3. Wire harness -

Wipers are inoperative in Chapter 51 steering column -
intermittent mode - windshield 2. Wiper and washer switch combination switch, replacement
3. Wire harness -

Washer pump is inoperative - Chapter 65 wiper and washer -
windshield 2. Windshield wiper motor wiper motor, replacement
3. Wire harness -

When the wiper and washer switch
is OFF, the wiper blade does not Chapter 51 steering column -
retract
3. Wire harness -

1. Rear window wiper motor wiper motor, replacement

Wiper is inoperative - rear window
3. Multi-function controller -
4. Wire harness -

1. Rear window wiper motor wiper motor, replacement
2. Multi-function controller (3-in1) -

Wiper is inoperative in intermittent
mode - rear window Chapter 51 steering column -
4. Wire harness
1. Washer pump - rear window -
Washer pump is inoperative - rear Chapter 51 steering column -

window 2. Wiper and washer switch combination switch, replacement
3. Wire harness -
WIPERS ARE INOPERATIVE - WINDSHIELD

WIRING DIAGRAM
04
04
1. INSPECT FUSE
(b) Inspect the wipe and washer fuse in body junction box: F4
(20 A).

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (WINDSHIELD WIPER MOTOR - GROUND)

(b) Disconnect the C014 windshield wiper motor connector.

table below.

C014 (3) - Ground ≥ 1 ΜΩ


(b) Disconnect the C014 windshield wiper motor connector. 04
table below.

04
C014 (5) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR (WIPER AND WASHER SWITCH - GROUND)

(b) Disconnect the C039 wiper and washer switch connector.

table below.

C039 (2) - Ground ＜2Ω

5. INSPECT WINDSHIELD WIPER MOTOR

(c) Inspect the windshield wiper motor in LOW mode.
Condition Tester Connection Specified

Condition
Apply battery Battery (+) - 1 Windshield wiper
voltage to motor operates at
terminal 1 and 5 Battery (-) - 5 low speed
(d) Inspect the windshield wiper motor in HIGH mode.
Condition Tester Connection Specified

Condition
terminal 4 and 5 Battery (-) - 5 high speed

NO > Replace windshield wiper motor.
6. CHECK HARNESS AND CONNECTOR (WINDSHIELD WIPER FUSE - WINDSHIELD WIPER MOTOR)


table below.

F4 (20 A) - C014 (3) ＜2Ω

7. CHECK HARNESS AND CONNECTOR (WINDSHIELD WIPER FUSE - WIPER AND WASHER
SWITCH)


table below.

F4 (20 A) - C039 (17) ＜2Ω

YES > Replace wiper and washer switch.
WIPERS ARE INOPERATIVE AT LOW SPEED - WINDSHIELD

WIRING DIAGRAM
1. INSPECT WIPER AND WASHER SWITCH

04
(c) Check the wiper and washer switch.
Tester Specified
Condition
04
Set the wiper and
washer switch 17 - 7 ≥ 1 MΩ
OFF
Set the wiper and

washer switch 17 - 7 ＜2Ω
LOW

NO > Replace wiper and washer switch.
2. CHECK HARNESS AND CONNECTOR (WIPER AND WASHER FUSE - WIPER AND WASHER
SWITCH)


table below.

F4 (20 A) - C039 (17) ＜2Ω

3. CHECK HARNESS AND CONNECTOR (WIPER AND WASHER SWITCH - WINDSHIELD WIPER
MOTOR )

(c) Disconnect the C014 windshield wiper motor connector.

table below.

C014 (1) - C039 (7) ＜2Ω

YES > Replace windshield wiper motor.
WIPERS ARE INOPERATIVE AT HIGH SPEED - WINDSHIELD

WIRING DIAGRAM
04
04

(c) Inspect the wiper and washer switch.
Tester Specified
Condition
Set the wiper and
17 - 8 ≥ 1 MΩ
washer switch OFF
Set the wiper and

washer switch 17 - 8 ＜ 2Ω
HIGH

SWITCH)


table below.

F4 (20 A) - C039 (17) ＜2Ω

MOTOR)

(c) Disconnect the C014 windshield wiper motor connector.

table below.
04
C014 (4) - C039 (8) ＜2Ω

WIPERS ARE INOPERATIVE IN INTERMITTENT MODE - WIND-

SHIELD
WIRING DIAGRAM
1. INSPECT WINDSHIELD WIPER MOTOR

04
(c) Inspect the windshield wiper motor in INT mode.
Tester Specified
Condition
04
voltage to terminal motor operates at
1 and 5 Battery (-) - 5 low speed

NO > Replace windshield wiper motor.
SWITCH)


table below.

F4 (20 A) - C039 (17) ＜2Ω

MOTOR)

(c) Disconnect the C014 windshield wiper connector.

table below.

C014 (1) - C039 (7) ＜2Ω

YES > Replace wiper and washer switch.
WASHER PUMP IS INOPERATIVE - WINDSHIELD

WIRING DIAGRAM
04
04


table below.

C039 (2) - Ground ＜2Ω

2. CHECK HARNESS AND CONNECTOR (WINDSHIELD WIPER FUSE - WINDSHIELD WASHER PUMP)

(b) Disconnect the C036 windshield washer pump connector.

table below.

F4 (20 A) - C036 (1) ＜2Ω

3. CHECK HARNESS AND CONNECTOR (WINDSHIELD WASHER PUMP - WIPER AND WASHER
SWITCH)

(c) Disconnect the C036 windshield washer pump connector.

table below.
04
C036 (2) - C039 (11) ＜2Ω


(c) Inspect the wiper and washer switch.
Condition Tester Specified

Set the wiper and
11 - 2 ≥ 1 MΩ
washer switch OFF
Set the wiper and

washer switch 11 - 2 ＜2Ω
WASH

YES > Replace windshield washer pump.
WHEN THE WIPER SWITCH IS OFF, THE WIPER BLADE DOES NOT
RETRACT
WIRING DIAGRAM


table below.
04
C014 (5) - Ground ＜2Ω



table below.

Set the wiper and washer
17 - 8
switch HIGH

17 - 7 ＜2Ω
switch LOW

11 - 2
switch WASH
17 - 8
17 - 7 ≥ 1 MΩ
switch OFF
11 - 2

3. CHECK HARNESS AND CONNECTOR (WINDSHIELD WIPER FUSE - WINDSHIELD WIPER MOTOR)


table below.

F4 (20 A) - C014 (3) ＜2Ω

WIPER IS INOPERATIVE - REAR WINDOW

WIRING DIAGRAM
04
04
1. INSPECT FUSE
(b) Inspect the wipe and washer fuse in body junction box:
F4 (20 A).

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (REAR WINDOW WIPER MOTOR - GROUND)

(b) Disconnect the J002 rear window wiper motor connector.

table below.

J002 (2) - Ground ≥ 1 ΜΩ


(b) Disconnect the J002 rear window wiper motor connector. 04
table below.

04
J002 (3) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR (REAR WINDOW WIPER FUSE - REAR WINDOW WIPER
MOTOR)

(b) Disconnect the C002 multi-function controller (3-in-1) connector.

table below.

F4 (20 A) - J002 (2)
＜2Ω
F4 (20 A) - C002 (10)

5. INSPECT REAR WINDOW WIPER MOTOR

(c) Inspect rear window wiper motor .
Tester Connection Specified

Condition
Condition
Apply battery Battery (+) - 4 Rear window wiper
terminal 3 and 4 Battery (-) - 3 normal speed

NO > Replace rear window wiper motor.


table below.

C039 (2) - Ground ＜2Ω

7. CHECK HARNESS AND CONNECTOR (MULTI-FUNCTION CONTROLLER - GROUND)

(b) Disconnect the C002 multi-function controller (3-in-1) connector. 04
table below.

04
C002 (11) - Ground ＜2Ω

8. CHECK HARNESS AND CONNECTOR (MULTI-FUNCTION CONTROLLER - WIPER AND
WASHER SWITCH)

(c) Disconnect the C003 multi-function controller (3-in-1) connector.

table below.

C039 (10) - C003 (4) ＜2Ω

9. CHECK HARNESS AND CONNECTOR (MULTI-FUNCTION CONTROLLER - REAR WINDOW

WIPER MOTOR)


table below.

C002 (13) - J002 (4) ＜2Ω

YES > Replace multi-function controller (3-in-1).
WIPER IS INOPERATIVE IN INTERMITTENT MODE - REAR WIN-

DOW
WIRING DIAGRAM 04
04


table below.

J002 (3) - Ground ＜2Ω



table below.

C039 (2) - Ground ＜2Ω

3. INSPECT REAR WINDOW WIPER MOTOR

(c) Inspect rear window wiper motor.
Tester Specified
Condition
04
Apply battery Battery (+) - 4 Rear window wiper
voltage to terminal motor operates at
3 and 4 Battery (-) - 3 normal speed
04

NO > Replace rear window wiper motor.
4. CHECK HARNESS AND CONNECTOR (MULTI-FUNCTION CONTROLLER - WIPER AND
WASHER SWITCH)


table below.

C039 (13) - C003 (5) ＜2Ω

5. CHECK HARNESS AND CONNECTOR (MULTI-FUNCTION CONTROLLER - REAR WINDOW
WIPER MOTOR)


table below.

C002 (13) - J002 (4) ＜2Ω



table below.

C002 (11) - Ground ＜2Ω

YES > Replace multi-function controller (3-in-1).
WASHER PUMP IS INOPERATIVE - REAR WINDOW

WIRING DIAGRAM
04
04


table below.

C039 (2) - Ground ＜2Ω

2. CHECK HARNESS AND CONNECTOR (REAR WINDOW WIPER FUSE - REAR WINDOW WIPER
MOTOR)

(b) Disconnect the C037 rear window wiper motor connector.

table below.

F4 (20 A) - C037 (1) ＜2Ω

3. CHECK HARNESS AND CONNECTOR (REAR WINDOW WIPER MOTOR - WIPER AND WASHER
SWITCH)

(c) Disconnect the C037 rear window wiper motor connector.
table below.
04
C037 (2) - C039 (12) ＜2Ω



table below.
Tester Specified
Condition
Set the wiper and
10 - 2
washer switch ON
Set the wiper and

13 - 2
washer switch INT ＜2Ω
Set the wiper and
washer switch 12 - 2
WASH 1
10 - 2
Turn the wiper and
washer switch 13 - 2 ≥ 1 MΩ
OFF
12 - 2

YES > Replace rear window wiper motor.
04-452 DIAGNOSTICS - REAR WINDOW DEFROSTER SYSTEM
REAR WINDOW DEFROSTER SYSTEM

LOCATION
1 Outside Mirror Defrost Grid LH 3 Rear Window Defrost Grid
2 Outside Mirror Defrost Grid RH

DIAGNOSTICS - REAR WINDOW DEFROSTER SYSTEM 04-453
SYSTEM DESCRIPTION
1. GENERAL
The defrost system's thin heater wires are attached to the inside of the rear window and defog the
window surface quickly. The rear window defrost switch controls the operation of the rear window 04
defrost grid. The rear window defrost grid only operates when the rear window defrost switch is ON.
There are two optional equipments with the defrost system.
(a) With rod antenna: When the rear window defrost switch is pressed, the rear window defrost relay is
actived, the current flows through fuse F27 (20A) in body junction box, to rear window defrost relay,
then to rear window defrost grid directly. Ground is provided to pin 1 of the rear window defrost grid.
The rear window defrost grid operates at normal. 04
(b) With glass antenna: When the rear window defrost switch is pressed, the rear window defrost relay is
actived, the current flows through fuse F27 (20A) to antenna amplifier. Then the rear window defrost
grid receives voltage through antenna amplifier. Ground is provided to pin 1 of the rear window defrost
grid. The rear window defrost grid operates at normal.
2. FUNCTION OF MAIN COMPONENTS
Component Description
Receives rear defrost activation signals from rear window defrost

Rear window defrost relay
switch and supplies power to rear window defrost grid.
Receives power from rear window defrost relay and heats defrost
Rear window defrost grid
grid.
BASIC INSPECTION
Yes Go to next step
Check battery voltage.
replacement”
Yes Go to next step

Check ignition switch.
Repair or replace ignition switch. Refer to
2 • The ignition switch should work correctly. “Chapter 91 vehicle control system - assy,
Is the check result normal? No
removal & installation and disassembly &
reassembly”
Check rear window defrost fuse. Yes Go to next step

3 • Check the rear window defrost fuse.
Is the check result normal? No Go to problem symptoms table
Check rear window defrost switch. Replace rear window defrost switch. Refer to
• Press the rear window defrost switch. Yes “Chapter 83 instrument panel - instrument
4 • The rear window defrost switch should cluster, replacement”
work correctly.
Is the check result normal? No Go to next step
Check rear window defrost grid. Replace rear window defrost grid. Refer to
• Press the rear window defrost switch. Yes “chapter 82 Windshield - windshield,
5 • The rear window defrost grid should work replacement”
correctly.

04
1. Fuse -
2. Rear window defrost relay -
Defroster system is inoperative Chapter 83 instrument panel -

3. Rear window defrost switch instrument cluster, replacement 04
Chapter 82 Windshield - rear win-
4. Rear window defrost grid dow glass, replacement
DEFROSTER SYSTEM IS INOPERATIVE

WIRING DIAGRAM - WITH 4G63/4G64 ENGINE
WIRING DIAGRAM - WITH BJ493ZQ3 ENGINE
04
04
1. INSPECT FUSE
(a) Disconnect the battery negative cable.
(b) Check rear window defrost grid fuse in engine room junc-
tion box.
• With BJ493ZQ3 engine: F27 (20 A)
• With 4G63/4G64 engine: FL6 (30 A)
(c) Check rear window defrost grid fuse in body junction box.
• With BJ493ZQ3 engine: F1 (15 A)
• With 4G63/4G64 engine: F1 (15 A), F20 (20A)

YES > Go to step 4.
NO > If the fuses FL6 (30 A), F20 (20 A)(4G63, 4G64 engine) or F27 (20 A)(BJ493ZQ3 engine) is blown, go
to next step.
If the fuse F1 (15 A) is blown, go to step 3.
2. CHECK HARNESS AND CONNECTOR (REAR WINDOW DEFROST RELAY - GROUND)

(b) Remove the rear window defrost relay R8.

table below.

R8 (5) - Ground ≥ 1 ΜΩ

3. CHECK HARNESS AND CONNECTOR (REAR WINDOW DEFROST SWITCH - GROUND)

(b) Disconnect the C022 rear window defrost switch connector. 04
table below.

04
C022 (4) - Ground ≥ 1 ΜΩ

4. INSPECT REAR WINDOW DEFROST SWITCH

(b) Disconnect the C022 rear window defrost switch connector.
(c) Check the rear window defrost switch.

Standard resistance
Position Tester Connection Specified Condition

OFF 3-6 ≥ 1 ΜΩ
ON 3-6 ＜2Ω

NO > Replace rear window defrost switch.
5. INSPECT REAR WINDOW DEFROST RELAY

(c) Inspect the rear window defrost relay R8.

Standard resistance

1–2 Continuity
3–5 ＜2Ω
(Apply battery voltage to terminal 1 and 2)

NO > Replace the rear window defrost relay.


table below.

C022 (6) - Ground ＜2Ω

7. CHECK HARNESS AND CONNECTOR (REAR WINDOW DEFROST RELAY - REAR WINDOW
DEFROST SWITCH)

(c) Disconnect the C022 rear window defrost switch connector.

table below.

R8 (1) - C022 (3) ＜2Ω

YES > For the vehicles equiped with BJ493ZQ3 engine, go to next step.
For the vehicles equiped with 4G63/4G64 engine, go to step 9.
NO > Repair or replace harness or connector. 04
8. CHECK HARNESS AND CONNECTOR (REAR WINDOW DEFROST FUSE - REAR WINDOW
DEFROST RELAY) (WITH BJ493ZQ3 ENGINE)

04
table below.

F27 (20 A) - R8 (5) ＜2Ω

9. CHECK HARNESS AND CONNECTOR (REAR WINDOW DEFROST FUSE - REAR WINDOW
DEFROST RELAY) (WITH 4G63/4G64 ENGINE)


table below.

FL6 (30 A) - R8 (5) ＜2Ω

10. CHECK HARNESS AND CONNECTOR (REAR WINDOW DEFROST GRID - GROUND)

(b) Disconnect the J001 rear window defrost grid connector.

table below.

J001 (1) - Ground ＜2Ω

YES > With antenna amplifier, go to next step.
With glass antenna, go to step 14.
11. INSPECT ANTENNA AMPLIFIER (WITH ANTENNA AMPLIFIER)

(b) Replace the antenna amplifier with a new one.(Refer to”Chapter 66 audio system - antenna amplifier,
replacement“)
Does the rear window defrost grid work correctly?
YES > Replace the antenna amplifier.
12. CHECK HARNESS AND CONNECTOR (REAR WINDOW DEFROST RELAY - ANTENNA
AMPLIFIER) (WITH ANTENNA AMPLIFIER)

(b) Disconnect the F006 antenna amplifier connector.
(c) Remove the rear window defrost relay R8.

table below.

R8 (3) - F006 (4) ＜2Ω

04
13. CHECK HARNESS AND CONNECTOR (ANTENNA AMPLIFIER - REAR WINDOW DEFROST GRID)
(WITH ANTENNA AMPLIFIER)

(b) Disconnect the F006 antenna amplifier connector.
(c) Disconnect the J006 rear window defrost grid connector.
04
table below.

F006 (3) - J006 (1) ＜2Ω

YES > Replace the rear window defrost grid.
14. CHECK HARNESS AND CONNECTOR (REAR WINDOW DEFROST RELAY - REAR WINDOW
DEFROST GRID) (WITH GLASS ANTENNA)

(c) Disconnect the J006 rear window defrost grid connector.

table below.

R8 (3) - J006 (1) ＜2Ω

YES > Replace the rear window defrost grid.
04-464 DIAGNOSTICS - HEATER AND AIR CONDITIONING SYSTEM
HEATER AND AIR CONDITIONING SYSTEM

PRECAUTION
1. DO NOT DEPOSIT REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME.
2. ALWAYS WEAR SAFETY GOGGLES.
3. AVOID CONTACTING WITH LIQUID REFRIGERANT R-134A.
If liquid refrigerant is in your eyes or on your skin:
(a) Wash the area with lots of cold water.
(b) Apply clean petroleum jelly to the skin.
(c) Immediately go to a hospital or see a physician for professional treatment.
4. DO NOT HEAT CONTAINER OR EXPOSE THE CONTAINER TO OPEN FLAME.
5. DO NOT DROP DOWN CONTAINER OR APPLY PHYSICAL SHOCKS TO IT.
6. DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT
SYSTEM.
If there is not enough refrigerant in the A/C system, oil lubrication will be insufficient and the
compressor may be damaged.
7. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING.
(a) Open and close only the low pressure valve.
If the high pressure valve is opened, refrigerant flowing in the reverse direction will cause the charging
cylinder to rupture.
8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT.
(a) If refrigerant is overcharged, it will cause problems such as insufficient cooling, poor fuel economy,
engine overheating, etc.
9. DO NOT OPERATE ENGINE AND COMPRESSOR WITH NO REFRIGERANT.


Expression
Ignition switch on (IG)07 ON On (IG)

DIAGNOSTICS - HEATER AND AIR CONDITIONING SYSTEM 04-465
BASIC INSPECTION
Check the refrigerant. Yes Go to next step 04
• Open the cap of release valve.
1
• Press the release valve. No Charge the refrigerant system
Check the A/C switch. Yes Go to next step

• Start the engine.
2 • Press the A/C switch. 04
• Check the A/C switch. No Go to problem symptoms table
Check the A/C clutch field coil. Yes Go to next step

3 • check the A/C clutch field coil.
Check compressor belt. Yes Go to next step

4 • Check compressor belt.
Check the compressor. Yes Go to next step

5 • Check the compressor cluth for noisy.
Check the condenser. Yes Go to next step

6 • Check the dirt between the condenser
and radiator. No Clear the dirt or repalce the condenser
Check pressure A/C liquid line. Yes Go to problem symptoms table

7 • Check the line for inhibition or leakage.
Is the check result normal? No Replace the pressure A/C liquid line
LOCATION
1 Accumulator Assy 2 Condenser Assy

04
04
1 Front Blower Assy 3 Front A/C Control Panel
2 Front Heater Assy

1 Nut 12 Accumulator – Rear Evaporator Pipe Assy
2 Bolt With Spring Washer And Flat Washer Rear A/C Longitudinal Beam Pipeline
13
Assy
3 Big Washer
14 Bolt With Spring Washer And Flat Washer
4 Rear Evaporator Assy
15 Clamp
5 Bolt With Spring Washer
16 High-pressure Pipe Rubber Ring
6 Bracket
17 Rear Evaporator Suction Pipe Assy
7 Bracket
18 Bracket
8 Rear Evaporator Exhaust Pipe Assy
19 Bracket
9 Clamp
20 Nut
10 Rear Dripping Pipe B RH
21 Bolt With Big Washer
11 Rear Dripping Pipe B LH
04
04
1 A/C Controller Assy (Auto A/C) 3 A/C Controller Assy (Manual A/C)
2 Screw

MANUAL A/C:
1. Fuse -
2. A/C relay -
Chapter 61 heater and air

A/C system is inoperative 3. A/C amplifier conditioning - front evaporator,
overhaul

4. A/C compressor conditioning - compressor, overhaul
5. Wire harness -
1. Fuse -
2. Relay -

3. Blower switch conditioning - front blower,
replacement

Air flow control: Front blower motor 4. Front blower motor resistor conditioning - front blower,
is inoperative replacement

5. Front blower motor conditioning - front blower,
replacement

6. Front A/C controller conditioning - A/C controller,
replacement
7. Wire harness -
1. Fuse -
2. Relay -

3. Rear evaporator blower switch conditioning - rear evaporator,
replacement

Air flow control: Rear evaporator 4. Rear evaporator resistor conditioning - rear evaporator,
motors are inoperative replacement

5. Rear A/C switch conditioning - A/C controller,
replacement

6. A/C amplifier conditioning - front evaporator,
overhaul
7. Wire harness -

1. Blower switch(front control) conditioning - front blower,
replacement 04
2. Front blower motor resistor conditioning - front blower,
replacement

3. Front blower motor conditioning - front blower,
Air flow control: Front air flow is
replacement 04
insufficient
replacement

5. Front A/C air output pipe conditioning - heater hose,
replacement
6. Wire harness -

1. Rear evaporator blower switch conditioning - rear evaporator,
replacement

2. Rear evaporator resistor conditioning - rear evaporator,
Air flow control: Rear air flow is
replacement
insufficient
overhaul
4. Wire harness -
1. Fuse -
2. Relay -


replacement
Temperature Control: Temperature
control is inoperative Chapter 61 heater and air
overhaul
6. Refrigerant -

7. A/C pressure line conditioning - A/C pipe,
replacement
8. Wire harness -
1. Refrigerant -


Temperature Control: Temperature 3. Front A/C controller conditioning - A/C controller,
control is operative poorly replacement

overhaul
5. Wire harness -

1. Heater blower motor conditioning - front heater blower,
overhaul

2. Heater switch conditioning - front heater blower,
overhaul

Warm air flow control: No warm air
comes out
overhaul

4. Heater blower switch conditioning - front heater blower,
overhaul
5. Water valve -
6. Wire harness -

1. Heater blower motor conditioning - front heater blower,
overhaul

conditioning - front heater blower,
2. Heater switch overhaul
Warm air flow control: Warm air Chapter 61 heater and air
comes out rarely 3. A/C amplifier conditioning - front evaporator,
overhaul

4. Heater blower switch conditioning - front heater blower,
overhaul
5. Water valve -
6. Wire harness -
A/C SYSTEM IS INOPERATIVE

04
04

1. INSPECT FUSE
(b) Inspect the fuses in engine room junction box: (with

4G63/4G64 engine)
• FL2 (40 A)
• FL5 (30 A)
• FL6 (50 A)
(c) Inspect the fuses in body junction box: (with BJ493ZQ3
engine)
• F2 (15 A)
• F16 (7.5 A)
• F20 (20 A)
(d) Inspect the fuses in engine room junction box: (with
4G63/ 4G64 engine)
• FL2 (40 A)
• FL5 (30 A)
(e) Inspect the fuses in body junction box: (with 4G63/4G64
engine)
• F2 (15 A)
• F16 (7.5 A)

YES > For vehicles equiped with 4G63/4G64 engine, go to next step.
For vehicles equiped with BJ493ZQ3 engine, go to step 3.
NO > Replace the fuse.
2. INSPECT A/C CUT RELAY (WITH 4G63/4G64 ENGINE)

(b) Disconnect the connector C005 A/C cut relay.
(c) Inspect the A/C cut relay.

Standard resistance

1–2 Continuity
3–5 ＜2Ω

YES > Go to step 4.
NO > Replace the A/C cut relay.
3. INSPECT MAIN RELAY (WITH BJ493ZQ3 ENGINE)

(b) Remove the main relay R2 in engine room junction box. 04
(c) Inspect the main relay R2.
Standard resistance

1–2 Continuity
04
3–5 ＜2Ω

NO > Replace the main relay.
4. CHECK HARNESS AND CONNECTOR (FRONT A/C CONTROLLER - GROUND)

(b) Disconnect the C060 front A/C controller connector.

table below.

C060 (2) - Ground ＜2Ω

5. CHECK HARNESS AND CONNECTOR (A/C CUT RELAY - FRONT A/C CONTROLLER) (WITH
4G63/4G64 ENGINE)

(c) Remove the connector C005 A/C cut relay.

table below.

C005 (3) - C060 (1) ＜2Ω

YES > Go to step 7.
6. CHECK HARNESS AND CONNECTOR (MAIN RELAY - FRONT A/C CONTROLLER) (WITH
BJ493ZQ3 ENGINE)

(c) Remove the main relay R2.

table below.

R2 (5) - C060 (1) ＜2Ω

7. CHECK HARNESS AND CONNECTOR (FRONT A/C AMPLIFIER - GROUND)

(b) Disconnect the C008 A/C amplifier connector.

table below.

C008 (6) - Ground ＜2Ω

NO > Repair or replace harness or connector. 04
8. CHECK HARNESS AND CONNECTOR(A/C AMPLIFIER - A/C CUT RELAY) (WITH 4G63/4G64
ENGINE)

(b) Remove the connector C005 A/C cut relay.
04
(c) Disconnect the C008 A/C amplifier connector.

table below.

C005 (3) - C008 (3)
＜2Ω
C005 (3) - C008 (13)

YES > Replace the A/C amplifier.
9. CHECK HARNESS AND CONNECTOR (MAIN RELAY - A/C AMPLIFIER) (WITH BJ493ZQ3
ENGINE)

(b) Remove the main relay R2.

table below.

R2 (5) - C008 (13) ＜2Ω

10. CHECK HARNESS AND CONNECTOR (A/C CUT RELAY - A/C AMPLIFIER) (WITH BJ493ZQ3
ENGINE)


table below.

C005 (3) - C008 (3) ＜2Ω

AIR FLOW CONTROL: FRONT BLOWER MOTOR IS INOPERATIVE

WIRING DIAGRAM
04
04
1. INSPECT FUSE
(b) Inspect the fuse in engine room junction box: FL2 (40 A).
(c) Inspect the fuse in body junction box: F2 (15 A).

2. INSPECT FRONT BLOWER MOTOR RELAY

(b) Remove the front blower relay R11.
(c) Check the front blower relay R11.

Standard resistance

85 – 86 Continuity
＜2Ω
30 – 87 (Apply battery voltage to
terminal 85 and 86)

3. CHECK HARNESS AND CONNECTOR (FRONT BLOWER MOTOR RELAY - FRONT BLOWER
MOTOR)
(a) Disconnect the battery negative cable. 04

(b) Disconnect the C047 front blower motor connector.
(c) Remove the front blower motor relay.

table below.
04
R11 (30) - C047 (2) ＜2Ω

4. CHECK HARNESS AND CONNECTOR (FRONT BLOWER MOTOR - BLOWER SWITCH)

(b) Disconnect the C024 blower motor switch connector.
(c) Disconnect the C047 front blower motor connector.

table below.

C047 (1) - C024 (4) ＜2Ω

5. CHECK HARNESS AND CONNECTOR (BLOWER SWITCH- GROUND)


table below.

C024 (3) - Ground ＜2Ω

6. CHECK HARNESS AND CONNECTOR (BLOWER SWITCH - FRONT A/C CONTROLLER)

(c) Disconnect the C060 front a/c controller connector.

table below.

C024 (2) - C060 (8) ＜2Ω

YES > Replace the blower switch.
AIR FLOW CONTROL: REAR EVAPORATOR MOTORS ARE INOP-

ERATIVE
WIRING DIAGRAM 04
04
1. INSPECT FUSE
(b) Inspect the rear evaporator motors fuses: 7.5 A.

2. CHECK HARNESS AND CONNECTOR (REAR EVAPORATOR MOTOR RELAY - GROUND)

(b) Remove the C009 rear evaporator motor relay.
(c) Connect the battery negative cable.
(d) Start the engine.
(e) Press the rear evaporator motor switch.

table below.
Standard voltage

C009 (1) - Ground
Battery voltage
C009 (5) - Ground

3. INPECT REAR EVAPORATOR MOTOR RELAY

(c) Check the rear evaporator motor relay.

Standard resistance

3–5 Continuity
＜2Ω
1–2 (Apply battery voltage to
terminal 3 and 5)
04
NO > Replace the rear evaporator motor relay.
4. INSPECT REAR A/C SWITCH

(b) Disconnect the C023 rear A/C switch connector.
(c) Inspect the rear A/C switch.

Standard resistance
Tester Specified
Condition
Release rear A/C

6-2 ≥ 1 ΜΩ
switch
Press rear A/C switch 6-2 ＜2Ω

NO > Replace the rear A/C switch.
5. CHECK HARNESS AND CONNECTOR (REAR EVAPORATOR MOTOR RELAY - REAR
EVAPORATOR MOTOR)

(c) Disconnect the F305 rear evaporator motor LH connector.
(d) Disconnect the F306 rear evaporator motor RH connector.

table below.

C009 (2) - F305 (2)
＜2Ω
C009 (2) - F306 (2)

6. CHECK HARNESS AND CONNECTOR (REAR A/C SWITCH - REAR EVAPORATOR BLOWER
SWITCH)

(b) Disconnect the F309 rear evaporator blower switch connector.
(c) Disconnect the C023 rear A/C switch connector.

table below.

C023 (2) - F309 (4) ＜2Ω

7. CHECK HARNESS AND CONNECTOR (REAR EVAPORATOR MOTOR - REAR EVAPORATOR
BLOWER SWITCH)

(b) Disconnect the F305 rear evaporator motor LH connector.
(c) Disconnect the F306 rear evaporator motor RH connector.
(d) Disconnect the F309 rear evaporator blower switch connector.

table below.

F305 (1) - F309 (6)
＜2Ω
C306 (1) - F309 (6)

8. CHECK HARNESS AND CONNECTOR (REAR EVAPORATOR BLOWER SWITCH - GROUND)

(b) Disconnect the F309 rear evaporator blower switch connector. 04
table below.

04
F309 (8) - Ground ＜2Ω

YES > Replace the rear evaporator blower switch.
AIR FLOW CONTROL: FRONT AIR FLOW IS INSUFFICIENT

WIRING DIAGRAM
1. INSPECT FRONT BLOWER MOTOR RESISTOR

(b) Replace the front blower motor resistor with a new one.
NO > Replace the front blower motor resistor.
2. CHECK HARNESS AND CONNECTOR (FRONT BLOWER MOTOR - FRONT BLOWER MOTOR 04
RESISTOR)

(b) Disconnect the C006 front blower motor resistor connector.

table below.

C047 (1) - C006 (1) ＜2Ω

3. CHECK HARNESS AND CONNECTOR (BLOWER SWITCH - GROUND)


table below.

C024 (3) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR (FRONT BLOWER MOTOR RESISTOR - BLOWER

SWITCH)

(c) Disconnect the C006 front blower motor resistor connector.

table below.

C006 (3) - C024 (1)
＜2Ω
C006 (2) - C024 (5)


(c) Disconnect the C060 front A/C controller connector.

table below.

C024 (2) - C060 (8) ＜2Ω

AIR FLOW CONTROL: REAR AIR FLOW IS INSUFFICIENT

WIRING DIAGRAM
04
04
1. INSPECT REAR EVAPORATOR RESISTOR

(b) Disconnect the F304 rear evaporator resistor connector.
(c) Inspect the rear evaporator resistor.

1-3 3.1 Ω
1-2 0.5 Ω
2-3 2.6 Ω

NO > Replace the rear evaporator resistor.
2. CHECK HARNESS AND CONNECTOR (REAR EVAPORATOR RESISTOR - GROUND)


table below.

F304 (3) - Ground ＜2Ω

3. CHECK HARNESS AND CONNECTOR (REAR EVAPORATOR RESISTOR - REAR EVAPORATOR

BLOWER SWITCH)

(c) Disconnect the F309 rear evaporator blower switch connector.

table below.
04
F304 (2) - F309 (1) ＜2Ω

4. CHECK HARNESS AND CONNECTOR (REAR A/C SWITCH - REAR EVAPORATOR RESISTOR)


table below.

C023 (2) - F309 (4) ＜2Ω

TEMPERATURE CONTROL: TEMPERATURE CONTROL IS INOPER-

ATIVE
04
04
1. INSPECT COMPRESSOR
(a) Start the engine and hold it at idle speed.

(b) Press the A/C switch to get the compressor clutch engaged.
Does the compressor work correctly?
YES > Go to step 8.
2. INSPECT COMPRESSOR FUSE
(b) Inspect the A/C clutch fuse in the body junction box: F2
(15 A).

NO > Replace the compressor fuse.
3. INSPECT A/C CLUTCH RELAY

(b) Remove the A/C clutch relay.
(c) Check the A/C clutch relay.

Standard resistance

1–3 Continuity
＜2Ω
terminal 1 and 3)

NO > Replace the A/C clutch relay.
4. CHECK HARNESS AND CONNECTOR (A/C CLUTCH RELAY - GROUND)

(e) Press the A/C switch.

table below.
Standard voltage

C010 (2) - Ground
Battery voltage
C010 (1) - Ground

5. CHECK HARNESS AND CONNECTOR (A/C CLUTCH RELAY - DUAL FUNCTION PRESSURE
SWITCH)

(c) Disconnect the A012 dual function pressure switch switch.

table below.
04
C010 (3) - A012 (2) ＜2Ω

6. CHECK HARNESS AND CONNECTOR (DUAL FUNCTION PRESSURE SWITCH - A/C AMPLIFIER )

(b) Disconnect the A012 dual function pressure switch switch.

table below.

A012 (4) - C008 (15) ＜2Ω

7. CHECK HARNESS AND CONNECTOR (A/C CLUTCH RELAY - A/C CLUTCH)

(c) Disconnect the E305 A/C clutch field coil connector.(with BJ493ZQ3 engine)
(d) Disconnect the E022 A/C clutch connector.(with 4G63/4G64 engine)

table below.(with BJ493ZQ3 engine)

C010 (4) - E305 (1) ＜2Ω

table below.(with 4G63/4G64 engine)

C010 (4) - E022 (1) ＜2Ω

YES > Replace the A/C clutch.


table below.
Standard voltage



(b) Disconnect the C060 front A/C controller connector. 04
table below.

04
C060 (2) - Ground ＜2Ω

10. CHECK HARNESS AND CONNECTOR (A/C AMPLIFIER - GROUND)


table below.
Standard voltage

C008 (3) - Ground
Battery voltage
C008 (13) - Ground



table below.

C008 (6) - Ground ＜2Ω

WARM AIR FLOW CONTROL: NO WARM AIR COMES OUT

WIRING DIAGRAM - SWITCH LOCATED SIDE WALL LH
04
04
WIRING DIAGRAM - SWITCH LOCATED MIDDLE PLATFORM

1. INSPECT FUSE
(b) Inspect the fuses in the engine room junction box:

Switch located side wall LH:
• FL1 (60 A) (with 4G63/4G64 engine)
• FL6 (50 A) (with BJ493ZQ3 engine)
Switch located middle platform: 04
• FL1 (60 A)
(c) Inspect the fuses in the body junction box:
• F7 (15 A)
• F2 (15 A)
• F16 (7.5 A)

2. INSPECT REAR EVAPORATOR MOTOR RELAY

(b) Remove the rear evaporator motor relay1 R10.
(c) Inspect the rear evaporator motor relay.

Standard resistance

1–2 Continuity
3–5 ＜2Ω

3. INSPECT REAR HEATER SWITCH (FRONT CONTROL)

(b) Disconnect the C020 rear heater switch (front control) switch connector.
(c) Check the rear heater switch (front control) switch.

Standard resistance
Tester Specified
Connection
Release rear heater
2-6 ≥ 1 ΜΩ
switch (front control)
Press rear heater switch

2-6 ＜2Ω
(front control)

NO > Replace the rear heater switch (front control) switch.
4. INSPECT REAR HEATER SWITCH (REAR CONTROL)

(b) Disconnect the H007 rear heater switch (rear control). (Switch located side wall LH)
(c) Disconnect the Q001 rear heater switch (rear control). (Switch located middle platform)
(d) Check the rear heater switch (rear control).

Standard resistance
Tester Specified
Connection
Release rear heater
3-4
switch (rear control)
＜2Ω
Press rear heater switch
2-4
(rear control)

NO > Replace the rear heater switch (rear control).
5. CHECK HARNESS AND CONNECTOR (REAR HEATER BLOWER SWITCH - GROUND)

(b) Disconnect the H006 rear heater blower switch connector. (Switch located side wall LH) 04
(c) Disconnect the Q007 rear heater blower switch connector. (Switch located middle platform)

table below. (Switch located side wall LH)

H006 (1) - Ground ＜2Ω

table below. (Switch located middle platform)

Q007 (1) - Ground ＜2Ω

6. CHECK HARNESS AND CONNECTOR (REAR HEATER SWITCH - GROUND)

(c) Disconnect the Q001 rear heater switch (rear control).(witch located middle platform)


H007 (4) - Ground ＜2Ω


Q001 (4) - Ground ＜2Ω

7. CHECK HARNESS AND CONNECTOR (REAR HEATER BLOWER MOTOR - REAR EVAPORATOR
MOTOR RELAY)

(c) Disconnect the H008 rear heater blower motor.(Switch located side wall LH)
(d) Disconnect the Q003 rear heater blower motor.(Switch located middle platform)

table below.(Switch located side wall LH)

R10 (5) - H008 (1) ＜2Ω

table below.(Switch located middle platform)

R10 (5) - Q003 (1) ＜2Ω

8. CHECK HARNESS AND CONNECTOR (WATER VALVE - A/C CUT RELAY)

(b) Disconnect the C005 A/C cut relay connector. 04
(c) Disconnect the L008 water valve connector.

table below.

C005 (3) - L008 (1) ＜2Ω

9. CHECK HARNESS AND CONNECTOR (REAR HEATER BLOWER MOTOR RELAY 2 - WATER
VALVE)

(b) Remove the rear heater blower motor relay 2 R9.

table below.

R9 (30) - L008 (2) ＜2Ω

YES > Replace the water valve.
WARM AIR FLOW CONTROL: WARM AIR COMES OUT RARELY

04
04
1. INSPECT REAR HEATER BLOWER MOTOR

(b) Remove the rear heater blower switch.
(c) Disconnect the H006 rear heater blower switch connector.(Switch located side wall LH)
(d) Disconnect the Q007 rear heater blower switch connector.(Switch located middle platform)
(e) Check the front blower motor resistor. (Switch located

side wall LH)

2-4 0.6 Ω
2-3 1.6 Ω
4-3 1.03 Ω

NO > Replace the rear heater blower motor.
2. CHECK HARNESS AND CONNECTOR (REAR HEATER BLOWER MOTOR - REAR HEATER
BLOWER SWITCH)

(b) Disconnect the H008 rear heater blower motor.(Switch located side wall LH)
(c) Disconnect the Q003 rear heater blower motor.(Switch located middle platform)
(d) Disconnect the H006 rear heater blower switch connector.(Switch located side wall LH)
(e) Disconnect the Q007 rear heater blower switch connector.(Switch located middle platform)


H008 (2) - H006 (6)
＜2Ω
H008 (4) - H006 (3)
(g) Measure the resistance according to the value(s) in the

04
Q003 (2) - Q007 (6)
＜2Ω
Q003 (3) - Q007 (4)
04
YES > Replace the rear heater blower switch.

AUTO A/C:
1. Fuse -
2. A/C relay -
A/C system is Chapter 61 heater and air conditioning - front

3. A/C amplifier evaporator, overhaul
inoperative
Chapter 61 heater and air conditioning -
4. A/C compressor compressor, overhaul
5. Wire harness -
1. Fuse -
2. Relay -
Chapter 61 heater and air conditioning - front

3. Blower switch blower, replacement
Air flow control: Front Chapter 61 heater and air conditioning - front
blower motor is inoper- 4. Front blower motor resistor blower, replacement
ative
5. Front blower motor blower, replacement
Chapter 61 heater and air conditioning - A/C

6. Front A/C controller controller, replacement
7. Wire harness -
1. Fuse -
2. Relay -
Chapter 61 heater and air conditioning - rear

3. Rear evaporator blower switch evaporator, replacement
Air flow control: Rear Chapter 61 heater and air conditioning - rear
evaporator motors are 4. Rear evaporator resistor evaporator, replacement
inoperative
5. Rear A/C switch controller, replacement

7. Wire harness -

1. Blower switch(front control) blower, replacement
04
2. Front blower motor resistor blower, replacement

Air flow control: Front 3. Front blower motor blower, replacement
air flow is insufficient
4. Front A/C controller controller, replacement 04
Chapter 61 heater and air conditioning - heater
5. Front A/C air output pipe hose, replacement
6. Wire harness -

1. Rear evaporator blower switch evaporator, replacement

Air flow control: Rear 2. Rear evaporator resistor evaporator, replacement
air flow is insufficient
4. Wire harness -
1. Fuse -
2. Relay -


Temperature Control: 4. Front A/C controller controller, replacement
Temperature control is
inoperative Chapter 61 heater and air conditioning - front
6. Refrigerant -

7. A/C pressure line pipe, replacement
8. Wire harness -
1. Refrigerant -

Temperature Control:
Temperature control is 3. Front A/C controller controller, replacement
operative poorly
5. Wire harness -

1. Heater blower motor heater blower, overhaul

2. Heater switch heater blower, overhaul

Warm air flow control: 3. A/C amplifier evaporator, overhaul
No warm air comes out
4. Heater blower switch heater blower, overhaul
5. Water valve -
6. Wire harness -

1. Heater blower motor heater blower, overhaul

2. Heater switch heater blower, overhaul
Warm air flow control:

Warm air comes out 3. A/C amplifier evaporator, overhaul
rarely
4. Heater blower switch heater blower, overhaul
5. Water valve -
6. Wire harness -
A/C SYSTEM IS INOPERATE

WIRING DIAGRAM
04
04
1. INSPECT FUSE
(b) Inspect the fuses in engine room junction box:

• FL2 (40 A)
• FL5 (30 A)
(c) Inspect the fuses in body junction box:
• F2 (15 A)
• F16 (7.5 A)



table below.

C017 (11) - Ground
＜2Ω
C017 (14) - Ground

3. CHECK HARNESS AND CONNECTOR (A/C CUT RELAY - FRONT A/C CONTROLLER)

(b) Remove the A/C cut relay.

table below.

C005 (3) - C017 (10) ＜2Ω


(b) Disconnect the C008 A/C amplifier connector. 04
table below.

04
C008 (6) - Ground ＜2Ω

5. CHECK HARNESS AND CONNECTOR (A/C CUT RELAY - A/C AMPLIFIER)

(b) Remove the main relay C005.

table below.

C005 (3) - C008 (13)
＜2Ω
C005 (3) - C008 (3)

AIR FLOW CONTROL: FRONT BLOWER MOTOR IS INOPERATIVE

WIRING DIAGRAM
1. INSPECT FUSE
(c) Inspect the fuse in body junction box: F2 (15 A).
04

YES > GO to step 4.
NO > If the fuse FL2 (40 A) is blown, go to next step.
2. CHECK HARNESS AND CONNECTOR (FRONT HEATER BLOWER MOTOR RELAY - GROUND)

(b) Remove the front blower motor relay R11.

table below.

R11 (87) - Ground ≥ 1 ΜΩ

3. CHECK HARNESS AND CONNECTOR (A/C CUT RELAY - GROUND)


table below.

C005 (4) - Ground ≥ 1 ΜΩ

4. CHECK HARNESS AND CONNECTOR (FRONT HEATER BLOWER MOTOR - FRONT BLOWER
MOTOR)

(b) Disconnect the C047 front blower motor connector.
(c) Remove the front blower motor relay R11.

table below.

R11 (30) - C047 (2) ＜2Ω


(b) Disconnect the C024 blower motor switch connector. 04
table below.

04
C024 (3) - Ground ＜2Ω

6. CHECK HARNESS AND CONNECTOR (FRONT BLOWER MOTOR - BLOWER SWITCH)


table below.

C047 (1) - C024 (4) ＜2Ω



table below.

C024 (2) - C017 (2) ＜2Ω

AIR FLOW CONTROL: REAR EVAPORATOR MOTORS ARE INOP-

ERATIVE
WIRING DIAGRAM 04
04
1. INSPECT FUSE
(b) Inspect the rear evaporator motor fuse: 7.5 A.

(c) Inspect the fuse in engine room junction box: FL5 (30 A).
Is the inspect result normal?

2. CHECK HARNESS AND CONNECTOR (REAR EVAPORATOR MOTOR RELAY - GROUND)

(b) Remove the rear evaporator motor relay C009.
(e) Press the rear A/C switch.

table below.
Standard voltage

C009 (1) - Ground
Battery voltage
C009 (5) - Ground


(b) Remove the rear evaporator motor relay C009. 04
(c) Inspect rear evaporator motor relay C009.
Standard resistance

3–5 Continuity
04
＜2Ω
terminal 3 and 5)

4. INSPECT REAR A/C SWITCH

(c) Inspect the rear A/C switch.
Tester Specified
Condition
Release rear A/C
6-2 ≥ 1 ΜΩ
switch
Press rear A/C

6-2 ＜2Ω
switch

NO > Replace the rear A/C switch.
5. CHECK HARNESS AND CONNECTOR (REAR EVAPORATOR MOTOR RELAY - REAR
EVAPORATOR MOTOR)

(b) Remove the rear evaporator motor relay C009.
(c) Disconnect the F305 rear evaporator motor LH connector.
(d) Disconnect the F306 rear evaporator motor RH connector.

table below.

C009 (2) - F305 (2)
＜2Ω
C009 (2) - F306 (2)

SWITCH)

(c) Disconnect the C023 rear A/C switch connector.

table below.

C023 (2) - F309 (4) ＜2Ω

7. CHECK HARNESS AND CONNECTOR (REAR EVAPORATOR MOTOR - REAR EVAPORATOR
BLOWER SWITCH)

(b) Disconnect the F305 rear evaporator motor LH connector.
(c) Disconnect the F306 rear evaporator motor RH connector.
(d) Disconnect the F309 rear evaporator blower switch connector.

table below.
04
F305 (1) - F309 (6)
＜2Ω
C306 (1) - F309 (6)
04
8. CHECK HARNESS AND CONNECTOR (REAR EVAPORATOR BLOWER SWITCH - GROUND)


table below.

F309 (8) - Ground ＜2Ω

AIR FLOW CONTROL: FRONT AIR FLOW IS INSUFFICIENT

WIRING DIAGRAM
1. INSPECT FRONT BLOWER MOTOR RESISTOR

(b) Replace the front blower motor resistor with new one.
YES > Replace the front blower motor resistor.
2. CHECK HARNESS AND CONNECTOR (FRONT BLOWER MOTOR - FRONT BLOWER MOTOR 04
RESISTOR)

(b) Disconnect the C006 front blower motor resistor connector.

table below.

C047 (1) - C006 (1) ＜2Ω



table below.

C024 (3) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR (RONT BLOWER MOTOR RESISTOR - BLOWER SWITCH)


table below.

C006 (3) - C024 (1)
＜2Ω
C006 (2) - C024 (5)



table below.

C024 (2) - C017 (2) ＜2Ω

AIR FLOW CONTROL: REAR AIR FLOW IS INSUFFICIENT

WIRING DIAGRAM
04
04
1. INSPECT REAR EVAPORATOR RESISTOR

(c) Inspect the rear evaporator resistor.

1-3 3.1 Ω
1-2 0.5 Ω
2-3 2.6 Ω

NO > Replace the rear evaporator resistor.
2. CHECK HARNESS AND CONNECTOR (REAR EVAPORATOR RESISTOR - GROUND)


table below.

F304 (3) - Ground ＜2Ω

3. CHECK HARNESS AND CONNECTOR (REAR EVAPORATOR RESISTOR - REAR EVAPORATOR
BLOWER SWITCH)


table below.
04
F304 (2) - F309 (1) ＜2Ω
04
SWITCH)


table below.

C023 (2) - F309 (4) ＜2Ω

TEMPERATURE CONTROL: TEMPERATURE CONTROL IS INOPER-

ATIVE
WIRING DIAGRAM
1. INSPECT COMPRESSOR
(a) Start the engine and hold it at idle speed. 04

(b) Press the A/C switch to get the compressor clutch engaged.
Does the compressor work correctly?
YES > Go to step 8.
2. INSPECT A/C CLUTCH RELAY 04

(b) Remove the A/C clutch relay C010.
(c) Inspect the A/C clutch relay.

Standard resistance

1–3 Continuity
＜2Ω
terminal 1 and 3)

NO > Replace the A/C clutch relay.
3. CHECK HARNESS AND CONNECTOR (A/C CLUTCH RELAY - GROUND)


table below.
Standard voltage

C010 (2) - Ground
Battery voltage
C010 (1) - Ground

4. CHECK HARNESS AND CONNECTOR (A/C CLUTCH RELAY - DUAL FUNCTION PRESSURE
SWITCH)

(c) Disconnect the A012 dual function pressure switch connector.

table below.

C010 (3) - A012 (2) ＜2Ω

5. CHECK HARNESS AND CONNECTOR (DUAL FUNCTION PRESSURE SWITCH - A/C AMPLIFIER)

(b) Disconnect the A012 dual function pressure switch connector.

table below.

A012 (4) - C008 (15) ＜2Ω

6. CHECK HARNESS AND CONNECTOR (A/C CLUTCH RELAY - A/C CLUTCH)

(c) Disconnect the E022 A/C clutch connector.

table below.
04
C010 (4) - E022 (1) ＜2Ω
04
YES > Replace the A/C clutch.


table below.
Standard voltage



(b) Disconnect the C060 front a/c controller connector.

table below.

C017 (11) - Ground
＜2Ω
C017 (14) - Ground



table below.
Standard voltage

C008 (3) - Ground
Battery voltage
C008 (13) - Ground



table below.

C008 (6) - Ground ＜2Ω

WARM AIR FLOW CONTROL: NO WARM AIR COMES OUT

04
04

1. INSPECT FUSE
(b) Inspect the fuses in the engine room junction box:

Switch located side wall LH:
• FL1(60 A) (with 4G63/4G64 engine)
• FL6(50 A) (with BJ493ZQ3 engine)
Switch located middle platform: 04
• FL1(60 A)
(c) Inspect the fuses in the body junction box:
• F7(15 A)
• F2(15 A)
• F16(7.5 A)


(c) Inspect the rear evaporator motor relay.

Standard resistance

1–2 Continuity
＜2Ω
terminal 1 and 2)

3. INSPECT REAR HEATER SWITCH (FRONT CONTROL)

(b) Disconnect the C020 rear heater switch (front control) switch connector.
(c) Check the rear heater switch (front control) switch.

Standard resistance

Connection
Condition
Release rear heater
2-6 ≥ 1 ΜΩ
Press rear heater

2-6 ＜2Ω

NO > Replace the rear heater switch (front control) switch.
4. INSPECT REAR HEATER SWITCH (REAR CONTROL)

(c) Disconnect the Q001 rear heater switch (rear control). (Switch located middle platform)
(d) Check the rear heater switch (rear control).

Standard resistance

Connection
Condition
Release rear heater
3-4
＜2Ω
Press rear heater
2-4

NO > Replace the rear heater switch (rear control).
5. CHECK HARNESS AND CONNECTOR (REAR HEATER BLOWER SWITCH - GROUND)

(b) Disconnect the H006 rear heater blower switch connector. (Switch located side wall LH) 04
(c) Disconnect the Q007 rear heater blower switch connector. (Switch located middle platform)


H006 (1) - Ground ＜2Ω


Q007 (1) - Ground ＜2Ω


(b) Disconnect the H007 rear heater switch (rear control).(Switch located side wall LH)
(c) Disconnect the Q001 rear heater switch (rear control).(witch located middle platform)


H007 (4) - Ground ＜2Ω


Q001 (4) - Ground ＜2Ω

7. CHECK HARNESS AND CONNECTOR (REAR HEATER BLOWER MOTOR - REAR EVAPORATOR
MOTOR RELAY)

(b) Remove the rear evaporator motor relay1(R10).
(c) Disconnect the H008 rear heater blower motor.(Switch located side wall LH)
(d) Disconnect the Q003 rear heater blower motor.(Switch located middle platform)

table below.(Switch located side wall LH)

R10 (5) - H008 (1) ＜2Ω


R10 (5) - Q003 (1) ＜2Ω

8. CHECK HARNESS AND CONNECTOR(WATER VALVE - A/C CUT RELAY)

(b) Disconnect the C005 A/C cut relay connector. 04

table below.

C005 (3) - L008 (1) ＜2Ω

9. CHECK HARNESS AND CONNECTOR (REAR HEATER BLOWER MOTOR RELAY 2 - WATER
VALVE)

(b) Remove the rear heater blower motor relay 2.

table below.

R9 (30) - L008 (2) ＜2Ω

YES > Replace the water valve.
WARM AIR FLOW CONTROL: WARM AIR COMES OUT RARELY

04
04
1. INSPECT REAR HEATER BLOWER MOTOR

(b) Remove the rear heater blower switch.
(c) Disconnect the H006 rear heater blower switch connector. (Switch located side wall LH)
(d) Disconnect the Q007 rear heater blower switch connector. (Switch located middle platform)
(e) Check the front blower motor resistor. (Switch located

side wall LH)

2-4 0.6 Ω
2-3 1.6 Ω
4-3 1.03 Ω

NO > Replace the rear heater blower motor.
2. CHECK HARNESS AND CONNECTOR (REAR HEATER BLOWER MOTOR - REAR HEATER
BLOWER SWITCH)

(b) Disconnect the H008 rear heater blower motor. (Switch located side wall LH)
(c) Disconnect the Q003 rear heater blower motor. (Switch located middle platform)
(d) Disconnect the H006 rear heater blower switch connector. (Switch located side wall LH)
(e) Disconnect the Q007 rear heater blower switch connector. (Switch located middle platform)


H008 (2) - H006 (6)
＜2Ω
H008 (4) - H006 (3)
(g) Measure the resistance according to the value(s) in the

04
Q003 (2) - Q007 (6)
＜2Ω
Q003 (3) - Q007 (4)
04
YES > Replace the rear heater blower switch.
04-550 DIAGNOSTICS - HORN SYSTEM
HORN SYSTEM
LOCATION
1 Horn Switch 3 Alt Horn
2 Engine Room Junction Box 4 Bass Horn

DIAGNOSTICS - HORN SYSTEM 04-551

04
1. Horn fuse -
2. Horn relay -
3. Horn switch Chapter 51 steering column - steering wheel, replacement

Horn is inoperative 04
4. Clock spring Chapter 51 steering column - steering wheel, replacement
5. Horn Chapter 81 communication system - horn, replacement
6. Wire harness -
1. Horn relay -
Horn is always on 2. horn switch Chapter 51 steering column - steering wheel, replacement
3. Wire harness -
1. Alt horn Chapter 81 communication system - horn, replacement

Alt horn is inoperative
(the bass horn is normal) -
2. Wire harness
1. Bass horn Chapter 81 communication system - horn, replacement

Bass horn is inoperative
(the alt horn is normal) -
2. Wire harness
HORN IS INOPERATIVE
WIRING DIAGRAM
1. INSPECT FUSE
(b) Inspect the horn fuse in engine room junction box: F25
(15 A).

YES > Go to step 3.

2. CHECK HARNESS AND CONNECTOR (HORN FUSE - HORN RELAY)
04
(b) Remove the horn relay R6.

table below.
Standard resistance (check for short) 04
R6 (2) - Ground
≥ 1 ΜΩ
R6 (5) - Ground

3. INSPECT HORN RELAY

(c) Inspect the horn relay in the engine room junction box.
Standard resistance

1–2 Continuity
＜2Ω
terminal 1 and 2)

NO > Replace the horn relay.
4. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - HORN RELAY)

(c) Disconnect the C039 combination switch (wiper control) connector.

table below.

R6 (1) - C039 (18) ＜2Ω

YES > For vehicles equiped without SRS, go to next step.
For vehicles equiped with SRS, go to step 7.
5. INSPECT HORN SWITCH (WITHOUT SRS)
(a) Remove the horn switch. (Refer to“Chapter 51 steering column - steering wheel, replacement”)
(b) Check the horn switch for corrosion or damaged pins.
(c) Replace the horn switch. (Refer to“Chapter 51 steering column - steering wheel, replacement”)
(d) Press the horn switch.
Does the horn sound?
YES > Repair or replace the horn switch.
6. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - GROUND) (WITHOUT SRS)

(b) Disconnect the C039 combination switch (wiper control) connector.
(d) Connect a fused (5 A) jumper wire between the C039

combination switch (wiper control) connector, pin 18 and
ground.

NO > Go to step 12.
7. INSPECT CLOCK SPRING (WITH SRS)

(b) Remove the clock spring. (Refer to“Chapter 51 steering column - steering wheel, replacement”) 04
(c) Measure the resistance between the clock spring, pin 4
(up) (component side) and pin 4 (down) (component
side).
Resistance：＜ 2 Ω
04

NO > Replace the clock spring.
8. CHECK HARNESS AND CONNECTOR (HORN RELAY - CLOCK SPRING) (WITH SRS)

(b) Disconnect the C046 clock spring connector.

table below.

R6 (1) - C046 (1) ＜2Ω

9. INSPECT HORN SWITCH (WITH SRS)

(b) Remove the horn switch. (Refer to“Chapter 51 steering column - steering wheel, replacement”)
(c) Check the horn switch for corrosion or damaged pins.
(d) Replace the horn switch. (Refer to“Chapter 51 steering column - steering wheel, replacement”)
(e) Press the horn switch.
10. CHECK HARNESS AND CONNECTOR (CLOCK SPRING - HORN SWITCH) (WITH SRS)

(b) Remove the horn switch. (Refer to“Chapter 51 steering column - steering wheel, replacement”)
(d) Connect a fused (5A) jumper wire between the horn switch and ground.
11. CHECK HARNESS AND CONNECTOR (HORN SWITCH - GROUND) (WITH SRS)

(b) Remove the combination switch (wiper control). (Refer to“Chapter 51 steering column - steering wheel,
replacement”)
(c) Disconnect the C039 combination switch (wiper control) connector.
(d) Connect the battery negative cable.
(e) Connect a fused (5A) jumper wire between the C039

combination switch (wiper control) connector, pin 18 and
ground.

12. CHECK HARNESS AND CONNECTOR (HORN - GROUND)

(b) Disconnect the A009 horn connector.
(c) Disconnect the A010 horn connector.

table below.

A009 (2) - Ground
＜2Ω
A010 (2 ) - Ground

13. CHECK HARNESS AND CONNECTOR (HORN RELAY - HORN)

(b) Remove the horn relay R6. 04
(c) Disconnect the A009 horn connector.
(d) Disconnect the A010 horn connector.

table below.
04
R6 (3) - A009 (1)
＜2Ω
R6 (3) - A010 (1)

YES > Replace the horn.
HORN IS ALWAYS ON
WIRING DIAGRAM
1. INSPECT HORN RELAY

(c) Check the horn relay in the engine room junction box.
Standard resistance

1–2 Continuity
＜2Ω
terminal 1 and 2)

YES > For vehicles equiped without SRS, go to next step.
For vehicles equiped with SRS, go to step 4.
NO > Replace the horn relay.
2. INSPECT HORN SWITCH (WITHOUT SRS)
(a) Remove the horn switch. (Refer to“Chapter 51 steering column - steering wheel, replacement”)
(b) Check the horn switch for corrosion or damaged pins. 04
(c) Replace the horn switch. (Refer to“Chapter 51 steering column - steering wheel, replacement”)
04
3. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - GROUND) (WITHOUT SRS)


table below.

C039 (18) - Ground ≥ 1 ΜΩ

YES > Go to step 8.
4. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - GROUND) (WITH SRS)


table below.

C039 (18) - Ground ≥ 1 ΜΩ

5. CHECK HARNESS AND CONNECTOR (CLOCK SPRING - GROUND) (WITH SRS)


table below.

C046 (1) - Ground ≥ 1 ΜΩ

6. INSPECT CLOCKSPRING

(b) Replace the clock spring. (Refer to “Chapter 51 steering column - steering wheel, overhaul”)
Does the horn work correctly?
YES > Replace the clock spring.
7. INSPECT HORN SWITCH (WITH SRS)

Does the horn still sound?
8. CHECK HARNESS AND CONNECTOR (HORN - GROUND)

table below.
Standard voltage

A009 (1) - Ground
0V
A010 (1) - Ground

YES > Replace the horn.
ALT HORN IS INOPERATIVE

WIRING DIAGRAM
04
04
1. CHECK HARNESS AND CONNECTOR (ALT HORN - GROUND)

(b) Disconnect the A009 alt horn connector.

table below.

A009 (2) - Ground ＜2Ω

2. CHECK HARNESS AND CONNECTOR (ALT HORN - GROUND)

(b) Disconnect the A009 alt horn connector.

table below.
Standard voltage

A009 (1) - Ground Battery voltage

3. CHECK HARNESS AND CONNECTOR (HORN RELAY - ALT HORN)

(c) Disconnect the A009 alt horn connector.

table below.

R6 (3) - A009 (1) ＜2Ω

YES > Replace the alt horn.
BASS HORN IS INOPERATIVE

WIRING DIAGRAM
04
04
1. CHECK HARNESS AND CONNECTOR (BASS HORN - GROUND)

(b) Disconnect the A010 bass horn connector.

table below.

A010 (2) - Ground ＜2Ω

2. CHECK HARNESS AND CONNECTOR (BASS HORN - GROUND)

(b) Disconnect the A010 bass horn connector.

table below.
Standard voltage

A010 (1) - Ground Battery voltage

3. CHECK HARNESS AND CONNECTOR (HORN RELAY - BASS HORN)

(c) Disconnect the A010 bass horn connector.

table below.

R6 (3) - A010 (1) ＜2Ω

YES > Replace the bass horn.
DIAGNOSTICS - AUDIO SYSTEM 04-565
AUDIO SYSTEM
PRECAUTION
1. IT IS FORBIDDEN TO RECONSTRUCT THE AUDIO SYSTEM. 04
2. BOTH GLASS ANTENNA AND ANTENNA AMPLIFIER ARE EQUIPPED ON THE VEHICLE. BUT
THERE IS NO ANTENNA AMPLIFIER ASSY FOR VEHICLES EQUIPPED WITH ROD ANTENNA.
3. THE RADIO WAVE BANDS USED IN RADIO BROADCASTING ARE AS FOLLOWS:
Radio Wave AM FM
Modulation Amplitude Modulation Frequency Modulation 04
Designation AM1 AM2 FM1 FM2 FM3
Frequency 522 ～ 1620 KHz 87.5 ～ 108 MHz
4. CD/DVD PRECAUTION.
NOTE
Do not look the laser head, because radio units use an invisible laser beam which could cause
hazardous radiation exposure. Be sure to operate the player correctly as instruction.
(a) CD/DVD player uses a laser beam pick–up to read the digital signals recorded on the CD and
reproduce analog signals of the music, etc.
(b) There are 8 cm and 12 cm discs available for the radio unit.
(c) CD player only reads this logo disc.
(d) DVD player only reads these logo discs as follows:
(e) DVD remote control uses 3 V button cell. The cell model is CR2025.
(f) Precautions for disc use.
• Dish player only inserts once a disc, or it will damage radio unit.
• The piratic disc can not be played normally.
• Due to the characteristics of disc, leaving it in the vehicle for long time will cause the disc damage, dirt
or aging, etc.
04-566 DIAGNOSTICS - AUDIO SYSTEM
• Do not damage the disc or leave your fingerprints on the disc surface.
• The side of disc with label is upward, through holding disc flange and center hole access to disc.
• Exposing disc outside for long time after pressing “CD/DVD Ejection Button” will cause the disc defor-
mation or be unavailable.
• If discs have sticking labels, adhesive tags or any similar tags pasted on the disc surface will cause the
disc not to eject or mechanical fault.
• Do not put the disc in sunlight. (In sunlight, it could cause the disc deformation or be unavailable.)
• Do not use strange discs, or it will cause the radio unit fault.
• Do not use transparent or translucent discs, or it can not be inserted, ejected or played normally.
(g) Do not use discs as following list, or it will damage the radio unit.
NOTE
• In cold and rainy weather, if the window appears fog in radio unit, it may also form the mist and
condensation. In this case, the CD/DVD player may staccato or stop playing. So before using
the CD/DVD player, please ventilate and dehumidify the vehical for a period time.
• Fierce vibration occurred when travel on bumpy road, this may lead the CD/DVD player staccato
or stop play.
(h) CD/DVD cleaning.

• If the disc gets dirty, clean the disc by wiping the surface
from the center to outside in the radial directions with a
soft cloth. 04
04
NOTE
• Do not use conventional CD cleaner, because it will cause the laser head fault.
• It may scratch the disc surface with hands or coarse cloth cleaning the disc.
• It may damage the disc or be unavailable with similar disc sprays, antistatic, alcohol, benzene
dilution and the cloth with the chemical preparation.
5. POWER OFF.
(a) Before removing or installing any electrical device,please disconnect the negative battery cable to pre-
vent damaging to the device or personal injury.
(b) Ignition switch must be off if no specific instructions.
IS DISCONNECTED.
NOTE
instructions”).
LOCATION
1 Front Speaker Assy LH 5 Rear Speaker Assy RH
2 Rod Antenna (optional) 6 Antenna Amplifier Assy (optional)
3 Radio Unit 7 Glass Antenna Assy (optional)
4 Front Speaker Assy RH 8 Rear Speaker Assy LH

TERMINALS OF RADIO UNIT
04
04
Terminal No. Wiring Color Description

1 - -
2 - -
3 - -
4 R Battery （+）
C032
5 V To antenna amplifier
6 G Radio illumination
7 GR Ignition switch: ACC
8 BR Ground
1 R Rear Speaker RH （＋）
2 W Rear Speaker RH （－）
3 LG Front Speaker RH （＋）
4 L Front Speaker RH （－）

C031
5 P Front Speaker LH （＋）
6 V Front Speaker LH （－）
7 B Rear Speaker LH （＋）
8 Y Rear Speaker LH （－）

BASIC INSPECTION
Yes Go to step 2. 04
1 • The battery voltage should be above 12 V. Charge or replace the battery. Refer to
Is the check result normal？ No
“Chapter 20A starting and charging - battery”.
Check the antenna. Yes Go to step 3.

• Check if the antenna is pulled out and
pulled out to end. 04
• Check if the antenna is covered with
2
obstacles. No Repair or replace the antenna.
• Check if the antenna is bended or defor-
mation.
Check the radio unit. Yes Go to step 4.

• Press the radio unit power button, check
3
if the LCD is displaying. No Go to the problem symptoms table.
Check the radio unit. Yes Go to step 5.

• Set the radio unit volume level above 5
4
VOL, check if the speaker sounds. No Go to the problem symptoms table.
Check the radio broadcasting signal. Yes Go to the problem symptoms table
• There are great differences in the size of
the service area for AM and FM
broadcasting. Sometimes FM stereo
broadcasting cannot be received even
though AM can be received very clearly.
Not only does FM stereo have the
smallest service area, but it also picks up
static and other types of interference
easily.
• AM broadcasting receives two signals
from the same transmitter at night. One is
from the transmitter directly and the other
is from the ionosphere. It will cause
5 “faiding”.
• Check if tall buildings or mountains are No Move the vehicle to signals is good place
around the vehicle. Because tall buildings
and mountains will weaken the radio
broadcasting signals between the trans-
mitter and the vehicle.
• Check if large substation or power station
is around the vehicle. Because they gen-
erate so strong electromagnetism that it
can’t receive radio broadcasting signals.
• Due to the characteristics of materials,
some buildings can reflect the radio
waves so that the vehicle is receiving two
signals, which will cause the interference.

these parts.

Chapter 04 diagnostics - audio system, the audio system
1. Power, ground circuits is inoperative
The audio system is
inoperative Chapter 04 diagnostics - audio system, the audio system
2. Radio unit is inoperative
1. In mute mode Audio system instructions
Chapter 04 diagnostics - audio system, no sound is heard

2. Speaker circuits from speaker in all modes
No sound is heard
from speaker in all
modes 3. Speakers from speaker in all modes

4. Radio unit from speaker in all modes
1. Incorrect setting Audio system instructions
Sound quality is poor Chapter 04 diagnostics - audio system, sound quality is

2. Speaker circuits poor in all modes
in all modes
Chapter 04 diagnostics - audio system, sound quality is
3. Speakers poor in all modes
1. Incorrect setting Audio system instructions
Chapter 04 diagnostics - audio system, volume is too low

2. Speaker circuits in all modes
Volume is too low in all
modes Chapter 04 diagnostics - audio system, volume is too low
3. Speakers in all modes
Chapter 04 diagnostics - audio system, volume is too low

4. Radio unit in all modes
Chapter 04 diagnostics - audio system, sound quality is

Sound quality is poor 1. Source file poor only when playing CD/DVD
only when playing CD/
DVD Chapter 04 diagnostics - audio system, sound quality is
2. Radio unit poor only when playing CD/DVD
1. Electromagnetic Chapter 04 diagnostics - audio system, radio broadcasting

interference signal can not be received. (Bad reception)
Radio broadcasting
signal can not be Chapter 04 diagnostics - audio system, radio broadcasting
received. (Poor 2. Antenna signal can not be received. (Bad reception)
reception)
Chapter 04 diagnostics - audio system, radio broadcasting
3. Radio unit signal can not be received. (Bad reception)

Chapter 04 diagnostics - audio system, CD/DVD can not
1. Unknown disc be inserted or CD/DVD is ejected right now after being
CD/DVD can not be
inserted 04
inserted or CD/DVD is
ejected right now after Chapter 04 diagnostics - audio system, CD/DVD can not
being inserted be inserted or CD/DVD is ejected right now after being
2. Radio unit
inserted
1. Unknown disc Audio system instructions

CD/DVD can not be
ejected
2. Radio unit Chapter 66 audio system - radio unit， replacement
04
Chapter 04 diagnostics - audio system, CD/DVD sound

1. Source file skips
CD/DVD sound skips
Chapter 04 diagnostics - audio system, CD/DVD sound
2. Radio unit skips
CD/DVD LCD does not 1. Disc Audio system instructions

display (Audio system
is operating normally) 2. Radio unit Chapter 66 audio system - radio unit， raplacement
1. Disc Audio system instructions

No sound, but LCD is
displaying normally 2. Incorrect setting Audio system instructions
(Only CD/DVD mode)
3. Radio unit Chapter 66 audio system - radio unit， replacement
THE AUDIO SYSTEM IS INOPERATIVE

WIRING DIAGRAM
1. CHECK AUDIO SYSTEM POWER FUSES
(b) Verify fuses in the body junction box: F13 (10 A), F14 (10
A).

YES > Go to step 4.
NO > If fuse F13 (10 A) is not OK, go to step 3.
If fuse F14 (10 A) is not OK, go to step 2.
2. CHECK HARNESS AND CONNECTOR (FUSE - RADIO UNIT)
(a) Disconnect the radio unit connector.

NOTE 04
Do not drop the radio unit down.
04

table below.
C032 (7) - Ground ≥ 1 MΩ

YES > Replace the CD/DVD radio unit.
NO > Replace the fuse F14 (10 A). Repair or replace harness or connector.

NOTE

table below.
C032 (4) - Ground ≥ 1 MΩ

NO > Replace the fuse F13 (10 A). Repair or replace harness or connector.
4. CHECK HARNESS AND CONNECTOR (RADIO UNIT - GROUND)
(b) Disconnect the radio unit connector.

NOTE

table below.
Standard voltage
C032 (7) - C032 (8)

Battery Voltage
C032 (7) - Ground

YES > Go to step 5.
NO > If no battery voltage, repair the circuit for an open from the fuse F14 (10 A) to the radio unit connector
C032, pin 7. 04
If no battery voltage only between the radio unit connector C032, pin 7 and pin 8 , repair the circuit for
an open from the radio unit connector C032, pin 7 to ground.

table below.
Standard voltage

NO SOUND IS HEARD FROM SPEAKER IN ALL MODES

WIRING DIAGRAM
• Press the radio unit power button (PWR).
• In the radio unit working status, shortly pressing the power button (PWR) will enter mute mode.
• Adjust the volume level above 5 VOL.
Is any sound heard?
YES > Set the radio unit correctly.
NO > Go to step 1.
1. INSPECT SPEAKER

(b) Remove the speaker (Refer to “Chapter 66 audio system - speaker assy, replacement”).
(c) Check the paper cone of speaker for damage.
(d) Measure the resistance between the front speakers pin 1

and pin 2.
Standard resistance
04
M003 (1) - M003 (2)
4Ω
N005 (1) - N005 (2)
04
(e) Measure the resistance between the rear speakers pin 1
and pin 2.
Standard resistance

G002 (1) -G002 (2)
4Ω
H001 (1) -H001 (2)

YES > Go to step 2.
NO > Replace the speaker.
2. CHECK HARNESS AND CONNECTOR (RADIO UNIT - SPEAKER)

(b) Measure the resistance among the pins of radio unit con-
nector C031.

C031 (1) - C031 (2)
C031 (3) - C031 (4)

≥ 1 MΩ
C031 (5) - C031 (6)
C031 (7) - C031 (8)

YES > Go to step 3.

table below.
C031 (1) - Ground
C031 (2) - Ground
C031 (3) - Ground
C031 (4) - Ground
≥ 1 MΩ
C031 (5) - Ground
C031 (6) - Ground
C031 (7) - Ground
C031 (8) - Ground

YES > Go to step 4.

(b) Measure the voltage according to the value(s) in the 04
table below.
Standard voltage
C031 (1) - Ground
C031 (2) - Ground 04
C031 (3) - Ground
C031 (4) - Ground
0V
C031 (5) - Ground
C031 (6) - Ground
C031 (7) - Ground
C031 (8) - Ground

SOUND QUALITY IS POOR IN ALL MODES

1. CHECK RADIIO UNIT SETTING

(b) Press the radio unit power button (PWR).
(c) Adjust the volume level above 5 VOL.
(d) Set “BAS”, “TRE”, “BAL” to the initial value. Set “BAS”, “TRE” value as ”0 ～ 3”.Set “BAL” as “0” value.
(e) Pressing and holding “ VOL ” button 2 seconds will open “LOUDNESS” function.
Is the sound quality from speaker normal?
NO > Go to step 2.
2. INSPECT SPEAKER

(c) Check if the speaker is around by obstacles.
(d) Check if the speaker cone accumulates dust.
(e) Check the speaker cone for damage.
(f) Measure the resistance between the front speaker pin 1

and pin 2.
Standard resistance

M003 (1) - M003 (2)
4Ω
N005 (1) - N005 (2)
(g) Measure the resistance between the rear speaker pin 1

and pin 2.
Standard resistance

G002 (1) - G002 (2)
4Ω
H001 (1) - H001 (2)

YES > Go to step 3.
NO > Clean the obstacles, dust or replace the speaker if necessary.
3. COMPARE IT WITH ANOTHER CAR OF SAME MODEL
(a) Set “BAS”, “TRE”, “BAL” to the initial value.

(b) Compare it with another car of same model. 04
Is the sound quality from speaker same?
YES > Check end.
NO > Replace the CD/DVD radio unit.
04
VOLUME IS TOO LOW IN ALL MODES

WIRING DIAGRAM

(d) Set “BAL” value as “0”.
Is the speaker volume normal?
NO > Go to step 2.
2. INSPECT SPEAKER

(c) Check the speaker cone for damage.
(d) Measure the resistance between the front speakers pin 1

and pin 2.
Standard resistance
04
M003 (1) - M003 (2)
4Ω
N005 (1) - N005 (2)
04
(e) Measure the resistance between the rear speakers pin 1
and pin 2.
Standard resistance

G002 (1) - G002 (2)
4Ω
H001 (1) - H001 (2)

YES > Go to step 3.
NO > Replace the speaker.


table below.
C031 (5) - N005 (1)

＜2Ω
C031 (6) - N005 (2)

table below.
C031 (3) - M003 (1)

＜2Ω
C031 (4) - M003 (2)

table below.
C031 (1) - G002 (1)

＜2Ω
C031 (2) - G002 (2)

table below.
C031 (7) - H001 (1)

＜2Ω
C031 (8) - H001 (2)

YES > Go to step 4.
4. COMPARE IT WITH ANOTHER CAR OF SAME MODEL
(a) Set “BAS”, “TRE”, “BAL” to the initial value.

(b) Compare it with another car of same model. 04
Is the speaker volume same?
YES > Check end.
04
SOUND QUALITY IS POOR ONLY WHEN PLAYING CD/DVD

1. CHECK CD/DVD SOURCE FILE
(a) Change a known original disc to play.

YES > Replace the disc.
NO > Go to step 2.
2. CHECK RADIO UNIT SETTING

(d) Set “BAS”, “TRE”, “BAL” to the initial value.
(e) Pressing and holding “ VOL ” button 2 seconds will open “LOUDNESS” function.
RADIO BROADCASTING SIGNAL CAN NOT BE RECEIVED. (POOR

RECEPTION)
INSPECTION PROCEDURE 04

(d) Repeatedly pressing “BAND” button, choose “FM1” band. (For vehicles equipped with CD player) 04
(e) Repeatedly pressing “AM / FM” button, choose “FM1” band. (For vehicles equipped with DVD player)
(f) Shortly pressing “ ︽ ” or “ ︾ ” to button at right side, seek the radio signal up / down automatically.
Is the function of auto searching radio channel normal?
NO > Go to step 2.
2. INSPECT ANTENNA
(a) Check if the antenna is pulled out and pulled out to end. (For vehicles equipped with rod antenna)
(b) Check if the antenna is bended or deformation. (For vehicles equipped with rod antenna)
(c) Check if the antenna is covered with obstacles.
(d) Check if the antenna wiring is breakage or disconnection. (For vehicles equipped with glass antenna)
NOTE
For glass antenna, if the rear windshield pastes the protective film, it will interfere with receiving sig-
nals.
YES > Go to step 3.
NO > Replace the antenna.
3. CHECK RADIO UNIT
(b) Pull out the antenna connector.


(d) Press the radio unit power button (PWR).
(e) Adjust the volume level above 5 VOL.
(f) Repeatedly pressing “BAND” button, choose “FM1” band.
(For vehicles equipped with CD player)
(g) Repeatedly pressing “AM / FM” button, choose “FM1”
band. (For vehicles equipped with DVD player)
(h) Place a flat–head screwdriver or a metal such as a thin
wire on the antenna jack of the radio receiver assembly
and check the noise heard from the speaker.
Does the radio unit receive the radio broadcasting signal?

YES > For vehicles equipped with rod antenna, replace the rod antenna.
For vehicles equipped with glass antenna, go to step 4.
4. CHECK ANTENNA
(b) Connect the antenna connector.

(c) Disconnect the glass antenna No. 1 connector.

(e) Press the radio unit power button (PWR).
(f) Adjust the volume level above 5 VOL. 04
(g) Repeatedly pressing “BAND” button, choose “FM1”
band. (For vehicles equipped with CD player)
(h) Repeatedly pressing “AM / FM” button, choose “FM1”
(i) Place a flat–head screwdriver or a metal such as a thin
wire on the No. 1 antenna jack of the radio receiver
04
assembly and check the noise heard from the speaker.

YES > Go to step 5.
NO > Replace the No.1 glass antenna cable.
5. INSPECT NO. 2 GLASS ANTENNA CABLE
(b) Connect the glass antenna No. 1 connector.

(c) Disconnect the glass antenna No. 2 connector. (Black)

(f) Adjust the volume level above 5 VOL.
(g) Repeatedly pressing “BAND” button, choose “FM1”
(h) Repeatedly pressing “AM / FM” button, choose “FM1”
(i) Place a flat–head screwdriver or a metal such as a thin
wire on the No. 2 antenna jack of the radio receiver
assembly and check the noise heard from the speaker.

YES > Go to step 6.
NO > Replace the No. 2 glass antenna cable.
6. INSPECT ANTENNA AMPLIFIER ASSY
(b) Connect the glass antenna No. 2 connector. (Black)

(c) Disconnect the antenna amplifier F006 connector.

(f) Repeatedly pressing “BAND” button, choose “FM1” 04
(g) Repeatedly pressing “AM / FM” button, choose “FM1”
04
(h) Measure the voltage according to the value(s) in the

table below.
Standard voltage
F006 (2) - Ground 10 ~ 11 V

YES > Go to step 9.
NO > Go to step 7.
7. INSPECT RADIO UNIT OUTPUT SIGNALS

table below.
Standard voltage
C032 (5) - Ground 10 ~ 11 V

NO > Go to step 8.
8. CHECK RADIO UNIT SIGNAL CIRCUITS

(b) Disconnect the radio unit connector.

table below.
C032 (5) - Ground ≥ 1 MΩ

9. INSPECT REAR DEFROST CIRCUITS

table below.
Standard voltage
F006 (3) - Ground 0V

10. INSPECT REAR DEFROST CIRCUITS

(b) Connect the antenna amplifier F006 connector. 04
(d) Operate the rear defrost function.
04

table below.
Standard voltage
F006 (3) - Ground 10 ~ 11 V

table below..
Standard voltage
F006 (4) - Ground Battery Voltage

YES > IIf turn rear window defogger switch on,it does not receive the radio broadcasting signal, Go to step 11.
If the radio broadcasting signals are obvious, replace the antenna amplifier assy.
NO > If only between the antenna amplifier connector F006, pin 3 and ground battery voltage is abnormally,
replace the antenna amplifier assy.
If only between the antenna amplifier connector F006, pin 4 and ground battery voltage is abnormally,
inspect and repair the the rear defrost circuits.
11. CHECK ANTENNA AMPLIFIER
(b) Disconnect the glass antenna No. 3 connector. (Red)

(f) Repeatedly pressing “BAND” button, choose “FM1” band. (For vehicles equipped with CD player)
(g) Repeatedly pressing “AM / FM” button, choose “FM1” band. (For vehicles equipped with DVD player)
(h) Place a flat–head screwdriver or a metal such as a thin wire on the No. 3 antenna jack of the radio
receiver assembly and check the noise heard from the speaker.
Does the radio unit receive the radio broadcasting signal normally?
NO > Replace the antenna amplifier assy. (Refer to “Chapter 66 audio system - antenna amplifier assy,
replacement”)
12. CHECK No. 3 GLASS ANTENNA CABLE
(b) Disconnect the rear windshield glass antenna connector. 04
04

(f) Repeatedly pressing “BAND” button, choose “FM1” band. (For vehicles equipped with CD player)
(g) Repeatedly pressing “AM / FM” button, choose “FM1” band. (For vehicles equipped with DVD player)
(h) Place a metal such as a thin wire on the No. 3 antenna jack of the radio receiver assembly and check
the noise heard from the speaker.
YES > Replace the rear windshield. (Refer to “Chapter 82 windsheild - rear window glass, replacement”)
NO > Replace the No. 3 glass antenna cable.
CD/DVD CAN NOT BE INSERTED OR CD/DVD IS EJECTED RIGHT

NOW AFTER BEING INSERTED
1. INSPECT DISC
(a) Check if CD disc is damaged, scratched, dirty or corrosion etc.

NOTE
• Translucent or unique model of CD/DVD disc can not be played.
• The disc with pasting label can not be played.
• Business audio or video disc can be played.
• Concerning the CD/DVD player detailed information, please refer to“Audio system
instructions”
YES > Go to step 2.
NO > Replace and use appropriate CD/DVD disc.
2. CHECK IF DISC IS INSERTED CORRECTLY
(a) Check if the disc is placed upside down.

YES > Go to step 3.
NO > Please insert CD/DVD disc correctly. (Refer to “Audio system instructions”)
3. INSPECT DISC
(a) Check if the disc is dirty.
(b) If the disc gets dirty, clean the disc by wiping the surface
from the center to outside in the radio directions with a
soft cloth.
NOTE
Do not use a conventional record cleaner or anti-static pre-
servative.
(c) Insert the disc.

Does the radio unit play disc normally?
YES > Use clean disc.
NO > Go to step 4.
4. CHECK CD/DVD DISC SOURCE FILE

Does the radio unit play disc normally? 04
YES > Use The original CD/DVD disc.
NO > Go to step 5.
5. INSPECT RADIO UNIT
(a) Check if there is any obstacles in the player. 04

(b) Check if there is disc in the player.
(c) The player is always in loading state because of misoperation. You need to press the ejection button to
reload the deck.
YES > Replace the radio unit.
NO > Take out the disc, reset the radio unit.
If there is obstacle, please send it to authorized dealer to service.
CD/DVD SOUND SKIPS

NOTE
It is normal that radio unit sometimes will cause sound skipping when the vehicle is driving on the
bumpy roads.
1. CHECK DISC
(a) Ensure CD/DVD disc is no deformation, dirt and scratches.
(b) If the disc gets dirty, clean the disc by wiping the surface
from the center to outside in the radio directions with a
soft cloth.
NOTE
Do not use a conventional record cleaner or anti-static pre-
servative.
(c) Insert the disc.

YES > Use clean disc.
NO > Go to step 2.
2. CHECK CD/DVD DISC SOURCE FILE

YES > Please use the original CD/DVD disc.
NO > Go to step 3.
3. INSPECT RADIO UNIT
(a) Check if the radio unit is installed correctly.

(b) Check retaining screws on radio unit within specified value.
(c) Ensure the radio unit is away from the dust.
NO > Reinstall the radio unit and away from the dust.
DIAGNOSTICS - LIGHTING SYSTEM 04-601
LIGHTING SYSTEM
PRECAUTION
1. PRECAUTION FOR USING BATTERY DURING INSPECTION. 04
(a) While using the battery during inspection, do not bring the positive and negative tester probes too close
to each other as a short circuit may occur.
2. PRECAUTION FOR HEADLIGHT BULB REPLACEMENT.
(a) If even a thin film of oil is left on the surface of the halogen light, the bulb may be damaged because the
light will burn at a higher temperature.
(b) Handle any halogen light with great care. Dropping, hitting or damaging the bulb, in any way, may result 04
in exploding and shattering because the internal pressure is high.
(c) Always prepare a new bulb for immediate replacement. While replacing the bulb, the lens may attract
dust and moisture if removed from the vehicle for too long.
(d) Always use a bulb of the same wattage for replacement.
(e) Firmly reinstall the socket after bulb replacement. The lens may become cloudy or the light cavity may
fill with water through the gaps around the socket.
3. EXPRESSIONS OF IGNITION SWITCH.61


Expression

04-602 DIAGNOSTICS - LIGHTING SYSTEM
BASIC INSPECTION
Yes Go to next step
replacement”
Check the LO-beam lamps. Yes Go to next step

2
• Check the LO-beam lamps. No Go to problem symptoms table
Check the HI-beam lamps. Yes Go to next step

3
• Check the HI-beam lamps. No Go to problem symptoms table
Check the "Flash" lamps. Yes Go to next step

4
• Check the "Flash" lamps. No Go to problem symptoms table
Check the turn signal lamps. Yes Go to next step

5
• Check the turn signal lamps. No Go to problem symptoms table
Check the hazard lamps. Yes Go to next step

6
• Check the hazard lamps. No Go to problem symptoms table
Check the Indoor Lamps. Yes Check harness and connector

7
• Check the Indoor Lamps. No Go to problem symptoms table
LOCATION
04
04
1 Front Combination Lamp Assy RH 8 Front Fog Lamp Assy RH
2 Front Indoor Lamp Assy 9 Rear Combination Lamp Assy LH
3 Indoor Roof Lamp 10 High-mounted Stop Lamp Assy
4 Rear Indoor Lamp Assy 11 Rear Combination Lamp Assy RH
5 Step Lamp Assy 12 Rear Fog Lamp Assy RH
6 Front Combination Lamp Assy LH 13 Rear Fog Lamp Assy LH
7 Front Fog Lamp Assy LH 14 License Plate Lamp Assy


1. Headlamp 04

Chapter 64 lighting - front combination lamp bulb LH,
LO-beam headlamp is inop- 1. Bulb replacement
erative (One side)
-
2. Wire harness 04
1. Bulb replacement
2. Relay -
LO-beam headlamps are
inoperative (Both sides) -
3. Wire harness
4. Combination switch Chapter 51 steering column - combination switch assy,

(light control) replacement

HI-beam headlamp is inoper- 1. Bulb replacement
ative (One side)
2. Wire harness -
1. Relay -
HI-beam headlamps are 2. Combination switch Chapter 51 steering column - combination switch assy,
inoperative (Both sides) (light control) replacement
3. Wire harness -

LO-beam and HI-beam
headlamps are inoperative Chapter 64 lighting - front combination lamp bulb LH,
(One side) 2. Bulb replacement
3. Wire harness -
1. Relay -
LO-beam and HI-beam Chapter 51 steering column - combination switch assy,
headlamps are inoperative 2. Combination switch
(Both sides)
3. Wire harness -
2. Fog lamp

Chapter 64 lighting - front fog lamp bulb LH,
1. Bulb replacement
Front fog lamp is inoperative Chapter 51 steering column - combination switch assy,
2. Combination switch
(One side) replacement
(light control)
3. Wire harness -
1. Fuse -
2. Relay -
Front fog lamps are inopera-
tive (Both sides) 3. Combination switch Chapter 51 steering column - combination switch assy,
4. Wire harness -

Front fog lamps are always -
on 2. Front fog lamp
relay
3. Wire harness -
Chapter 64 lighting - rear combination lamp bulb LH,

1. Bulb replacement
Rear fog lamp is inoperative Chapter 51 steering column - combination switch assy,
(One side) replacement
(light control)
3. Wire harness -

1. Bulb replacement
2. Rear fog lamp Chapter 64 lighting - rear fog lamp switch, replacement
Rear fog lamps are inopera- switch
tive (Both sides)
3. Multi-function -
controller (3-in-1)
4. Wire harness -
1. Rear fog lamp Chapter 64 lighting - rear fog lamp switch, replacement
switch
Rear fog lamps are always -
on 2. Multi-function
controller (3-in-1)
3. Wire harness -
3. Turn signal and hazard warning lamp
1. Fuse - 04
Chapter 83 instrument panel - instrument cluster,
Hazard warning lamps are 2. Hazard switch replacement
inoperative (Turn signal
lamps are normal) 3. Multi-function -
controller (3-in-1)
4. Wire harness - 04
1. Fuse -

Turn signal lamps are (light control) replacement
inoperative (Hazard warning
lamps are normal) 3. Multi-function -
controller (3-in-1)
4. Wire harness -
1. Multi-function -
controller (3-in-1)
Hazard warning and turn Chapter 51 steering column - combination switch assy,
signal lamps are inoperative 2. Combination switch
3. Wire harness -

Turn signal lamp is -
inoperative (One side) 2. Multi-function
controller (3-in-1)
3. Wire harness -
1. Multi-function -
controller (3-in-1)

Hazard warning lamps are 2. Hazard switch replacement
always on
4. Wire harness -
4. Stop lamp
1. Fuse -
Stop lamps are inoperative Chapter 35 brake - brake pedal, replacement
(Both sides) 2. Stop lamp switch
3. Wire harness -

Stop lamp is inoperative 1. Bulb replacement
(One side)
2. Wire harness -
Chapter 88 exterior and interior trim - spoiler assy,

High-mounted stop lamp is 1. Bulb replacement
inoperative
2. Wire harness -
5. Buck-up lamp

Chapter 64 lighting - rear combination
1. Bulb lamp bulb LH, replacement
Back-up lamp is inoperative (One side)
2. Wire harness -
1. Fuse -
Chapter 41 transmission - input shaft and

2. Back-up lamp switch reverse idler gear shaft, replacement
Back-up lamps are inoperative (Both
sides) Chapter 64 lighting - rear combination
3. Bulb lamp bulb LH, replacement
4. Wire harness -
6. Indoor lamp

Chapter 64 lighting - front indoor lamp assy,
1. Bulb replacement
Front indoor lamp is inoperative 2. Front indoor lamp Chapter 64 lighting - front indoor lamp assy,
switch replacement
3. Wire harness -
Chapter 64 lighting - rear indoor lamp assy,

1. Bulb replacement
Rear indoor lamp is inoperative 2. Rear indoor lamp Chapter 64 lighting - rear indoor lamp assy,
switch replacement
3. Wire harness -
1. Front door ajar Chapter 64 lighting - Sliding door step lamp,

switch replacement
Sliding door step lamps are
Chapter 64 lighting - Sliding door step lamp,
inoperative 2. Bulb replacement
3. Wire harness -
1. Bulb -
2. Front door ajar Chapter 64 lighting - Sliding door step lamp, 04

Cargo lamp is inoperative replacement
switch
3. Wire harness -
7. Indoor illumination system
Symptom Suspect Area Reference 04

Instrument cluster 1. Instrument cluster replacement
illumination is inoperative
2. Wire harness -
1. Electronic clock Chapter 83 instrument panel - dashboard, replacement

Electronic clock illumination
is inoperative
2. Wire harness -
1. Hazard switch Chapter 83 instrument panel - dashboard, replacement

Hazard switch illumination is
inoperative
2. Wire harness -
1. 12V power point Chapter 83 instrument panel - dashboard, replacement

12V power point socket socket
2. Wire harness -
1. Cigarette lighter Chapter 83 instrument panel - dashboard, replacement

Cigarette lighter illumination
is inoperative
2. Wire harness -
1. Front A/C controller Chapter 83 instrument panel - dashboard, replacement

Front A/C controller
2. Wire harness -
1. Audio Chapter 83 instrument panel - dashboard, replacement

Audio illumination is
inoperative
2. Wire harness -
1. Rear fog lamp Chapter 83 instrument panel - dashboard, replacement

Rear fog lamp switch switch
2. Wire harness -
1. Rear outside mir- Chapter 83 instrument panel - dashboard, replacement

Outside mirror defrost switch ror defrost switch
2. Wire harness -
1. Combined display Chapter 83 instrument panel - dashboard, replacement

Combined display
2. Wire harness -
1. Rear window Chapter 83 instrument panel - dashboard, replacement

Rear window defrost switch defrost switch
2. Wire harness -
Rear heater switch (front 1. Rear heater switch Chapter 83 instrument panel - dashboard, replacement
control) illumination is (front control)
inoperative
2. Wire harness -
Rear heater switch (rear 1. Rear heater switch Chapter 83 instrument panel - dashboard, replacement
control) illumination is (rear control)
inoperative
2. Wire harness -
1. Rear heater control Chapter 83 instrument panel - dashboard, replacement

Rear heater control panel panel
2. Wire harness -
Rear A/C switch (front 1. Rear A/C switch Chapter 83 instrument panel - dashboard, replacement
control) illumination is (front control)
inoperative
2. Wire harness -
8. Parking lamp, tail lamp and license lamp

Front parking lamps are inop- 1. Bulb replacement
erative
2. Wire harness -

1. Bulb replacement
Tail lamps are inoperative
2. Wire harness -
1. Fuse -
2. Relay -
License lamp is inoperative Chapter 51 steering column - combination switch assy,
4. Wire harness -
1. Fuse -
2. Relay -
Parking lamps, tail lamps and
license lamp are inoperative 3. Combination switch Chapter 51 steering column - combination switch assy,
4. Wire harness -
LO-BEAM HEADLAMP IS INOPERATIVE (ONE SIDE)

WIRING DIAGRAM
04
04
1. INSPECT FUSE
(b) Inspect the fuse in body junction box: F11 (15 A).

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (FRONT COMBINATION LAMP LH - GROUND)

(b) Disconnect the A007 front combination lamp LH connector.

table below.

A007 (5) - Ground ≥ 1 ΜΩ

3. INSPECT COMBINATION SWITCH (LIGHT CONTROL)

(b) Disconnect the C040 combination switch (light control) connector. 04
(c) Inspect the combination switch (light control).
Standard resistance

04
Turn the combina-
16 - 17 ≥ 1 MΩ
tion switch OFF
Turn the combina-

16 - 17 ＜2Ω
tion switch ON

NO > Replace the combination switch (light control).
4. CHECK HARNESS AND CONNECTOR (FRONT COMBINATION LAMP FUSE - FRONT
COMBINATION LAMP)


table below.

F11 (15 A) - A007 (5) ＜2Ω

5. CHECK HARNESS AND CONNECTOR (FRONT COMBINATION LAMP - GROUND)

(c) Disconnect the C040 combination switch (light control) connector.

table below.

A007 (3) - C040 (17) ＜2Ω

YES > Replace the front combination lamp LH bulb.
LO-BEAM HEADLAMPS ARE INOPERATIVE (BOTH SIDES)

WIRING DIAGRAM
04
04
1. INSPECT FUSE
(b) Inspect the fuses in body junction box: F11 (15 A), F12
(15 A).

YES > Go to step 3.

(c) Disconnect the A013 front combination lamp RH connector.

table below.

A007 (5) - Ground
≥ 1 ΜΩ
A013 (5) - Ground


Standard resistance

04
Turn the combination
16 - 17 ≥ 1 MΩ
switch OFF

16 - 17 ＜2Ω
switch ON


(b) Disconnect the C040 combination switch (light control) connector.
(c) Disconnect the A007 front combination lamp LH connector.
(d) Disconnect the A013 front combination lamp RH connector.

table below.

A007 (3) - C040 (17)
＜2Ω
A013 (3) - C040 (17)

YES > Replace the front combination lamp bulb.
HI-BEAM HEADLAMP IS INOPERATIVE (ONE SIDE)

WIRING DIAGRAM
1. INSPECT FUSE
04

YES > Go to step 3.


table below.

A007 (5) - Ground ≥ 1 ΜΩ



Standard resistance
Tester Specified
Condition
16 - 17 ≥ 1 MΩ
switch OFF

16 - 17 ＜2Ω
switch ON

COMBINATION LAMP LH)


table below.

F11 (15 A) - A007 (5) ＜2Ω

5. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - FRONT COMBINATION LAMP

LH)


table below.
04
A007 (2) - C040 (7) ＜2Ω

YES > Replace the front combination lamp LH bulb.
HI-BEAM HEADLAMPS ARE INOPERATIVE (BOTH SIDES)

WIRING DIAGRAM
1. INSPECT FUSE
(b) Inspect the fuses in body junction box: F11 (15 A), F12
(15 A).
04

YES > Go to step 3.


table below.

A007 (5) - Ground
≥ 1 MΩ
A013 (5) - Ground



Standard resistance
Tester Specified
Condition
16 - 7 ≥ 1 MΩ
switch OFF

16 - 7 ＜2Ω
switch ON

4. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - FRONT COMBINATION LAMP)

(d) Disconnect the A013 front combination lamp RH connector.

table below.

A007 (2) - C040 (7)
＜2Ω
A013 (2) - C040 (7)

YES > Replace the front combination lamp bulb.
LO-BEAM AND HI-BEAM HEADLAMPS ARE INOPERATIVE (ONE

SIDE)
WIRING DIAGRAM 04
04
1. INSPECT FUSE

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (FRONT COMBINATION LAMP LH - GROUND)


table below.

A007 (5) - Ground ≥ 1 ΜΩ


COMBINATION LAMP LH)


table below.

F11 (15 A) - A007 (5) ＜2Ω

YES > Replace the front combination lamp bulb LH.
LO-BEAM AND HI-BEAM HEADLAMPS ARE INOPERATIVE (BOTH

SIDES)
WIRING DIAGRAM
1. INSPECT FUSE
(c) Inspect the fuses in body junction box: F11(15 A), F12
(15 A).
04

YES > Go to step 4.
NO > If the fuse FL3(50 A) is blown, go to next step.
If the fuse F11(15 A) or F12 (15 A) is blown, go to step 3.
2. CHECK HARNESS AND CONNECTOR (HEADLAMP RELAY - GROUND)

(b) Remove the headlamp relay R3.

table below.

R3 (1) - Ground
≥ 1 ΜΩ
R3 (5) - Ground



table below.

A007 (5) - Ground
≥ 1 ΜΩ
A013 (5) - Ground

4. INSPECT HEADLAMP RELAY

(c) Inspect headlamp relay R3.

Standard resistance

1–2 Continuity
＜2Ω
terminal 1 and 2)

NO > Replace the headlamp relay R3.
5. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - HEADLAMP RELAY)

(b) Remove the headlamp relay R3. 04

table below.

R3 (2) - C040 (13)
＜2Ω
R3 (2) - C040 (8)

6. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - GROUND)


table below.

C040 (16) - Ground ＜2Ω

7. CHECK HARNESS AND CONNECTOR (HEADLAMP RELAY - FRONT COMBINATION LAMP FUSE)


table below.

R3 (3) - F11 (15 A)
＜2Ω
R3 (3) - F12 (15 A)

COMBINATION LAMP)


table below.

A007 (5) - F11 (15 A)
＜2Ω
A013 (5) - F12 (15 A)

YES > Replace the combination switch.
FRONT FOG LAMP IS INOPERATIVE (ONE SIDE)

WIRING DIAGRAM
04
04
1. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP LH - GROUND)

(b) Disconnect the A004 front fog lamp LH connector.

table below.

A004 (2) - Ground ＜2Ω

2. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP RELAY - FRONT FOG LAMP)

(b) Remove the front fog lamp relay R7.
(c) Disconnect the A004 front fog lamp LH connector.

table below.

R7 (3) - A004 (1) ＜2Ω

YES > Replace the front fog lamp bulb.
FRONT FOG LAMPS ARE INOPERATIVE (BOTH SIDES)

WIRING DIAGRAM
04
04
1. INSPECT FUSE
(b) Inspect the fuse in engine room junction box: F22 (20 A).

2. INSPECT FRONT FOG LAMP RELAY

(c) Inspect front fog lamp relay R7.

Standard resistance

1–2 Continuity
＜2Ω
terminal 1 and 2)

NO > Replace the front fog lamp relay.

Standard resistance
Tester Specified
Condition
04
Turn the front fog lamp 14 - 16
switch OFF ≥ 1 MΩ
11 - 10

switch ON ＜2Ω
11 - 10



table below.

C040 (16) - Ground
＜2Ω
C040 (10) - Ground

5. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - PARKING LAMP RELAY)

(b) Remove the parking lamp relay R4.

table below.

R4 (1) - C040 (14) ＜2Ω

6. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - FRONT FOG LAMP RELAY)


table below.

R7 (1) - C040 (11) ＜2Ω

7. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP RELAY - FRONT FOG LAMP)

(b) Remove the front fog lamp relay R7. 04
(c) Disconnect the A004 front fog lamp LH connector.
(d) Disconnect the A011 front fog lamp RH connector.

table below.
04
R7 (3) - A004 (1)
＜2Ω
R7 (3) - A011 (1)

YES > Replace the front fog lamp.
FRONT FOG LAMPS ARE ALWAYS ON

WIRING DIAGRAM
1. INSPECT FRONT FOG LAMP RELAY
(b) Inspect front fog lamp relay R7.

Standard resistance

1–2 Continuity 04
＜2Ω
terminal 1 and 2)

YES > Go to step 2.
NO > Replace the front fog lamp relay.

(e) Turn the front fog lamp switch ON.

table below.
Standard voltage

C040 (11) - Ground 0V

3. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP - GROUND)

(d) Turn the front fog lamp switch ON.

table below.
Standard voltage

A011 (1) - Ground 0V

YES > Replace the combination switch (light control).
REAR FOG LAMP IS INOPERATIVE (ONE SIDE)

WIRING DIAGRAM
04
04
1. CHECK HARNESS AND CONNECTOR (REAR FOG LAMP - GROUND)

(b) Disconnect the D002 rear fog lamp LH connector.

table below.

D002 (2) - Ground ＜2Ω

2. CHECK HARNESS AND CONNECTOR (MULTI-FUNCTION CONTROLLER - REAR FOG LAMP)


table below.

C003 (2) - D002 (1) ＜2Ω

YES > Replace the rear fog lamp bulb.
REAR FOG LAMPS ARE INOPERATIVE (BOTH SIDES)

WIRING DIAGRAM
04
04
1. INSPECT FUSE
(b) Inspect the fuse in engine room junction box: F23 (15A).
(c) Inspect the fuse in body junction box: F19 (7.5A).

YES > Go to step 4.
NO > If the fuse F19 (7.5 A) is blown, go to next step.
2. CHECK HARNESS AND CONNECTOR (REAR FOG LAMP SWITCH - GROUND)

(b) Disconnect the C001 rear fog lamp switch connector.

table below.

C001 (5) - Ground ≥ 1 ΜΩ


table below.

04
C003 (1) - Ground ≥ 1 ΜΩ

4. INSPECT REAR FOG LAMP SWITCH

(b) Remove the rear fog lamp switch.
(c) Inspect the rear fog lamp switch.

Standard resistance
Tester Specified
Condition
Turn the rear fog lamp
3-6 ≥ 1 MΩ
switch OFF

3-6 ＜2Ω
switch ON

NO > Replace the rear fog lamp switch.


Standard resistance
Tester Specified
Condition
Turn the parking lamp
14 - 16 ≥ 1 MΩ
switch OFF
Turn the parking lamp

14 - 16 ＜2Ω
switch ON
Turn the headlamp switch

16 - 13 ≥ 1 MΩ
OFF
Turn the headlamp switch

16 - 13 ＜2Ω
ON

11 - 10

switch ON ＜2Ω
14 - 16

6. CHECK HARNESS AND CONNECTOR (FUSE - REAR FOG LAMP SWITCH )

table below.

F19 (7.5 A) - C001 (5) ＜2Ω

04
7. CHECK HARNESS AND CONNECTOR (MULTI-FUNCTION CONTROLLER - FUSE )

table below.
04

F23 (15 A) - C003 (1) ＜2Ω

8. CHECK HARNESS AND CONNECTOR (MULTI-FUNCTION CONTROLLER - REAR FOG LAMP
SWITCH )

(d) Disconnect the C001 rear fog lamp switch connector.

table below.

C001 (5) - C003 (8)
＜2Ω
C001 (6) - C003 (3)

9. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - MULTI-FUNCTION

CONTROLLER)


table below.

C003 (7) - C040 (11)
＜2Ω
C003 (6) - C040 (13)


(b) Disconnect the D002 rear fog lamp LH connector.
(c) Disconnect the D005 rear fog lamp RH connector.

table below.

D002 (2) - Ground
＜2Ω
D005 (2) - Ground

11. CHECK HARNESS AND CONNECTOR (MULTI-FUNCTION CONTROLLER - REAR FOG LAMP)

(c) Disconnect the D002 rear fog lamp LH connector.
(d) Disconnect the D005 rear fog lamp RH connector.

table below.
04
C003 (2) - D002 (1)
＜2Ω
C003 (2) - D005 (1)
04
YES > Replace the multi-function controller (3-in-1).
REAR FOG LAMPS ARE ALWAYS ON

WIRING DIAGRAM
1. INSPECT REAR FOG LAMP SWITCH

(b) Remove the rear fog lamp switch.
(c) Inspect the rear fog lamp switch.

Standard resistance
Tester Specified
Condition
3-6 ≥ 1 MΩ
switch OFF

3-6 ＜2Ω
switch ON

NO > Replace the rear fog lamp switch.
04

(c) Disconnect the D002 rear fog lamp LH connector.
(d) Disconnect the D005 rear fog lamp RH connector. 04
(e) Connect the battery negative cable.
(f) Turn the rear fog lamp switch ON.
(g) Measure the voltage according to the value(s) in the

table below.
Standard voltage

D002 (1) - Ground
0V
D005 (1) - Ground

HAZARD WARNING LAMPS ARE INOPERATIVE (TURN SIGNAL

LAMPS ARE NORMAL)
WIRING DIAGRAM
1. INSPECT FUSE
(b) Inspect the fuses in engine room junction box: F23 (15
A), F25(15 A).
04

YES > Go to step 4.
NO > If the fuse F23 (15 A) is blown, go to next step.


table below.

C003 (1) - Ground ≥ 1 ΜΩ

3. CHECK HARNESS AND CONNECTOR (HAZARD SWITCH - GROUND)

(b) Disconnect the C034 hazard switch connector.

table below.

C034 (8) - Ground ≥ 1 ΜΩ

4. INSPECT HAZARD SWITCH

(c) Inspect the hazard switch.

Standard resistance
Tester Specified
Condition
Turn the hazard
7 - 10
switch OFF
7-8 ＜2Ω
Turn the hazard
switch ON 5-6-9

NO > Replace the hazard switch.
5. CHECK HARNESS AND CONNECTOR (MULTI-FUNCTION CONTROLLER - FUSE )

table below.

04
F23 (15 A) - C003 (1) ＜2Ω

6. CHECK HARNESS AND CONNECTOR (MULTI-FUNCTION CONTROLLER - HAZARD SWITCH)

(d) Disconnect the C002 multi-function controller (3-in-1) connector.

table below.

C002 (12) - C034 (9) ＜2Ω

TURN SIGNAL LAMPS ARE INOPERATIVE (HAZARD WARNING

LAMPS ARE NORMAL)
WIRING DIAGRAM
1. INSPECT FUSE
04

YES > Go to step 3.


table below.

C034 (10) - Ground ≥ 1 ΜΩ



Standard resistance
Tester Specified
Condition
Turn hazard switch
7 - 10 ＜2Ω
OFF
7 - 10 ≥ 1 ΜΩ
Turn hazard switch
ON 5-6-9
＜2Ω
7-8



Standard resistance
Tester Specified
Condition
Turn the combination 2-1

switch (light control) OFF ≥ 1 MΩ
2-3

switch (light control) LH 2-1
ON
＜2Ω
switch (light control) RH 2-3
ON

5. CHECK HARNESS AND CONNECTOR (MULTI-FUNCTION CONTROLLER - COMBINATION

SWITCH )


table below.
04
C002 (12) - C040 (2) ＜2Ω

6. CHECK HARNESS AND CONNECTOR (MULTI-FUNCTION CONTROLLER - HAZARD SWITCH)

(c) Disconnect the C034 hazard switch connector.

table below.

C034 (7) - C002 (9) ＜2Ω

HAZARD WARNING AND TURN SIGNAL LAMPS ARE INOPERATIVE

WIRING DIAGRAM
1. INSPECT FUSE

(c) Inspect the fuses in engine room junction box: F25 (15
A), F23 (15 A).
04

YES > Go to step 5.
NO > If the fuse F5(10 A) is blown, go to next step.
If the fuse F25(15 A) is blown, go to step 3.


table below.

C034 (10) - Ground ≥ 1 ΜΩ



table below.

C034 (8) - Ground ≥ 1 ΜΩ



table below.

C003 (1) - Ground ≥ 1 ΜΩ



table below.
04
C002 (11) - Ground ＜2Ω
04


Standard resistance
Tester Specified
Condition
Turn the hazard
7 - 10
switch OFF
7-8 ＜2Ω
Turn the hazard
switch ON 5-6-9

7. CHECK HARNESS AND CONNECTOR (MULTI-FUNCTION CONTROLLER - FUSE)


table below.

F23 (15 A) - C003 (1) ＜2Ω

8. CHECK HARNESS AND CONNECTOR (MULTI-FUNCTION CONTROLLER - HAZARD SWITCH )


table below.

C034 (7) - C002 (9) ＜2Ω

9. CHECK HARNESS AND CONNECTOR (MULTI-FUNCTION CONTROLLER - COMBINATION

SWITCH)


table below.
04
C002 (12) - C034 (9)
＜2Ω
C002 (12) - C040 (2)

TURN SIGNAL LAMP IS INOPERATIVE (ONE SIDE)

WIRING DIAGRAM

Standard resistance
Tester Specified
Condition
Connection Condition 04
Turn the combination 2-1

switch (light control) OFF ≥ 1 MΩ
2-3

switch (light control) LH 2-1
ON
＜2Ω
switch (light control) RH 2-3
ON

2. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - FRONT COMBINATION LAMP)

(d) Disconnect the H005 rear combination lamp LH connector.
(e) Disconnect the N003 outside mirror LH connector.
table below.

C040 (1) - A006 (1)
C040 (1) - H005 (3) ＜2Ω

C040 (1) - N003 (7)

HAZARD WARNING LAMPS ARE ALWAYS ON

WIRING DIAGRAM


Standard resistance
Tester Specified 04
Condition
Turn the hazard
7 - 10
switch OFF
7-8 ＜2Ω
Turn the hazard
switch ON 5-6-9


(c) Disconnect the C034 hazard switch connector.

table below.
Standard voltage


STOP LAMPS ARE INOPERATIVE (BOTH SIDES) - WITH 4G63/4G64

ENGINE
WIRING DIAGRAM
1. INSPECT FUSE
(b) Inspect the fuse in engine room junction box: F27(15 A).

YES > Go to step 3.
04
2. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - GROUND)

(b) Disconnect the C004 stop lamp switch connector.

table below. 04

C004 (2) - Ground ≥ 1 ΜΩ

3. INSPECT STOP LAMP SWITCH

(b) Remove the stop lamp switch.
(c) Inspect the stop lamp switch.

Standard resistance
Tester Specified
Condition
Turn the stop lamp
1-2 ≥ 1 MΩ
switch OFF
Turn the stop lamp

1-2 ＜2Ω
switch ON

NO > Replace the stop lamp switch.
4. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH FUSE - STOP LAMP SWITCH)


table below.

F27 (15 A) - C004 (2) ＜2Ω

5. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - STOP LAMP)


table below.

C004 (1) - H005 (2)
C004 (1) - G005 (2) ＜2Ω

C004 (1) - I001 (2)

YES > Replace the stop lamp bulb.
STOP LAMP IS INOPERATIVE (ONE SIDE) - WITH 4G63/ 4G64

ENGINE
WIRING DIAGRAM 04
04
1. CHECK HARNESS AND CONNECTOR (REAR COMBINATION LAMP - GROUND)

(b) Disconnect the H005 rear combination lamp LH connector.

table below.

H005 (4) - Ground ＜2Ω

2. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - REAR COMBINATION LAMP )

(c) Disconnect the H005 rear combination lamp LH connector.

table below.

C004 (1) - H005 (2) ＜2Ω

YES > Replace the bulb.
HIGH-MOUNTED STOP LAMP IS INOPERATIVE - WITH 4G63/4G64

ENGINE
WIRING DIAGRAM 04
04
1. CHECK HARNESS AND CONNECTOR (HIGH-MOUNTED STOP LAMP - GROUND)

(b) Disconnect the I001 high-mounted stop lamp connector.

table below.

I001 (1) - Ground ＜2Ω

2. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - HIGH-MOUNTED STOP LAMP)

(c) Disconnect the I001 high-mounted stop lamp connector.

table below.

C004 (1) - I001 (2) ＜2Ω

STOP LAMPS ARE INOPERATIVE (BOTH SIDES) - WITH BJ493ZQ3

ENGINE
WIRING DIAGRAM 04
04
1. INSPECT FUSE

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - GROUND)


table below.

C051 (1) - Ground
≥ 1 ΜΩ
C051 (3) - Ground

3. INSPECT STOP LAMP SWITCH

(b) Remove the stop lamp switch. 04
(c) Inspect the stop lamp switch.
Standard resistance
Tester Specified
Condition
04
Turn the stop lamp 1-4
3-2
Turn the stop lamp 1-4

switch ON ＜2Ω
3-2

NO > Replace the stop lamp switch.
4. CHECK HARNESS AND CONNECTOR (FUSE - STOP LAMP SWITCH)


table below.

F20 (20 A) - C051 (1)
＜2Ω
F20 (20 A) - C051 (3)

5. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - STOP LAMP)

(b) Disconnect the C051 stop lamp connector.
(d) Disconnect the G005 rear combination lamp RH connector.
(e) Disconnect the I001 high-mounted stop lamp connector.

table below.

C051 (2) - H005 (2)
C051 (2) - G005 (2) ＜2Ω

C051 (2) - I001 (2)

STOP LAMP IS INOPERATIVE (ONE SIDE) - WITH BJ493ZQ3

ENGINE
WIRING DIAGRAM 04
04


table below.

H005 (4) - Ground ＜2Ω

2. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - REAR COMBINATION LAMP )

(c) Disconnect the C051 stop lamp switch connector.

table below.

H005 (2) - C051 (2) ＜2Ω

HIGH-MOUNTED STOP LAMP IS INOPERATIVE - WITH BJ493ZQ3

ENGINE
WIRING DIAGRAM 04
04
1. CHECK HARNESS AND CONNECTOR (HIGH-MOUNTED STOP LAMP - GROUND)

(b) Disconnect the I001 high-mounted stop lamp connector.

table below.

I001 (1) - Ground ＜2Ω

2. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - HIGH-MOUNTED STOP LAMP)

(c) Disconnect the I001 high-mounted stop lamp connector.

table below.

C051 (2) - I001 (2) ＜2Ω

BACK-UP LAMP IS INOPERATIVE (ONE SIDE) - WITH 4G63/4G64

ENGINE
WIRING DIAGRAM 04
04
1. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP - GROUND)


table below.

H005 (4) - Ground ＜2Ω

2. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP SWITCH - BACK-UP LAMP)

(b) Disconnect the E011 Back-up lamp switch connector.

table below.

H005 (5) - E011(1) ＜2Ω

BACK-UP LAMPS ARE INOPERATIVE (BOTH SIDES) - WITH 4G63/

4G64 ENGINE
WIRING DIAGRAM 04
04
1. INSPECT FUSE

YES > Go to step 3.


table below.
Specified
Tester Connection
Condition
E011 (2) - Ground ≥ 1 ΜΩ


(b) Remove the back-up lamp switch.

Standard resistance
Tester Specified
Condition
Turn the back-up
1-2 ≥ 1 MΩ
lamp switch OFF
Turn the back-up

1-2 ＜2Ω
lamp switch ON

4. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP SWITCH FUSE - BACK-UP LAMP
SWITCH)


table below.
04
Specified
Tester Connection
Condition
F1 (15 A) - E011 (2) ＜2Ω
04

5. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP SWITCH - REAR COMBINATION LAMP )


table below.

E011 (1) - H005 (5)
＜2Ω
E011 (1) - G005 (5)

BACK-UP LAMP IS INOPERATIVE (ONE SIDE) - WITH BJ493ZQ3

ENGINE
WIRING DIAGRAM


table below.

H005 (4) - Ground ＜2Ω


(b) Disconnect the K004 back-up lamp connector. 04

table below.

K004 (1) - H005 (5) ＜2Ω

BACK-UP LAMPS ARE INOPERATIVE (BOTH SIDES) - WITH

BJ493ZQ3 ENGINE
WIRING DIAGRAM
1. INSPECT FUSE

YES > Go to step 3.

(b) Disconnect the K004 back-up lamp connector. 04
table below.

04
K004 (2) - Ground ≥ 1 ΜΩ


(b) Remove the back-up lamp switch.

Standard resistance
Tester Specified
Condition
Turn the back-up lamp
1-2 ≥ 1 MΩ
switch OFF
Turn the back-up lamp

1-2 ＜2Ω
switch ON

4. CHECK HARNESS AND CONNECTOR ( BACK-UP LAMP SWITCH FUSE - BACK-UP LAMP
SWITCH)

(b) Disconnect the K004 back-up lamp connector.

table below.

F1 (15 A) - K004 (2) ＜2Ω


(b) Disconnect the K004 back-up lamp connector.

table below.

K004 (1) - H005 (5)
＜2Ω
K004 (1) - G005 (5)

FRONT INDOOR LAMP IS INOPERATIVE

WIRING DIAGRAM
04
04
1. INSPECT FRONT INDOOR LAMP

(b) Remove the front indoor lamp.
(c) Inspect the front indoor lamp.
Specified
Condition Action
Condition
Battery(+) → Press front indoor Front indoor lamp

terminal 1 lamp button switch LH illuminate
RH
Battery(-) → Press front indoor Front indoor lamp

termina 2 lamp button switch RH illuminate
LH

NO > Replace the front indoor lamp.
2. CHECK HARNESS AND CONNECTOR (FRONT INDOOR LAMP FUSE - FRONT INDOOR LAMP)

(b) Disconnect the F001 front indoor lamp connector.

table below.

F13 (10 A) - F001 (1) ＜2Ω

3. CHECK HARNESS AND CONNECTOR (FRONT INDOOR LAMP - FRONT DOOR AJAR SWITCH
RH)

(c) Disconnect the K002 front door ajar switch RH connector.

table below.

F001 (2) - K002 (1) ＜2Ω

YES > Replace the front door ajar switch RH.
4. CHECK HARNESS AND CONNECTOR (FRONT INDOOR LAMP - FRONT DOOR AJAR SWITCH
LH)

(c) Disconnect the L001 front door ajar switch LH connector.
(d) Disconnect the C012 diode connector.
(e) Connect a fused (5A) jumper wire between pin 1 and pin2 of diode connector.

table below.
04

F001 (2) - L001 (1) ＜2Ω

YES > Replace the front door ajar switch.
REAR INDOOR LAMP IS INOPERATIVE

WIRING DIAGRAM
1. INSPECT REAR INDOOR LAMP

(b) Remove the rear indoor lamp.
(c) Inspect the front indoor lamp.
Specified
Condition Action
Condition
04
Battery(+) → terminal 3 Turn the rear
indoor lamp
Battery(-) → terminal 1 switch ON Rear indoor
lamp LH illu-
Battery(+) → terminal 3 Turn the rear minate
indoor lamp
Battery(-) → terminal 2 switch AJAR

NO > Replace the rear indoor lamp.
2. CHECK HARNESS AND CONNECTOR (REAR INDOOR LAMP - GROUND)

(b) Disconnect the F004 rear indoor lamp connector.

table below.

F004 (1) - Ground ＜2Ω

3. CHECK HARNESS AND CONNECTOR (INDOOR LAMP FUSE - REAR INDOOR LAMP)


table below.

F13 (10 A) - F004 (3) ＜2Ω

4. CHECK HARNESS AND CONNECTOR (REAR INDOOR LAMP - FRONT DOOR AJAR SWITCH)

(c) Disconnect the G001 sliding door ajar switch RH connector.
(d) Disconnect the H001 sliding door ajar switch LH connector.

table below.

F004 (2) - G001 (1)
＜2Ω
F004 (2) - H001 (1)

YES > Replace the door ajar switch.
SLIDING DOOR STEP LAMPS ARE INOPERATIVE

WIRING DIAGRAM
04
04
1. INSPECT SLIDING DOOR STEP LAMP

(b) Disconnect the L003 sliding door step lamp LH connector.
(c) Replace the sliding door step lamp LH with a new one.
Does the sliding door step lamp work correctly?
YES > Replace the sliding door step lamp.
2. CHECK HARNESS AND CONNECTOR (INDOOR LAMP FUSE - SLIDING DOOR STEP LAMP)

(c) Disconnect the G007 sliding door step lamp RH connector.

table below.

F13 (10 A) - L003 (1)
＜2Ω
F13 (10 A) - G007 (1)

3. CHECK HARNESS AND CONNECTOR (SLIDING DOOR STEP LAMP - DOOR AJAR SWITCH)

(c) Disconnect the G001 sliding door ajar switch RH connector.

table below.

L003 (2) - H001 (1)
L003 (2) - G001 (1)

＜2Ω
G007 (2) - H001 (1)
G007 (2) - G001 (1)

YES > Replace the door ajar switch.
CARGO LAMP IS INOPERATIVE

WIRING DIAGRAM
04
04
1. INSPECT CARGO LAMP

(b) Disconnect the G004 cargo lamp connector.
(c) Replace the cargo lamp with a new one.
Does the cargo lamp work correctly?
NO > Replace the cargo lamp.
2. CHECK HARNESS AND CONNECTOR (REAR HATCH AJAR SWITCH - GROUND)

(b) Disconnect the J005 rear hatch ajar switch connector.

table below.

J005 (2) - Ground ＜2Ω

3. CHECK HARNESS AND CONNECTOR (INDOOR LAMP FUSE - CARGO LAMP)


table below.

F13 (10 A) - G004 (1) ＜2Ω

4. CHECK HARNESS AND CONNECTOR (CARGO LAMP - REAR HATCH AJAR SWITCH)

(c) Disconnect the J005 rear hatch ajar switch connector.

table below.

G004 (2) - J005(1) ＜2Ω

YES > Replace the rear hatch ajar switch.
INSTRUMENT CLUSTER ILLUMINATION IS INOPERATIVE

WIRING DIAGRAM
04
04
1. INSPECT FUSE

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - GROUND)


table below.

C045 (13) - Ground ≥ 1 ΜΩ


(b) Disconnect the C045 instrument cluster connector. 04
table below.

04
C045 (3) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR (FUSE - INSTRUMENT CLUSTER)


table below.

F1 (15 A) - C045 (13) ＜2Ω

YES > Replace the instrument cluster.
ELECTRONIC CLOCK ILLUMINATION IS INOPERATIVE

WIRING DIAGRAM
1. INSPECT FUSE
(b) Inspect the fuse in body junction box: F19 (7.5 A).
04

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (ELECTRONIC CLOCK - GROUND)

(b) Disconnect the C035 electronic clock connector.

table below.

C035 (3) - Ground ≥ 1 ΜΩ

3. CHECK HARNESS AND CONNECTOR (ELECTRONIC CLOCK - GROUND)


table below.

C035 (1) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR (FUSE - ELECTRONIC CLOCK)


table below.

F19 (7.5 A) - C035 (3) ＜2Ω

YES > Replace the electronic clock.
HAZARD SWITCH ILLUMINATION IS INOPERATIVE

WIRING DIAGRAM
04
04
1. INSPECT FUSE

YES > Go to step 3.


table below.

C034 (2) - Ground ≥ 1 ΜΩ


(b) Disconnect the C034 hazard switch connector. 04
table below.

04
C034 (2) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR (FUSE - HAZARD SWITCH)


table below.

F19 (7.5 A) - C034 (2) ＜2Ω

YES > Replace the hazard switch.
12V POWER POINT SOCKET ILLUMINATION IS INOPERATIVE

WIRING DIAGRAM
1. INSPECT FUSE
04

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (12V POWER POINT SOCKET - GROUND)

(b) Disconnect the C018 12V power point socket connector.

table below.

C018 (3) - Ground ≥ 1 ΜΩ

3. CHECK HARNESS AND CONNECTOR (12V POWER POINT SOCKET - GROUND)


table below.

C018 (2) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR (FUSE - 12V POWER POINT SOCKET)


table below.

F19 (7.5 A) - C018 (3) ＜2Ω

YES > Replace the 12V power point socket.
CIGARETTE LIGHTER ILLUMINATION IS INOPERATIVE

WIRING DIAGRAM
04
04
1. INSPECT FUSE

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (CIGARETTE LIGHTER - GROUND)

(b) Disconnect the C021 cigarette lighter connector.

table below.

C021 (3) - Ground ≥ 1 ΜΩ

3. CHECK HARNESS AND CONNECTOR (CIGARETTE LIGHTER - GROUND)

(b) Disconnect the C021 cigarette lighter connector. 04
table below.

04
C021 (2) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR (FUSE - CIGARETTE LIGHTER)

(b) Disconnect the C021 cigarette lighter connector.

table below.

F19 (7.5 A) - C021 (3) ＜2Ω

YES > Replace the cigarette lighter.
FRONT A/C CONTROLLER ILLUMINATION IS INOPERATIVE

WIRING DIAGRAM
1. INSPECT FUSE
04

YES > Go to step 3.


table below.

C017 (13) - Ground ≥ 1 ΜΩ



table below.

C017 (14) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR (FUSE - FRONT A/C CONTROLLER)


table below.

F19 (7.5 A) - C017 (13) ＜2Ω

YES > Replace the front A/C controller.
AUDIO ILLUMINATION IS INOPERATIVE

WIRING DIAGRAM
04
04
1. INSPECT FUSE

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (AUDIO - GROUND)

(b) Disconnect the C032 audio connector.

table below.

C032 (6) - Ground ≥ 1 ΜΩ

3. CHECK HARNESS AND CONNECTOR (AUDIO - GROUND)

(b) Disconnect the C032 audio connector. 04
table below.

04
C032 (8) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR (FUSE - AUDIO)

(b) Disconnect the C032 audio connector.

table below.

F19 (7.5 A) - C032 (6) ＜2Ω

YES > Replace the audio.
REAR FOG LAMP SWITCH ILLUMINATION IS INOPERATIVE

WIRING DIAGRAM
1. INSPECT FUSE
04

YES > Go to step 3.


table below.

C001 (5) - Ground ≥ 1 ΜΩ



table below.

C001 (1) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR (FUSE - REAR FOG LAMP SWITCH)


table below.

F19 (7.5 A) - C001 (5) ＜2Ω

YES > Repalce the rear fog lamp switch.
OUTSIDE MIRROR DEFROST SWITCH ILLUMINATION IS INOPERA-

TIVE
WIRING DIAGRAM 04
04
1. INSPECT FUSE

YES > Go to step 3.


table below.

C019 (5) - Ground ≥ 1 ΜΩ

YES > Repalce the fuse.

(b) Disconnect the C019 outside mirror defrost switch connector. 04
table below.

04
C019 (1) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR (FUSE - OUTSIDE MIRROR DEFROST SWITCH)


table below.

F19 (7.5 A) - C019 (5) ＜2Ω

YES > Replace the outside mirror defrost switch.
COMBINED DISPLAY ILLUMINATION IS INOPERATIVE

WIRING DIAGRAM
1. INSPECT FUSE
04

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (COMBINED DISPLAY - GROUND)


table below.

C401 (11) - Ground ≥ 1 ΜΩ



table below.

C401 (9) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR (FUSE - COMBINED DISPLAY)


table below.

F19 (7.5 A) - C401 (11) ＜2Ω

YES > Repalce the combined display.
REAR WINDOW DEFROST SWITCH ILLUMINATION IS INOPERA-

TIVE
WIRING DIAGRAM 04
04
1. INSPECT FUSE

YES > Go to step 3.


table below.

C022 (5) - Ground ≥ 1 ΜΩ


(b) Disconnect the C022 rear window defrost switch connector. 04
table below.

04
C022 (1) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR (FUSE - REAR WINDOW DEFROST SWITCH)


table below.

F19 (7.5 A) - C022 (5) ＜2Ω

YES > Replace the rear window defrost switch.
REAR HEATER SWITCH (FRONT CONTROL) ILLUMINATION IS

INOPERATIVE
WIRING DIAGRAM
1. INSPECT FUSE
04

YES > Go to step 3.

(b) Disconnect the C020 rear heater switch (front control) connector.

table below.

C020 (5) - Ground ≥ 1 ΜΩ



table below.

C020 (1) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR (REAR HEATER SWITCH - FUSE)


table below.

F19 (7.5 A) - C020 (5) ＜2Ω

YES > Repalce the rear heater switch (front control).
REAR HEATER SWITCH (REAR CONTROL) ILLUMINATION IS INOP-

ERATIVE
WIRING DIAGRAM 04
04
1. INSPECT FUSE

YES > Go to step 3.

(b) Disconnect the Q001 rear heater switch (rear control) connector.

table below.

Q001 (5) - Ground ≥ 1 ΜΩ


(b) Disconnect the Q001 rear heater switch (rear control) connector. 04
table below.

04
Q001 (1) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR (REAR HEATER SWITCH - FUSE)

(b) Disconnect the Q001 rear heater switch (rear control) connector.

table below.

F19 (7.5 A) - Q001 (5) ＜2Ω

YES > Repalce the rear heater switch (rear control).
REAR HEATER CONTROL PANEL ILLUMINATION IS INOPERATIVE

WIRING DIAGRAM
1. INSPECT FUSE
04

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (REAR HEATER CONTROLLER - GROUND)

(b) Disconnect the Q002 rear heater controller connector.

table below.

Q002 (2) - Ground ≥ 1 ΜΩ

3. CHECK HARNESS AND CONNECTOR (REAR HEATER CONTROLLER - GROUND)


table below.

Q002 (1) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR (FUSE - REAR HEATER CONTROLLER )


table below.

F19 (7.5 A) - Q002 (2) ＜2Ω

YES > Repalce the rear heater controller.
REAR A/C SWITCH (FRONT CONTROL) ILLUMINATION IS INOPER-

ATIVE
WIRING DIAGRAM 04
04
1. INSPECT FUSE

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (REAR A/C SWITCH - GROUND)

(b) Disconnect the C023 rear A/C switch (front control) connector.

table below.

C023 (5) - Ground ≥ 1 ΜΩ

3. CHECK HARNESS AND CONNECTOR (REAR A/C SWITCH - GROUND)

(b) Disconnect the C023 rear A/C switch (front control) connector. 04
table below.

04
C023 (1) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR (REAR A/C SWITCH - FUSE)

(b) Disconnect the C023 rear A/C switch (front control) connector.

table below.

F19 (7.5 A) - C023 (5) ＜2Ω

YES > Replace the rear A/C switch (front control).
FRONT PARKING LAMPS ARE INOPERATIVE

WIRING DIAGRAM
1. CHECK HARNESS AND CONNECTOR (FRONT PARKING LAMP - GROUND)


table below.
Standard resistance (check for open) 04
A007 (4) - Ground
＜2Ω
A013 (4) - Ground

2. CHECK HARNESS AND CONNECTOR (FUSE - FRONT PARKING LAMP)


table below.

F18 (7.5 A) - A007 (1)
＜2Ω
F18 (7.5 A) - A013 (1)

YES > Replace the front parking lamp bulb.
TAIL LAMPS ARE INOPERATIVE

WIRING DIAGRAM

(b) Disconnect the G005 rear combination lamp LH connector.
(c) Disconnect the H005 rear combination lamp RH connector.
table below.
04
G005 (4) - Ground
＜2Ω
H005 (4) - Ground

2. CHECK HARNESS AND CONNECTOR (FUSE - REAR COMBINATION LAMP )

(b) Disconnect the G005 rear combination lamp LH connector.
(c) Disconnect the H005 rear combination lamp RH connector.
table below.

F18 (7.5 A) - G005 (1)
＜2Ω
F18 (7.5 A) - H005 (1)

YES > Replace the tail lamp bulb.
LICENSE LAMP IS INOPERATIVE

WIRING DIAGRAM
1. CHECK HARNESS AND CONNECTOR (LICENSE LAMP - GROUND)

(b) Disconnect the J003 license lamp connector.

table below.
04
J003 (2) - Ground ＜2Ω

2. CHECK HARNESS AND CONNECTOR (FUSE - LICENSE LAMP)

(b) Disconnect the J003 license lamp connector.

table below.

F18 (7.5 A) - J003 (1) ＜2Ω

YES > Replace the license lamp.
PARKING LAMPS, TAIL LAMPS AND LICENSE LAMP ARE INOPER-

ATIVE
WIRING DIAGRAM
1. INSPECT FUSE
(c) Inspect the fuses in engine room junction box :FL1 (60
A), FL6 (50 A).

YES > Go to step 4.
NO > If the fuse FL1 (60A) (with 4G63/4G64 engine) or the fuse FL6 (50A) (with BJ493ZQ3 engine) is blown,
go to step 2. 04
If the fuse F18 (7.5A) is blown, go to step 3.
2. CHECK HARNESS AND CONNECTOR (PARKING LAMP RELAY - GROUND)

04
table below.

R4 (2) - Ground
≥ 1 ΜΩ
R4 (5) - Ground



table below.

A007 (1) - Ground
≥ 1 ΜΩ
H005 (1) - Ground

4. INSPECT PARKING LAMP RELAY

(c) Inspect the parking lamp relay.

Standard resistance

1–2 Continuity
＜2Ω
terminal 1 and 2)

NO > Replace the parking lamp relay.
.

table below.

04
C040 (16) - Ground ＜2Ω

6. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - PARKING LAMP RELAY)


table below.

R4 (1) - C040 (14) ＜2Ω

7. CHECK HARNESS AND CONNECTOR (PARKING LAMP DELAY - FRONT COMBINATION LAMP)


table below.

R4 (3) - A007 (1)
＜2Ω
R4 (3) - H005 (1)

YES > Replace the combination switch (light control).
DIAGNOSTICS - INSTRUMENT CLUSTER 04-763
INSTRUMENT CLUSTER
PRECAUTION
1. POWER OFF. 04
(a) Before removing or installing any electrical device, please disconnect the negative battery cable to
prevent damage to the device or personal injury.
(b) Make sure ignition switch must be off if no specific instructions.
AND THE CLOCK TO ‘ 0 ’.
04
NOTE
The total odometer can not be reset to ‘ 0 ’.
IS DISCONNECTED.
NOTE
instructions”).
Switch Type Ignition Switch (position) Engine (condition)


Expression

04-764 DIAGNOSTICS - INSTRUMENT CLUSTER
LOCATION
1 Instrument Cluster 4 Engine Oil Pressure Switch
2 Engine Coolant Temperature Sensor 5 Fuel Level Sensor
3 Speedometer Sensor
INSTRUMENT CLUSTER INFORMATION
04
04
GAUGES
No Content Description
6 Fuel gauge
The fuel gauge indicates the approximate fuel level in
the tank.
According to the signal received from the speedometer sen-
9 Speedometer
sor, the speedometer indicates the vehicle running speed.
26 Tachometer Receiving signal from the ECM, the tachometer indicates

engine revolutions per minute (RPM).
WARNING / INDICATOR LIGHTS

SRS warning light will turn on when SRS is detected malfunc-
1 SRS warning light
tion.
Engine oil pressure warning light will be illuminated when

2 Engine oil pressure warning light
receiving signal from the engine oil pressure switch.
3 ABS warning light Warning light will turn on when ABS is detected malfunction.
The ECM will turn on malfunction indicator light when engine

4 Malfunction indicator light
electronic control system is detected malfunction.
Left turn signal/hazard indicator Left turn signal/hazard indicator light flashes when the turn
5
light signal switch or hazard switch is activated.
Right turn signal/hazard indicator Right turn signal/hazard indicator light flashes when the turn
7
light signal switch or hazard switch is activated.
SVS indicator light will be illuminated when the ECM detect

8 SVS indicator light (Gasoline)
general malfunctions. It will be always on until faults resolved.
Trip odometer and clock change

11 Among trip A, trip B, odometer and clock change or setup.
button
Rear fog switch receive signal from the multi-functional control-

12 Rear fog lamp indicator light ler (3-in-1) to illuminate rear fog lamp indicator light when rear
fog switch is pressed.
Seat belt warning light turns on when receiving the seat belt
13 Seat belt warning light
warning signal.
Brake warning light turns on when receiving signals from park-

14 Brake warning light
ing brake switch or brake fluid level sensor.
Vacuum warning light turns on when receiving the vacuum

15 Vacuum warning light (Diesel)
warning signal.
Door ajar warning light turns on when receiving the door ajar
16 Door ajar warning light
signal.
Sediment water indicator light Sediment water indicator light turns on when receiving signal
17
(Diesel) from the oil-water separation sensor.
The ECM will illuminate preheat indicator light when engine

18 Preheat indicator light (Diesel)
coolant temperature lower than specified value.
The ABS will illuminate EBD warning light when EBD is

19 EBD warning light
detected malfunction.
Fuel level warning light turns on when fuel level lower than
20 Fuel level warning light
specified level.
21 Charging warning light Charging warning light turns on when charging system is fault.
High beam indicator light turns on when high beam is on and

22 High beam indicator light
receive headlamp relay signal.
Front fog lamp indicator light receive the front fog lamp relay
23 Front fog lamp indicator light
signal and turns on when front fog lamp switch is pressed.
Engine coolant temperature Engine coolant temperature indicator light will illuminate when
24
indicator light engine coolant temperature is between -20 ℃ ～ 110 ℃ .
04
Engine coolant temperature Engine coolant temperature warning light will illuminate when
25
warning light engine coolant temperature is above 110 ℃ .
LIQUID CRYSTAL DISPLAY
04
Display time and can be reset. Clock is switched to odometer
Clock
10 via the trip odometer and clock change button.
Odometer Display driving distance and can not be reset to “0”.

TERMINALS OF INSTRUMENT CLUSTER
Terminals No Wiring Color Description

1 R Door ajar signal, to door ajar switch
2 V-W Engine coolant level signal, to engine coolant level sensor
3 BR Indicator ground
4 R Battery (Diesel)
C045 5 BR Gauge ground
6 LG Front fog lamp indicator light signal, to fog lamp relay
Rear fog lamp indicator light signal, to the multi-functional

7 R-Y
controller (3-in-1)
8 L-W Preheat indicator light signal, to ECM

Terminals No Wiring Color Description

Engine oil pressure warning light signal, to engine oil pres-
9 L
sure switch
04
10 Y-W Tachometer signal, to ECM
11 R Power supply for memory, to battery
12 G Instrument cluster illumination
13 R-B To ignition switch (ON/START)

04
14 Y-G ABS warning light signal, to ABS unit
15 - -
16 P-L Charging warning light signal, to generator
17 B-Y SRS warning light signal, to RCM (Gasoline)
18 - -
19 B-W Seat belt warning light signal, to seat belt warning switch
20 B-L Malfunction indicator light signal, to ECM
21 V Fuel gauge signal output, to fuel level sensor

C045
Left turn signal/hazard indicator light signal, to combination
22 G-B
switch and hazard switch
23 Y-G Engine coolant temperature signal, to ECT sensor
Right turn signal/hazard indicator light signal, to combina-

24 G-Y
tion switch and hazard switch
25 R-G High beam indicator light signal, to combination switch
Brake warning light signal, to parking brake switch and

26 R-W
brake fluid level sensor
27 R-B Speedometer sensor signal input, to speedometer sensor
28 Y-R EBD warning light signal, to ABS unit
29 R-L Vacuum warning light signal, to vacuum switch (Diesel)
Sediment water indicator light signal (+), to the oil-water

30 G
separation sensor (diesel)
31 V SVS indicator light signal, to ECM (Gasoline)
Sediment water indicator light signal (-), to the oil-water

32 BR
separation sensor(Diesel)
BASIC INSPECTION
NOTE
Do not perform basic inspection until engine temperature reaches the specified value. If on-road test is
needed， must have at least two people to perform the test.
Step Conditions Action

Yes Go to step 2.
1 • The battery voltage should above 12 V. Charge or replace the battery.
Is the check result normal？ No Refer to “Chapter 20A starting
and charging - battery”.
Check tachometer. Yes Go to step 3.

• Connect hand-held tester, reading the engine
rotating speed data.
• Separate reading engine rotating speed data with
2 Go to the problem symptoms
1000 ～ 2000 r/min， 3000 ～ 6000 r/min. No
• The variation of error in ± 100 ～ 200 r/min，± 150 table.
～ 300 r/min.
Check speedometer. Yes Go to step 4.

• Connect hand-held tester, reading the vehicle
speed data.
• Separate reading vehicle speed data with 20 ～
100 Km/h， 120 Km/h ， 140 Km/h.
• The variation of error in + 5， + 6， + 7 Km/h.
3 Go to the problem symptoms
• The pointer should be without jump when vehicle No
is at constant speed or constant acceleration. table.
NOTE
Tire wear and incorrect tire pressure will lead
inaccurate data.
Check engine oil pressure warning light. Yes Go to step 5.

• Engine oil pressure warning light should be illumi-
4 nated. Go to the problem symptoms
• After engine starts, engine oil pressure warning No
table.
light should go off.
Check charging warning light. Go to the problem symptoms

Yes
• Turn the ignition switch ACC. table.
5 • Charging warning light turns on.
• Charging warning light should turn off after engine Refer to “Chapter 20A starting
starts. No
and charging - generator”.

these parts. 04
SYSTEM

Chapter 04 diagnostics - instrument cluster, the
1. Power, ground circuits instrument cluster is inoperative
The instrument cluster
is inoperative 04
2. Instrument cluster instrument cluster is inoperative
1. Instrument cluster illumi- Chapter 04 diagnostics - lighting, problem symptoms

The instrument cluster
nation circuits table
background
illumination is
inoperative 2. Instrument cluster replacement
GAUGES

Chapter 04 diagnostics - instrument cluster, malfunc-
1. Speedometer sensor tion in speedometer
Malfunction in Chapter 04 diagnostics - instrument cluster, the

speedometer 2. Speedometer circuits instrument cluster is inoperative

3. Speedometer instrument cluster is inoperative

1. CKP sensor tion in tachometer
Malfunction in Chapter 04 diagnostics - instrument cluster, malfunc-

tachometer 2. Tachometer circuits tion in tachometer

3. Tachometer tion in tachometer

1. Fuel level sensor tion in fuel gauge
Malfunction in fuel Chapter 04 diagnostics - instrument cluster, malfunc-

gauge 2. Fuel gauge circuits tion in fuel gauge

3. Fuel gauge tion in fuel gauge
WARNING LIGHTS
1. Engine electronic control Chapter 04 diagnostics - gasoline engine control sys-

system tem, diagnostic trouble code chart
Malfunction indicator 2. Malfunction indicator light Chapter 04 diagnostics - diesel engine control sys-
light never/always on circuits tem, diagnostic trouble code chart
Chapter 04 diagnostics - diesel engine control sys-

3. Instrument cluster tem, diagnostic trouble code chart
1. Engine electronic control Chapter 04 diagnostics - gasoline engine control

system system, diagnostic trouble code chart
SVS indicator light
never/always on Chapter 04 diagnostics - gasoline engine control
2. SVS indicator light circuits system, diagnostic trouble code chart
(Gasoline)
Chapter 04 diagnostics - gasoline engine control
3. Instrument cluster system, diagnostic trouble code chart
Chapter 04 diagnostics - instrument cluster, brake

1. Brake fluid level sensor warning light never/always on

2. Parking brake switch warning light never/always on
Brake warning light
never/always on Chapter 04 diagnostics - instrument cluster, brake
3. Brake warning light
circuits warning light never/always on

4. Instrument cluster warning light never/always on
Chapter 04 diagnostics - anti-lock brake system,

1. ABS system problem symptoms table
ABS warning light Chapter 04 diagnostics - anti-lock brake system,

never/always on 2. ABS warning light circuits problem symptoms table
Chapter 04 diagnostics - anti-lock brake system,

3. Instrument cluster problem symptoms table
Chapter 04 diagnostics - instrument cluster, door ajar

1. Door ajar switch warning light never/always on
Door ajar warning light 2. Door ajar warning light Chapter 04 diagnostics - instrument cluster, door ajar
never/always on circuits warning light never/always on
Chapter 04 diagnostics - instrument cluster, door ajar

3. Instrument cluster warning light never/always on
Chapter 04 diagnostics - instrument cluster, engine

1. ECT sensor coolant temperature warning light never/always on
2. Engine coolant level Chapter 04 diagnostics - instrument cluster, engine

sensor coolant temperature warning light never/always on
Engine coolant
temperature warning
3. Engine coolant Chapter 04 diagnostics - instrument cluster, engine
light never/always on
temperature warning light coolant temperature warning light never/always on
circuits

4. Instrument cluster coolant temperature warning light never/always on

Chapter 04 diagnostics - supplemental restraint
1. SRS system circuits system, SRS warning light never/always on
04
SRS warning light
never/always on 2. SRS warning light circuits coolant temperature warning light never/always on
(Gasoline)
3. Instrument cluster coolant temperature warning light never/always on
INDICATOR LIGHTS 04

Chapter 04 diagnostics - instrument cluster, enging
1. Enging oil pressure switch oil pressure warning light never/always on
Enging oil pressure
warning light never/ 2. Enging oil pressure Chapter 04 diagnostics - instrument cluster, enging
always on warning light circuits oil pressure warning light never/always on
Chapter 04 diagnostics - instrument cluster, enging

3. Instrument cluster oil pressure warning light never/always on

1. ECT sensor coolant temperature indicator light never on
Engine coolant
temperature indicator 2. ECT sensor circuits coolant temperature indicator light never on
light never on
3. Instrument cluster coolant temperature indicator light never on
Chapter 04 diagnostics - lighting, problem symptoms

table (If exterior turn signal/hazard lights are normal,
1. Fuses repair turn signal/hazard indicator light circuits for an
open or replace the instrument cluster)

2. Combination switch repair turn signal/hazard indicator light circuits for an

3. Hazard switch repair turn signal/hazard indicator light circuits for an
Turn signal/hazard open or replace the instrument cluster)
indicator light never/
always on Chapter 04 diagnostics - lighting, problem symptoms
4. Multi-functional controller table (If exterior turn signal/hazard lights are normal,
(3-in-1) repair turn signal/hazard indicator light circuits for an

5. Turn signal/hazard table (If exterior turn signal/hazard lights are normal,
indicator light circuits repair turn signal/hazard indicator light circuits for an

6. Instrument cluster repair turn signal/hazard indicator light circuits for an

table(If exterior high light are normal, repair high beam
1. Fuses indicator light circuits for an open or replace the instru-
ment cluster)

2. Combination switch indicator light circuits for an open or replace the instru-
ment cluster)

High beam indicator 3. Multi-functional controller table(If exterior high light are normal, repair high beam
light never/always on (3-in-1) indicator light circuits for an open or replace the instru-
ment cluster)

4. High beam indicator light table(If exterior high light are normal, repair high beam
circuits indicator light circuits for an open or replace the instru-
ment cluster)

5. Instrument cluster indicator light circuits for an open or replace the instru-
ment cluster)
Chapter 04 diagnostics -lighting, problem symptoms

table(If exterior front fog light are normal, repair front
1. Fuses fog lamp indicator light circuits for an open or replace
the instrument cluster)

2. Combination switch fog lamp indicator light circuits for an open or replace
Front fog lamp the instrument cluster)
always on Chapter 04 diagnostics -lighting, problem symptoms
3. Front fog lamp indicator table(If exterior front fog light are normal, repair front
light circuits fog lamp indicator light circuits for an open or replace

4. Instrument cluster fog lamp indicator light circuits for an open or replace

table(If exterior rear fog light are normal, repair rear fog
1. Fuses lamp indicator light circuits for an open or replace the 04
instrument cluster)

2. Combination switch lamp indicator light circuits for an open or replace the
instrument cluster)
Chapter 04 diagnostics - lighting, problem symptoms 04

3. Rear fog lamp switch lamp indicator light circuits for an open or replace the
Rear fog lamp instrument cluster)
always on Chapter 04 diagnostics -lighting, problem symptoms
4. Multi-functional controller table(If exterior rear fog light are normal, repair rear fog
(3-in-1) lamp indicator light circuits for an open or replace the
instrument cluster)

5. Rear fog lamp indicator table(If exterior rear fog light are normal, repair rear fog
light circuits lamp indicator light circuits for an open or replace the
instrument cluster)

6. Instrument cluster lamp indicator light circuits for an open or replace the
instrument cluster)
LIQUID CRYSTAL DISPLAY

Clock - No display or Chapter 83 instrument panel - instrument clus-
blurry display 1. Liquid crystal display ter,replacement
1. Incorrect setup currently Change status to clock for setup

The clock can not be
set 2. Trip odometer and clock Chapter 83 instrument panel - instrument cluster,
change button replacement
Can not switch

1. Trip odometer and clock Chapter 83 instrument panel - instrument cluster,
between clock and
change button replacement
odometer
Odometer - No display ChapterChapter 83 instrument panel - instrument clus-

or blurry display 1. Liquid crystal display ter, replacement
THE INSTRUMENT CLUSTER IS INOPERATIVE

WIRING DIAGRAM
1. CHECK FUSE
(b) Verify the fuse in the body junction box: F1 (15A).

(c) Verify the fuse in the engine room junction box: F26 (7.5A).

YES > Go to step 2.
NO > Go to step 4.
04
2. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER- GROUND)
(a) Disconnect the instrument cluster connector C045.
04

table below.
Standard voltage
C045 (11) - Ground

Battery Voltage
C045 (13) - Ground

YES > Go to step 3.
NO > If no battery voltage at the instrument cluster connector C045, pin 13 , repair the circuit for an open
from the fuse F1 (15A) to the instrument cluster connector C045, pin 13.
If no battery voltage at the instrument cluster connector C045, pin 11, repair the circuit for an open from
the fuse F26 (7.5A) to the instrument cluster connector C045, pin 11.
Turn the ignition switch OFF.

table below.

C045 (3) - Ground
≤2Ω
C045 (5) - Ground

4. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - POWER SUPPLY)
(b) Disconnect the instrument cluster connector C045.

table below.
C045 (11) - Ground ≥ 1 MΩ

table below.
C045 (13) - Ground ≥ 1 MΩ

MALFUNCTIN IN SPEEDOMETER
WIRING DIAGRAM
04
04
1. CHECK HARNESS AND CONNECTOR (SPEEDOMETER SENSOR - POWER SUPPLY)
(b) Disconnect the speedometer sensor connector E016.


table below.
Standard voltage
E016 (1) - E016 (2)

Battery Voltage
E016 (1) - Ground

YES > Go to step 3.
NO > If no battery voltage at all checked pins, go to step 2.
If battery voltage exists only between pin 1 and ground, repair the circuit for an open from the
speedometer sensor connector E016, pin 2 to ground E201.
2. CHECK HARNESS AND CONNECTOR (SPEEDOMETER SENSOR - POWER SUPPLY)

table below.
Standard voltage

YES > Repair the circuit for an open from the connector C102, pin 6 to the speedometer sensor connector
E016, pin 1.
NO > Repair the circuit from the fuse F1 (15A) to the connector C102, pin 6.
3. INSPECT SPEEDOMETER SENSOR

(b) Remove the speedometer sensor.
(c) Rotate the speedometer sensor axle.

(d) Measure the resistance between the speedometer
sensor pin 2 and pin 3.
Pulse signal: 8 pulse of resistance signal pre revo-
lution.

YES > Go to step 4.
NO > Replace the speedometer sensor.
04
4. CHECK HARNESS AND CONNECTOR (SPEEDOMETER SENSOR - INSTRUMENT CLUSTER)
04

table below.
E016 (3) - Ground ≥ 1 MΩ

table below.
E016 (3) - C045 (27) ＜2Ω

MALFUNCTION IN TACHOMETER
WIRING DIAGRAM
NOTE
An abnormal running engine will lead the tachometer pointer instable.
Check if the engine has normal start.
YES > Go to step 1.
NO > Refer to “Chapter 04 diagnostics - gasoline engine control system, problem symptoms table.
1. CHECK HARNESS AND CONNECTOR (ECM - INSTRUMENT CLUSTER)


table below.
Standard voltage 04
C045 (10) - Ground Appr 0 V
04
(e) Start the engine until the engine temperature reaches to normal condition.
(f) Measure the pulse signal between the instrument cluster

connector C045, pin 10 and ground.
Pulse signal: Appr 33.3 Hz (1000 r / min)

NO > If no tachometer signal, go to step 2.
If tachometer signal is available, repair the circuit from the instrument cluster connector C045, pin 10 to
the ECM connector E023, pin 45.
2. CHECK HARNESS AND CONNECTOR (ECM - INSTRUMENT CLUSTER)
(b) Disconnect negative cable from the battery.
(c) Disconnect the ECM connector E023.


table below.

C045 (10) - E023 (45) ＜2Ω

table below.
C045 (10) - Ground ≥ 1 MΩ

YES > Replace the ECM.
MALFUNCTION IN FUEL GAUGE

WIRING DIAGRAM
04
04
• Turn the ignition switch ON and ensure fuel tank have enough fuel (more than 1/4 in fuel tank).
• Fuel level warning light will be illuminated when fuel level lower than 345 mm ( ≤ 7 ～ 10 L) or fuel level
sensor resistance greater than 96.5 ± 4 Ω.
• Fuel level warning light will turn off when fuel level higher than 345 mm ( ＞ 7～ 10 L) or fuel level sensor
resistance smaller than 96.5 ± 4 Ω.
1. INSPECT FUEL LEVEL SENSOR
(b) Disconnect the fuel level sensor connector L005.

(c) Measure the resistance between the fuel level sensor pin
1 and pin 2.
(d) Remove the fuel level sensor and measure the resis-
tance following the table below.
Position Empty Warn threshold 1/4 1/2 3/4 Full
Resistance(Ω) 110 ± 7 96.5 ± 4 84.3 ± 4 32.5 ± 4 18.2 ± 4 3.4 ± 1

YES > Go to step 2.
NO > Replace the fuel level sensor.
2. CHECK HARNESS AND CONNECTOR (FUEL LEVEL SENSOR - GROUND)

table below.
L005 (2) - Ground ＜2Ω

YES > Go to step 3.
3. CHECK HARNESS AND CONNECTOR (FUEL LEVEL SENSOR - INSTRUMENT CLUSTER)

table below.
Standard voltage
L005 (1) - Ground 5V


YES > Replace the fuel level sensor.
NO > Go to step 4.
04

table below.
Standard voltage

C045 (21) - Ground 5V

NO > Go to step 5.

table below.
L005 (1) - Ground ≥ 1 MΩ

ENGINE COOLANT TEMPERATURE WARNING LIGHT NEVER/

ALWAYS ON
WIRING DIAGRAM
• Engine coolant temperature warning light never turns on when the ECT sensor resistance is more than
5 KΩ.
• Engine coolant temperature warning light never turns on when the ECT sensor circuit is open.
• Engine coolant temperature warning light always turns on when engine coolant level is lower than
specified value.
• Engine coolant temperature warning light will flash when engine coolant temperature is more than 110
℃.
• Engine coolant temperature warning light will flash when the ECT sensor circuit is short.
• Engine coolant temperature warning light will turn on approximately 3 seconds when the ignition switch
turns ON.
• Ensure engine coolant level within specified value.
• Ensure engine coolant temperature normal.
Check if engine coolant temperature warning light never or always on.

YES > (Never on) Go to step 1.
NO > (Always on) Go to step 4.
04
1. INSPECT ECT SENSOR

(b) Remove the ECT sensor.
CAUTION
Whenever remove the ECT sensor, ensure the engine is cold (Engine coolant temperature lower than 04
40 ℃ ).
(c) Measure the ECT sensor resistance following the table below.
Temperature ( ℃ ) 50 85 110 115
Resistance (Ω) 226 ± 35 64 ± 8 28 26.4 ± 2

YES > Go to step 2.
2. CHECK HARNESS AND CONNECTOR (ECT SENSOR - INSTRUMENT CLUSTER)
(b) Disconnect the ECT sensor connector E001 (Gasoline).
(c) Disconnect the ECT sensor connector E001 (Diesel).


table below.
Standard voltage

NO > Go to step 3.

table below.
Standard voltage
C045 (23) - Ground 5V

NO > Replace the instrument cluster.

CAUTION
Whenever remove the ECT sensor, ensure the engine temperature is cold (Engine coolant temperature
lower than 40 ℃ ).
(c) Measure the ECT sensor resistance following below table.
Temperature （℃） 50 85 110 115
Resistance （Ω） 226 ± 35 64 ± 8 28 26.4 ± 2

YES > Go to step 5.
(b) Disconnect the instrument cluster connector C045. 04
04

table below.
E001 (1) - Ground ≥ 1 MΩ

YES > Go to step 6.
6. INSPECT ENGINE COOLANT LEVEL SENSOR
(a) Disconnect the engine coolant level sensor connector

A005.

Check if engine coolant temperature warning light turns off.
YES > Replace the engine coolant level sensor.
NO > Go to step 7.
7. CHECK HARNESS AND CONNECTOR (ENGINE COOLANT LEVEL SENSOR - INSTRUMENT

CLUSTER)

table below.
Standard voltage

NO > Go to step 8.
8. CHECK HARNESS AND CONNECTOR (ENGINE COOLANT LEVEL SENSOR - INSTRUMENT
CLUSTER)

table below.
A005 (1) - A005 (2) ≥ 1 MΩ

YES > Repair the circuit for a short from the engine coolant level sensor connector A005, pin 1 to pin 2.
NO > Repair the circuit for a short from the engine coolant level sensor connector A005, pin 2 to the instru-
ment cluster connector C045, pin 2.
ENGINE COOLANT TEMPERATURE INDICATOR LIGHT NEVER ON

WIRING DIAGRAM
04
04
• Engine coolant temperature indicator light never turns on when the ECT sensor resistance is more than
5 KΩ.
• Engine coolant temperature indicator light never turns on when the ECT sensor is fault or the ECT sen-
sor circuit open.
• Engine coolant temperature indicator light always turns on when the engine coolant temperature is
within － 20 ～ 110 ℃ .
• Ensure that repair engine coolant temperature warning light fault first if the engine coolant temperature
warning light never/always turns on.
• Ensure that the engine coolant temperature is normal.

CAUTION
Whenever remove the ECT sensor, ensure the engine cold (Engine coolant temperature lower than
40 ℃ ).
(c) Measure the ECT sensor resistance following below table.
Temperature ( ℃ ) 50 85 110 115
Resistance (Ω) 226 ± 35 64 ± 8 28 26.4 ± 2

YES > Go to step 2.
(b) Disconnect the ECT sensor connector E001 (Gasoline).
(c) Disconnect the ECT sensor connector E001(Diesel).

table below.
Standard voltage


NO > Go to step 3.
04

table below.
Standard voltage

C045 (23) - Ground 5V

BRAKE WARNING LIGHT NEVER/ALWAYS ON

WIRING DIAGRAM
• Check if the brake fluid (or clutch) level is too low. If the brake fluid (or clutch) level is low, fill the brake
fluid reservoir with genuine FOTON specified fluid.
• Fix four tires.
• Pull and release the parking brake.
Check if the brake warning light never or always on.
YES > (Always on) Go to step 1.
NO > (Never on) Go to step 4.
1. CHECK PARKING BRAKE SWITCH CIRCUIT

(b) Release the parking brake.
(c) Disconnect the parking brake switch connector Q006 .

04
04
Check if the brake warning light turns off.

YES > Replace the parking brake switch.
NO > Go to step 2.
2. CHECK PARKING BRAKE SWITCH CIRCUIT

(b) Disconnect connector C116.
YES > Repair the circuit for a short from the connector C116, pin 24 to the parking brake switch connector
Q006, pin 1.
NO > Go to step 3.
3. CHECK HARNESS AND CONNECTOR (BRAKE FLUID LEVEL SENSOR - INSTRUMENT CLUS-
TER)
(b) Disconnect the brake fluid level sensor connector A003.


YES > Replace the brake fluid level sensor.
NO > Repair the circuit for a short from the instrument cluster connector C045, pin 26 to the connector C116,
pin 24 and the brake fluid level sensor connector A003, pin 1.
NOTE
The brake fluid level sensor can not be replaced alone. It should be replaced with the brake fluid reser-
voir assy.
4. CHECK HARNESS AND CONNECTOR (PARKING BRAKE SWITCH - GROUND)
(b) Disconnect the parking brake switch connector Q006.
(c) Pull parking brake.

table below.

Q006(1) - Ground ＜2Ω

YES > Go to step 5.
NO > Replace the parking brake switch.
5. CHECK HARNESS AND CONNECTOR (PARKING BRAKE SWITCH - INSTRUMENT CLUSTER)

04
04

table below.
C045 (26) - Q006 (1) ＜2Ω

ENGING OIL PRESSURE WARNING LIGHT NEVER/ALWAYS ON

WIRING DIAGRAM
• When turning the ignition switch ON, the engine oil pressure warning light will turn on.
• Engine oil pressure warning light will turn off after engine starts.
• Engine oil pressure warning light will turn on when the engine oil pressure lower than 0.050 ± 0.011
MPa.
• Engine oil pressure warning light will turn off when the engine oil pressure higher than 0.050 ± 0.011
MPa.
NOTE
If the engine oil pressure warning light is always on after engine starts. Do not shut off engine immedi-
ately. Check oil level, if oil level is out of specification, it needs to be repaired first.
Check if engine oil pressure warning light is always on or never.
1. CHECK HARNESS AND CONNECTOR (ENGING OIL PRESSURE SWITCH - INSTRUMENT CLUS-
TER)

(b) Disconnect the engine oil pressure switch connector
E024 (Gasoline).
04
(c) Disconnect the engine oil pressure switch connector

E024 (Diesel).

Check if the engine oil pressure warning light turns off.
YES > Replace the engine oil pressure switch.
NO > Go to step 2.
TER)

table below.
E024 (1) - Ground ≥ 1 MΩ

TER)
(b) Disconnect the engine oil pressure switch connector

E024 (Gasoline).
(c) Disconnect the engine oil pressure switch connector

E024. (Diesel)
04
04

table below.
Standard voltage
E024 (1) - Ground Battery Voltage

YES > Replace the engine oil pressure switch.
NO > Go to step 4.
TER)

table below.
Standard voltage

SEAT BELT WARNING LIGHT NEVER/ALWAYS ON

WIRING DIAGRAM
• Seat belt warning light will turn on.
• Seat belt warning light will turn off when seat belt is fastened.
Check if seat belt warning light always or never on.
1. CHECK HARNESS AND CONNECTOR (SEAT BELT WARNING SWITCH - INSTRUMENT CLUS-
TER)

(b) Disconnect the seat belt warning switch connector Q004.
04
Check if the seat belt warning light turns off.

YES > Replace the seat belt warning switch.
NO > Go to step 2.
TER)

table below.
Q004 (1) - Ground ≥ 1 MΩ


TER)
(b) Disconnect the seat belt warning switch connector Q004.


table below.
Standard voltage
Q004 (1) - Q004 (2)

Battery Voltage
Q004 (1) - Ground

YES > Replace the seat belt warning switch.
NO > If no battery voltage at all checked pins, go to step 4.
If no battery voltage between the seat belt warning switch connector Q004, pin 1 and pin 2, repair or
replace harness or connector.
TER)

table below.
Standard voltage

04

DOOR AJAR WARNING LIGHT NEVER/ALWAYS ON

WIRING DIAGRAM
• Door ajar warning light will turn off when all doors are closed.
• Door ajar warning light will turn on when any door is open.
04
Check if door ajar warning light always/never on.
1. CHECK HARNESS AND CONNECTOR (DOOR AJAR SWITCH - INSTRUMENT CLUSTER)
(a) Close all doors. 04
(b) Following sequence disconnect each connector.

• Disconnect the L001 front door ajar switch LH connector.
• Disconnect the K002 front door ajar switch RH connec-
tor.
• Disconnect the H001 rear door ajar switch LH connector.
• Disconnect the G001 rear door ajar switch RH connector.
(c) Disconnect the rear hatch ajar switch connector J005.
Check if the door ajar warning light turns off.

YES > Replace the door ajar switch which is fault.
NO > Go to step 2.
2. CHECK HARNESS AND CONNECTOR (FRONT INDOOR LAMP - INSTRUMENT CLUSTER)
(a) Disconnect the front indoor lamp connector F001.

YES > Replace the front indoor lamp assy.
NO > Go to step 3.
3. CHECK HARNESS AND CONNECTOR (FRONT INDOOR LAMP - INSTRUMENT CLUSTER)
(a)Disconnect the rear indoor lamp connector F004.

YES > Replace the rear indoor lamp assy.
NO > Go to step 4.
INSTRUMENT CLUSTER)
(a)Disconnect the ignition key position remind controller con-

nector C042.

YES > Replace the ignition key position remind controller.
NO > Go to step 5.
04
5. CHECK HARNESS AND CONNECTOR (CENTRAL DOOR LOCK CONTROLLER - INSTRUMENT
CLUSTER)

C043.
04

NO > Go to step 6.
6. CHECK HARNESS AND CONNECTOR (DIODE - INSTRUMENT CLUSTER)
(a) Disconnect the diode connector C012.

YES > Repair the circuit for a short from the diode connector C012, pin 2 to the ignition key position remind
controller connector C042, pin 2.
NO > Go to step 7.
7. CHECK HARNESS AND CONNECTOR (DOUBLE DIODE - INSTRUMENT CLUSTER)
(a) Disconnect the double diode connector G003.

YES > Repair the circuit for a short from the double diode connector G003, pin 1 to the sliding door connector
G001 and connector H001, pin 1.
Repair the circuit for a short from the double diode connector G003, pin 1 to the cargo lamp connector
G004, pin 2 and rear step lamp connector L003 and connector G007, pin 2.
Repair the circuit for a short from the double diode connector G003, pin 3 to the cargo lamp connector
G004, pin 2 and the rear hatch ajar switch connector J005, pin 1.
NO > Go to step 8.
(a) Disconnect the double diode connector C044.

YES > Repair the circuit for a short from the double diode connector C044, pin 1 to the diode connector C012,
pin 1.
Repair the circuit for a short from the double diode connector C044, pin 1 to the front indoor lamp con-
nector F001, pin 2 and FR door ajar switch connector K002, pin 1.
Repair the circuit for a short from the double diode connector C044, pin 3 to the diode connector G003,
pin 2.
NO > Go to step 9.
9. CHECK INSTRUMENT CLUSTER CIRCUIT

table below.
C045 (1) - Ground ≥ 1 MΩ

(a) Open all doors.

(b) Disconnect the double diode connector C044.

table below.
Standard voltage
04
04

YES > Replace the double diode.
NO > Go to step 11.

table below.
C045 (1) - C044 (2) ＜2Ω

04-814 DIAGNOSTICS - COMBINED DISPLAY
COMBINED DISPLAY
PRECAUTION
1. EXPRESSIONS OF IGNITION SWITCH


Expression
2. POWER OFF
(a) Before removing or installing any electrical device, please disconnect the nagative battery cable to pre-
DIAGNOSTICS - COMBINED DISPLAY 04-815
LOCATION
04
04
1 Combined Display 2 Front Control Panel

SYSTEM DESCRIPTION
1 Compass Display 3 Reversing Distance Display
2 Reversing Display 4 In-Vehicle Temperature Display

TERMINALS OF COMBINED DISPLAY
04
04
Terminals No. Wiring Color Terminal Description

1 R In-vehicle temperature sensor
2 - -
3 - -
4 BR - W Odometer sensor
5 Y Reversing radar controller
6 W-L Reversing radar controller
7 - -
8 - -
9 W-B Ground
10 W-B Ground
11 G Indoor lamp
12 - -
13 GR Combined display fuse

BASIC INSPECTION
Yes Go to next step
Check battery voltage.
Is the check result normal? No 20A/20B Starting and Charging - battery,
replacement”
Check combined display illumination. Yes Go to next step

2
• Turn on the fog lamp. No Go to problem symptoms table
Does the combined display illuminate?
Check combined display indication. Yes Go to problem symptoms table

• Start the engine.
3 • Set the shift lever in reverse position.
Does the combined display work cor- No Replace combined display
rectly?

04
1. Fuse -
Combined display is Chapter 81 communication system - combined display,

inoperative 2. Combined display replacement
3. Wire harness - 04
1. In-vehicle temperature -
sensor
In-Vehicle temperature
does not display or Chapter 81 communication system - combined display,
display incorrectly 2. Combined display replacement
3. Wire harness -
Chapter 81 communication system - combined display,

1. Combined display replacemen
Reverse data does not
display or display Chapter 81 communication system - reverse radar,
2. Reversing radar controller replacement
incorrectly
3. Wire harness -
COMBINED DISPLAY IS INOPERATIVE

WIRING DIAGRAM
1. INSPECT FUSE
(b) Inspect the combined display fuse in body junction box:

F14 (10 A).

YES > Go to step 3.

(b) Disconnect the C401 combined display connector. 04
table below.

04
C401 (13) - Ground ≥ 1 ΜΩ

3. CHECK HARNESS AND CONNECTOR (COMBINED DISPLAY FUSE - COMBINED DISPLAY)


table below.

F14 (10 A) - C401 (13) ＜2Ω



table below.

C401 (9) - Ground
＜2Ω
C401 (10) - Ground

IN-VEHICLE TEMPERATURE DOES NOT DISPLAY OR DISPLAY

INCORRECTLY
WIRING DIAGRAM 04
04
1. INSPECT IN-VEHICLE TEMPERATURE SENSOR
(a) Immerse the in-vehicle temperature sensor in water, and then gradually heat the water.
(b) Inspect the in-vehicle temperature sensor according to

Condition Standard Resistance(KΩ)
0℃ 6.143 ± 8%
25 ℃ 2.186 ± 3%

NO > Replace the in-vehicle temperature sensor.
2. CHECK HARNESS AND CONNECTOR (IN-VEHICLE TEMPERATURE SENSOR - GROUND)

(b) Disconnect the Q005 in-vehicle temperature sensor connector.

table below.

Q005 (2) - Ground ＜2Ω

3. CHECK HARNESS AND CONNECTOR (IN-VEHICLE TEMPERATURE SENSOR - COMBINED DIS-
PLAY)

(b) Disconnect the Q005 in-vehicle temperature sensor connector.
(c) Disconnect the C401 combined display connector.

table below.

Q005 (1) - C401 (1) ＜2Ω


(b) Disconnect the Q005 in-vehicle temperature sensor connector. 04
(c) Disconnect the C401 combined display connector.

table below.

C401(1) - Ground ≥ 1 ΜΩ

REVERSE DATA DOES NOT DISPLAY OR DISPLAY INCORRECTLY

WIRING DIAGRAM
1. INSPECT REVERSING RADAR CONTROLLER

(b) Replace the reversing radar controller. (Refer to “Chapter 81 communication system - reverse radar,
replacement“)
Does the combined display work correctly?
YES > Replace the reversing radar controller.
2. CHECK HARNESS AND CONNECTOR (COMBINED DISPLAY - REVERSE RADAR CONTROLLER)

(c) Disconnect the C041 reversing radar controller connector.

table below.
04
C401 (5) - C041 (13)
＜2Ω
C401 (6) - C041 (5)
04


(c) Disconnect the C041 reversing radar controller connector.

table below.

C041 (5) - Ground
≥ 1 ΜΩ
C041 (13) - Ground

MEMO
INDEX 1
（ORGNIZED ALPHABETICALLY）
A C 1
A SINGLE MIRROR IS INOPERATIVE CAPTURING DATA

(OUTSIDE MIRROR) ................................................................04-352 (DIESEL ENGINE CONTROL SYSTEM) ................................. 04-134
1
ABBREVIATIONS USED IN THIS MANUAL(TERMS) ...............01-35 CAPTURING DATA
ABS MODULE CONNECTOR(ANTI-LOCK BRAKE SYSTEM) 04-219 (GAOSLINE ENGINE CONTROL SYSTEM) .............................. 04-22 1
ABS WARNING LIGHT IS ALWAYS ON CARGO LAMP IS INOPERATIVE
(ANTI-LOCK BRAKE SYSTEM) ................................................04-256 (LIGHTING SYSTEM) .............................................................. 04-705
ABS WARNING LIGHT IS INOPERATIVE CAUTIONS FOR CIRCUIT TROUBLESHOOTING 1
(ANTI-LOCK BRAKE SYSTEM) ................................................04-256 (DIESEL ENGINE CONTROL SYSTEM) ................................. 04-120
ALL POWER WINDOWS ARE INOPERATIVE CD/DVD CAN NOT BE INSERTED OR CD/DVD IS EJECTED
(POWER WINDOWS) ...............................................................04-314 RIGHT NOW AFTER BEING INSERTED(AUDIO SYSTEM) ... 04-598
1
ALT HORN IS INOPERATIVE(HORN SYSTEM) ......................04-561 CD/DVD SOUND SKIPS(AUDIO SYSTEM) ............................. 04-600
ANTI-LOCK BRAKE SYSTEM ..................................................04-217 CIGARETTE LIGHTER ILLUMINATION IS INOPERATIVE 1
AUDIO ILLUMINATION IS INOPERATIVE (LIGHTING SYSTEM) .............................................................. 04-719
(LIGHTING SYSTEM) ...............................................................04-725 CLUTCH .......................................................................... 02-25, 03-36
AUDIO SYSTEM .......................................................................04-565 COMBINED DISPLAY .............................................................. 04-814 1
AXLE AND PROPELLER SHAFT ................................... 02-18, 03-25 COMBINED DISPLAY ILLUMINATION IS INOPERATIVE
A/C SYSTEM IS INOPERATE (LIGHTING SYSTEM) .............................................................. 04-734
(HEATER AND AIR CONDITIONING SYSTEM) ......................04-515 COMBINED DISPLAY IS INOPERATIVE WITHIN SPECIFIED
1
A/C SYSTEM IS INOPERATIVE DISTANCE(REVERSE RADAR SYSTEM) .............................. 04-304
(HEATER AND AIR CONDITIONING SYSTEM) ......................04-473 COMBINED DISPLAY IS INOPERATIVE 1
(COMBINED DISPLAY) ............................................................ 04-820
B COOLING ........................................................................ 02-11, 03-17
C0200 - FRONT WHEEL SPEED SENSOR RH MALFUNCTION 1
BACK-UP LAMP IS INOPERATIVE (ONE SIDE) - WITH (ANTI-LOCK BRAKE SYSTEM) ............................................... 04-225
BJ493ZQ3 ENGINE(LIGHTING SYSTEM) ...............................04-692 C0205 - FRONT WHEEL SPEED SENSOR LH MALFUCTION
BACK-UP LAMP IS INOPERATIVE (ONE SIDE) - WITH (ANTI-LOCK BRAKE SYSTEM) ............................................... 04-230
1
4G63/4G64 ENGINE(LIGHTING SYSTEM) ..............................04-687 C0210 - REAR WHEEL SPEED SENSOR RH MALFUCTION
BACK-UP LAMPS ARE INOPERATIVE (BOTH SIDES) - (ANTI-LOCK BRAKE SYSTEM) ............................................... 04-235 1
WITH BJ493ZQ3 ENGINE(LIGHTING SYSTEM) .....................04-694 C0215 - REAR WHEEL SPEED SENSOR LH MALFUCTION
BACK-UP LAMPS ARE INOPERATIVE (BOTH SIDES) - WITH (ANTI-LOCK BRAKE SYSTEM) ............................................... 04-235
4G63/4G64 ENGINE(LIGHTING SYSTEM) ..............................04-689 C0278 - THE MAIN RELAY ELECTRICAL RESISTANCE 1
BASIC INSPECTION ................................................................04-416 EXCEEDS LIMIT OR FUSE IS BLOWN IN THE KL30 CIRCUIT
BASIC INSPECTION(AUDIO SYSTEM) ...................................04-571 (ANTI-LOCK BRAKE SYSTEM) ............................................... 04-240
BASIC INSPECTION(COMBINED DISPLAY) ..........................04-818 C1249 - OPEN CIRCUIT IN STOP LAMP SWITCH CIRCUIT
1
BASIC INSPECTION (WITH BJ493ZQ3 ENGINE)(ANTI-LOCK BRAKE SYSTEM) .. 04-248
(HEATER AND AIR CONDITIONING SYSTEM) ......................04-465 C1249 - OPEN CIRCUIT IN STOP LAMP SWITCH CIRCUIT 1
BASIC INSPECTION(INSTRUMENT CLUSTER) .....................04-770 (WITH 4G63/4G64 ENGINE)(ANTI-LOCK BRAKE SYSTEM) . 04-243
BASIC INSPECTION(LIGHTING SYSTEM) .............................04-602 C1251 - PUMP MOTOR MALFUNCTION
BASIC INSPECTION(OUTSIDE MIRROR) ..............................04-347 (ANTI-LOCK BRAKE SYSTEM) ............................................... 04-253 1
BASIC INSPECTION(POWER DOOR LOCKS) .......................04-367
BASIC INSPECTION(POWER WINDOWS) .............................04-310 D
BASIC INSPECTION 1
(REAR WINDOW DEFROSTER SYSTEM) ..............................04-454 DATA STREAM LISTACTIVE TEST
BASIC INSPECTION(SLIDING ROOF SYSTEM) ....................04-394 (DIESEL ENGINE CONTROL SYSTEM) ................................. 04-135
1
BASIC INSPECTION(WIPER AND WASHER) .........................04-416 DATA STREAM LIST/ACTIVE TEST
BASIC SERVICE PROCEDURE (GAOSLINE ENGINE CONTROL SYSTEM) .............................. 04-25
(DIESEL ENGINE CONTROL SYSTEM) ..................................04-124 DEFROST ER SYSTEM IS INOPERATIVE 1
BASIC SERVICE PROCEDURE (REAR WINDOW DEFROSTER SYSTEM) ............................. 04-456
(GAOSLINE ENGINE CONTROL SYSTEM) ..............................04-12 DIAGNOSTIC HELP - INTERMITTENT FAULT
BASS HORN IS INOPERATIVE(HORN SYSTEM) ...................04-563 (GAOSLINE ENGINE CONTROL SYSTEM) .............................. 04-10
BRAKE ............................................................................ 02-21, 03-28 DIAGNOSTIC SYSTEM
BRAKE WARNING LIGHT NEVER/ALWAYS ON (DIESEL ENGINE CONTROL SYSTEM) ................................. 04-130
(INSTRUMENT CLUSTER) ......................................................04-796 DIAGNOSTIC SYSTEM
BUZZER IS INOPERATIVE OR OPERATIVE INCORRECTLY (GAOSLINE ENGINE CONTROL SYSTEM) .............................. 04-18
WITHIN SPECIFIED DISTANCE DIAGNOSTIC TROUBLE CODE CHART
(REVERSE RADAR SYSTEM) .................................................04-302 (ANTI-LOCK BRAKE SYSTEM) ............................................... 04-220
(DIESEL ENGINE CONTROL SYSTEM) ................................. 04-138
(GAOSLINE ENGINE CONTROL SYSTEM) .............................. 04-29
DIAGNOSTIC TROUBLE CODE CHART G
(SUPPLEMENTAL RESTRAINT SYSTEM) ............................. 04-263
DIAGNOSTICS ............................................................................. 02-1 GENERAL INFORMATION(HOW TO TROUBLESHOOT) .........01-20
DIAGNOSTICS TROUBLE CODE?DTC?CHECK GENERAL INFORMATION(HOW TO USE THIS MANUAL) ........01-1
(DIESEL ENGINE CONTROL SYSTEM) ................................. 04-138
DIAGNOSTICS TROUBLE CODE?DTC?CHECK H
(ENGINE CONTROL SYSTEM) ................................................. 04-29
DIESEL ENGINE CONTROL SYSTEM .................................... 04-112 HAZARD SWITCH ILLUMINATION IS INOPERATIVE
DIESEL ENGINE SYMPTOM DIAGNOSIS AND TESTS (LIGHTING SYSTEM) ...............................................................04-713
(DIESEL ENGINE CONTROL SYSTEM) ................................. 04-200 HAZARD WARNING AND TURN SIGNAL LAMPS ARE
DOOR AJAR WARNING LIGHT NEVER/ALWAYS ON INOPERATIVE(LIGHTING SYSTEM) ......................................04-662
(INSTRUMENT CLUSTER) ...................................................... 04-808 HAZARD WARNING LAMPS ARE ALWAYS ON(LIGHTING
DOOR LOCKS ............................................................................ 02-36 SYSTEM) ..................................................................................04-670
HAZARD WARNING LAMPS ARE INOPERATIVE
E (TURN SIGNAL LAMPS ARE NORMAL)(LIGHTING SYSTEM) ....04-
654
EBD WARNING LIGHT IS ALWAYS ON HEATER AND AIR CONDITIONING ...............................02-28, 03-40
(ANTI-LOCK BRAKE SYSTEM) ............................................... 04-258 HEATER AND AIR CONDITIONING SYSTEM ........................04-464
EBD WARNING LIGHT IS INOPERATIVE HI-BEAM HEADLAMP IS INOPERATIVE (ONE SIDE)
(ANTI-LOCK BRAKE SYSTEM) ............................................... 04-258 (LIGHTING SYSTEM) ...............................................................04-618
ELECTRONIC CIRCUIT INSPECTION PROCEDURE HI-BEAM HEADLAMPS ARE INOPERATIVE (BOTH SIDES
(HOW TO TROUBLESHOOT) .................................................... 01-31 )(LIGHTING SYSTEM) ..............................................................04-622
ELECTRONIC CLOCK ILLUMINATION IS INOPERATIVE HIGH-MOUNTED STOP LAMP IS INOPERATIVE - WITH
(LIGHTING SYSTEM) .............................................................. 04-710 BJ493ZQ3 ENGINE(LIGHTING SYSTEM) ...............................04-685
EMISSION CONTROL ........................................................ 02-4, 03-5 HIGH-MOUNTED STOP LAMP IS INOPERATIVE - WITH
ENGINE CONTROL SYSTEM ............................................ 02-2, 03-2 4G63/4G64 ENGINE(LIGHTING SYSTEM) .............................04-677
ENGINE COOLANT TEMPERATURE INDICATOR LIGHT HORN IS ALWAYS ON(HORN SYSTEM) ................................04-558
NEVER ON(INSTRUMENT CLUSTER) ................................... 04-793 HORN IS INOPERATIVE(HORN SYSTEM) .............................04-552
ENGINE COOLANT TEMPERATURE WARNING LIGHT HORN SYSTEM ........................................................................04-550
NEVER/ALWAYS ON(INSTRUMENT CLUSTER) ................... 04-788 HOW TO DIAGNOSTICS ANALYSE
ENGINE HOOD AND DOORS ........................................ 02-38, 03-47 (DIESEL ENGINE CONTROL SYSTEM) ..................................04-118
ENGINE MECHANICAL ...................................................... 02-6, 03-7 HOW TO DIAGNOSTICS ANALYSE
ENGINE SYMPTOM DIAGNOSTIC(GAOSLINE ENGINE (GAOSLINE ENGINE CONTROL SYSTEM) ................................04-7
CONTROL SYSTEM) ................................................................. 04-75 HOW TO PROCEED WITH TROUBLESHOOTING
ENGING OIL PRESSURE WARNING LIGHT (HOW TO TROUBLESHOOT) ....................................................01-22
NEVER/ALWAYS ON(INSTRUMENT CLUSTER) ................... 04-800 HOW TO TROUBLESHOOT ......................................................01-20
EXHAUST ........................................................................ 02-10, 03-16 HOW TO USE THIS MANUAL ......................................................01-1
EXTERIOR AND INTERIOR TRIM ............................................. 03-48
J
F
IDENTIFICATION INFORMATION ...............................................01-6
FAIL-SAFE CHART IGNITION ....................................................................................03-19
(GAOSLINE ENGINE CONTROL SYSTEM) .............................. 04-23 IGNITION KEY POSITION REMIND CONTROLLER IS
FRONT A/C CONTROLLER ILLUMINATION IS INOPERATIVE(POWER DOOR LOCKS) .................................04-382
INOPERATIVE(LIGHTING SYSTEM) ...................................... 04-722 INSTRUMENT CLUSTER .........................................................04-763
FRONT FOG LAMP IS INOPERATIVE INSTRUMENT CLUSTER ILLUMINATION IS INOPERATIVE
(ONE SIDE)(LIGHTING SYSTEM) ........................................... 04-633 (LIGHTING SYSTEM) ...............................................................04-707
FRONT FOG LAMPS ARE ALWAYS ON INSTRUMENT CLUSTER INFORMATION
(LIGHTING SYSTEM) .............................................................. 04-640 (INSTRUMENT CLUSTER) ......................................................04-765
FRONT FOG LAMPS ARE INOPERATIVE INSTRUMENT PANEL ................................................................02-34
(BOTH SIDES)(LIGHTING SYSTEM) ...................................... 04-635 INTAKE AIR .........................................................................02-5, 03-6
FRONT INDOOR LAMP IS INOPERATIVE INTERMITTENT FAULT
(LIGHTING SYSTEM) .............................................................. 04-697 (DIESEL ENGINE CONTROL SYSTEM) ..................................04-122
FRONT PARKING LAMPS ARE INOPERATIVE IN-VEHICLE TEMPERATURE DOES NOT DISPLAY OR
(LIGHTING SYSTEM) .............................................................. 04-752 DISPLAY INCORRECTLY(COMBINED DISPLAY) ..................04-823
FRONT POWER WINDOW LH DOES NOT CLOSE
(POWER WINDOWS) .............................................................. 04-334 L
FRONT POWER WINDOW LH DOES NOT OPEN
(POWER WINDOWS) .............................................................. 04-331 LICENSE LAMP IS INOPERATIVE(LIGHTING SYSTEM) .......04-756
FRONT POWER WINDOW LH IS INOPERATIVE LIGHTING ...................................................................................03-43
(POWER WINDOWS) .............................................................. 04-328 LIGHTING SYSTEM .................................................................04-601
FRONT POWER WINDOW RH IS INOPERATIVE LIST OF SYMPTOM OF FAILURE
(POWER WINDOWS) .............................................................. 04-337 (DIESEL ENGINE CONTROL SYSTEM) ..................................04-195
FRONT SUSPENSION .................................................... 02-15, 03-22 LO-BEAM AND HI-BEAM HEADLAMPS ARE INOPERATIVE
FRONT WINDOW RH IS INOPERATIVE (USING THE FRONT (BOTH SIDES)(LIGHTING SYSTEM) ......................................04-628
POWER WINDOW SWITCH RH)(POWER WINDOWS) ......... 04-340 LO-BEAM AND HI-BEAM HEADLAMPS ARE INOPERATIVE
FUEL ................................................................................... 02-3, 03-4 (LIGHTING SYSTEM)(ONE SIDE) ..........................................04-625
LO-BEAM HEADLAMP IS INOPERATIVE
(ONE SIDE)(LIGHTING SYSTEM) ...........................................04-611
LO-BEAM HEADLAMPS ARE INOPERATIVE PRECAUTION(POWER WINDOWS) ....................................... 04-306
(BOTH SIDES)(LIGHTING SYSTEM) ......................................04-615 PRECAUTION(REPAIR INSTRUCTION) ..................................... 01-9
LOCATION(ANTI-LOCK BRAKE SYSTEM) .............................04-218 PRECAUTION(REVERSE RADAR SYSTEM) ......................... 04-283
LOCATION(AUDIO SYSTEM) ..................................................04-568 PRECAUTION(SUPPLEMENTAL RESTRAINT SYSTEM) ...... 04-260
LOCATION(COMBINED DISPLAY) ..........................................04-815 PRECAUTION(WIPER AND WASHER) .................................. 04-412 1
LOCATION(DIESEL ENGINE CONTROL SYSTEM) ...............04-115 PRECHECK(SUPPLEMENTAL RESTRAINT SYSTEM) ......... 04-265
LOCATION(GAOSLINE ENGINE CONTROL SYSTEM) ..............04-4 PREPARATION(AXLE AND PROPELLER SHAFT) .................. 02-18
LOCATION(HEATER AND AIR CONDITIONING SYSTEM) ....04-466 PREPARATION(BRAKE) ........................................................... 02-21 1
LOCATION(HORN SYSTEM) ...................................................04-550 PREPARATION(CLUTCH) ......................................................... 02-25
LOCATION(INSTRUMENT CLUSTER) ....................................04-764 PREPARATION(COOLING) ....................................................... 02-11
LOCATION(LIGHTING SYSTEM) .............................................04-603 PREPARATION(DIAGNOSTICS) ................................................. 02-1
1
LOCATION(OUTSIDE MIRROR) ..............................................04-345 PREPARATION(DOOR LOCKS) ............................................... 02-36
LOCATION(POWER DOOR LOCKS) .......................................04-365 PREPARATION(EMISSION CONTROL) ..................................... 02-4 1
LOCATION(POWER WINDOWS) .............................................04-307 PREPARATION(ENGINE CONTROL SYSTEM) ......................... 02-2
LOCATION(REAR WINDOW DEFROSTER SYSTEM) ............04-452 PREPARATION(ENGINE HOOD AND DOORS) ....................... 02-38
LOCATION(REVERSE RADAR SYSTEM) ...............................04-284 PREPARATION(ENGINE MECHANICAL) ................................... 02-6 1
LOCATION(SLIDING ROOF SYSTEM) ....................................04-391 PREPARATION(EXHAUST) ...................................................... 02-10
LOCATION(SUPPLEMENTAL RESTRAINT SYSTEM) ...........04-261 PREPARATION(FRONT SUSPENSION) .................................. 02-15
LOCATION(WIPER AND WASHER) ........................................04-413 PREPARATION(FUEL) ................................................................ 02-3
1
LUBRICATION ................................................................ 02-12, 03-18 PREPARATION(HEATER AND AIR CONDITIONING) .............. 02-28
PREPARATION(INSTRUMENT PANEL) ................................... 02-34 1
M PREPARATION(INTAKE AIR) ..................................................... 02-5
PREPARATION(LUBRICATION) ............................................... 02-12
MALFUNCTIN IN SPEEDOMETER PREPARATION(PARKING BRAKE) .......................................... 02-22 1
(INSTRUMENT CLUSTER) ......................................................04-779 PREPARATION(POWER STEERING) ...................................... 02-27
MALFUNCTION IN FUEL GAUGE PREPARATION(REAR SUSPENSION) ..................................... 02-16
(INSTRUMENT CLUSTER) ......................................................04-785 PREPARATION(SEAT BELT) .................................................... 02-31
1
MALFUNCTION IN TACHOMETER PREPARATION(SEAT) .............................................................. 02-35
(INSTRUMENT CLUSTER) ......................................................04-782 PREPARATION(SLIDNG ROOF) ............................................... 02-37
MIRROR ADJUSTMENT LEFT/RIGHT IS INOPERATIVE
1
PREPARATION(STARTING AND CHARGING) ........................ 02-14
(OUTSIDE MIRROR) ................................................................04-356 PREPARATION(SUPPLEMENTAL RESTRAINT SYSTEM) ..... 02-30
MIRROR ADJUSTMENT UP/DOWN IS INOPERATIVE PREPARATION(TIRE AND WHEEL) ......................................... 02-17 1
(OUTSIDE MIRROR) ................................................................04-354 PREPARATION(TRANSMISSION) ............................................ 02-23
MIRROR HEATING IS INOPERATIVE PREPARATION(VEHICLE CONTROL SYSTEM) ...................... 02-39
(OUTSIDE MIRROR) ................................................................04-360 PREPARATION(WINDSHIELD) ................................................. 02-33
1
MIRRORS ARE INOPERATIVE PREPARATION(WIPER AND WASHER) .................................. 02-32
(BOTH SIDES)(OUTSIDE MIRROR) .......................................04-349 PROBLEM SYMPTOMS TABLE(AUDIO SYSTEM) ................ 04-572 1
N PROBLEM SYMPTOMS TABLE(COMBINED DISPLAY) ........ 04-819
PROBLEM SYMPTOMS TABLE(GAOSLINE ENGINE CONTROL
SYSTEM) .................................................................................... 04-74 1
NO SOUND IS HEARD FROM SPEAKER IN ALL MODES
(AUDIO SYSTEM) .....................................................................04-578
(HEATER AND AIR CONDITIONING SYSTEM) ......... 04-470, 04-512
O PROBLEM SYMPTOMS TABLE(HORN SYSTEM) ................. 04-551
1
PROBLEM SYMPTOMS TABLE(INSTRUMENT CLUSTER) .. 04-771
ONE DOOR IS INOPERATIVE(POWER DOOR LOCKS) ........04-379 PROBLEM SYMPTOMS TABLE(LIGHTING SYSTEM) ........... 04-605 1
OUTSIDE MIRROR ...................................................................04-345 PROBLEM SYMPTOMS TABLE(OUTSIDE MIRROR) ............ 04-348
OUTSIDE MIRROR DEFROST SWITCH ILLUMINATION IS PROBLEM SYMPTOMS TABLE(POWER DOOR LOCKS) ..... 04-368
INOPERATIVE(LIGHTING SYSTEM) .......................................04-731 PROBLEM SYMPTOMS TABLE(POWER WINDOWS) ........... 04-312 1
P (REAR WINDOW DEFROSTER SYSTEM) ............................. 04-455
1
PARKING BRAKE ........................................................... 02-22, 03-30 (REVERSE RADAR SYSTEM) ................................................. 04-288
PARKING LAMPS, TAIL LAMPS AND LICENSE LAMP ARE PROBLEM SYMPTOMS TABLE 1
INOPERATIVE(LIGHTING SYSTEM) ......................................04-758 (SLIDING ROOF SYSTEM) ...................................................... 04-395
POWER DOOR LOCKS ............................................................04-364 PROBLEM SYMPTOMS TABLE
POWER FOLDING IS INOPERATIVE(OUTSIDE MIRROR) ....04-358 (SUPPLEMENTAL RESTRAINT SYSTEM) ............................. 04-264 1
POWER STEERING ....................................................... 02-27, 03-38 PROBLEM SYMPTOMS TABLE(WIPER AND WASHER) ...... 04-417
POWER WINDOWS .................................................................04-306 P0100 - AIR MASS SIGNAL CUTOFFOR SHORT CIRCUIT TO
PRE - CHECK(ANTI-LOCK BRAKE SYSTEM) ........................04-223 EITHER BATTERY OR GROUND
PRECAUTION(ANTI-LOCK BRAKE SYSTEM) ........................04-217 (DIESEL ENGINE CONTROL SYSTEM) ................................. 04-153
PRECAUTION(AUDIO SYSTEM) .............................................04-565 P0101 - AIR MASS SIGNAL RANGE CHECK ERROR
PRECAUTION(COMBINED DISPLAY) .....................................04-814 (DIESEL ENGINE CONTROL SYSTEM) ................................. 04-153
PRECAUTION(DIESEL ENGINE CONTROL SYSTEM) ..........04-112 P0102 - AIR MASS RATIO IS LOWER THRESHOLD LOW
PRECAUTION(GAOSLINE ENGINE CONTROL SYSTEM) .........04-1 (DIESEL ENGINE CONTROL SYSTEM) ................................. 04-153
PRECAUTION P0103 - AIR MASS RATIO IS HIGHER THRESHOLD HIGH
(HEATER AND AIR CONDITIONING SYSTEM) ......................04-464 (DIESEL ENGINE CONTROL SYSTEM) ................................. 04-153
PRECAUTION(INSTRUMENT CLUSTER) ...............................04-763 P0107 - MAP SENSOR CIRCUIT LOW VOLTAGE
PRECAUTION(LIGHTING SYSTEM) .......................................04-601 OR OPEN(GAOSLINE ENGINE CONTROL SYSTEM) ............. 04-38
PRECAUTION(POWER DOOR LOCKS) ..................................04-364
P0108 - MAP SENSOR CIRCUIT HIGH VOLTAGE R
(GAOSLINE ENGINE CONTROL SYSTEM) .............................. 04-38
P0112 - IAT SENSOR CIRCUIT LOW VOLTAGE RADIO BROADCASTING SIGNAL CAN NOT BE RECEIVED
OR OPEN(GAOSLINE ENGINE CONTROL SYSTEM) ............. 04-43 (POOR RECEPTION)(AUDIO SYSTEM) .................................04-589
P0113 - IAT SENSOR CIRCUIT HIGH VOLTAGE READING AND ERASING DIAGNOSTIC TROUBLE
(GAOSLINE ENGINE CONTROL SYSTEM) .............................. 04-43 CODE (DTC)(DIESEL ENGINE CONTROL SYSTEM) ............04-132
P0117 - COOLANT TEMPERATURE SENSOR VOLTAGE READING AND ERASING DIAGNOSTIC TROUBLE
BELOW LOWER LIMIT CODE (DTC)(GAOSLINE ENGINE CONTROL SYSTEM) .........04-20
(DIESEL ENGINE CONTROL SYSTEM) ................................. 04-160 REAR A/C SWITCH (FRONT CONTROL) ILLUMINATION IS
P0117 - ENGINE COOLING TEMPERATURE SENSOR INOPERATIVE(LIGHTING SYSTEM) .......................................04-749
CIRCUIT LOW VOLTAGE REAR FOG LAMP IS INOPERATIVE
(GAOSLINE ENGINE CONTROL SYSTEM) .............................. 04-34 (ONE SIDE)(LIGHTING SYSTEM) ..........................................04-643
P0118 - COOLANT TEMPERATURE SENSOR VOLTAGE ABOVE REAR FOG LAMP SWITCH ILLUMINATION IS
UPPER LIMIT(DIESEL ENGINE CONTROL SYSTEM) .......... 04-160 INOPERATIVE(LIGHTING SYSTEM) .......................................04-728
P0118 - ENGINE COOLING TEMPERATURE SENSOR CIRCUIT REAR FOG LAMPS ARE ALWAYS ON
HIGH VOLTAGE(GAOSLINE ENGINE CONTROL SYSTEM) .. 04-34 (LIGHTING SYSTEM) ...............................................................04-652
P0122 - ACCELERATOR PEDAL 1 VOLTAGE BELOW LOWER REAR FOG LAMPS ARE INOPERATIVE
LIMIT(DIESEL ENGINE CONTROL SYSTEM) ........................ 04-186 (BOTH SIDES)(LIGHTING SYSTEM) ......................................04-645
P0122 - THROTTLE POSITION LOW VOLTAGE REAR HEATER CONTROL PANEL ILLUMINATION IS
(GAOSLINE ENGINE CONTROL SYSTEM) .............................. 04-47 INOPERATIVE(LIGHTING SYSTEM) .......................................04-746
P0123 - ACCELERATOR PEDAL 1 VOLTAGE ABOVE UPPER REAR HEATER SWITCH (FRONT CONTROL)
LIMIT(DIESEL ENGINE CONTROL SYSTEM) ........................ 04-186 ILLUMINATION IS INOPERATIVE(LIGHTING SYSTEM) .......04-740
P0123 - THROTTLE POSITION HIGH VOLTAGE REAR HEATER SWITCH (REAR CONTROL)
(GAOSLINE ENGINE CONTROL SYSTEM) .............................. 04-47 ILLUMINATION IS INOPERATIVE(LIGHTING SYSTEM) .......04-743
P0131 - FRONT OXYGEN SENSOR SHORT LOW REAR INDOOR LAMP IS INOPERATIVE
(GAOSLINE ENGINE CONTROL SYSTEM) .............................. 04-52 (LIGHTING SYSTEM) ...............................................................04-700
P0132 - FRONT OXYGEN SENSOR SHORT HIGH REAR SUSPENSION ......................................................02-16, 03-23
(GAOSLINE ENGINE CONTROL SYSTEM) .............................. 04-52 REAR WINDOW DEFROST SWITCH ILLUMINATION IS
P0134 - FRONT OXYGEN SENSOR OPEN INOPERATIVE(LIGHTING SYSTEM) .......................................04-737
(GAOSLINE ENGINE CONTROL SYSTEM) .............................. 04-52 REAR WINDOW DEFROSTER SYSTEM ................................04-452
P0192 - RAIL PRESSURE VOLTAGE BELOW LOWER LIMIT REPAIR INSTRUCTION ...............................................................01-9
(DIESEL ENGINE CONTROL SYSTEM) ................................. 04-170 RESTRAINT CONTROL MODULE CONNECTOR
P0193 - RAIL PRESSURE VOLTAGE ABOVE UPPER LIMIT (SUPPLEMENTAL RESTRAINT SYSTEM) ..............................04-262
(DIESEL ENGINE CONTROL SYSTEM) ................................. 04-170 REVERSE DATA DOES NOT DISPLAY OR DISPLAY
P0201 - INJECTOR 1 OPEN LOAD INCORRECTLY(COMBINED DISPLAY) ..................................04-826
(DIESEL ENGINE CONTROL SYSTEM) ................................. 04-175 REVERSE RADAR SYSTEM ...................................................04-283
P0222 - ACCELERATOR PEDAL 2 VOLTAGE BELOW REVERSE RADAR SYSTEM IS INOPERATIVE AT ALL
LOWER LIMIT(DIESEL ENGINE CONTROL SYSTEM) .......... 04-186 (REVERSE RADAR SYSTEM) .................................................04-290
P0223 - ACCELERATOR PEDAL 2 VOLTAGE ABOVE UPPER REVERSE RADAR SYSTEM IS INOPERATIVE WITHIN
LIMIT(DIESEL ENGINE CONTROL SYSTEM) ........................ 04-186 SPECIFIED DISTANCE(REVERSE RADAR SYSTEM) ...........04-298
P0261 - INJECTOR 1 SHORT CIRCUIT LOW SIDE TO REVERSE RADAR SYSTEM IS OPERATIVE BUT THERE IS NO
HIGH SIDE(DIESEL ENGINE CONTROL SYSTEM) ............... 04-175 OBSTACLE BEHIND VEHICLE
P0262 - INJECTOR 1 SHORT CIRCUIT ON LOW SIDE TO (REVERSE RADAR SYSTEM) .................................................04-300
BATTERY(DIESEL ENGINE CONTROL SYSTEM) ................. 04-175 REVERSE RADAR SYSTEM IS OPERATIVE WHEN THE SHIFT
P0325 - KNOCK SYSTEM FAULT(GAOSLINE ENGINE LEVER IS OUT OF REVERSE POSITION
CONTROL SYSTEM) ................................................................. 04-63 (REVERSE RADAR SYSTEM) .................................................04-296
P0327 - KNOCK SENSOR FAULT
(GAOSLINE ENGINE CONTROL SYSTEM) .............................. 04-63 S
P0336 - CKP SENSOR CIRCUIT NOISY SIGNAL
(GAOSLINE ENGINE CONTROL SYSTEM) .............................. 04-58 SEAT ................................................................................02-35, 03-45
P0340 - NO CAMSHAFT SIGNAL SEAT BELT ......................................................................02-31, 03-42
(DIESEL ENGINE CONTROL SYSTEM) ................................. 04-165 SEAT BELT WARNING LIGHT NEVER/ALWAYS ON
P0341 - WRONG CAMSHAFT SIGNAL (INSTRUMENT CLUSTER) ......................................................04-804
(DIESEL ENGINE CONTROL SYSTEM) ................................. 04-165 SELF-CHECK FUNCTION IS INOPERATIVE
P0401 - EGR NEGATIVE GOVERNOR DEVIATION BELOW (REVERSE RADAR SYSTEM) .................................................04-294
LIMIT(DIESEL ENGINE CONTROL SYSTEM) ........................ 04-180 SERIAL NUMBER (SN)(IDENTIFICATION INFORMATION) .......01-7
P0402 - EGR POSITIVE GOVERNOR DEVIATION SERVICE DATA(AXLE AND PROPELLER SHAFT) ..................03-25
ABOVE LIMIT(DIESEL ENGINE CONTROL SYSTEM) ........... 04-180 SERVICE DATA(BRAKE) ...........................................................03-28
P0480 - FAN 1 FAULT SERVICE DATA(CLUTCH) .........................................................03-36
(GAOSLINE ENGINE CONTROL SYSTEM) .............................. 04-67 SERVICE DATA(COOLING) .......................................................03-17
P0481 - FAN 2 FAULT SERVICE DATA(ENGINE HOOD AND DOORS) .......................03-47
(GAOSLINE ENGINE CONTROL SYSTEM) .............................. 04-67 SERVICE DATA(ENGINE MECHANICAL) ...................................03-7
P2135 - ACCELERATOR PEDAL 1 PLAUSIBILITY WITH SERVICE DATA(EXHAUST) ......................................................03-16
APP2VIOLATED(DIESEL ENGINE CONTROL SYSTEM) ..... 04-186 SERVICE DATA(FRONT SUSPENSION) ..................................03-22
SERVICE DATA(HEATER AND AIR CONDITIONING) .............03-40
SERVICE DATA(IGNITION) .......................................................03-19
SERVICE DATA(INTAKE AIR) .....................................................03-6
SERVICE DATA(LUBRICATION) ...............................................03-18
SERVICE DATA(POWER STEERING) ......................................03-38
SERVICE DATA(REAR SUSPENSION) .....................................03-23 THE FUNCTION OF POWER DOOR LOCKS IS
SERVICE DATA(STARTING AND CHARGING) ........................03-20 INOPERATIVE(POWER DOOR LOCKS) ................................ 04-369
SERVICE DATA(STEERING COLUMN) ....................................03-37 THE INSTRUMENT CLUSTER IS INOPERATIVE
SERVICE DATA(SUPPLEMENTAL RESTRAINT SYSTEM) .....03-41 (INSTRUMENT CLUSTER) ...................................................... 04-776
SERVICE DATA(TIRE AND WHEEL) .........................................03-24 TIRE AND WHEEL .......................................................... 02-17, 03-24 1
SERVICE DATA(TRANSMISSION) ............................................03-31 TORQUE SPECIFICATION
SERVICE DATA(WIPER AND WASHER) ..................................03-44 (AXLE AND PROPELLER SHAFT) ............................................ 03-27
SEVICE DATA(ENGINE CONTROL SYSTEM) ............................03-2 TORQUE SPECIFICATION(BRAKE) ......................................... 03-28 1
SEVICE DATA(FUEL) ...................................................................03-4 TORQUE SPECIFICATION(CLUTCH) ....................................... 03-36
SLIDING DOOR STEP LAMPS ARE INOPERATIVE TORQUE SPECIFICATION(COOLING) ..................................... 03-17
(LIGHTING SYSTEM) ...............................................................04-703 TORQUE SPECIFICATION(EMISSION CONTROL) ................... 03-5
1
SLIDING ROOF ..........................................................................03-46 TORQUE SPECIFICATION(ENGINE CONTROL SYSTEM) ....... 03-3
SLIDING ROOF DOES NOT CLOSE OR CLOSE INCORRECTLY TORQUE SPECIFICATION(ENGINE HOOD AND DOORS) ..... 03-47 1
(OPEN IS NORMAL)(SLIDING ROOF SYSTEM) ....................04-406 TORQUE SPECIFICATION(ENGINE MECHANICAL) ............... 03-13
SLIDING ROOF DOES NOT OPEN OR OPEN INCORRECTLY TORQUE SPECIFICATION(EXHAUST) .................................... 03-16
(CLOSE IS NORMAL)(SLIDING ROOF SYSTEM) ..................04-402 TORQUE SPECIFICATION 1
SLIDING ROOF STOPS OPERATION HALFWAY (EXTERIOR AND INTERIOR TRIM) .......................................... 03-48
(SLIDING ROOF SYSTEM) ......................................................04-410 TORQUE SPECIFICATION(FRONT SUSPENSION) ................ 03-22
SLIDING ROOF SYSTEM .........................................................04-391 TORQUE SPECIFICATION(FUEL) .............................................. 03-4
1
SLIDING ROOF SYSTEM IS INOPERATIVE TORQUE SPECIFICATION
(SLIDING ROOF SYSTEM) ......................................................04-396 (HEATER AND AIR CONDITIONING) ....................................... 03-40 1
SLIDNG ROOF ...........................................................................02-37 TORQUE SPECIFICATION(IGNITION) ..................................... 03-19
SOUND QUALITY IS POOR IN ALL MODES TORQUE SPECIFICATION(INTAKE AIR) ................................... 03-6
(AUDIO SYSTEM) .....................................................................04-582 TORQUE SPECIFICATION(LIGHTING) .................................... 03-43 1
SOUND QUALITY IS POOR ONLY WHEN PLAYING CD/DVD TORQUE SPECIFICATION(LUBRICATION) ............................. 03-18
(AUDIO SYSTEM) .....................................................................04-588 TORQUE SPECIFICATION(PARKING BRAKE) ........................ 03-30
SPECIFIED TORQUE FOR SPECIFICATION BOLTS .................03-1 TORQUE SPECIFICATION(POWER STEERING) .................... 03-39
1
SRS WARNING LIGHT IS ALWAYS ON(SUPPLEMENTAL TORQUE SPECIFICATION(REAR SUSPENSION) ................... 03-23
RESTRAINT SYSTEM) .............................................................04-280 TORQUE SPECIFICATION(SEAT BELT) .................................. 03-42 1
SRS WARNING LIGHT IS INOPERATIVE TORQUE SPECIFICATION(SEAT) ............................................ 03-45
(SUPPLEMENTAL RESTRAINT SYSTEM) ..............................04-280 TORQUE SPECIFICATION(SLIDING ROOF) ........................... 03-46
STARTING AND CHARGING ......................................... 02-14, 03-20 TORQUE SPECIFICATION(STARTING AND CHARGING) ...... 03-21 1
STEERING COLUMN ..................................................... 02-26, 03-37 TORQUE SPECIFICATION(STEERING COLUMN) .................. 03-37
STOP LAMP IS INOPERATIVE (ONE SIDE) - WITH TORQUE SPECIFICATION
BJ493ZQ3 ENGINE(LIGHTING SYSTEM) ...............................04-683 (SUPPLEMENTAL RESTRAINT SYSTEM) ............................... 03-41
1
STOP LAMP IS INOPERATIVE (ONE SIDE) - WITH TORQUE SPECIFICATION(TIRE AND WHEEL) ....................... 03-24
4G63/ 4G64 ENGINE(LIGHTING SYSTEM) .............................04-675 TORQUE SPECIFICATION(TRANSMISSION) .......................... 03-34 1
STOP LAMPS ARE INOPERATIVE (BOTH SIDES) - WITH TORQUE SPECIFICATION(WIPER AND WASHER) ................ 03-44
BJ493ZQ3 ENGINE(LIGHTING SYSTEM) ..............................04-679 TRANSMISSION ............................................................. 02-23, 03-31
STOP LAMPS ARE INOPERATIVE (BOTH SIDES) - WITH TURN SIGNAL LAMP IS INOPERATIVE 1
4G63/4G64 ENGINE(LIGHTING SYSTEM) ..............................04-672 (ONE SIDE)(LIGHTING SYSTEM) .......................................... 04-668
SUPPLEMENTAL RESTRAINT SYSTEM ......... 02-30, 03-41, 04-260 TURN SIGNAL LAMPS ARE INOPERATIVE (HAZARD
SYSTEM DESCRIPTION(COMBINED DISPLAY) ....................04-816 WARNING LAMPS ARE NORMAL)(LIGHTING SYSTEM) ...... 04-658
1
SYSTEM DESCRIPTION
(REAR WINDOW DEFROSTER SYSTEM) ..............................04-453 W
1
SYSTEM DESCRIPTION(REVERSE RADAR SYSTEM) .........04-285
SYSTEM DESCRIPTION(SLIDING ROOF SYSTEM) ..............04-392 WASHER PUMP IS INOPERATIVE - REAR WINDOW
SYSTEM DESCRIPTION(WIPER AND WASHER) ..................04-415 (WIPER AND WASHER) .......................................................... 04-449 1
WASHER PUMP IS INOPERATIVE - WINDSHIELD
T (WIPER AND WASHER) .......................................................... 04-433
VEHICLE CONTROL SYSTEM .................................................. 02-39 1
TAIL LAMPS ARE INOPERATIVE(LIGHTING SYSTEM) .........04-754 VEHICLE IDENTIFICATION NUMBER (VIN)(IDENTIFICATION
TERMINALS OF CENTRAL DOOR LOCK CONTROLLER INFORMATION) ........................................................................... 01-6
(POWER DOOR LOCKS) .........................................................04-366 VEHICLE LIFT AND SUPPORT LOCATIONS
1
TERMINALS OF CENTRAL DOOR LOCK CONTROLLER (REPAIR INSTRUCTION) .......................................................... 01-18
(POWER WINDOWS) ...............................................................04-309 WHEN THE WIPER SWITCH IS OFF, THE WIPER BLADE DOES 1
TERMINALS OF COMBINED DISPLAY NOT RETRACT(WIPER AND WASHER) ................................ 04-436
(COMBINED DISPLAY) ............................................................04-817 WINDSHIELD ............................................................................. 02-33
TERMINALS OF INSTRUMENT CLUSTER(INSTRUMENT WIPER AND WASHER ......................................02-32, 03-44, 04-412
CLUSTER) ................................................................................04-768 WIPER IS INOPERATIVE - REAR WINDOW
TERMINALS OF MAIN COMPONENTS (WIPER AND WASHER) .......................................................... 04-439
(SLIDING ROOF SYSTEM) ......................................................04-393 WIPER IS INOPERATIVE IN INTERMITTENT MODE -
TERMINALS OF MAIN POWER WINDOW AND DOOR REAR WINDOW(WIPER AND WASHER) ............................... 04-445
LOCK/UNLOCK SWITCH(POWER WINDOWS) ......................04-308 WIPERS ARE INOPERATIVE - WINDSHIELD
TERMINALS OF OUTSIDE MIRROR DEFROST SWITCH (WIPER AND WASHER) .......................................................... 04-419
(OUTSIDE MIRROR) ................................................................04-346 WIPERS ARE INOPERATIVE AT HIGH SPEED -
TERMINALS OF RADIO UNIT(AUDIO SYSTEM) ....................04-569 WINDSHIELD(WIPER AND WASHER) ................................... 04-427
TERMS ........................................................................................01-35 WIPERS ARE INOPERATIVE AT LOW SPEED -
THE AUDIO SYSTEM IS INOPERATIVE(AUDIO SYSTEM) ....04-574 WINDSHIELD(WIPER AND WASHER) ................................... 04-424
WIPERS ARE INOPERATIVE IN INTERMITTENT Z
MODE - WINDSHIELD(WIPER AND WASHER) ..................... 04-430
VOLUME IS TOO LOW IN ALL MODES(AUDIO SYSTEM) .... 04-584 12V POWER POINT SOCKET ILLUMINATION IS
INOPERATIVE(LIGHTING SYSTEM) .......................................04-716

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Edition: September 2010 VOLUME 1

Printing: October 2010 INTRODUCTION 01

HOW TO USE THIS MANUAL

WARNING Indicates the possibility of injury to you or other persons.

L / RHD Series Engine Transmission Models

MPX BJ493ZQ3 ZM001AJ2 6526B1DDA-S1ZA03 6526B1DDA-S1ZA03 01

4G63S4M + 6526B1EVA-S1Z044 6526B1EVA-S1Z045

4G63S4M + 6526B1EVA-S1Z040 6526B1EVA-S1Z041

SERIAL NUMBER (SN)

2. PROPELLER SHAFT SERIAL NUMBER.

• Be sure to wear a clean uniform. 01

• Diagnose with a thorough understanding of the trouble

• Place the removed parts in the correct order to avoid mixing up or

(b) Jacking up and supporting vehicle.

Illustration Symbol Part Name Abbreviation

Shape (Example) Removal / Installation 01

Shape (Example) Removal / Installation

(h) Removal and installation of vacuum hoses.

• Formula: T’ = T × L2 / (L1 + L2) 01

T’ Reading of torque wrench (N·m) 01

L2 Length of torque wrench (mm)

2. FOR VEHICLES EQUIPPED WITH SUPPLEMENTAL RESTRAINT SYSTEM.

(b) Clock spring.

• When removing the horn switch assy or handling a new

(b) Handling of electronic parts.

• Do not drop electronic components, such as sensors or

(a) When removing and installing the inlet system parts,

6. HANDLING OF HOSE CLAMPS.

VEHICLE LIFT AND SUPPORT LOCATIONS

Audio System Chapter 04 diagnostics - audio system

Combined Display Chapter 04 diagnostics - combined display

Chapter 04 diagnostics - gasoline engine control system

Horn Chapter 04 diagnostics - horn system

Instrument Cluster Chapter 04 diagnostics - instrument cluster

Lighting Chapter 04 diagnostics - light system

Outside Mirror Chapter 04 diagnostics - outside mirrors

Power Door Locks Chapter 04 diagnostics - power door locks

Power Windows Chapter 04 diagnostics - power windows

Reverse Radar Chapter 04 diagnostics - reverse radar system

Sliding Roof Chapter 04 diagnostics - sliding roof system

Supplemental Restrait System Chapter 04 diagnostics - supplemental restraint system

Wiper And Washer Chapter 04 diagnostics - wiper and washer

FOR USING HAND-HELD TESTER

HOW TO PROCEED WITH TROUBLESHOOTING

2. CUSTOMER PROBLEM ANALYSIS

(a) Check the battery positive voltage.

CUSTOMER PROBLEM ANALYSIS

Under what conditions? Running conditions, driving conditions, weather conditions 01

SYMPTOM CONFIRMATION AND DTC (INCLUDING DATA STREAM) CHECK

Wiper And Washer ○ - - - ○

2. MAKE A NOTE AND CLEAR THE DTC

Do the problem symptoms still exist? 01

4. SIMULATION TEST WITH THE METHODS OF SYMPTOM SIMULATION (Refer to “Chapter 01 01

1. VIBRATION METHOD: When vibration seems to be

2. HEAT METHOD: If the problem seems to occur when

PROBLEM SYMPTOMS TABLE

ELECTRONIC CIRCUIT INSPECTION PROCEDURE

(b) Handling of connectors. 01

Check when the connector is disconnected: 01

Check the contact pressure of the terminal:

(d) Repair method of connector terminal.

(e) Handling of wire harness.

2. CHECK OPEN CIRCUIT.

(b) Check the resistance.