Engine Control System

ENGINE CONTROL SYSTEM
SECTION EC
CONTENTS
DIAGNOSTIC TROUBLE CODE INDEX.........................2 Malfunction Indicator Lamp (MIL)..............................28
Alphabetical & Numerical Index for DTC ....................2 CONSULT ..................................................................32
PRECAUTIONS AND PREPARATION............................3 TROUBLE DIAGNOSIS - Introduction ........................41
Special Service Tools ..................................................3 Introduction ................................................................41
Commercial Service Tool.............................................5 Diagnostic Worksheet................................................41
Supplemental Restraint System (SRS) ″AIR TROUBLE DIAGNOSIS - Work Flow...........................43
BAG″ and ″SEAT BELT PRE-TENSIONER″...............5 Work Flow..................................................................43
Description for Work Flow .........................................44
TB45E TROUBLE DIAGNOSIS - Basic Inspection ................45
Idle Speed/Ignition Timing/Throttle Position
PRECAUTIONS AND PREPARATION............................6 Sensor/Idle Mixture Ratio Check and Adjustment.....45
Engine Fuel & Emission Control System ....................6 TROUBLE DIAGNOSIS - General Description...........51
Precautions ..................................................................7 Fail-Safe Chart...........................................................51
ENGINE AND EMISSION CONTROL OVERALL Symptom Matrix Chart...............................................52
SYSTEM...........................................................................9 CONSULT Reference Value in Data Monitor
Circuit Diagram ............................................................9 Mode ..........................................................................54
System Diagram ........................................................10 Major Sensor Reference Graph in Data Monitor
Engine Control Component Parts Location...............11 Mode ..........................................................................56
Vacuum Hose Drawing ..............................................13 ECM Terminals and Reference Value .......................58
System Chart .............................................................14 TROUBLE DIAGNOSIS FOR POWER SUPPLY..........65
ENGINE AND EMISSION BASIC CONTROL Main Power Supply and Ground Circuit....................65
SYSTEM DESCRIPTION ...............................................15 TROUBLE DIAGNOSIS FOR ″CAMSHAFT POSI
Multiport Fuel Injection (MFI) System .......................15 SEN″ (DTC 11)...............................................................70
Distributor Ignition (DI) System .................................18 Camshaft Position Sensor (CMPS) ...........................70
Air Conditioning Cut Control......................................19 TROUBLE DIAGNOSIS FOR ″MASS AIR FLOW
Fuel Cut Control (at no load & high engine SEN″ (DTC 12) ..............................................................77
speed) ........................................................................19 Mass Air Flow Sensor (MAFS) ..................................77
EVAPORATIVE EMISSION SYSTEM ...........................20 TROUBLE DIAGNOSIS FOR ″COOLANT TEMP
Description .................................................................20 SEN″ (DTC 13) ..............................................................82
Inspection...................................................................20 Engine Coolant Temperature Sensor (ECTS) ...........82
POSITIVE CRANKCASE VENTILATION......................22 TROUBLE DIAGNOSIS FOR ″IGN
Description .................................................................22 SIGNAL-PRIMARY″ (DTC 21).......................................86
Inspection...................................................................22 Ignition Signal ............................................................86
BASIC SERVICE PROCEDURE ...................................23 TROUBLE DIAGNOSIS FOR ″OVER HEAT″ (DTC
Fuel Pressure Release ..............................................23 28) ..................................................................................92
Fuel Pressure Check .................................................23 Cooling Fan Control (Overheat) ................................92
Injector Removal and Installation ..............................24 TROUBLE DIAGNOSIS FOR ″KNOCK SENSOR″
Fast Idle Cam (FIC) Inspection and Adjustment .......25 (DTC 34).......................................................................105
ON BOARD DIAGNOSTIC SYSTEM Knock Sensor (KS) ..................................................105
DESCRIPTION ...............................................................26 TROUBLE DIAGNOSIS FOR ″THROTTLE POSI
Introduction ................................................................26 SEN″ (DTC 43) ............................................................108
Diagnostic Trouble Code (DTC) ................................26 Throttle Position Sensor ..........................................108
CONTENTS (Cont’d) GI
TROUBLE DIAGNOSIS FOR ″A/T COMM LINE″ IDLE COMPENSATOR ................................................184
(DTC 54).......................................................................114 Component Description ...........................................184 MA
A/T Control...............................................................114 Inspection.................................................................184
TROUBLE DIAGNOSIS FOR NON-DETECTABLE AUTOMATIC TEMPERATURE CONTROL (ATC)
ITEMS...........................................................................117 AIR CLEANER SYSTEM.............................................185
EM
Vehicle Speed Sensor (VSS) ..................................117 System Description..................................................185
Oxygen Sensor (O2S) .............................................121 System Inspection ...................................................185 LC
Idle Air Control Valve (IACV) - Auxiliary Air Vacuum Motor..........................................................186
Control (AAC) Valve ................................................125 Temperature Sensor ................................................186
Park/Neutral Position Switch ...................................130 COOLING FAN MOTOR ELECTRICAL CIRCUIT ......187
Injector .....................................................................136 Wiring Diagram - COOL/F -.....................................187
Start Signal ..............................................................140 System Description..................................................188
Fuel Pump ...............................................................142 Inspection.................................................................188 FE
Power Steering Oil Pressure Switch .......................148 Electrical Components Inspection ...........................189
IACV-FICD Solenoid Valve ......................................152 EVAPORATIVE EMISSION CONTROL SYSTEM.......190
CL
MIL & Data Link Connectors ...................................156 System Description..................................................190
Inspection.................................................................190
TB42S CRANKCASE EMISSION CONTROL SYSTEM.........192 MT
System Description..................................................192
ENGINE AND EMISSION CONTROL OVERALL Inspection.................................................................192
SYSTEM.......................................................................157 EXHAUST EMISSION CONTROL SYSTEM...............194 AT
Component Parts Location ......................................157 Boost Controlled Deceleration Device (BCDD).......194
System Diagram ......................................................158 Circuit Check ...........................................................197
Circuit Diagram ........................................................159 BCDD Control Solenoid Valve.................................197
TF
Vacuum Hose Drawing ............................................160
CARBURETOR ............................................................161
Construction.............................................................161
RD28ETi PD
Major Service Operation..........................................163 PRECAUTIONS AND PREPARATION........................198
Disassembling Carburetor Harness Connector.......163 Engine Fuel & Emission Control System ................198 FA
Checking and Adjusting Idle Speed, Ignition Precautions ..............................................................199
Timing and Mixture Ratio.........................................164 ENGINE AND EMISSION CONTROL OVERALL
Checking and Adjusting Idle-rpm, Ignition Timing SYSTEM.......................................................................201 RA
and Mixture Ratio ....................................................165 ECCS-D Component Parts Location .......................201
Fuel Level ................................................................168 Circuit Diagram ........................................................204
Automatic Choke .....................................................170 System Diagram ......................................................205 BR
Fast Idle ...................................................................172 Vacuum Hose Drawing ............................................206
Vacuum Break .........................................................172 System Chart ...........................................................207
ST
Accelerator Pump ....................................................173 ENGINE AND EMISSION BASIC CONTROL
Fuel Cut Control System .........................................174 SYSTEM DESCRIPTION .............................................208
ISC-FI Pot ................................................................176 Fuel Injection System ..............................................208 RS
ALTITUDE COMPENSATION SYSTEM......................178 Fuel Injection Timing System ..................................211
System Description..................................................178 Air Conditioning Cut Control....................................212
System Inspection ...................................................179 Fuel Cut Control (at no load & high engine BT
MECHANICAL FUEL PUMP .......................................180 speed) ......................................................................213
Component Description ...........................................180 CRANKCASE VENTILATION SYSTEM......................214
Operation Check......................................................180 Description ...............................................................214
HA
Fuel Pressure ..........................................................180 Inspection.................................................................214
IGNITION CONTROL SYSTEM...................................181 INJECTION NOZZLE...................................................215 EL
Wiring Diagram - IGN -............................................181 Removal and Installation .........................................215
System Description..................................................182 Disassembly (No. 2 - 4 nozzles) .............................215
Component Parts Inspection ...................................182 Inspection (No. 2 - 4 nozzles) .................................216 SE
Distributor Component Check .................................182 Cleaning (No. 2 - 4 nozzles) ...................................216
Assembly (No. 2 - 4 nozzles) ..................................217
IDX
CONTENTS (Cont’d)
Test and Adjustment ................................................218 TROUBLE DIAGNOSIS FOR ″F/INJ TIMG F/B″
ELECTRONIC FUEL INJECTION PUMP....................220 (DTC 21).......................................................................294
Removal...................................................................220 Injection Timing Control Valve .................................294
Installation................................................................221 TROUBLE DIAGNOSIS FOR ″ACCEL POS SW
Disassembly and Assembly.....................................222 (F/C)″ (DTC 23)............................................................299
ON BOARD DIAGNOSTIC SYSTEM Accelerator Switch (F/C)..........................................299
DESCRIPTION .............................................................223 TROUBLE DIAGNOSIS FOR ″ECM 1″ (DTC 27),
DTC and MIL Detection Logic .................................223 ″ECM 2″ (DTC 31) .......................................................304
Diagnostic Trouble Code (DTC) ..............................223 Engine Control Module (ECM)-ECCS-D Control
Malfunction Indicator Lamp (MIL)............................224 Module .....................................................................304
CONSULT ................................................................229 TROUBLE DIAGNOSIS FOR ″OVER HEAT″ (DTC
TROUBLE DIAGNOSIS - Introduction ......................235 28) ................................................................................306
Introduction ..............................................................235 Cooling Fan (Overheat) ...........................................306
Diagnostic Worksheet..............................................236 TROUBLE DIAGNOSIS FOR ″I/C INT/A TEMP
TROUBLE DIAGNOSIS - Work Flow.........................237 SEN″ (DTC 33) ............................................................315
Work Flow................................................................237 Charge Air Temperature Sensor..............................315
Description for Work Flow .......................................238 TROUBLE DIAGNOSIS FOR ″NEEDLE LIFT SEN″
TROUBLE DIAGNOSIS - Basic Inspection ..............239 (DTC 34).......................................................................319
Basic Inspection.......................................................239 Needle Lift Sensor (NLS) ........................................319
TROUBLE DIAGNOSIS - General Description.........241 TROUBLE DIAGNOSIS FOR ″FUEL CUT S/V 1″
Symptom Matrix Chart.............................................241 (DTC 36), ″FCV SHORT″ (DTC 37), ″FUEL CUT
CONSULT Reference Value in Data Monitor S/V 2″ (DTC 38)...........................................................323
Mode ........................................................................244 Fuel Cut Solenoid Valve ..........................................323
Major Sensor Reference Graph in Data Monitor TROUBLE DIAGNOSIS FOR ″FUEL TEMP
Mode ........................................................................246 SENSOR″ (DTC 42).....................................................328
ECM Terminals and Reference Value .....................247 Fuel Temperature Sensor (FTS)..............................328
TROUBLE DIAGNOSIS FOR POWER SUPPLY........256 TROUBLE DIAGNOSIS FOR ″ACCEL POS
Main Power Supply and Ground Circuit..................256 SENSOR″ (DTC 43).....................................................332
TROUBLE DIAGNOSIS FOR ″CAM POS SEN Accelerator Position Sensor ....................................332
(PUMP)″ (DTC 11) .......................................................262 TROUBLE DIAGNOSIS FOR ″CRANK POS SEN
Camshaft Position Sensor (CMPS) (PUMP) ...........262 (TDC)″ (DTC 47) ..........................................................337
TROUBLE DIAGNOSIS FOR ″MASS AIR FLOW Crankshaft Position Sensor (TDC) ..........................337
SEN″ (DTC 12) ............................................................267 TROUBLE DIAGNOSIS FOR ″GOV CUT
Mass Air Flow Sensor (MAFS) ................................267 CIRCUIT″ (DTC 48) .....................................................342
TROUBLE DIAGNOSIS FOR ″COOLANT TEMP Governor Cut Circuit................................................342
SEN″ (DTC 13) ............................................................272 TROUBLE DIAGNOSES FOR NON-DETECTABLE
Engine Coolant Temperature (ECT) Sensor ...........272 ITEMS...........................................................................344
TROUBLE DIAGNOSIS FOR ″VEHICLE SPEED Glow Control System...............................................344
SEN″ (DTC 14) ............................................................276 EGRC-Solenoid Valve A, B and Throttle Control
Vehicle Speed Sensor (VSS) ..................................276 Solenoid Valve .........................................................349
TROUBLE DIAGNOSIS FOR ″CONT SLEEV POS Start Signal ..............................................................356
SEN″ (DTC 15) ............................................................280 Accelerator Position Switch .....................................358
Control Sleeve Position Sensor (CSPS) .................280 Park/Neutral Position Switch ...................................363
TROUBLE DIAGNOSIS FOR ″ADJUST A/T Control...............................................................368
RESISTOR″ (DTC 17)..................................................285 Charge Air Cooler Fan Control................................371
Adjustment Resistor.................................................285 Heat Up Switch........................................................376
TROUBLE DIAGNOSIS FOR ″F/INJ F/B 2″ (DTC Air Conditioner Control ............................................380
18), ″F/INJ F/B″ (DTC 22), ″ELECTRIC GOV″ MIL & Data Link Connectors ...................................381
(DTC 25).......................................................................289
Electric Governor .....................................................289 TD
INJECTION SYSTEM ..................................................382
Fuel System.............................................................382
CONTENTS (Cont’d) GI
INJECTION PUMP.......................................................384 FUEL CUT SYSTEM....................................................421
Inspection.................................................................384 Wiring Diagram ........................................................421 MA
Removal...................................................................385 FAST IDLE CONTROL CIRCUIT ................................422
Installation and Adjustment......................................387 Wiring Diagram ........................................................422
Disassembly.............................................................389 Electrical Components Inspection ...........................423
EM
Load Timer Adjustment............................................389 ENGINE ROOM FAN MOTOR ELECTRICAL
INJECTION NOZZLE...................................................391 CIRCUIT .......................................................................424 LC
Removal and Installation .........................................391 Wiring Diagram ........................................................424
Disassembly.............................................................391 Cooling Fan (Motor driven)......................................425
Inspection.................................................................392 Electrical Components Inspection ...........................425
Cleaning...................................................................392
Assembly .................................................................394 TB45E
Test and Adjustment ................................................394 FE
FUEL SYSTEM CHECK ..............................................396 SERVICE DATA AND SPECIFICATIONS (SDS) ........427
Bleeding Fuel System..............................................396 General Specifications.............................................427
Inspection and Adjustment ......................................427 CL
Bleeding Fuel Filter..................................................397
Checking Priming Pump ..........................................397
Checking Fuel Filter Switch.....................................397 TB42S MT
POSITIVE CRANKCASE VENTILATION....................398 SERVICE DATA AND SPECIFICATIONS (SDS) ........428
Description ...............................................................398 General Specifications.............................................428
Inspection.................................................................398 Inspection and Adjustment ......................................429
AT
QUICK-GLOW SYSTEM..............................................399
Component Parts Location ......................................399
Circuit Diagram ........................................................400
RD28ETi TF
Description ...............................................................402 SERVICE DATA AND SPECIFICATIONS (SDS) ........430
Wiring Diagram ........................................................404 General Specifications.............................................430 PD
Glow Control Unit Circuit Inspection (Except for Injection Nozzle .......................................................430
Cold Areas) ..............................................................410 Inspection and Adjustment ......................................430
Glow Control Unit Circuit Inspection (For Cold FA
Areas) ......................................................................412 TD
Component Inspection.............................................415
SOLENOID TIMER ......................................................417 SERVICE DATA AND SPECIFICATIONS (SDS) ........432 RA
Description ...............................................................417 VE-type Injection Pump ...........................................432
Operation .................................................................417 Injection Nozzle .......................................................432
Injection Pump Calibration Standard.......................433 BR
Wiring Diagram ........................................................418
Inspection.................................................................419
ST
When you read wiring diagrams:
I Read GI section, “HOW TO READ WIRING DIAGRAMS”.
I See EL section, “POWER SUPPLY ROUTING” for power distribution circuit. RS
When you perform trouble diagnoses, read GI section, “HOW TO FOLLOW FLOW CHART IN
TROUBLE DIAGNOSES” and “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL
INCIDENT”. BT
HA
EL
SE
IDX
DIAGNOSTIC TROUBLE CODE INDEX
Alphabetical & Numerical Index for DTC

ALPHABETICAL INDEX FOR DTC NUMERICAL INDEX FOR DTC
X: Applicable X: Applicable
TB45E —: Not applicable TB45E —: Not applicable
Items MIL Reference MIL Items Reference
DTC DTC
(CONSULT screen terms) illumination page illumination (CONSULT screen terms) page
A/T COMM LINE 54 — EC-114 11 — CAMSHAFT POSI SEN EC-70
CAMSHAFT POSI SEN 11 — EC-70 12 — MASS AIR FLOW SEN EC-77
COOLANT TEMP SEN 13 X EC-82 13 X COOLANT TEMP SEN EC-82
IGN SIGNAL-PRIMARY 21 — EC-86 21 — IGN SIGNAL-PRIMARY EC-86
KNOCK SENSOR 34 — EC-105 28 X OVER HEAT EC-92
MASS AIR FLOW SEN 12 — EC-77 34 — KNOCK SENSOR EC-105
NO SELF DIAGNOSTIC 43 — THROTTLE POSI SEN EC-108
55 — —
FAILURE INDICATED
54 — A/T COMM LINE EC-114
OVER HEAT 28 X EC-92
NO SELF DIAGNOSTIC
55 — —
THROTTLE POSI SEN 43 — EC-108 FAILURE INDICATED
X: Applicable X: Applicable
RD28ETi —: Not applicable RD28ETi —: Not applicable
Items MIL Reference MIL Items Reference
DTC DTC
(CONSULT screen terms) illumination page illumination (CONSULT screen terms) page
ACCEL POS SENSOR 43 X EC-332 11 X CAM POS SEN (PUMP) EC-262
ACCEL POS SW (F/C) 23 X EC-299 12 — MAS AIR FLOW SEN EC-267
ADJUST RESISTOR 17 — EC-285 13 X COOLANT TEMP SEN EC-272
CAM POS SEN (PUMP) 11 X EC-262 14 — VEHICLE SPEED SEN EC-276
CONT SLEEV POS SEN 15 X EC-280 15 X CONT SLEEV POS SEN EC-280
COOLANT TEMP SEN 13 X EC-272 17 — ADJUST RESISTOR EC-285
CRANK POS SEN (TDC) 47 X EC-337 18 X F/INJ F/B 2 EC-289
ECM 1 27 X EC-304 21 — F/INJ TIMG F/B EC-294
ECM 2 31 X EC-304 22 X F/INJ F/B EC-289
ELECTRIC GOV 25 X EC-289 23 X ACCEL POS SW (F/C) EC-299
FCV SHORT 37 X EC-323 25 X ELECTRIC GOV EC-289
FUEL CUT S/V 1 36 X EC-323 27 X ECM 1 EC-304
FUEL CUT S/V 2 38 X EC-323 28 X OVER HEAT EC-306
FUEL TEMP SENSOR 42 — EC-328 31 X ECM 2 EC-304
F/INJ F/B 22 X EC-289 33 — I/C INT/A TEMP SEN EC-315
F/INJ F/B 2 18 X EC-289 34 — NEEDLE LIFT SEN EC-319
F/INJ TIMG F/B 21 — EC-294 36 X FUEL CUT S/V 1 EC-323
GOV CUT CIRCUIT 48 X EC-342 37 X FCV SHORT EC-323
I/C INT/A TEMP SEN 33 — EC-315 38 X FUEL CUT S/V 2 EC-323
MAS AIR FLOW SEN 12 — EC-267 42 — FUEL TEMP SENSOR EC-328
NATS MALFUNCTION 141 - 148 X EL section* 43 X ACCEL POS SENSOR EC-332
NEEDLE LIFT SEN 34 — EC-319 47 X CRANK POS SEN (TDC) EC-337
NO SELF DIAGNOSTIC 48 X GOV CUT CIRCUIT EC-342
55 — —
FAILURE INDICATED
NO SELF DIAGNOSTIC
OVER HEAT 28 X EC-306 55 — —
FAILURE INDICATED
VEHICLE SPEED SEN 14 — EC-276
141 - 148 X NATS MALFUNCTION EL section*
*: Refer to “NATS (Nissan Anti-Theft System)” in EL section.
EC-2
PRECAUTIONS AND PREPARATION
Special Service Tools GI

FOR TB45E ENGINE MODELS
Tool number
MA
Description
Tool name
KV10114400 Loosening or tightening oxygen sensor EM
Oxygen sensor wrench
LC
NT636 a: 22 mm (0.87 in)
FOR DIESEL ENGINE INJECTION PUMP

Tool number
Description
Engine application FE
Tool name RD TD
KV11229352 Measuring plunger lift
Measuring device CL
q
1 KV11229350
Holder
q
2 KV11229360
MT
Nut X X
q
3 KV11229370
Pin
AT
q
4 KV11254410
Dial gauge
TF
NT570
KV11102900 Removing injection pump

Pulley puller sprocket
PD
X —
FA
NT647
RA
KV11103000 Removing injection pump
Pulley puller drive gear
BR
— X
ST
NT676
KV10111100 Removing injection pump RS

Seal cutter drive gear cover
— X BT
NT046
HA
WS39930000 Pressing the tube of liq-
Tube presser uid gasket
— X
EL
NT052 SE
X: Applicable
IDX
EC-3
Special Service Tools (Cont’d)
FOR DIESEL ENGINE INJECTION NOZZLE
Tool number Engine application
Description
Tool name RD TD
KV11289004
Nozzle cleaning kit
q
1 KV11290012
Box
q
2 KV11290110
Brush
q
3 KV11290122
Nozzle oil sump scraper
q
4 KV11290140
Nozzle needle tip
q
5 KV11290150 X X
Nozzle seat scraper
q
6 KV11290210
Nozzle holder
q
7 KV11290220
Nozzle hole cleaning
needle
NT296
KV11292010
Nozzle centering device
X —
NT293
KV11100300
Nozzle holder socket
(For No. 2 - 4 injection
nozzles) X —
NT563
KV119E0010
No. 1 injection nozzle
holder socket
X —
NT648
KV11292210
Nozzle cleaning device
— X
NT293
X: Applicable
EC-4
Special Service Tools (Cont’d)
Engine application
GI
Tool number
Description
Tool name RD TD
MA
KV11290632
Nozzle oil sump scraper
EM
— X
LC
NT294
KV11290620
Nozzle seat scraper
— X FE
NT295
CL
X: Applicable
Commercial Service Tool MT
Tool name Description
Fuel filler cap adapter Checking fuel tank vacuum relief valve opening AT
pressure
TF
PD
NT653
FA
Supplemental Restraint System (SRS) “AIR
BAG” and “SEAT BELT PRE-TENSIONER” RA
The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER” used along with
a seat belt, helps to reduce the risk or severity of injury to the driver and front passenger in a frontal collision.
The SRS system composition which is available to NISSAN MODEL Y61 is as follows (The composition var- BR
ies according to the destination.):
Driver air bag module (located in the center of the steering wheel), front passenger air bag module (located
on the instrument panel on passenger side), seat belt pre-tensioner, a diagnosis sensor unit, warning lamp, ST
wiring harness and spiral cable.
Information necessary to service the system safely is included in the RS section of this Service Manual.
WARNING: RS
I To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death
in the event of a collision which would result in air bag inflation, all maintenance must be performed
by an authorized NISSAN dealer.
BT
I Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-
sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air HA
Bag Module, see the RS section.
I Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this
Service Manual. Spiral cable and wiring harnesses covered with yellow insulation either just before EL
the harness connectors or for the complete harness are related to the SRS.
SE
IDX
EC-5
PRECAUTIONS AND PREPARATION TB45E
Engine Fuel & Emission Control System
SEF620V
EC-6
Precautions GI
I Before connecting or disconnecting the ECM harness
connector, turn ignition switch OFF and disconnect nega- MA
tive battery terminal. Failure to do so may damage the
ECM. Because battery voltage is applied to ECM even if
ignition switch is turned off. EM
LC
SEF289H
I When connecting ECM harness connector, tighten secur-

ing bolt until the gap between the orange indicators disap-
pears.
: 3.0 - 5.0 N⋅m (0.3 - 0.5 kg-m, 26 - 43 in-lb) FE
CL
MT
SEF308Q
AT
I When connecting or disconnecting pin connectors into or
from ECM, take care not to damage pin terminals (bend or
break). TF
Make sure that there are not any bends or breaks on ECM
pin terminal, when connecting pin connectors.
PD
FA
SEF291H
RA
I Before replacing ECM, perform ECM input/output signal
inspection and make sure whether ECM functions properly
or not. (See page EC-58.) BR
ST
RS
MEF040D BT
I After performing each TROUBLE DIAGNOSIS, perform
“OVERALL FUNCTION CHECK” or “DTC (Diagnostic HA
Trouble Code) CONFIRMATION PROCEDURE”.
The DTC should not be displayed in the “DTC CONFIRMA-
TION PROCEDURE” if the repair is completed. The “OVER- EL
ALL FUNCTION CHECK” should be a good result if the
repair is completed.
SE
SEF051P
IDX
EC-7
Precautions (Cont’d)
I When measuring ECM signals with a circuit tester, never
bring the two tester probes into contact.
Accidental contact of probes will cause a short circuit and
damage the ECM power transistor.
SEF348N
EC-8
ENGINE AND EMISSION CONTROL OVERALL SYSTEM TB45E
Circuit Diagram GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC357
EC-9
System Diagram
SEF510V
EC-10
Engine Control Component Parts Location GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
SEF511VA BT
HA
EL
SE
IDX
EC-11
Engine Control Component Parts Location
(Cont’d)
SEF514VA SEF512V
SEF518V SEF516V
EC-12
Vacuum Hose Drawing GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
SEF629V
RA
q
1 EVAP canister purge control valve q
3 Fuel pressure regulator to vacuum q
4 EVAP canister to fuel tank
to vacuum hose connector (Intake hose connector (Intake manifold
manifold collector) collector) BR
q
2 EVAP canister purge control valve
to throttle body
ST
Refer to “System Diagram”, EC-10, for vacuum control system.
Note: Do not use soapy water or any type of solvent while installing vacuum hoses or purge hoses. RS
BT
HA
EL
SE
IDX
EC-13
System Chart
Camshaft position sensor E Fuel injection &

mixture ratio control E Injectors
Mass air flow sensor E
Engine coolant temperature sensor E
Distributor ignition system E Power transistor
Oxygen sensor* E
Ignition switch E
IACV-AAC valve
E
Idle air control system E IACV-FICD solenoid valve
Throttle position sensor
Neutral position switch (M/T models) E

ECM
TCM (Transmission control module) (A/T E

models)
Fuel pump control E Fuel pump relay
Vehicle speed sensor E
Air conditioner switch E
Oxygen sensor monitor* & Malfunction indicator lamp

on board diagnostic system E (On the instrument panel)
Battery voltage E
Knock sensor E
Power steering oil pressure switch E Air conditioner cut control E Air conditioner relay
*: For Australia and specific areas
EC-14
ENGINE AND EMISSION BASIC CONTROL SYSTEM
DESCRIPTION TB45E
Multiport Fuel Injection (MFI) System GI

INPUT/OUTPUT SIGNAL LINE
Engine speed and piston position
MA
Camshaft position sensor
E
Amount of intake air EM

Mass air flow sensor
E
Engine coolant temperature sensor Engine coolant temperature LC

E
Oxygen sensor* Density of oxygen in exhaust gas

E
Throttle position
Throttle position sensor E FE
Throttle valve idle position
ECM E Injector
Neutral position switch (M/T models) Gear position CL
E
TCM (Transmission control module) (A/T mod- Gear position MT

els) E
Vehicle speed
AT
Vehicle speed sensor
E
Start signal
TF
Ignition switch
E
Battery voltage Battery voltage PD

E
*: For Australia and specific areas FA
BASIC MULTIPORT FUEL INJECTION VARIOUS FUEL INJECTION RA

SYSTEM INCREASE/DECREASE COMPENSATION
The amount of fuel injected from the fuel injector is The amount of fuel injected is compensated for to BR
determined by the ECM. The ECM controls the improve engine performance. This will be made
length of time the valve remains open (injection under various operating conditions as listed below.
pulse duration). The amount of fuel injected is a <Fuel increase> ST
program value in the ECM memory. The program I During warm-up
value is preset by engine operating conditions. I When starting the engine
These conditions are determined by input signals I During acceleration RS
(for engine speed and intake air) from both the cam- I Hot-engine operation
shaft position sensor and the mass air flow sensor. <Fuel decrease>
I During deceleration BT
I When the vehicle speed is extremely high
I Extremely high-engine coolant temperature
I When select lever is changed from “N” to “D” at HA
high engine speed (A/T models only)
EL
SE
IDX
EC-15
DESCRIPTION TB45E
Multiport Fuel Injection (MFI) System (Cont’d)
MIXTURE RATIO FEEDBACK CONTROL
The mixture ratio feedback system provides the best air-fuel mix-
ture ratio for driveability and emission control. The three way cata-
lyst can then better reduce CO, HC and NOx emissions. This sys-
tem uses an oxygen sensor in the exhaust manifold to monitor if
the engine is rich or lean. The ECM adjusts the injection pulse width
according to the sensor voltage signal. For more information about
oxygen sensor, refer to page EC-121. This maintains the mixture
ratio within the range of stoichiometric (ideal air-fuel mixture).
This stage is referred to as the closed loop control condition.
MEF025DF
OPEN LOOP CONTROL
The open loop system condition refers to when the ECM detects
any of the following conditions. Feedback control stops in order to
maintain stabilized fuel combustion.
I Deceleration and acceleration
I High-load, high-speed operation
I Engine idling
I Malfunction of oxygen sensor or its circuit
I Insufficient activation of oxygen sensor at low engine coolant
temperature
I High-engine coolant temperature
I During warm-up
I When starting the engine
MIXTURE RATIO SELF-LEARNING CONTROL

The mixture ratio feedback control system monitors the mixture
ratio signal transmitted from the oxygen sensor. This feedback sig-
nal is then sent to the ECM. The ECM controls the basic mixture
ratio as close to the theoretical mixture ratio as possible. However,
the basic mixture ratio is not necessarily controlled as originally
designed. Both Manufacturing differences (i.e. mass air flow sen-
sor hot wire) and characteristic changes during operation (i.e. injec-
tor clogging) directly affect mixture ratio.
Accordingly, the difference between the basic and theoretical mix-
ture ratios is monitored in this system. This is then computed in
terms of “injection pulse duration” to automatically compensate for
the difference between the two ratios.
EC-16
DESCRIPTION TB45E
Multiport Fuel Injection (MFI) System (Cont’d)
FUEL INJECTION SYSTEM GI
Two types of systems are used.
Simultaneous multiport fuel injection system MA

Fuel is injected simultaneously into all four cylinders twice each
engine cycle. In other words, pulse signals of the same width are EM
simultaneously transmitted from the ECM.
The four injectors will then receive the signals two times for each
engine cycle. LC
This system is used when the engine is being started and/or if the
fail-safe mode (CPU) is operating.
Sequential multiport fuel injection system

Fuel is injected into each cylinder during each engine cycle accord-
ing to the firing order. This system is used when the engine is run- FE
ning.
FUEL SHUT-OFF CL
Fuel to each cylinder is cut off during deceleration or operation of
the engine at excessively high speeds. MT
SEF630V
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-17
DESCRIPTION TB45E
Distributor Ignition (DI) System

Camshaft position sensor Engine speed and piston position
E
Mass air flow sensor Amount of intake air

E
Engine coolant temperature sensor Engine coolant temperature

E
Throttle position
Throttle position sensor Throttle valve idle position
E
Vehicle speed sensor Vehicle speed

E
E
Power
Start signal ECM
Ignition switch transistor
E
Intake air temperature sensor Intake air temperature

E
Neutral position switch (M/T models) Neutral position

E
TCM (Transmission control module) (A/T mod- Neutral position

els) E
Battery Battery voltage

E
SYSTEM DESCRIPTION
The ignition timing is controlled by the ECM to maintain the best
air-fuel ratio for every running condition of the engine.
The ignition timing data is stored in the ECM. This data forms the
map shown left.
The ECM detects information such as the injection pulse width and
camshaft position sensor signal. Responding to this information,
ignition signals are transmitted to the power transistor.
e.g. N: 1,800 rpm, Tp: 1.50 msec
A °BTDC
SEF742M During the following conditions, the ignition timing is revised by the
ECM according to the other data stored in the ECM.
I At starting
I During warm-up
I At idle
I Hot-engine operation
I At acceleration
EC-18
DESCRIPTION TB45E
Air Conditioning Cut Control GI

MA
Camshaft position sensor Engine speed
E
Air conditioner “ON” signal

EM
Air conditioner switch
E
Air condi-
Throttle position sensor Throttle valve opening angle ECM E tioner
LC
E
relay
Ignition switch Start signal

E
Engine coolant temperature sensor Engine coolant temperature

E FE
CL
SYSTEM DESCRIPTION I When the accelerator pedal is fully depressed
This system improves engine operation when the air I When cranking the engine
I During the engine coolant temperature is exces- MT
conditioner is used.
Under the following conditions, the air conditioner is sively high
turned off. I During high-engine speed operation
AT
Fuel Cut Control (at no load & high engine TF

speed)
INPUT/OUTPUT SIGNAL LINE PD
Vehicle speed
FA
Neutral position
Neutral position switch (M/T models) E
RA
Neutral position
TCM (Transmission control module) (A/T E
models) ECM E Injectors
BR
Engine coolant temperature
ST
Engine speed
Camshaft position sensor E
RS
If the engine speed is above 2,800 rpm with no load (for example,
in neutral and engine speed over 2,800 rpm) fuel will be cut off after
some time. The exact time when the fuel is cut off varies based on BT
engine speed.
Fuel cut will operate until the engine speed reaches 1,000 rpm,
then fuel cut is cancelled. HA
NOTE:
This function is different than deceleration control listed under
multiport fuel injection on EC-15. EL
SE
IDX
EC-19
EVAPORATIVE EMISSION SYSTEM TB45E
Description
SEF520V
The evaporative emission system is used to reduce hydrocarbons

emitted into the atmosphere from the fuel system. This reduction of
hydrocarbons is accomplished by activated charcoals in the EVAP
canister.
The fuel vapor from sealed fuel tank is led into the EVAP canister
when the engine is off. The fuel vapor is then stored in the EVAP
canister. The EVAP canister retains the fuel vapor until the EVAP
canister is purged by air.
When the engine is running, the air is drawn through the bottom of
the EVAP canister. The fuel vapor will then be led to the intake
manifold.
When the engine runs at idle, the EVAP canister purge control
valve is closed. Only a small amount of vapor flows into the intake
manifold through the constant purge orifice.
As the engine speed increases and the throttle vacuum rises, the
EVAP canister purge control valve opens. The vapor is sucked
through both main purge and constant purge orifices.
Inspection
EVAP CANISTER
Check EVAP canister as follows:
1. Blow air in port q
A and check that there is no leakage.
2. Apply vacuum to port q A . [Approximately −13.3 to −20.0 kPa
(−133 to −200 mbar, −100 to −150 mmHg, −3.94 to −5.91
inHg)]
3. Cover port q D by hand.
C and check that it flows freely out of port q
B .
SEF521V
EC-20
EVAPORATIVE EMISSION SYSTEM TB45E
Inspection (Cont’d)
FUEL CHECK VALVE GI
1. Blow air through connector on fuel tank side.
A considerable resistance should be felt and a portion of air flow
should be directed toward the EVAP canister side. MA
2. Blow air through connector on EVAP canister side.
Air flow should be smoothly directed toward fuel tank side.
3. If fuel check valve is suspected of not properly functioning in EM
steps 1 and 2 above, replace it.
LC
SEF631V
FUEL CUT VALVE

Cut valve operation
Ensure that continuity of air passage does not exist when the FE
installed cut valve is tilted to 90° or 180°.
CL
MT
SEF632V
AT
FUEL TANK VACUUM RELIEF VALVE
1. Wipe clean valve housing.
2. Check valve opening pressure and vacuum. TF
Pressure:
15.3 - 20.0 kPa (0.1530 - 0.2001 bar, 0.156 - 0.204
kg/cm2, 2.22 - 2.90 psi) PD
Vacuum:
−6.0 to −3.3 kPa (−0.0598 to −0.0333 bar, −0.061 to
−0.034 kg/cm2, −0.87 to −0.48 psi) FA
3. If out of specification, replace fuel filler cap as an assembly.
CAUTION:
SEF427N
Use only a genuine fuel filler cap as a replacement. RA
BR
ST
RS
SEF943S BT
HA
EL
SE
IDX
EC-21
POSITIVE CRANKCASE VENTILATION TB45E
Description
This system returns blow-by gas to the intake manifold collector.
The positive crankcase ventilation (PCV) valve is provided to conduct crankcase blow-by gas to the intake
manifold.
During partial throttle operation of the engine, the intake manifold sucks the blow-by gas through the PCV
valve.
Normally, the capacity of the valve is sufficient to handle any blow-by and a small amount of ventilating air.
The ventilating air is then drawn from the air duct into the crankcase. In this process the air passes through
the hose connecting air inlet tubes to the rocker cover.
Under full-throttle condition, the manifold vacuum is insufficient to draw the blow-by flow through the valve.
The flow goes through the hose connection in the reverse direction.
On vehicles with an excessively high blow-by, the valve does not meet the requirement. This is because some
of the flow will go through the hose connection to the intake collector under all conditions.
SEF522V
Inspection
PCV (Positive Crankcase Ventilation) VALVE
With engine running at idle, remove PCV valve from breather sepa-
rator. A properly working valve makes a hissing noise as air passes
through it. A strong vacuum should be felt immediately when a fin-
ger is placed over the valve inlet.
SEC137A
PCV HOSE
1. Check hoses and hose connections for leaks.
2. Disconnect all hoses and clean with compressed air. If any
hose cannot be freed of obstructions, replace.
ET277
EC-22
BASIC SERVICE PROCEDURE TB45E
Fuel Pressure Release GI

Before disconnecting fuel line, release fuel pressure from fuel
line to eliminate danger. MA
1. Start engine.
2. Perform “FUEL PRESSURE RELEASE” in “WORK
SUPPORT” mode with CONSULT. EM
(Touch “START” and after engine stalls, crank it two or
three times to release all fuel pressure.)
3. Turn ignition switch off. LC
SEF823K
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
1. Remove fuse for fuel pump.
2. Start engine.
3. After engine stalls, crank it two or three times to release FE
all fuel pressure.
4. Turn ignition switch off and reconnect fuel pump fuse.
CL
MT
SEF523V
AT
Fuel Pressure Check
I When reconnecting fuel line, always use new clamps.
I Make sure that clamp screw does not contact adjacent TF
parts.
I Use a torque driver to tighten clamps.
I Use Pressure Gauge to check fuel pressure. PD
1. Release fuel pressure to zero, refer to above.
2. Disconnect fuel hose between fuel filter and fuel tube (engine
side).
FA
3. Install pressure gauge between fuel filter and fuel tube.
SEF524V 4. Start engine and check for fuel leakage. RA
5. Read the indication of fuel pressure gauge.
At idling:
Approximately 245 kPa (2.45 bar, 2.5 kg/cm2, 36 BR
psi)
A few seconds after ignition switch is turned OFF to
ON: ST
Approximately 294 kPa (2.94 bar, 3.0 kg/cm2, 43
psi)
6. Stop engine and disconnect fuel pressure regulator vacuum RS
hose from intake manifold.
7. Plug intake manifold with a rubber cap.
SEF718BA
8. Connect variable vacuum source to fuel pressure regulator. BT
9. Start engine and read indication of fuel pressure gauge as
vacuum is changed.
Fuel pressure should decrease as vacuum increases. If results
HA
are unsatisfactory, replace fuel pressure regulator.
EL
SE
IDX
EC-23
Injector Removal and Installation

1. Release fuel pressure to zero.
2. Disconnect air duct connecting to intake manifold collector.
3. Disconnect injector harness connectors.
4. Disconnect fuel hoses from fuel tube assembly.
5. Remove injectors with fuel tube assembly.
SEF634V
6. Push out any malfunctioning injector from fuel tube assembly.

Do not extract injector by pinching connector.
7. Replace or clean injector as necessary.
SEF633V
8. Install injector to fuel tube assembly.

Always replace O-rings and insulators with new ones.
Lubricate O-rings with a smear of silicone oil.
9. Install injectors with fuel tube assembly to intake manifold.
Tighten fuel tube bolts to the specified torque.
Tightening procedure:
1) Tighten all bolts to 9.3 to 10.8 N⋅m (0.95 to 1.1
kg-m, 6.9 to 8.0 ft-lb).
2) Tighten all bolts to 21 to 26 N⋅m (2.1 to 2.7
kg-m, 15 to 20 ft-lb).
10. Install fuel hoses to fuel tube assembly.
SEF245QD
Lubricate fuel hoses with a smear of silicone oil.
Insert fuel hoses more than 28 mm (1.10 in) from tube end.
EC-24
Fast Idle Cam (FIC) Inspection and Adjustment GI

1. Stop engine.
2. Turn ignition switch “ON” and see “COOLAN
TEMP/S” in “DATA MONITOR” mode with CONSULT. MA
3. When engine temperature is 25±5°C (77±9°F), make
sure that the center of mark q A is aligned with mark q C
as shown in the figure. EM
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
2. When the resistance of engine temperature sensor is
1.65 to 2.40 kΩ, make sure that the center of mark q A LC
is aligned with mark q C as shown in the figure.
SEF002P I If NG, replace thermo-element and perform the above inspec-
tion and adjustment again.
FE
CL
MT
SEF536H
AT
TF
PD
FA
SEF070V
RA
4. Turn ignition switch “ON”.
5. See “COOLAN TEMP/S” in “DATA MONITOR” mode
with CONSULT. BR
6. Start engine and warm it up.
When engine temperature is 80±5°C (176±9°F), make
sure that the center of mark q A is aligned with mark q B ST
as shown in the figure.
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
3. Turn ignition switch “OFF”. RS
4. Disconnect engine temperature sensor harness con-
nector and check resistance as shown in the figure.
SEF069V
5. Start engine and warm it up. BT
When the resistance of engine temperature sensor is
0.26 to 0.39 kΩ, make sure that the center of mark q A
is aligned with mark q B as shown in the figure.
HA
I If NG, adjust by turning adjusting screw.
Adjusting screw tightening torque: EL
0.98 - 1.96 N⋅m (10 - 20 kg-cm, 8.7 - 17.4 in-lb)
SE
SEF595PA
IDX
EC-25
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION TB45E
Introduction
The ECM (ECCS control module) has an on board diagnostic system, which detects malfunctions related to
engine sensors or actuators. Self-diagnosis items are listed in “DIAGNOSTIC TROUBLE CODE INDEX”, EC-2.
The malfunction indicator lamp (MIL) on the instrument panel lights up when a specific malfunction is detected,
or when the ECM enters fail-safe mode (Refer to EC-51.). For diagnostic items causing the MIL to light up,
refer to “DIAGNOSTIC TROUBLE CODE INDEX”, EC-2.
Diagnostic Trouble Code (DTC)

HOW TO CONFIRM MALFUNCTION ITEMS
Malfunction items can be confirmed by the following methods.
1. The number of blinks of the malfunction indicator lamp in the Diagnostic Test Mode II (Self- Diagnos-
tic Results) indicates the DTC. Examples: 11, 21 etc.
2. CONSULT displays the malfunctioning component or system in “SELF DIAGNOSTIC RESULTS”
mode.
I Output of a DTC indicates a malfunction. However, Mode II does not indicate whether the malfunc-
tion is still occurring or has occurred in the past and has returned to normal.
CONSULT can identify malfunction status as shown below. Therefore, using CONSULT (if available)
is recommended.
A sample of CONSULT display is shown at left. The malfunction is

displayed in SELF-DIAGNOSTIC RESULTS mode of CONSULT.
Time data indicates how many times the vehicle was driven after
the last detection of a malfunction.
If the malfunction is being detected currently, the time data will be
“0”.
SEF854T
HOW TO ERASE DTC

The DTC can be erased from the back-up memory in the ECM by the following methods.
Selecting “ERASE” in the SELF- DIAG RESULTS” mode with CONSULT
Changing the diagnostic test mode from Diagnostic Test Mode II to Mode I by switching between CHK
and IGN terminals on the data link connector for CONSULT terminals. (Refer to EC-29.)
I If the battery terminal is disconnected, the DTC will be lost within 24 hours.
I Erasing the DTC, using CONSULT is easier and quicker than switching between CHK and IGN ter-
minals on the data link connector for CONSULT terminals.
I Be careful not to erase the stored memory before starting trouble diagnoses.
EC-26
Diagnostic Trouble Code (DTC) (Cont’d)
How to erase DTC (With CONSULT) GI
1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least
5 seconds and then turn it “ON” (engine stopped) again.
2. Turn CONSULT “ON” and touch “ENGINE”. MA
3. Touch “SELF-DIAG RESULTS”.
4. Touch “ERASE”. (The DTC in the ECM will be erased.)
EM
LC
FE
CL
MT
AT
TF
SEF054U
PD
How to erase DTC (Without CONSULT)
1. If the ignition switch stays “ON” after repair work, be sure to turn ignition switch “OFF” once. Wait at least FA
5 seconds and then turn it “ON” again.
2. Change the diagnostic test mode from Mode II to Mode I by switching between CHK and IGN terminals
on the data link connector for CONSULT terminals. (See EC-29.) RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-27
Malfunction Indicator Lamp (MIL)

The malfunction indicator lamp is located on the instrument panel.
1. The malfunction indicator lamp will light up when the ignition
switch is turned ON without the engine running. This is for
checking the blown lamp.
I If the malfunction indicator lamp does not light up, see the
WARNING LAMPS AND CHIME in the EL section.
(Or see EC-156.)
2. When the engine is started, the malfunction indicator lamp
should go off.
SEF530V If the lamp remains on, the on board diagnostic system has
detected an engine system malfunction.
ON BOARD DIAGNOSTIC SYSTEM FUNCTION

The on board diagnostic system has the following four functions.
Diagnostic Test Mode I

1. BULB CHECK : This function checks the bulb for damage (blown, open circuit, etc.) of
the malfunction indicator lamp.
If the MIL does not come on, check MIL circuit and ECM test mode
selector. (See next page.)
2. MALFUNCTION : This is a usual driving condition. When a specific malfunction is
WARNING detected, the MIL will light up to inform the driver that a malfunction has
been detected.
Diagnostic Test Mode II

3. SELF-DIAGNOSTIC : This function allows DTCs to be read.
RESULTS
4. OXYGEN SENSOR : This function allows the fuel mixture condition (lean or rich), monitored
MONITOR by oxygen sensor, to be read.
MIL Flashing without DTC

If the ECM is in Diagnostic Test Mode II, the MIL may flash when the engine is running. In this case, check
ECM test mode following “HOW TO SWITCH DIAGNOSTIC TEST MODES” on next page.
How to switch the diagnostic test (function) modes and details of the above functions are described later. (See
page EC-29.)
Diagnostic Diagnostic
Condition
Test Mode I Test Mode II
Engine
stopped SELF-DIAGNOSTIC
BULB CHECK
RESULTS
Ignition switch
in “ON” posi-
tion Engine
running MALFUNCTION OXYGEN SENSOR
WARNING MONITOR
EC-28
Malfunction Indicator Lamp (MIL) (Cont’d)
HOW TO SWITCH DIAGNOSTIC TEST MODES AND ERASE DTC CODE GI
Turn ignition switch “ON”. (Do
not start engine.) MA
EM
H
NG
Check MIL circuit. E Repair harness or
Diagnostic Test Mode I — BULB NG (See EC-156.) connectors.
E CHECK. Refer to previous page. E LC
MIL should come on. OK
F
OK
E
G E
Diagnostic Test
Mode I
Start engine. — MALFUNC- FE
TION WARN-
ING.
Refer to previ-
ous page. CL
H
NG
E Check MIL circuit and data link connector for
CONSULT circuit. (See EC-156.) MT
OK NG
AT
H H
Check ECM fail- Repair harness or
Data link connector for CONSULT safe. connectors.
(Connect CHK and IGN terminals with a (See EC-51.) TF
suitable harness.) OK
MIL should go off. OK
OK PD
H
Wait at least 2 seconds. F H
FA
H
RA
BR
Data link connector for CONSULT ST

(Disconnect the suitable harness between
CHK and IGN terminals.)
H
For Australia and specific area
RS
DIAGNOSTIC TEST MODE II
— SELF-DIAGNOSTIC RESULTS
E G E Diagnostic Test
Mode II
— OXYGEN
Start engine. SENSOR BT
MONITOR
(For Australia
only)
HA
H
q
B q
A
EL
SE
IDX
EC-29
q
B q
A
G
I Switching the modes is not possible when the

engine is running.
I When ignition switch is turned off during
diagnosis, power to ECM will drop after approx.
5 seconds.
The diagnosis will automatically return to Diag-
Data link connector for CONSULT nostic Test Mode I.
(Connect CHK and IGN terminals with a
suitable harness.)
H
Wait at least 2 seconds.
Data link connector for CONSULT

If the suitable harness is disconnected
at this time, the diagnostic trouble code
will be erased from the backup memory
in the ECM.
EC-30
DIAGNOSTIC TEST MODE I—BULB CHECK GI
In this mode, the MALFUNCTION INDICATOR LAMP on the instrument panel should stay ON. If it remains
OFF, check the bulb. (See the WARNING LAMPS AND CHIME in the EL section. Or see EC-156.) MA
DIAGNOSTIC TEST MODE I—MALFUNCTION WARNING
MALFUNCTION
EM
INDICATOR LAMP Condition
ON When the malfunction is detected (Refer to EC-2.) or the ECM’s CPU is malfunctioning.
OFF No malfunction
LC
I These Diagnostic Trouble Code Numbers are clarified in Diagnostic Test Mode II (SELF-DIAGNOSTIC
RESULTS).
DIAGNOSTIC TEST MODE II—SELF-DIAGNOSTIC RESULTS

In this mode, a diagnostic trouble code is indicated by the number of blinks of the MALFUNCTION INDICA- FE
TOR LAMP as shown below.
CL
MT
AT
TF
SEF212NA
Long (0.6 second) blinking indicates the number of ten digits, and short (0.3 second) blinking indicates the PD
number of single digits. For example, the malfunction indicator lamp blinks 4 times for about 5 seconds (0.6
sec x 8 times) and then it blinks three times for about 1 second (0.3 sec x 3 times). This indicates the DTC
“43” and refers to the malfunction of the throttle position sensor. FA
In this way, all the detected malfunctions are classified by their diagnostic trouble code numbers. The DTC
“55” refers to no malfunction. (See DIAGNOSTIC TROUBLE CODE INDEX, refer to page EC-2.)
RA
How to erase diagnostic test mode II (Self-diagnostic results)
The diagnostic trouble code can be erased from the backup memory in the ECM when the diagnostic test mode BR
is changed from Diagnostic Test Mode II to Diagnostic Test Mode I. (Refer to “HOW TO SWITCH DIAGNOS-
TIC TEST MODES”.)
I If the battery terminal is disconnected, the diagnostic trouble code will be lost from the backup ST
memory within 24 hours.
RS
DIAGNOSTIC TEST MODE II—OXYGEN SENSOR MONITOR
In this mode, the MALFUNCTION INDICATOR LAMP displays the condition of the fuel mixture (lean or rich)
which is monitored by the oxygen sensor. BT
MALFUNCTION INDICATOR LAMP Fuel mixture condition in the exhaust gas Air fuel ratio feedback control
condition
ON Lean
HA
Closed loop control
OFF Rich
*Remains ON or OFF Any condition Open loop control EL
*: Maintains conditions just before switching to open loop.
To check the oxygen sensor function, start engine in the Diagnostic Test Mode II and warm it up until engine SE
coolant temperature indicator points to the middle of the gauge.
Next run engine at about 2,000 rpm for about 2 minutes under no-load conditions. Then make sure that the
MALFUNCTION INDICATOR LAMP comes ON more than 5 times every 10 seconds when measured at 2,000 IDX
rpm under no-load.
EC-31
CONSULT
CONSULT INSPECTION PROCEDURE
1. Turn ignition switch OFF.
2. Connect “CONSULT” to data link connector for CONSULT.
(Data link connector for CONSULT is located under the instru-
ment lower cover on the driver’s side on both LHD and RHD
models.)
SEF532V
3. Turn ignition switch ON.

4. Touch “START”.
SBR455D
5. Touch “ENGINE”.
SEF895K
6. Perform each diagnostic test mode according to each service

procedure.
For further information, see the CONSULT Operation Manual.
SEF288S
EC-32
CONSULT (Cont’d)
FUNCTION GI
Diagnostic test mode Function
A technician can adjust some devices faster MA
Work support and more accurately by following indications
on CONSULT.
Self-diagnostic results can be read and
EM
Self-diagnostic results
erased quickly.
Data monitor Input/Output data in the ECM can be read. LC
CONSULT drives some actuators apart from
Active test the ECM’s and also shifts some parameters in
a specified range.
Conducted by CONSULT instead of a techni-
Function test cian to determine whether each system is FE
“OK” or “NG”.
ECM part number ECM part number can be read.
CL
WORK SUPPORT MODE
MT
WORK ITEM CONDITION USAGE
THRTL POS SEN ADJ CHECK THE THROTTLE POSITION SENSOR SIGNAL. When adjusting throttle position
ADJUST IT TO THE SPECIFIED VALUE BY ROTATING sensor initial position AT
THE SENSOR BODY UNDER THE FOLLOWING CONDI-
TIONS.
I IGN SW “ON” TF
I ENG NOT RUNNING
I ACC PEDAL NOT PRESSED
IACV-AAC VALVE ADJ SET ENGINE SPEED AT THE SPECIFIED VALUE UNDER
PD
THE FOLLOWING CONDITIONS.
I ENGINE WARMED UP
FA
I NO-LOAD
FUEL PRESSURE RELEASE I FUEL PUMP WILL STOP BY TOUCHING “START” When releasing fuel pressure
DURING IDLING. from fuel line RA
CRANK A FEW TIMES AFTER ENGINE STALLS.
BR
ST
RS
BT
HA
EL
SE
IDX
EC-33
CONSULT (Cont’d)
ENGINE CONTROL COMPONENT PARTS/CONTROL SYSTEMS APPLICATION
DIAGNOSTIC TEST MODE
Item SELF-DIAG-
WORK DATA ACTIVE FUNCTION
NOSTIC
SUPPORT MONITOR TEST TEST
RESULTS
Camshaft position sensor X X
Mass air flow sensor X X
Engine coolant temperature sen-
X X X
sor
Oxygen sensor X
Vehicle speed sensor X X
ENGINE CONTROL COMPONENT PARTS
Throttle position sensor X X X X

INPUT
Knock sensor X
Ignition switch (start signal) X X
Closed throttle position switch X X
Air conditioner switch X
Neutral position switch X X
Power steering oil pressure
X X
switch
Battery voltage X
Injectors X X X
X (Ignition sig-
Power transistor (Ignition timing) X X X
nal)
OUTPUT
IACV-AAC valve X X X X
Air conditioner relay X
Fuel pump relay X X X X
Cooling fan X X
X: Applicable
EC-34
CONSULT (Cont’d)
SELF-DIAGNOSTIC MODE GI
Regarding items detected in “SELF-DIAG RESULTS” mode, refer to “DIAGNOSTIC TROUBLE CODE
INDEX”, EC-2.
MA
DATA MONITOR MODE
Monitored item ECM
[Unit] input
Main
Description Remarks
EM
signals
signals
CMPS⋅RPM I Indicates the engine speed computed
(POS) [rpm] q q from the POS signal (1° signal) of the
camshaft position sensor.
LC
MAS AIR/FL SE [V]

q q I The signal voltage of the mass air flow
sensor is displayed.
I When the engine is stopped, a certain
value is indicated.
COOLAN TEMP/S I The engine coolant temperature (deter- I When the engine coolant temperature
[°C] or [°F] mined by the signal voltage of the engine sensor is open or short-circuited, ECM FE
q q coolant temperature sensor) is displayed. enters fail-safe mode. The engine coolant
temperature determined by the ECM is
displayed.
CL
O2 SEN [V]*
q I The signal voltage of the oxygen sensor
is displayed.
M/R F/C MNT* I Display of oxygen sensor signal during I After turning ON the ignition switch, MT
[RICH/LEAN] air-fuel ratio feedback control: “RICH” is displayed until air-fuel mixture
RICH ... means the mixture became ratio feedback control begins.
q q “rich”, and control is being affected

toward a leaner mixture.
I When the air-fuel ratio feedback is
clamped, the value just before the clamp- AT
LEAN ... means the mixture became ing is displayed continuously.
“lean”, and control is being affected
toward a rich mixture. TF
VHCL SPEED SE
[km/h] or [mph] q q I The vehicle speed computed from the
vehicle speed sensor signal is displayed.
PD
BATTERY VOLT [V]
q q I The power supply voltage of ECM is dis-
played.
THRTL POS SEN [V]
q q I The throttle position sensor signal volt-
age is displayed.
FA
START SIGNAL
[ON/OFF] q q I Indicates [ON/OFF] condition from the
starter signal.
I After starting the engine, [OFF] is dis-
played regardless of the starter signal. RA
I Indicates [ON/OFF] condition from the
q q
CLSD THL/POSI
[ON/OFF] throttle position sensor signal.
BR
AIR COND SIG I Indicates [ON/OFF] condition of the air
[ON/OFF] q q conditioner switch as determined by the
air conditioner signal.
ST
I Indicates [ON/OFF] condition from the
q q
P/N POSI SW
[ON/OFF] park/neutral position switch signal.
RS
PW/ST SIGNAL I [ON/OFF] condition of the power steering
[ON/OFF]
q q oil pressure switch determined by the
power steering oil pressure signal is indi-
BT
cated.
NOTE:
Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.
*: Models with three way catalyst. HA
EL
SE
IDX
EC-35
CONSULT (Cont’d)
Monitored item ECM
Main
[Unit] input Description Remarks
signals
signals
INJ PULSE [msec] I Indicates the actual fuel injection pulse I When the engine is stopped, a certain
width compensated by ECM according to computed value is indicated.
the input signals.
I Indicates the ignition timing computed by I When the engine is stopped, a certain
q
IGN TIMING [BTDC]
ECM according to the input signals. value is indicated.
I Indicates IACV-AAC/V control value com-

q
IACV-AAC/V [%]
puted by ECM according to the input sig-
nals.
A/F ALPHA [%]* I The mean value of the air-fuel ratio feed- I When the engine is stopped, a certain
back correction factor per cycle is indi- value is indicated.
cated. I This data also includes the data for the
air-fuel ratio learning control.
I The air conditioner relay control condition
q
AIR COND RLY
[ON/OFF] (determined by ECM according to the
input signal) is indicated.
I Indicates the fuel pump relay control con-
q
FUEL PUMP RLY
[ON/OFF] dition determined by ECM according to
the input signals.
COOLING FAN I The control condition of the cooling fan
[HI/LOW/OFF] (determined by ECM according to the
q input signal) is indicated.

HI ... High speed operation
LOW ... Low speed operation
OFF ... Stop
VOLTAGE I Voltage measured by the voltage probe.
[V]
PULSE I Pulse width, frequency or duty cycle I Only “#” is displayed if item is unable to
[msec] or [Hz] or [%] measured by the pulse probe. be measured.
I Figures with “#”s are temporary ones.
They are the same figures as an actual
piece of data which was just previously
measured.
*: Models with three way catalyst.
EC-36
CONSULT (Cont’d)
ACTIVE TEST MODE GI
TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY)
I Engine: Return to the original trouble MA
I Harness and connector
condition If trouble symptom disappears, see
FUEL INJECTION I Fuel injectors
I Change the amount of fuel injection CHECK ITEM.
I Oxygen sensor
using CONSULT.
I Engine: After warming up, idle the EM
IACV-AAC/V engine. Engine speed changes according to the I Harness and connector
OPENING I Change the IACV-AAC valve opening opening percent. I IACV-AAC valve
percent using CONSULT.
I Engine: Return to the original trouble
LC
ENG COOLANT condition If trouble symptom disappears, see
I Engine coolant temperature sensor
TEMP I Change the engine coolant CHECK ITEM.
I Fuel injectors
temperature using CONSULT.
I Engine: Return to the original trouble
condition
If trouble symptom disappears, see I Adjust ignition timing (by moving
IGNITION TIMING I Timing light: Set
I Retard the ignition timing using
CHECK ITEM. camshaft position sensor) FE
CONSULT.
I Engine: After warming up, idle the
engine.
I Compression CL
I A/C switch “OFF”
POWER BALANCE Engine runs rough or dies. I Injectors
I Shift lever “N”
I Ignition coil with power transistor
I Cut off each injector signal one at a
I Spark plugs
time using CONSULT. MT
I Ignition switch: ON I Harness and connector
COOLING FAN I Turn the cooling fan “ON” and “OFF” Cooling fan moves and stops. I Cooling fan motor
using CONSULT. I Cooling fan relay
AT
I Ignition switch: ON (Engine stopped)
I Turn the fuel pump relay “ON” and Fuel pump relay makes the operating I Harness and connector
FUEL PUMP RELAY
“OFF” using CONSULT and listen to sound. I Fuel pump relay
operating sound. TF
SELF-LEARNING I In this test, the coefficient of self-learning control mixture ratio returns to the original coefficient by touching “CLEAR” on the
CONT* screen.
*: Models with three way catalyst. PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-37
CONSULT (Cont’d)
FUNCTION TEST MODE
FUNCTION TEST
CONDITION JUDGEMENT CHECK ITEM (REMEDY)
ITEM
I Ignition switch: ON
SELF-DIAG (Engine stopped)
— Objective system
RESULTS I Displays the results of on board
diagnostic system.
I Ignition switch: ON I Harness and connector
(Engine stopped) Throttle valve: I Throttle position sensor (Closed
OFF
I Throttle position sensor circuit is opened throttle position)
CLOSED THROTTLE tested when throttle is opened and I Throttle position sensor (Closed
POSI closed fully. (“IDLE POSITION” is throttle position) adjustment
the test item name for the vehicles Throttle valve: I Throttle linkage
ON
in which idle is selected by throttle closed I Verify operation in DATA
position sensor.) MONITOR mode.
I Ignition switch: ON I Throttle position sensor
Range (Throttle
(Engine stopped) I Throttle position sensor
THROTTLE POSI valve fully opened More than
I Throttle position sensor circuit is adjustment
SEN CKT — Throttle valve 3.0V
tested when throttle is opened and I Throttle linkage
fully closed)
closed fully. I Verify operation in DATA
MONITOR mode.
Out of N/P
(Engine stopped) OFF I Harness and connector
PARK/NEUT POSI positions
I Neutral position switch circuit is I Neutral position switch
SW CKT
tested when shift lever is I Linkage adjustment
In N/P positions ON
manipulated.
(Engine stopped)
I Fuel pump
FUEL PUMP I Fuel pump circuit is tested by There is pressure pulsation on
I Fuel pump relay
CIRCUIT checking the pulsation in fuel the fuel feed hose.
I Fuel filter clogging
pressure when fuel tube is
I Fuel level
pinched.
COOLING FAN (Engine stopped) The cooling fan rotates and
I Cooling fan motor
CIRCUIT I Cooling fan circuit is tested when stops every 3 seconds.
I Cooling fan relay
cooling fan is rotated.
I Ignition switch: ON , START
I Start signal circuit is tested when
engine is started by operating the
starter. Battery voltage and water
START SIGNAL I Harness and connector
temperature before cranking, and Start signal: OFF , ON
CIRCUIT I Ignition switch
average battery voltage, mass air
flow sensor output voltage and
cranking speed during cranking
are displayed.
EC-38
CONSULT (Cont’d)
FUNCTION TEST
GI
CONDITION JUDGEMENT CHECK ITEM (REMEDY)
ITEM
I Ignition switch: ON MA
(Engine running) Locked position ON
PW/ST SIGNAL I Power steering oil pressure switch
I Power steering oil pressure switch
CIRCUIT circuit is tested when steering
I Power steering oil pump
EM
wheel is rotated fully and then set Neutral position OFF
to a straight line running position.
I Vehicle speed sensor circuit is
LC
Vehicle speed sensor input I Harness and connector
VEHICLE SPEED tested when vehicle is running at
signal is greater than 4 km/h I Vehicle speed sensor
SEN CKT a speed of 10 km/h (6 MPH) or
(2 MPH). I Speedometer
higher.
I After warming up, idle the engine. I Adjust ignition timing (by moving
I Ignition timing is checked by read-
The timing light indicates the
camshaft position sensor or dis- FE
IGN TIMING ADJ ing ignition timing with a timing tributor)
same value on the screen.
light and checking whether it I Camshaft position sensor drive
agrees with specifications. mechanism CL
I INJECTION SYS (Injector, fuel
pressure regulator, harness or
connector)
MT
I Air-fuel ratio feedback circuit
I IGNITION SYS (Spark plug, igni-
(injection system, ignition system,
Oxygen sensor COUNT: More tion coil, power transistor harness
MIXTURE RATIO vacuum system, etc.) is tested by
than 5 times during 10 sec- or connector)
AT
TEST* examining the oxygen sensor out-
onds I VACUUM SYS (Intake air leaks)
put at 2,000 rpm under non-
I Oxygen sensor circuit
loaded state.
I Oxygen sensor operation
TF
I Fuel pressure high or low
I Mass air flow sensor
PD
I After warming up, idle the engine.
I Injector operation of each cylinder I Injector circuit (Injector, harness or
is stopped one after another, and
Difference in engine speed is
connector) FA
resultant change in engine rotation I Ignition circuit (Spark plug, ignition
greater than 25 rpm before
POWER BALANCE is examined to evaluate combus- coil, power transistor harness or
and after cutting off the injec-
tion of each cylinder. (This is only connector) RA
tor of each cylinder.
displayed for models where a I Compression
sequential multiport fuel injection I Valve timing
system is used.) BR
I After warming up, idle the engine. I Harness and connector
I IACV-AAC valve system is tested Difference in engine speed is I IACV-AAC valve
IACV-AAC/V by detecting change in engine greater than 150 rpm between I Air passage restriction between air
ST
SYSTEM speed when IACV-AAC valve when valve opening is at 80% inlet and IACV-AAC valve
opening is changed to 0%, 20% and at 20%. I IAS (Idle adjusting screw) adjust-
RS
and 80%. ment
*: Models with three way catalyst.
BT
HA
EL
SE
IDX
EC-39
CONSULT (Cont’d)
REAL TIME DIAGNOSIS IN DATA MONITOR MODE
CONSULT has two kinds of triggers and they can be selected by touching “SETTING” in “DATA MONITOR”
mode.
1. “AUTO TRIG” (Automatic trigger):
I The malfunction will be identified on the CONSULT screen in real time.
In other words, malfunction item will be displayed at the moment the malfunction is detected by ECM.
DATA MONITOR can be performed continuously until a malfunction is detected. However, DATA MONI-
TOR cannot continue any longer after the malfunction detection.
2. “MANU TRIG” (Manual trigger):
I Malfunction item will not be displayed automatically on CONSULT screen even though a malfunction
is detected by ECM.
DATA MONITOR can be performed continuously even though a malfunction is detected.
Use these triggers as follows:
1. “AUTO TRIG”
I While trying to detect the DTC by performing the “DTC CONFIRMATION PROCEDURE”, be sure to
select to “DATA MONITOR (AUTO TRIG)” mode. You can confirm the malfunction at the moment it is
detected.
I While narrowing down the possible causes, CONSULT should be set in “DATA MONITOR (AUTO
TRIG)” mode, especially in case the incident is intermittent.
When you are inspecting the circuit by gently shaking (or twisting) the suspicious connectors, compo-
nents and harness in the “DTC CONFIRMATION PROCEDURE”, the moment a malfunction is found
the malfunction item will be displayed. (Refer to GI section, “Incident Simulation Tests” in “HOW TO
PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”.)
2. “MANU TRIG”
I If the malfunction is displayed as soon as “DATA MONITOR” is selected, reset CONSULT to “MANU
TRIG”. By selecting “MANU TRIG” you can monitor and store the data. The data can be utilized for
further diagnosis, such as a comparison with the value for the normal operating condition.
SEF529Q
EC-40
TROUBLE DIAGNOSIS — Introduction TB45E
Introduction GI
The engine has an ECM to control major systems such as fuel
control, ignition control, idle air control system, etc. The ECM MA
accepts input signals from sensors and instantly drives actuators.
It is essential that both input and output signals are proper and
stable. At the same time, it is important that there are no problems EM
such as vacuum leaks, fouled spark plugs, or other problems with
the engine.
It is much more difficult to diagnose a problem that occurs intermit- LC
tently rather than continuously. Most intermittent problems are
MEF036D caused by poor electric connections or improper wiring. In this
case, careful checking of suspected circuits may help prevent the
replacement of good parts.
A visual check only may not find the cause of the problems. A road
test with CONSULT or a circuit tester connected should be per- FE
formed. Follow the “Work Flow” on EC-43.
Before undertaking actual checks, take just a few minutes to talk
with a customer who approaches with a driveability complaint. The CL
customer can supply good information about such problems, espe-
cially intermittent ones. Find out what symptoms are present and
under what conditions they occur. A “Diagnostic Worksheet” like the MT
example on next page should be used.
SEF233G Start your diagnosis by looking for “conventional” problems first.
This will help troubleshoot driveability problems on an electronically AT
controlled engine vehicle.
TF
PD
FA
SEF234G
RA
Diagnostic Worksheet
There are many operating conditions that lead to the malfunctions BR
of engine components. A good knowledge of such conditions can
make troubleshooting faster and more accurate.
In general, each customer may feel differently about a given prob- ST
lem. It is important to fully understand the symptoms or conditions
for a customer complaint.
Utilize a diagnostic worksheet like the one on next page in order to RS
organize all the information for troubleshooting.
SEF907L BT
HA
EL
SE
IDX
EC-41
TROUBLE DIAGNOSIS — Introduction TB45E
Diagnostic Worksheet (Cont’d)
WORKSHEET SAMPLE
Customer name MR/MS Model & Year VIN
Engine # Trans. Mileage
Incident Date Manuf. Date In Service Date
l Vehicle ran out of fuel causing misfire.
Fuel and fuel filler cap
l Fuel filler cap was left off or incorrectly screwed on.
l Impossible to start l No combustion l Partial combustion
l Partial combustion affected by throttle position
l Startability
l Partial combustion NOT affected by throttle position
l Possible but hard to start l Others [ ]
l No fast idle l Unstable l High idle l Low idle
l Idling
l Others [ ]
Symptoms
l Stumble l Surge l Knock l Lack of power
l Driveability l Intake backfire l Exhaust backfire
l Others [ ]
l At the time of start l While idling
l Engine stall l While accelerating l While decelerating
l Just after stopping l While loading
l Just after delivery l Recently
Incident occurrence
l In the morning l At night l In the daytime
Frequency l All the time l Under certain conditions l Sometimes
Weather conditions l Not affected
Weather l Fine l Raining l Snowing l Others [ ]
Temperature l Hot l Warm l Cool l Cold l Humid °F
l Cold l During warm-up l After warm-up
Engine conditions Engine speed
Road conditions l In town l In suburbs l Highway l Off road (up/down)

l Not affected
l At starting l While idling l At racing
l While accelerating l While cruising
Driving conditions l While decelerating l While turning (RH/LH)
Vehicle speed
Malfunction indicator lamp l Turned on l Not turned on
EC-42
TROUBLE DIAGNOSIS — Work Flow TB45E
Work Flow GI
CHECK IN
MA
H
CHECK INCIDENT CONDITIONS. ................................................. STEP I
Listen to customer complaints. (Get symptoms.) EM
H
CHECK DTC. LC
Check and print out (write down) Diagnostic Trouble Code (DTC). Then clear. ........................................... STEP II
If DTC is not available even if MIL lights up, check ECM fail-safe. (Refer to EC-51.)
Also check related service bulletins for information.
Symptoms collected No symptoms, except MIL
lights up, or
H
DTC exists at STEP II. FE
Verify the symptom by driving in the condition the cus- *1
tomer described. ............................................................................................. STEP III
CL
Normal Code Malfunction Code
(at STEP II) (at STEP II)
H H MT
*1
...........................................
INCIDENT INFORMATION STEP IV
Verify the DTC by performing the “DTC CONFIRMATION PROCEDURE”.
H
AT
Choose the appropriate action. ...........................................
E *2 STEP V
Malfunction Code (at STEP II or IV)
H
Normal Code (at both STEP II and IV) TF
BASIC INSPECTION
............................................................. E
SYMPTOM BASIS (at STEP I or III) PD
H
Perform inspections accord-
ing to Symptom Matrix
FA
Chart.
H H
STEP VI
RA
TROUBLE DIAGNOSIS FOR DTC XX.
H BR
REPAIR/REPLACE
H
NG FINAL CHECK ST
Confirm that the incident is completely fixed by performing BASIC INSPECTION and ........................................... STEP VII
DTC CONFIRMATION PROCEDURE (or OVERALL FUNCTION CHECK).
Then, erase the unnecessary (already fixed) DTCs in ECM. RS
OK
H
CHECK OUT BT
*1: If the incident cannot be duplicated, see “Incident Simulation Tests” of “HOW TO PERFORM EFFICIENT DIAGNO- HA
SIS FOR AN ELECTRICAL INCIDENT” in GI section.
*2: If the on board diagnostic system cannot be performed, check main power supply and ground circuit (See TROUBLE
DIAGNOSIS FOR POWER SUPPLY, EC-65). EL
SE
IDX
EC-43
TROUBLE DIAGNOSIS — Work Flow TB45E
Description for Work Flow

STEP DESCRIPTION
Get detailed information about the conditions and the environment when the incident/symptom occurred using the
STEP I
“DIAGNOSTIC WORK SHEET”, EC-41.
Before confirming the concern, check and write down (print out using CONSULT) the Diagnostic Trouble Code
(DTC), then erase the code. (Refer to EC-26.) The DTC can be used when duplicating the incident at STEP III &
IV.
STEP II
Study the relationship between the cause, specified by DTC, and the symptom described by the customer. (The
“Symptom Matrix Chart” will be useful. See page EC-52.)
Also check related service bulletins for information.
Try to confirm the symptom and under what conditions the incident occurs.
The “DIAGNOSTIC WORK SHEET” is useful to verify the incident. Connect CONSULT to the vehicle in DATA
STEP III MONITOR (AUTO TRIG) mode and check real time diagnosis results.
If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. (Refer to GI section.)
If the malfunction code is detected, skip STEP IV and perform STEP V.
Try to detect the Diagnostic Trouble Code by driving in (or performing) the “DTC CONFIRMATION PROCEDURE”.
Check and read the DTC by using CONSULT.
During the DTC verification, be sure to connect CONSULT to the vehicle in DATA MONITOR (AUTO TRIG) mode
and check real time diagnosis results.
STEP IV
If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. (Refer to GI section.)
In case the “DTC CONFIRMATION PROCEDURE” is not available, perform the “OVERALL FUNCTION CHECK”
instead. The DTC cannot be displayed by this check, however, this simplified “check” is an effective alternative.
The “NG” result of the “OVERALL FUNCTION CHECK” is the same as the DTC detection.
Take the appropriate action based on the results of STEP I through IV.
If the malfunction code is indicated, proceed to TROUBLE DIAGNOSIS FOR DTC XX.
STEP V
If the normal code is indicated, proceed to the BASIC INSPECTION on next page. Then perform inspections
according to the Symptom Matrix Chart. (Refer to EC-52.)
Identify where to begin diagnosis based on the relationship study between symptom and possible causes. Inspect
the system for mechanical binding, loose connectors or wiring damage using (tracing) “Harness Layouts”.
Gently shake the related connectors, components or wiring harness with CONSULT set in “DATA MONITOR
(AUTO TRIG)” mode.
Check the voltage of the related ECM terminals or monitor the output data from the related sensors with CON-
STEP VI
SULT. Refer to EC-54, EC-58.
The “DIAGNOSTIC PROCEDURE” in EC section contains a description based on open circuit inspection. A short
circuit inspection is also required for the circuit check in the DIAGNOSTIC PROCEDURE. For details, refer to GI
section (“HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”, “Circuit Inspection”).
Repair or replace the malfunction parts.
Once you have repaired the circuit or replaced a component, you need to run the engine in the same conditions
and circumstances which resulted in the customer’s initial complaint.
Perform the “DTC CONFIRMATION PROCEDURE” and confirm the normal code (Diagnostic trouble code No. 55)
STEP VII is detected. If the incident is still detected in the final check, perform STEP VI by using a different method from the
previous one.
Before returning the vehicle to the customer, be sure to erase the unnecessary (already fixed) DTC in ECM. (Refer
to EC-26.)
EC-44
TROUBLE DIAGNOSIS — Basic Inspection TB45E
Idle Speed/Ignition Timing/Throttle Position GI

Sensor/Idle Mixture Ratio Check and
Adjustment MA
Preparation (8) Fuel pressure
I Make sure that the following parts are in (9) Engine compression
(10) Throttle valve EM
good order.
(1) Battery I On air conditioner equipped models, checks
should be carried out while the air condi-
(2) Ignition system
tioner is “OFF”.
LC
(3) Engine oil and coolant levels
(4) Fuses I When measuring “CO” percentage, insert
(5) ECM harness connector probe more than 40 cm (15.7 in) into tail pipe.
(6) Vacuum hoses I Turn off headlamps, heater blower, rear win-
(7) Air intake system dow defogger.
(Oil filler cap, oil level gauge, etc.) I Keep front wheels pointed straight ahead. FE
CL
MT
AT
Precaution:
Perform Basic Inspection without electrical or mechanical
loads applied; TF
I Headlamp switch is OFF,
I Air conditioner switch is OFF,
I Rear window defogger switch is OFF, PD
I Steering wheel is in the straight-ahead position, etc.
FA
BEFORE STARTING
1. Check service records for any recent
SEF142I repairs that may indicate a related RA
problem, or the current need for sched-
uled maintenance.
2. Open engine hood and check the fol- BR
lowing:
I Harness connectors for improper con-
nections
I Vacuum hoses for splits, kinks, or ST
improper connections
I Wiring for improper connections,
pinches, or cuts
RS
H
SEF146U NG BT
CHECK FI CAM. E Check FI cam. Refer to
1. Start engine and warm it up until EC-25.
engine coolant temperature indicator
points to the middle of gauge and HA
ensure that engine speed is below
1,000 rpm.
2. Check that the center of mark qA is EL
aligned with mark q B as shown in the
figure at 75 to 85°C (167 to 185°F).
OK SE
H
q
A
IDX
SEF069V
EC-45
Adjustment (Cont’d)
q
A
H
CONNECT CONSULT TO THE VEHICLE.
Connect “CONSULT” to the data link con-
nector for CONSULT and select “ENGINE”
from the menu. Refer to EC-32.
SEF532V H
NG
Perform the diagnostic test mode II (Self- E Go to corresponding
diagnostic results). “TROUBLE DIAGNOSIS”.
OK
F
H
NG
1. Stop engine and disconnect throttle E Adjust ignition timing by
position sensor harness connector. turning camshaft position
2. Start engine and rev engine (2,000 to sensor.
3,000 rpm) 2 or 3 times under no-load
then let it idle.
3. Check ignition timing at idle using tim-
ing light.
Ignition timing:
SEF051P 5°±2° BTDC
OK
H
NG
CHECK BASE IDLE SPEED. E Adjust base idle speed by
When disconnecting throttle position sen- turning idle speed adjust-
sor harness connector, does engine run at ing screw.
600±50 rpm?
OK OK
H
For M/T models,
go to .
H
NG
SEF535V CHECK CLOSED THROTTLE POSITION E ADJUST TPS IDLE POSI-
SWITCH IDLE POSITION. TION.
I Warm engine up to normal operating 1. Adjust continuity signal
temperature. by rotating throttle posi-
I Check FI cam. Refer to procedure tion sensor body as fol-
. low.
I Always check ignition timing and 2. Check continuity
base idle before performing the fol- between closed throttle
lowings. position switch connec-
1. Disconnect throttle position sensor har- tor terminals q5 and q 6
ness connector and closed throttle under following condi-
position switch harness connector. tions.
2. Rev engine (2,000 to 3,000 rpm) 2 or 3 I Raise engine speed
times under no-load and then run to 2,000 rpm.
engine at idle speed. I Lower engine speed
3. Check continuity between closed as gradually as pos-
SEF284G throttle position switch connector termi- sible.
nals q 5 and q 6 under following condi- Engine speed at the
tions. point closed throttle
I Raise engine speed to 2,000 rpm. position “OFF” (No con-
I Lower engine speed as gradually as tinuity) → “ON” (Conti-
possible. nuity exists.):
Engine speed at the point closed 900±150 rpm (“P” or “N”
throttle position “OFF” (No continuity) position)
→ “ON” (Continuity exists.):
900±150 rpm (“P” or “N” position)
OK
H H
q
B q
C
SEF535V
EC-46
Sensor/Idle Mixture Ratio Check and GI
q
B q
C
MA
H
H
Reconnect throttle position sensor har- EM
ness connector and closed throttle posi- RESET IDLE POSITION
tion switch harness connector. MEMORY.
1. Disconnect throttle posi-
tion sensor harness
LC
SEF436Q
connector.
2. Warm up engine to nor-
mal operating tempera-
ture.
3. Select “CLSD
THL/POSI” in FE
“DATA MONI-
TOR” mode
(Manual trigger) CL
with CONSULT,
then stop
engine. MT
4. Reconnect throttle posi-
tion sensor harness
SEF864V connector.
5. Start engine and wait
AT
for a few seconds.
6. Turn ignition switch
“OFF” and wait at least TF
5 seconds.
7. Repeat steps 5.
and 6. until PD
“CLSD THL/
POSI” in “DATA
MONITOR” FA
mode with CON-
SULT changes
to “ON”.
SEF852V
Repeat steps 5.
RA
and 6. 10 times.
BR
F
H
NG
CHECK THROTTLE POSITION SENSOR E
Adjust output voltage to ST
IDLE POSITION. (M/T models) 0.5V by rotating throttle
1. Step engine and then turn ignition position sensor body.
switch “ON”.
2. Perform “THRTL POS SEN
RS
ADJ” in “WORK SUPPORT”
mode.
SEF853V 3. Check output voltage of throttle BT
position sensor.
Voltage: 0.4 - 0.6V
------------------------------------------------------------------- OR ------------------------------------------------------------------- HA
2. Reconnect throttle position sen-
sor harness connector.
3. Check voltage between ECM EL
terminal q 38 and ground with
voltmeter.
Voltage: 0.4 - 0.6V SE
OK
H H
q
D q
E IDX
EC-47
q
D q
E
H
RESET IDLE POSITION
MEMORY.
1. Disconnect throttle posi-
tion sensor sub-harness
connector.
SEF864V 2. Warm up engine to nor-
mal operating tempera-
ture.
3. Select “CLSD
THL/POSI” in
“DATA MONI-
TOR” mode
(Manual trigger)
with CONSULT,
then stop
engine.
4. Reconnect throttle posi-
tion sensor sub-harness
connector.
5. Start engine and wait
for a few seconds.
“OFF” and wait at least
5 seconds.
7. Repeat steps 5.
and 6. until
“CLSD THL/
POSI” in “DATA
MONITOR”
mode with CON-
SULT changes
to “ON”.
Repeat steps 5.
and 6. 10 times.
H
Rev engine (2,000 to 3,000 rpm) 2 or 3
times under no-load and run engine at idle
speed.
H
NG
CHECK TARGET IDLE SPEED. E
Adjust idle speed. Refer to
Read the engine idle speed in EC-45.
“DATA MONITOR” mode with
CONSULT.
650±50 rpm
------------------------------------------------------------------- OR -------------------------------------------------------------------
Check idle speed.
650±50 rpm
OK OK
With Without
three three way
way catalyst
catalyst
H H
q
F q
H
EC-48
Sensor/Idle Mixture Ratio Check and GI
q
F
MA
With three way
catalyst
H
Set the diagnostic test mode II (Oxygen EM
sensor monitor).
H LC
Run engine at about 2,000 rpm for about
SEF525V
2 minutes under no-load.
H
Check oxygen sensor signal.
NG
E Check oxygen sensor and FE
1. See “M/R F/C MNT” in “DATA the circuit.
MONITOR” mode. Refer to EC-123.
2. Maintaining engine at 2,000 CL
rpm under no-load (engine is OK
warmed up to normal operating
temperature), check that the
monitor fluctuates between MT
“LEAN” and “RICH” more than
5 times during 10 seconds.
SEF052U
1 cycle: RICH → LEAN →
RICH
AT
2 cycles: RICH → LEAN →
RICH → LEAN →
RICH TF
------------------------------------------------------------------- OR -------------------------------------------------------------------
Make sure that malfunction indica-
tor lamp goes on and off more
than 5 times during 10 seconds at PD
2,000 rpm.
q
H
OK FA
Without F
three way
SEF051P catalyst H H
NG
RA
Check “CO”%. E Connect oxygen sensor
-------------------------------------------------------------------------------------------------------------------------------------------------------- harness connector to oxy-
Idle CO: Less than 2.0% gen sensor (Models with
(Without three way catalyst) three way catalyst only).
BR
Less than 0.1%
(With three way catalyst)
ST
OK
H
Check fuel pressure regu-
lator. Refer to EC-23.
RS
H
BT
Check mass air flow sen-
sor and its circuit. Refer to
EC-77.
HA
H
Check injector and its cir-
cuit. Refer to EC-136.
EL
Clean or replace if neces-
sary.
SE
H H
q
I q
J
IDX
EC-49
q
I q
J
H
Check engine coolant tem-
perature sensor and its
circuit. Refer to EC-82.
H
Check ECM function* by
substituting another known
good ECM.
F
*: ECM may be the cause of
a problem, but this is rarely
H the case.
After this inspection, unnecessary diag-
nostic trouble code No. might be dis-
played.
Erase the stored memory in ECM.
Refer to “ON BOARD DIAGNOSTIC SYS-
TEM DESCRIPTION” (EC-26).
OK
H
INSPECTION END
EC-50
TROUBLE DIAGNOSIS — General Description TB45E
Fail-Safe Chart GI
The ECM enters fail-safe mode, if any of the following malfunctions are detected due to the open or short cir-
cuit. MA
When the ECM enters the ECM fail-safe mode listed in the last column below, the MIL illuminates.
Detected
DTC No.
items
Engine operating condition in fail-safe mode EM
Mass air
12 flow sensor Engine speed will not rise more than 2,400 rpm due to the fuel cut.
circuit LC
13 Engine cool- Engine coolant temperature will be determined by ECM based on the time after turning ignition switch
ant tempera- “ON” or “START”.
ture sensor CONSULT displays the engine coolant temperature decided by ECM.
circuit
Engine coolant temperature decided
Condition
(CONSULT display) FE
Just as ignition switch is turned ON or START 20°C (68°F)
More than 6 minutes after ignition START 80°C (176°F) CL

20 - 80°C (68 - 176°F)
Except as shown above
(Depends on the time)
MT
43 Throttle Throttle position will be determined based on the amount of mass air flow and the engine speed.
position sen- Therefore, acceleration will be poor.
sor circuit AT
Driving condition
When engine is idling Normal

TF
When accelerating Poor acceleration
Unable to ECM ECM fail-safe activating condition

PD
access Diag- The computing function of the ECM was judged to be malfunctioning.
nostic Test When the fail-safe system activates, i.e. if the ECM detects a malfunction condition in the CPU of
Mode II ECM, the MALFUNCTION INDICATOR LAMP on the instrument panel lights to warn the driver. FA
However, it is not possible to access ECM and DTC cannot be confirmed.
Engine control with ECM fail-safe
When the fail-safe system is operating, fuel injection, ignition timing, fuel pump operation and IACV-
AAC valve operation are controlled under certain limitations. RA
ECM fail-safe operation BR

Engine speed Engine speed will not rise more than 3,000 rpm.
Fuel injection Simultaneous multiport fuel injection system

ST
Ignition timing Ignition timing is fixed at the preset value.
Fuel pump relay is “ON” when engine is running and “OFF” when engine
Fuel pump
stalls. RS
IACV-AAC valve Full open
BT
Replace ECM, if ECM fail-safe condition is confirmed.
HA
EL
SE
IDX
EC-51
Symptom Matrix Chart

SYMPTOM
OVERHEATS/WATER TEMPERATURE HIGH

LACK OF POWER/POOR ACCELERATION
HARD/NO START/RESTART (EXCP. HA)
BATTERY DEAD (UNDER CHARGE)

HESITATION/SURGING/FLAT SPOT
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION

SPARK KNOCK/DETONATION
SLOW/NO RETURN TO IDLE

ROUGH IDLE/HUNTING
Reference page
HIGH IDLE/LOW IDLE
IDLING VIBRATION
OVERCHARGING
ENGINE STALL
OVERCOOLS
Warranty Symptom Code AA AB AC AD AE AF AG AH AJ AK AL AM HA 1P 1X
Fuel Fuel pump circuit I I I q I I q q q EC-142
Fuel pressure regulator system I I I q I q I I q I EC-23
Basic engine control system
Injector circuit I I I q I I I I EC-136

Evaporative emission system q q q q I q q q q q EC-20
Air Positive crankcase ventilation system q q q q I q q q q q q EC-22
Incorrect idle speed adjustment q q q q q q q EC-45
IACV-AAC valve circuit I I I q I I I I I q q EC-125
IACV-FICD solenoid valve circuit q q q q q q q q q q EC-152
Ignition Incorrect ignition timing adjustment q q I I I I I I EC-45
Ignition circuit I I I I I I I I EC-86
Main power supply and ground circuit I I I q q q q q q q EC-65
Air conditioner circuit q q q q q q q q q q q HA section
Engine Camshaft position sensor circuit I I I I I q q q EC-70
control Mass air flow sensor circuit I I I I I I q q EC-77
system Oxygen sensor circuit I I q I I q I EC-121
Engine control system
Engine coolant temperature sensor circuit I I I q I I I q q I EC-82

Throttle position sensor circuit I I I I I I I I EC-108
Incorrect throttle position sensor adjust- I q q I q q I q EC-45
ment
Vehicle speed sensor circuit q q q q EC-117
ECM q q q q q q q q q q q EC-51
Start signal circuit q EC-140
Neutral position switch circuit q q q q q EC-130
Power steering oil pressure switch circuit q q q EC-148
I ; High Possibility Item (continued on next page)
q; Low Possibility Item
EC-52
Symptom Matrix Chart (Cont’d)
SYMPTOM GI
OVERHEATS/WATER TEMPERATURE HIGH

LACK OF POWER/POOR ACCELERATION
MA
BATTERY DEAD (UNDER CHARGE)


EM
SPARK KNOCK/DETONATION

SYSTEM
ROUGH IDLE/HUNTING
— Engine mechanical & other Reference page
HIGH IDLE/LOW IDLE

LC
IDLING VIBRATION
OVERCHARGING
ENGINE STALL
OVERCOOLS
Warranty Symptom Code AA AB AC AD AE AF AG AH AJ AK AL AM HA 1P 1X
FE
Fuel Fuel tank I I
Fuel piping I I q q I q q q
Vapor lock q
CL
Valve deposit q q q q q q q q
Poor fuel (Heavy weight gasoline, Low
q q q q q q q q — MT
octane)
Air Air duct q q q q q q
Air cleaner q I I I q q
Air leakage from air duct
q q q q q q q q q q
AT
(Mass air flow sensor — throttle body)
Throttle body, Throttle wire q I I q I I q q q FE section
Air leakage from intake manifold/
q I q q q q I q q I — TF
Collector/Gasket
Cranking Battery q q q q q q q q q
Alternator circuit q q q q q q q q q EL section PD
Starter circuit I
Flywheel/Drive plate I —
Engine Cylinder head I q I q q I q q
FA
Cylinder head gasket q q q q q I q I q q
Cylinder block q q q q I q q q q
Piston q q q q q q I q I
Piston ring q q q q I I q q I
RA
Connecting rod I q q q q q q q
Bearing I I q I q q I q
Crankshaft q q q q q q q q
BR
Valve Timing chain I q I q I q q q
mechanism Camshaft I q q q q q q q
Intake valve q I I q q I q q q
ST
Exhaust valve I q I q I I q q I —
Exhaust Exhaust manifold/Tube/Muffler/Gasket q I I I I I q I
Three way catalyst q I q q I q q q RS
Lubrication Oil pan/Oil strainer/Oil pump/Oil filter/Oil
gallery
I q q I I q q q I
Oil level (Low)/Filthy oil q q q q q q q q q BT
Cooling Radiator/Hose/Radiator filler cap q q q q q q q I q
Thermostat q q q q q q I q q I q q
Water pump I q q q q q q I q HA
Water gallery q q q q q q q q q
Cooling fan q q q q I q I q q I q q
Coolant level (low)/Contaminated coolant q q q q q q q q q EL
I ; High Possibility Item
q; Low Possibility Item
SE
IDX
EC-53
CONSULT Reference Value in Data Monitor

Mode
Remarks:
I Specification data are reference values.
I Specification data are output/input values which are detected or supplied by the ECM at the connector.
* Specification data may not be directly related to their components signals/values/operations.
i.e. Adjust ignition timing with a timing light before monitoring IGN TIMING, because the monitor may show the specification data
in spite of the ignition timing not being adjusted to the specification data. This IGN TIMING monitors the data calculated by the
ECM according to the signals input from the camshaft position sensor and other ignition timing related sensors.
I If the real-time diagnosis results are NG and the on board diagnostic system results are OK when diagnosing the mass air flow
sensor, first check to see if the fuel pump control circuit is normal.
MONITOR ITEM CONDITION SPECIFICATION
I Tachometer: Connect Almost the same speed as the CON-
CMPS⋅RPM (POS)
I Run engine and compare tachometer indication with the CONSULT value. SULT value.
I Engine: After warming up Idle 1.3 - 1.8V
I Air conditioner switch: “OFF”
MAS AIR/FL SE
I Shift lever: Neutral position
I No-load 2,500 rpm 2.1 - 2.6V
COOLAN TEMP/S I Engine: After warming up More than 70°C (158°F)

O2 SEN 0 - 0.3V ) 0.6 - 1.0V
I Engine: After warming up Maintaining engine speed at 2,000 rpm LEAN ) RICH
M/R F/C MNTR Changes more than 5 times
during 10 seconds.
Almost the same speed as
VHCL SPEED SE I Turn drive wheels and compare speedometer indication with the CONSULT value
the CONSULT value
BATTERY VOLT I Ignition switch: ON (Engine stopped) 11 - 14V
I Ignition switch: ON Throttle valve: fully closed 0.4 - 0.6V

THRTL POS SEN
(Engine stopped) Throttle valve: fully opened Approx. 4.0V
START SIGNAL I Ignition switch: ON , START , ON OFF , ON , OFF
I Ignition switch: ON Throttle valve: Idle position ON

CLSD THL/POSI
(Engine stopped) Throttle valve: Slightly open OFF
Air conditioner switch: “OFF” OFF
AIR COND SIG Air conditioner switch: “ON”
engine ON
(Compressor operates.)
Shift lever: Neutral position ON
P/N POSI SW I Ignition switch: ON
Except above OFF
Steering wheel in neutral position
I Engine: After warming up, idle the OFF
PW/ST SIGNAL (forward direction)
engine
The steering wheel is turned. ON
EC-54
Mode (Cont’d) GI
I Engine: After warming up
MA
Idle 4.4 - 5.0 msec.
INJ PULSE
2,000 rpm 3.4 - 4.0 msec.
I No-load EM
Idle 5° BTDC
IGN TIMING ditto
2,000 rpm More than 25° BTDC
LC
Idle 5 - 50%
IACV-AAC/V ditto
2,000 rpm —
A/F ALPHA I Engine: After warming up Maintaining engine speed at 2,000 rpm 75 - 125%
AIR COND RLY I Air conditioner switch: OFF , ON OFF , ON
I Ignition switch is turned to ON (Operates for 5 seconds)
I Engine running and cranking ON
FE
FUEL PUMP RLY I When engine is stopped (Stops in 1 second)
Except as shown above OFF
CL
Engine coolant temperature is 94°C
OFF
(201°F) or less.
I After warming up engine, idle the
engine. Engine coolant temperature is between M/T models: LOW MT
I Air conditioner switch “OFF” 95°C (203°F) and 99°C (210°F). A/T models: ON
I Vehicle stopped
Engine coolant temperature is 100°C M/T models: HIGH
COOLING FAN
(212°F) or more. A/T models: ON AT
M/T models for the Middle East: HIGH
I After warming up engine, idle the Engine coolant temperature is 99°C M/T models except for the Middle East:
engine. (210°F) or less. LOW
A/T models ON
TF
I Air conditioner switch “ON”
I Vehicle stopped Engine coolant temperature is 100°C M/T models: HIGH
(212°F) or more. A/T models: ON
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-55
Major Sensor Reference Graph in Data Monitor

Mode
The following are the major sensor reference graphs in “DATA MONITOR” mode.
(Select “HI SPEED” in “DATA MONITOR” with CONSULT.)
THRTL POS SEN, CLSD THL/POSI

Below is the data for “THRTL POS SEN” and “CLSD THL/POSI” when depressing the accelerator pedal with
the ignition switch “ON”.
The signal of “THRTL POS SEN” should rise gradually without any intermittent drop or rise after “CLSD THL/
POSI” is changed from “ON” to “OFF”.
SEF754T
CMPS⋅RPM (POS), MAS AIR/FL SE, THRTL POS SEN, O2 SEN, INJ PULSE
Below is the data for “CMPS⋅RPM (POS)”, “MAS AIR/FL SE”, “THRTL POS SEN”, “O2 SEN” and “INJ PULSE”
when revving engine quickly up to 4,800 rpm under no load after warming up engine to normal operating tem-
perature.
Each value is for reference, the exact value may vary.
SEF598PB
EC-56
Mode (Cont’d) GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
SEF259QA
BT
HA
EL
SE
IDX
EC-57
ECM Terminals and Reference Value

PREPARATION
1. ECM is located behind the instrument lower panel.
For this inspection, remove the driver’s side instrument lower
cover.
SEF519V
SEF517V
2. Remove ECM harness protector.
MEF140D
3. Perform all voltage measurements with the connectors con-

nected. Extend tester probe as shown to perform tests easily.
MEC486B
ECM HARNESS CONNECTOR TERMINAL LAYOUT
MEC487BB
EC-58
ECM Terminals and Reference Value (Cont’d)
ECM INSPECTION TABLE GI
Remarks: Specification data are reference values, and are measured between each terminal and q
60 (ECCS ground) with a voltmeter.
TERMINAL WIRE
ITEM CONDITION
DATA MA
NO. COLOR (DC voltage)
Approximately 0.5V★
EM
Engine is running.
LC
Idle speed
SEF536V
1 W/G Ignition signal
Approximately 0.9V★ FE
Engine is running. CL
Engine speed is 2,000 rpm.
MT
SEF537V
AT
Approximately 13V★
TF
Engine is running.
Idle speed
PD
SEF538V FA
2 W Ignition check
RA
Engine is running.
Engine speed is 2,000 rpm. BR
SEF539V
ST
Engine is running.
7 - 10V RS
Idle speed
Engine is running.
4 L IACV-AAC valve
BT
Rear window defogger is operating.
5 - 10V
Steering wheel is being turned.
Air conditioner is operating.
Headlamps are in high position. HA
5 PU/W A/T signal No. 1 Ignition switch “ON” 6 - 8V
Engine is running. EL
BATTERY VOLTAGE
Cooling fan relay Cooling fan is not operating. (11 - 14V)
6 L/B (High speed) Cooling fan is operating at low speed.
SE
(M/T models only) Engine is running.
Approximately 0V
Cooling fan is operating at high speed.
IDX
★: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)
EC-59
TERMINAL WIRE DATA
ITEM CONDITION
Engine is running.
2.2 - 2.5V
Idle speed
7 Y/B Tachometer
Engine is running.
4.8 - 5.0V
Ignition switch “ON”
For 5 seconds after turning ignition switch

“ON” 0 - 1.0V
Engine is running.
8 R/Y Fuel pump relay

BATTERY VOLTAGE
5 seconds after turning ignition switch “ON” (11 - 14V)
and thereafter
Engine is running.
Both A/C switch and blower switch are 0 - 1.0V

Air conditioner “ON”.
9 Y/L
relay
Engine is running. BATTERY VOLTAGE
A/C switch is “OFF”. (11 - 14V)
Engine is running.
10 B ECM ground Engine ground
Idle speed
14 P/B A/T signal No. 2 Ignition switch “ON” 6 - 8V
15 P A/T signal No. 3 Ignition switch “ON” 0V
Engine is running.
Ignition switch “OFF” 0 - 1.0V
ECCS relay (Self- For a few seconds after turning ignition

16 B/Y switch “OFF”
shutoff)
Ignition switch “OFF”
BATTERY VOLTAGE
A few seconds after turning ignition switch (11 - 14V)
“OFF”

Cooling fan is not operating. (11 - 14V)
Cooling fan relay
19 L
(Low speed) Engine is running.
Approximately 0V
Cooling fan is operating.
Engine is running.
Idle speed
21 Y/G Approximately 0V
22 Y/R Data link connec- Engine is running. Approximately 5.5V
31 Y tor for CONSULT Idle speed Approximately 3.5V
47 Y/B Approximately 0V
EC-60
TERMINAL WIRE DATA
GI
ITEM CONDITION
Engine is running. MA
23 W Knock sensor Approximately 2.5V
Idle speed
Mass air flow sen- Engine is running. (Warm-up condition) EM

26 B Approximately 0V
sor ground Idle speed
Engine is running. (Warm-up condition)

LC
1.3 - 1.8V
Mass air flow sen- Idle speed
27 W
sor Engine is running. (Warm-up condition)
2.1 - 2.5V
FE
Engine coolant 0 - 5.0V
28 LG/B temperature sen- Engine is running. Output voltage varies with
sor engine coolant temperature. CL
Approximately 0 - 1.0V*
(periodically changes)
MT
Engine is running.
29 W Oxygen sensor After warming up to normal operating tem- AT
perature and engine speed is 2,000 rpm
TF
SEF540V
Engine is running. (Warm-up condition) PD

30 B Sensor’s ground Approximately 0V
Idle speed
Ignition switch “ON” 0 - 1.0V

FA
Malfunction indi-
32 Y/G Engine is running. BATTERY VOLTAGE
cator lamp
(11 - 14V)
RA
Idle speed
Engine is running.
Approximately 0V BR
Power steering oil Steering wheel is being turned.
34 OR/L
pressure switch Engine is running.
Approximately 5V ST
Steering wheel is not being turned.

0.35 - 0.65V
RS
Throttle position Accelerator pedal is released.
38 W
sensor Ignition switch “ON”
4.0V
BT
Accelerator pedal is fully depressed.
*: Actual pulse signal can be confirmed by oscilloscope. HA
EL
SE
IDX
EC-61
TER-
WIRE DATA
MINAL ITEM CONDITION
COLOR (DC Voltage)
NO.
Approximately
0.3 - 0.6V★
Idle speed
SEF542V
42 Camshaft position sensor
L
52 (REF) (120° signal) Approximately
0.4 - 0.5V★
Engine is running.
SEF543V
Approximately
2.6 - 2.7V★
Idle speed
SEF544V
51 B/W
(POS) (1° signal) Approximately
2.5 - 2.6V★
Engine is running.
SEF548T
Ignition switch “ON” Approximately 0V

43 R/W Start signal BATTERY VOLTAGE
Ignition switch “START”
(11 - 14V)
Approximately 0V
Park/neutral position sig- Gear position is “N” or “P”.
44 P/L
nal Ignition switch “ON”
Approximately 5V
Except above gear position
EC-62
TER-
GI
WIRE DATA
COLOR (DC Voltage)
NO.
MA
Engine is running.
Approximately 0V
Both A/C switch and blower switch are “ON” EM
46 LG/B Air conditioner switch (Compressor is operating).

LC
A/C switch is “OFF”. (11 - 14V)

48 OR Ignition switch “ON” Approximately 5V
power supply
49 B/R BATTERY VOLTAGE

Power supply for ECM Ignition switch “ON”
59 B/R (11 - 14V) FE
Engine is running.
Idle speed CL
Varies from approximately
Engine stopped and gear position is “Neutral”
MT
0 to BATTERY VOLTAGE
position. (11 - 14V)
While rotating drive wheel by hand
AT
5 - 7V★
53 L/OR Vehicle speed sensor TF

Engine is running.
Lift up the vehicle.

Suitable gear position PD
10 km/h (6 MPH)
FA
SEF541V
Ignition switch “ON” Approximately 0.35 - RA

Accelerator pedal is released. 0.65V
56 R/W
signal output Ignition switch “ON” BR
Approximately 4V
Accelerator pedal is fully depressed.
Ignition switch “OFF” ST

0V
57 L Ignition switch
Ignition switch “ON” BATTERY VOLTAGE RS
(11 - 14V)
BATTERY VOLTAGE
58 OR/B Power supply (Back-up) Ignition switch “OFF”
(11 - 14V) BT
Engine is running.
60 B ECM ground
Idle speed
Engine ground HA
EL
SE
IDX
EC-63
TER-
WIRE DATA
COLOR (DC Voltage)
NO.
BATTERY VOLTAGE
(11 - 14V)★
Idle speed
101 BR/W Injector No. 1

103 BR/Y Injector No. 3
SEF546V
105 GY/L Injector No. 2
110 BR Injector No. 5 BATTERY VOLTAGE
112 GY Injector No. 6 (11 - 14V)★
114 GY/R Injector No. 4
Engine is running.
SEF547V
107 B Engine is running.

ECM ground Engine ground
108 B Idle speed
BATTERY VOLTAGE
109 B/R Counter current return Ignition switch “ON”
(11 - 14V)
Engine is running.
Idle speed
EC-64
TROUBLE DIAGNOSIS FOR POWER SUPPLY TB45E
Main Power Supply and Ground Circuit GI

ECM TERMINALS AND REFERENCE VALUE
60 (ECM ground) with a voltmeter. MA
TER-
WIRE DATA
MINAL ITEM CONDITION EM
COLOR (DC voltage)
NO.
Engine is running.
LC
0 - 1.0V
For a few seconds after turning ignition switch
16 B/Y ECCS relay (Self-shutoff) “OFF”

BATTERY VOLTAGE
A few seconds passed after turning ignition (11 - 14V)
FE
switch “OFF”
Ignition switch “OFF” 0V CL

57 L Ignition switch
BATTERY VOLTAGE
(11 - 14V) MT
BATTERY VOLTAGE
58 OR/B Power supply (Back-up) Ignition switch “OFF”
(11 - 14V)
AT
49 BATTERY VOLTAGE
B/R Power supply for ECM Ignition switch “ON”
59 (11 - 14V)
Engine is running.
TF
BATTERY VOLTAGE
109 B/R Current return
Idle speed (11 - 14V)
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-65
Main Power Supply and Ground Circuit
(Cont’d)
TEC358
EC-66
(Cont’d) GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC359
EC-67
(Cont’d)
INSPECTION START
H
No
Start engine. E CHECK POWER SUP-
Is engine running? PLY-I.
Yes “ON”.
2. Check voltage between
ECM terminal q 57 and
ground with CONSULT
SEF553V
or tester.
Voltage: Battery volt-
age
If NG, check the following.
I Harness connectors
E127 , M21
M50 , F5
I Harness for open or
short between ECM and
ignition switch
If NG, repair harness or
connectors.
OK
H
SEF294S
Go to “CHECK GROUND
CIRCUIT” on next page.
H
NG
CHECK POWER SUPPLY-II. E Check the following.
1. Stop engine. I Harness connectors
2. Check voltage between ECM terminal E127 , M21
q
58 and ground with CONSULT or tester. I Harness connectors
Voltage: Battery voltage M52 , F7
I 7.5A fuse
OK I Harness for open or
battery
SEF554V connectors.
H
OK
CHECK POWER SUPPLY-III. E Go to “CHECK GROUND
1. Turn ignition switch “ON” and then turn CIRCUIT” on next page.
“OFF”.
2. Check voltage between ECM terminals
q49 , q
59 , 109 and ground with CON-
SULT or tester.
Voltage: Case-1: Battery voltage does
After turning ignition switch “OFF”, not exist.
battery voltage will exist for a few Case-2: Battery voltage exists
seconds, then drop to approximately for more than a few
0V. seconds.
SEF513V NG
Case-2
Case-1 E Go to “CHECK ECCS
RELAY” on next page.
H
q
A
SEF555V
EC-68
(Cont’d) GI
q
A
H
NG
MA
CHECK HARNESS CONTINUITY E Check the following.
BETWEEN ECCS RELAY AND ECM. I Harness connectors
1. Disconnect ECM harness connector. M52 , F7
2. Disconnect ECCS relay. I Harness for open or EM
3. Check harness continuity between ECM short between ECM and
terminals q
49 , q
59 , 109 and terminal q
5 . ECCS relay
Continuity should exist. If NG, repair open circuit,
If OK, check harness for short to short to ground or short to LC
ground and short to power. power in harness or con-
SEF073U nectors.
OK
H
NG
CHECK VOLTAGE BETWEEN ECCS E Check the following.
RELAY AND GROUND. I Harness connectors
Check voltage between terminals q
1 ,q
3 E127 , M21 FE
and ground with CONSULT or tester. I 7.5A fuse
Voltage: Battery voltage I Harness for open or
short between ECCS
OK relay and battery CL
connectors.
MT
H
NG
CHECK OUTPUT SIGNAL CIRCUIT. E Check the following.
SEF556V Check harness continuity between ECM I Harness connectors
16 and relay terminal q
terminal q 2 . M52 , F7 AT
Continuity should exist. I Harness for open or
If OK, check harness for short to ground short between ECM and
and short to power. ECCS relay
If NG, repair open circuit, TF
OK short to ground or short to
power in harness or con-
nectors. PD
H
NG
CHECK ECCS RELAY. E Replace ECCS relay.
1. Apply 12V direct current between relay FA
terminals q
1 and q 2 .
2. Check continuity between relay termi-
nals q
3 and q 5 .
SEF090M
12V (q1 -q 2 ) applied: RA
Continuity exists.
No voltage applied:
No continuity
BR
OK
H
NG ST
CHECK GROUND CIRCUIT. E Repair open circuit, short
1. Turn ignition switch “OFF”. to ground or short to power
2. Loosen and retighten engine ground in harness or connectors.
screws.
3. Disconnect ECM harness connector. RS
4. Check harness continuity between ECM
terminals q10 , q
20 , q
50 , q
60 , 107 , 108 ,
116 and engine ground.
SEF299S Continuity should exist. BT
If OK, check harness for short to
ground and short to power.
OK HA
H
Check ECM pin terminals for damage and
check the connection of ECM harness
connector. EL
H
INSPECTION END
SE
IDX
EC-69
TROUBLE DIAGNOSIS FOR “CAMSHAFT POSI SEN” (DTC 11) TB45E
Camshaft Position Sensor (CMPS)

COMPONENT DESCRIPTION
The camshaft position sensor is a basic component of the ECCS.
It monitors engine speed and piston position. These input signals
to the ECM are used to control fuel injection, ignition timing and
other functions.
The camshaft position sensor has a rotor plate and a wave-form-
ing circuit. The rotor plate has 360 slits for a 1° (POS) signal and
4 slits for a 120° (REF) signal. The wave-forming circuit consists of
Light Emitting Diodes (LED) and photo diodes.
SEF998R The rotor plate is positioned between the LED and the photo diode.
The LED transmits light to the photo diode. As the rotor plate turns,
the slits cut the light to generate rough-shaped pulses. These
pulses are converted into on-off signals by the wave-forming circuit
and sent to the ECM.
The distributor is not repairable and must be replaced as an
assembly, except distributor cap.
SEF614B
EC-70
Camshaft Position Sensor (CMPS) (Cont’d)
ECM TERMINALS AND REFERENCE VALUE GI
60 (ECM ground) with a voltmeter.
TER-
WIRE DATA MA
COLOR (DC voltage)
NO.
Approximately 0.3 - 0.6V★ EM
LC
Idle speed
42
L
Camshaft position sensor SEF542V FE
52 (REF) (120° signal) Approximately 0.4 - 0.5V★
CL
Engine is running.

MT
AT
SEF543V
Approximately 2.6 - 2.7V★
TF
Engine is running. (Warm-up condition) PD

Idle speed
FA
Camshaft position sensor SEF544V

51 B/W RA
(POS) (1° signal) Approximately 2.5 - 2.6V★
BR
Engine is running.
Engine speed is 2,000 rpm. ST
RS
SEF548T
BT
ON BOARD DIAGNOSIS LOGIC
HA
Diagnostic
Check Items
Trouble Code Malfunction is detected when ....
(Possible Cause)
No.
11 I Either 1° or 120° signal is not sent to ECM for the first I Harness or connectors EL
few seconds during engine cranking. (The camshaft position sensor circuit is open or
........................................................................................... shorted.)
I Either 1° or 120° signal is not sent to ECM during I Camshaft position sensor SE
engine running. I Starter motor (Refer to EL section.)
........................................................................................... I Starting system circuit (Refer to EL section.)
I Dead (Weak) battery
I Either 1° or 120° signal is not in the normal pattern IDX
during engine running.
EC-71
DIAGNOSTIC TROUBLE CODE CONFIRMATION
PROCEDURE
Before performing the following procedure, confirm that bat-
tery voltage is more than 10V.
1) Turn ignition switch “ON” and select “DATA MONITOR”
mode with CONSULT.
2) Start engine and run it for at least 2 seconds at idle
speed.
(If engine does not run, turn ignition switch to “START”
for at least 2 seconds.)
SEF647V ---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
speed.
2) Turn ignition switch “OFF”, wait at least 5 seconds and
then turn “ON”.
3) Perform “Diagnostic Test Mode II (Self-diagnostic
results)” with ECM.
EC-72
GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC360
EC-73
DIAGNOSTIC PROCEDURE
INSPECTION START
H
CHECK STARTING SYSTEM. No Check starting system.
E
Does the engine turn over? (Refer to EL section.)
(Does the starter motor operate?)
Yes
H
1. Turn ignition switch “OFF”.
SEF558V
2. Loosen and retighten engine ground
screws.
OK
H
CHECK POWER SUPPLY. NG Check the following.
E
1. Disconnect camshaft position sensor I Harness connectors
harness connector. M52 , F7
2. Turn ignition switch “ON”. I Harness for open or short
3. Check voltage between terminal q7 and between camshaft posi-
ground with CONSULT or tester. tion sensor and ECM
Voltage: Battery voltage I Harness for open or short
SEF557V
between camshaft posi-
OK
tion sensor and ECCS
relay
connectors.
H
CHECK GROUND CIRCUIT. NG Repair open circuit, short to
E
1. Turn ignition switch “OFF”. ground or short to power in
2. Check harness continuity between termi- harness or connectors.
nal q
8 and engine ground.
Continuity should exist.
SEF559V
If OK, check harness for short to ground
and short to power.
OK
H
q
A
SEF560V
EC-74
q
A GI
H
NG
MA
CHECK INPUT SIGNAL CIRCUIT. Repair open circuit, short to
E
2. Disconnect ECM harness connector. harness or connectors.
3. Check harness continuity between termi-
EM
nal q 6 and ECM terminals q 51 (1°
signal), terminal q5 and ECM terminals
q42 , q
52 (120° signal). LC
and short to power.
OK
H
CHECK COMPONENT NG Replace camshaft position FE
E
(Camshaft position sensor). sensor.
Refer to “COMPONENT INSPECTION”
below. CL
OK
H
CHECK SHIELD CIRCUIT. NG Check the following.
MT
E
1. Remove joint connector-6 F26 . I Joint connector-6 F26
SEF561V 2. Check the following. I Joint connector-5 F25
I Continuity between joint connector ter- I Harness for open or short AT
minal q1 and ground between joint connector-6
I Joint connector and engine ground
(Refer to “HARNESS LAYOUT” in EL If NG, repair harness or TF
section.) connectors.
If OK, check harness for short to ground PD
and short to power. Then reconnect joint
connector.
OK FA
H
Disconnect and reconnect harness connec-
tors in the circuit. Then retest. RA
Trouble is not fixed.
H
Check ECM pin terminals for damage and BR
check the connection of ECM harness con-
nector. Reconnect ECM harness connector
and retest. ST
H
INSPECTION END
RS
BT
HA
EL
SE
IDX
EC-75
COMPONENT INSPECTION
1. Start engine.
2. Check voltage between ECM terminals q
42 , q
52 , q
51 and ground
with DC range.
Condition Terminals Voltage

Approximately
q
42 , q
52 and ground
0.3 - 0.6V*
SEF562V
Engine running at idle
Approximately
q
51 and ground
2.6 - 2.7V*
*: Average voltage for pulse signal (Actual pulse signal can be confirmed by
oscilloscope.) (Refer to EC-71.)
If NG, replace distributor assembly with camshaft position sen-

sor.
3. Visually check signal plate for damage or dust.
After this inspection, DTC 11 might be displayed with camshaft
position sensor functioning properly. Erase the stored
memory.
SEF001S
EC-76
TROUBLE DIAGNOSIS FOR “MASS AIR FLOW SEN” (DTC 12) TB45E
Mass Air Flow Sensor (MAFS) GI

The mass air flow sensor is placed in the stream of intake air. It MA
measures the intake flow rate by measuring a part of the entire
intake flow. It consists of a hot wire that is supplied with electric
current from the ECM. The temperature of the hot wire is controlled EM
by the ECM a certain amount. The heat generated by the hot wire
is reduced as the intake air flows around it. The more air, the
greater the heat loss. LC
Therefore, the ECM must supply more electric current to the hot
SEF563V wire as air flow increases. This maintains the temperature of the hot
wire. The ECM detects the air flow by means of this current change.
CONSULT REFERENCE VALUE IN DATA MONITOR MODE FE

Remarks: Specification data are reference values.

CL
Idle 1.3 - 1.8V
MAS AIR/FL SE
I 2,500 rpm 2.1 - 2.5V
No-load MT
ECM TERMINALS AND REFERENCE VALUE AT

TER- TF
WIRE DATA
COLOR (DC voltage)
NO.
PD
1.3 - 1.8V
Idle speed
27 B Mass air flow sensor FA
2.1 - 2.5V
RA
Mass air flow sensor Engine is running. (Warm-up condition)
26 W Approximately 0V
ground Idle speed
BR
ON BOARD DIAGNOSIS LOGIC ST

Diagnostic
Check Items
Trouble Malfunction is detected when ...
(Possible Cause) RS
Code No.
12 I Harness or connectors
I An excessively high or low voltage from the sensor is
sent to ECM.*
(The sensor circuit is open or shorted.) BT
I Mass air flow sensor
*: When this malfunction is detected, the ECM enters fail-safe mode.
HA
Engine operating condition in fail-safe mode Engine speed will not rise more than 2,400 rpm due to the fuel cut.
EL
SE
IDX
EC-77
Mass Air Flow Sensor (MAFS) (Cont’d)
PROCEDURE
1) Turn ignition switch “ON”, and wait at least 6 seconds.
2) Select “DATA MONITOR” mode with CONSULT.
3) Start engine and wait at least 3 seconds.
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
then turn “ON”.
SEF648V 4) Perform “Diagnostic Test Mode II (Self-diagnostic
EC-78
GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC361
EC-79
INSPECTION START
H
screws.
OK
SEF558V H
E
1. Disconnect mass air flow sensor har- I Harness connectors
ness connector. M52 , F7
2. Turn ignition switch “ON”. I Harness for open or
3. Check voltage between terminal q2 and short between mass air
ground with CONSULT or tester. flow sensor and ECM
short between mass air
OK flow sensor and ECCS
relay
connectors.
SEF563V
H
CHECK GROUND CIRCUIT. NG Repair open circuit, short
E
2. Disconnect ECM harness connector. in harness or connectors.
3. Check harness continuity between ter-
minal q3 and ECM terminal q 26 .
OK
SEF566V H
NG
CHECK INPUT SIGNAL CIRCUIT. E
Repair open circuit, short
Check harness continuity between termi- to ground or short to power
4 and ECM terminal q
nal q 27 . in harness or connectors.
and short to power.
OK
H
CHECK COMPONENT NG Replace mass air flow sen-
E
(Mass air flow sensor). sor.
SEF564V
below.
OK
H
q
A
SEF565V
EC-80
q
A
GI
H MA
CHECK SHIELD CIRCUIT. NG Check the following.
E
2 Check the following. I Joint connector-5 F25 EM
I Continuity between joint connector I Harness for open or
terminal q1 and ground short between joint con-
I Joint connector nector-6 and engine LC
(Refer to “HARNESS LAYOUT” in EL ground
section.) If NG, repair harness or
Continuity should exist. connectors.
and short to power. Then reconnect joint
connector.
FE
OK
H
Disconnect and reconnect harness con- CL
nectors in the circuits. Then retest.

MT
H
check the connection of ECM harness AT
connector. Reconnect ECM harness con-
nector and retest.
TF
H
INSPECTION END PD
FA
RA
Mass air flow sensor BR
2. Start engine and warm it up to normal operating temperature.
3. Check voltage between ECM terminal q 27 and ground. ST
Conditions Voltage V
Ignition switch “ON” (Engine stopped.) Less than 1.0 RS
Idle (Engine is warmed-up sufficiently.) 1.3 - 1.8
SEF567V 2,500 rpm 2.1 - 2.6 BT
Idle to about 4,000 rpm* 2.5 to Approx. 4.0
*: Check for linear voltage rise in response to increase to about 4,000 rpm in engine HA
speed.
4. If NG, remove mass air flow sensor from air duct. Check hot
wire for damage or dust. EL
SE
SEF544S
IDX
EC-81
TROUBLE DIAGNOSIS FOR “COOLANT TEMP SEN” (DTC 13) TB45E
Engine Coolant Temperature Sensor (ECTS)

The engine coolant temperature sensor is used to detect the engine
coolant temperature. The sensor modifies a voltage signal from the
ECM. The modified signal returns to the ECM as the engine cool-
ant temperature input. The sensor uses a thermistor which is sen-
sitive to the change in temperature. The electrical resistance of the
thermistor decreases as temperature increases.
SEF594K
<Reference data>
Engine coolant tempera-
Voltage* Resistance
ture
(V) (kΩ)
°C (°F)
−10 (14) 4.4 7.0 - 11.4
20 (68) 3.5 2.1 - 2.9
50 (122) 2.2 0.68 - 1.00
90 (194) 1.0 0.236 - 0.260
*: These data are reference values and are measured between ECM terminal
q
28 (Engine coolant temperature sensor) and ECM terminal q 60 (ECM
SEF012P ground).

Diagnostic
Check Items
Trouble Code Malfunction is detected when ...
(Possible Cause)
No.
13 I An excessively high or low voltage from the sensor is I Harness or connectors
sent to ECM.* (The sensor circuit is open or shorted.)
Engine coolant temperature decided

Engine operating condition in fail-safe mode Condition
(CONSULT DISPLAY)
Engine coolant temperature will be determined Just as ignition switch is turned ON or START 20°C (68°F)
by ECM based on the time after turning igni-
tion switch “ON” or “START”. More than 6 minutes after ignition START 80°C (176°F)
CONSULT displays the engine coolant tem- 20 - 80°C (68 - 176°F)
perature decided by ECM. Except as shown above
(Depends on the time)

PROCEDURE
1) Turn ignition switch “ON”.
3) Wait at least 5 seconds.
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
1) Turn ignition switch “ON” and wait at least 5 seconds.
then turn “ON”.
SEF759T results)” with ECM.
EC-82
(Cont’d) GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC362
EC-83
(Cont’d)
INSPECTION START
H
NG
CHECK POWER SUPPLY. E
Repair harness or connec-
1. Turn ignition switch “OFF”. tors.
2. Disconnect engine coolant temperature
sensor harness connector.
SEF568V 3. Turn ignition switch “ON”.
4. Check voltage between terminal q
2 and
ground with CONSULT or tester.
Voltage:
Approximately 5V
OK
H
CHECK GROUND CIRCUIT. NG Check the following.
E
1. Turn ignition switch “OFF”. I Harness for open or
2. Check harness continuity between ter- short between ECM and
minal q1 and engine ground. engine coolant tempera-
Continuity should exist. ture sensor
SEF645R
If OK, check harness for short to I Harness connectors
ground and short to power. F6 , M51 (A/T models)
OK M88 , E106 (A/T models)
short between TCM and
engine coolant tempera-
ture sensor (A/T models)
If NG, repair open circuit,
short to ground or short to
nectors.
SEF646R
H
CHECK COMPONENT NG Replace engine coolant
E
(Engine coolant temperature sensor). temperature sensor.
Refer to “COMPONENT INSPECTION” on
next page.
OK
H
Disconnect and reconnect harness con-
nectors in the circuit. Then retest.
H
nector and retest.
H
INSPECTION END
EC-84
(Cont’d) GI
Engine coolant temperature sensor MA
Check resistance as shown in the figure.
EM
LC
SEF152P
<Reference data>
Temperature °C (°F) Resistance kΩ

FE
20 (68) 2.1 - 2.9
50 (122) 0.68 - 1.00
CL
90 (194) 0.236 - 0.260
If NG, replace engine coolant temperature sensor. MT

SEF012P
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-85
TROUBLE DIAGNOSIS FOR “IGN SIGNAL-PRIMARY” (DTC 21) TB45E
Ignition Signal
Ignition coil & power transistor (Built into distributor)
The ignition signal from the ECM is sent to and amplified by the
power transistor. The power transistor turns on and off the ignition
coil primary circuit. This on-off operation induces the proper high
voltage in the coil secondary circuit.
SEF557V
CONSULT REFERENCE VALUE IN DATA MONITOR MODE

I Engine: After warming up Idle 5° BTDC

IGN TIMING
I No-load 2,000 rpm More than 20° BTDC

TER-
WIRE DATA
COLOR (DC voltage)
NO.
Engine is running.
Idle speed
SEF536V
1 W/G Ignition signal
Engine is running.
SEF537V
EC-86
Ignition Signal (Cont’d)
TER-
GI
WIRE DATA
COLOR (DC voltage)
NO.
MA
EM
Engine is running.
Idle speed
LC
SEF538V
2 W Ignition check
Approximately 13V★ FE
Engine is running.
CL
MT
SEF539V AT
ON BOARD DIAGNOSIS LOGIC TF

Diagnostic Trouble Check Items
Malfunction is detected when ...
Code No. (Possible Cause) PD
21 I The ignition signal in the primary circuit is not sent I Harness or connectors
during engine cranking or running. (The ignition primary circuit is open or shorted.)
I Power transistor
FA
I Resistor
I Camshaft position sensor
I Camshaft position sensor circuit
RA
DIAGNOSTIC TROUBLE CODE CONFIRMATION BR

PROCEDURE
Note: If both DTC 21 and DTC 11 are displayed, perform
TROUBLE DIAGNOSIS FOR DTC 11 first. (See EC-70.)
ST
2) Select “DATA MONITOR” mode with CONSULT. RS
3) Start engine and wait at least 2 seconds. (If engine does
not run, turn ignition switch to “START” for at least 5
seconds.) BT
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
SEF647V 1) Turn ignition switch “ON”.
2) Start engine and wait at least 2 seconds. (If engine does HA
not run, turn ignition switch to “START” for at least 5
seconds.)
3) Turn ignition switch “OFF”, wait at least 5 seconds and EL
then turn “ON”.
results)” with ECM. SE
IDX
EC-87
TEC363
EC-88
DIAGNOSTIC PROCEDURE GI
INSPECTION START
MA
H
Yes
Turn ignition switch “OFF”, and restart E q
A (Go to next page.)
engine. EM
Is engine running?
No
H
LC
SEF558V
screws.
H
NG
CHECK POWER SUPPLY. E Check the following. FE
1. Turn ignition switch “OFF”. I Harness connectors
2. Disconnect ignition coil harness con- E127 , M21
nector. I Harness connectors
3. Turn ignition switch “ON”. M50 , F5 CL
4. Check voltage between terminal q 3 and I Harness for open or
ground with CONSULT or tester. short between ignition
Voltage: Battery voltage coil and ignition switch
If NG, repair harness or MT
OK connectors.
SEF557V
H AT
NG
CHECK GROUND CIRCUIT. E Repair open circuit, short
2. Disconnect power transistor harness in harness or connectors.
connector. TF
minal q2 and engine ground.
If OK, check harness for short to PD
OK FA
H
NG
CHECK OUTPUT SIGNAL CIRCUIT. E Repair open circuit, short
1. Disconnect ECM harness connector. to ground or short to power
SEF570V
2. Check harness continuity between ECM in harness or connectors.
RA
1 and terminal q
terminal q 1 .
BR
OK
H ST
NG
CHECK COMPONENTS E Replace malfunctioning
(Ignition coil, power transistor). component(s).
Refer to “COMPONENT INSPECTION”,
EC-91.
RS
OK
SEF571V H BT
HA
H
Check ECM pin terminals for damage and EL
nector and retest.
SE
H
INSPECTION END
SEF572V
IDX
EC-89
q
A
H
CHECK INPUT SIGNAL CIRCUIT. NG Repair open circuit, short
E
1. Stop engine. to ground or short to power
2. Turn ignition switch “OFF”. in harness or connectors.
3. Disconnect ignition coil harness con-
nector.
4. Disconnect ECM harness connector.
SEF573V
minal q 4 and ECM terminal q 2 .
OK
H
CHECK COMPONENT NG Replace resistor.
E
(Resistor).
next page.
OK
H
H
nector and retest.
H
INSPECTION END
EC-90
COMPONENT INSPECTION GI
Ignition coil & resistor
1. Disconnect camshaft position sensor, power transistor and igni- MA
tion coil harness connector.
2. Remove distributor cap.
3. Check resistance as shown in the figure. EM
Terminal Resistance [at 25°C (77°F)]
q
3 -q
4 Approximately 2.2 kΩ LC
q
3 -q
9 7 - 13 kΩ
SEF637V
If NG, replace distributor assembly.
FE
CL
MT
SEF636V
AT
Power transistor
1. Disconnect camshaft position sensor, power transistor and igni-
tion coil harness connector. TF
2. Check power transistor resistance between terminals q 2 and
q4 .
PD
Terminals Resistance Result
Except 0Ω OK
q
2 and q
4 FA
0Ω NG
If NG, replace distributor assembly.

SEF638V
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-91
TROUBLE DIAGNOSIS FOR “OVER HEAT” (DTC 28) TB45E
Cooling Fan Control (Overheat)

SYSTEM DESCRIPTION
Cooling fan control
Vehicle speed

Engine coolant temperature sensor E ECM E Cooling fan relay(s)

The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, and air
conditioner ON signal. M/T models have 3-step control [HIGH/LOW/OFF], which one cooling fan operates at
LOW and two cooling fans operate at HIGH. A/T models have 2-step control [ON/OFF] with one cooling fan.
Operation
M/T models for the Middle East
SEF823V
M/T models except for the Middle East
SEF824V
EC-92
Cooling Fan Control (Overheat) (Cont’d)
A/T models GI
MA
EM
LC
SEF825V

CL
Engine coolant temperature is 94°C
OFF
(201°F) or less.
I After warming up engine, idle the
engine. Engine coolant temperature is between M/T models: LOW MT
I Air conditioner switch “OFF” 95°C (203°F) and 99°C (210°F). A/T models: ON
I Vehicle stopped
Engine coolant temperature is 100°C M/T models: HIGH
COOLING FAN
(212°F) or more. A/T models: ON AT
M/T models for the Middle East: HIGH
I After warming up engine, idle the Engine coolant temperature is 99°C M/T models except for the Middle East:
(210°F) or less. LOW
engine.
A/T models ON
TF
I Air conditioner switch “ON”
I Vehicle stopped Engine coolant temperature is 100°C M/T models: HIGH
(212°F) or more. A/T models: ON
PD
Air conditioner switch: “OFF” OFF
AIR COND SIG Air conditioner switch: “ON”
engine ON
(Compressor operates.) FA

RA
TER- BR
WIRE DATA
COLOR (DC voltage)
NO.
ST
Cooling fan relay (Low
19 L
speed)
RS
Engine is running.
Approximately 0V
BT
Engine is running.
BATTERY VOLTAGE
Cooling fan relay Cooling fan is not operating. (11 - 14V)
6 L/B (High speed) Cooling fan is operating at low speed. HA
(M/T models only) Engine is running.
Approximately 0V
Cooling fan is operating at high speed. EL
SE
IDX
EC-93
This diagnosis continuously monitors the engine coolant temperature.
If the cooling fan or another component in the cooling system malfunctions, the engine coolant temperature
will rise.
When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is
detected by the ECM and the MIL lights on.
Diagnostic trouble Check Items
code No. (Possible Cause)
28 I Cooling fan does not operate properly (Overheat). I Harness or connectors.
I Cooling fan system does not operate properly (Over- (The cooling fan circuit is open or shorted.)
heat). I Cooling fan
I Engine coolant was not added to the system using I Radiator hose
the proper filling method. I Radiator
I Radiator cap
I Water pump
I Thermostat
For more information, refer to “MAIN 12
CAUSES OF OVERHEATING”, EC-103.
CAUTION:
When a malfunction is indicated, be sure to replace the coolant following the procedure in the MA
section (“Changing Engine Coolant”, “ENGINE MAINTENANCE”). Also, replace the engine oil.
a. Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute like pour-
ing coolant by kettle. Be sure to use coolant with the proper mixture ratio. Refer to MA section
(“Anti-freeze Coolant Mixture Ratio”, “RECOMMENDED LUBRICANTS AND FLUIDS”).
b. After refilling coolant, run engine to ensure that no water-flow noise is emitted.
EC-94
OVERALL FUNCTION CHECK GI
Use this procedure to check the overall function of the cooling fan.
During this check, a DTC might not be confirmed.
WARNING: MA
Never remove the radiator cap when the engine is hot. Serious
burns could be caused by high pressure fluid escaping from
the radiator. EM
Wrap a thick cloth around cap. Carefully remove the cap by
turning it a quarter turn to allow built-up pressure to escape.
Then turn the cap all the way off.
LC
AEC640 1) Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to “DIAGNOS-
TIC PROCEDURE”, EC-97. FE
2) Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to “DIAGNOS-
TIC PROCEDURE”, EC-97. CL
4) Perform “COOLING FAN” in “ACTIVE TEST” mode with
CONSULT. MT
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
3) Disconnect engine coolant temperature sensor harness
MEF314F
connector. AT
4) Connect 150Ω resistor to engine coolant temperature
5) Start engine and make sure that cooling fan operates. TF
Be careful not to overheat engine.
PD
FA
MEF312F
RA
BR
ST
RS
SEF784T BT
HA
EL
SE
IDX
EC-95
TEC375
EC-96
INSPECTION START
MA
H
CHECK COOLING FAN MOTOR-1 NG Check cooling fan motor-1
E EM
OPERATION. control circuit.
1. Disconnect cooling fan relay-2 (M/T (Go to PROCEDURE A .)
models only). LC
SEF574V 3. Perform “COOLING FAN CIR-
CUIT” in “FUNCTION TEST”
mode with CONSULT.
------------------------------------------------------------------- OR -------------------------------------------------------------------
2. Turn ignition switch “ON”. FE
3. Perform “COOLING FAN” in
“ACTIVE TEST” mode with CON-
SULT. CL
------------------------------------------------------------------- OR -------------------------------------------------------------------
2. Disconnect engine coolant tem-
perature sensor harness connec- MT
tor.
MEF311F
3. Connect 150Ω resistor to engine
coolant temperature sensor har- AT
ness connector.
4. Start engine.
5. Make sure that cooling fan TF
motor-1 operates.
Be careful not to overheat
engine. PD
OK
H
q
A FA
MEF313F
RA
BR
ST
RS
MEF312F BT
HA
EL
SE
SEF785T
IDX
EC-97
q
A
H
CHECK COOLING FAN MOTOR-2 NG Check cooling fan motor-2
E
OPERATION (M/T models only). control circuit.
1. Turn ignition switch “OFF”. (Go to PROCEDURE B .)
2. Reconnect cooling fan relay-2.
4. Perform “COOLING FAN CIR-
MEF311F mode with CONSULT.
5. Make sure that cooling fan
motor-1 and 2 operate.
------------------------------------------------------------------- OR -------------------------------------------------------------------
SULT.
5. Make sure that cooling fan
motor-1 and 2 operate.
------------------------------------------------------------------- OR -------------------------------------------------------------------
3. Restart engine and make sure
that cooling fan motor-1 and 2
MEF314F
operate.
Be careful not to overheat
engine.
OK
H
CHECK COOLING SYSTEM FOR LEAK. NG Check the following for
E
Apply pressure to the cooling system with leak.
a tester, and check if the pressure drops. I Hose
Testing pressure: I Radiator
98 kPa (0.98 bar, 1.0 kg/cm2, 14 psi) I Water pump
Pressure should not drop. Refer to LC section (“Water
SEF785T CAUTION: Pump”).
Higher than the specified pressure may
cause radiator damage.
OK
H
CHECK RADIATOR CAP. NG Replace radiator cap.
E
Apply pressure to cap with a tester.
Radiator cap relief pressure:
108 - 127 kPa (1.08 - 1.27 bar, 1.1 - 1.3
kg/cm2, 16 - 18 psi)
OK
SLC754AA H
q
B
SLC755AA
EC-98
q
B
GI
H MA
CHECK THERMOSTAT. NG Replace thermostat.
E
1. Check valve seating condition at normal
room temperatures. EM
It should seat tightly.
2. Check valve opening temperature and
valve lift. LC
3. Check if valve is closed at 5°C (9°F)
SLC343 below valve opening temperature.
For details, refer to “Thermostat”, “ENGINE
COOLING SYSTEM”, TB engine in LC
section.
OK
FE
H
Check engine coolant temperature sensor. NG Replace engine coolant
E
temperature sensor. CL
EC-85.
OK MT
H
If the cause cannot be isolated, go to
“MAIN 12 CAUSES OF OVERHEATING”,
EC-103.
AT
H TF
INSPECTION END
Perform FINAL CHECK by the following procedure after repair PD

is completed.
1. Warm up engine. Run the vehicle for at least 20 minutes. Pay
attention to engine coolant temperature gauge on the instrument FA
panel. If the reading shows an abnormally high temperature,
another part may be malfunctioning.
2. Stop vehicle and let engine idle. Check the intake and exhaust RA
systems for leaks by listening for noise or visually inspecting the
components.
3. Allow engine to cool and visually check for oil and coolant leaks. BR
Then, perform “OVERALL FUNCTION CHECK”.
ST
RS
BT
HA
EL
SE
IDX
EC-99
PROCEDURE A
INSPECTION START
H
E
1. Turn ignition switch “OFF”. I 10A fuse
2. Disconnect cooling fan relay-1. I 30A fusible link
SEF574V
4. Check voltage between terminals q
2 , between cooling fan
q5 and ground with CONSULT or tester. relay-1 and fuse
between cooling fan
OK
relay-1 and battery
connectors.
H
E
2. Disconnect cooling fan motor-1 harness harness or connectors.
connector.
SEF639V
3. Check harness continuity between
relay terminal q
3 and cooling fan
motor-1 terminals q1 ,q3 .
cooling fan motor-1 terminals q2 ,
q4 and ground.
SEF640V
OK
H
CHECK OUTPUT SIGNAL CIRCUIT. NG Check the following.
E
1. Disconnect ECM harness connector. I Harness connectors
2. Check harness continuity between ECM E127 , M21
terminal q19 and cooling fan relay-1 ter- I Harness connectors
minal q1 , ECM terminal q 6 and cooling M52 , F7
fan relay-1 terminal q
1 . I Diode F9 (M/T models)
Continuity should exist. I Harness for open or short
If OK, check harness for short to ground between cooling fan
and short to power. relay-1 and ECM
SEF641V If NG, repair open circuit,
OK
nectors.
H
q
C
SEF642V
EC-100
q
C GI
H
NG
CHECK COMPONENT Replace cooling fan relay.
(Cooling fan relay-1).
E MA
EC-104.
OK EM
H
NG
CHECK COMPONENT E
Replace cooling fan motor.
(Cooling fan motor-1).
Refer to “COMPONENT INSPECTION”, LC
EC-104.
OK
H
tors in the circuit. Then retest.
H
Trouble is not fixed. FE
Check ECM pin terminals for damage or
the connection of ECM harness connector.
Reconnect ECM harness connector and CL
retest.
H MT
INSPECTION END
AT
PROCEDURE B (M/T models only)
TF
INSPECTION START
PD
H
E
1. Turn ignition switch “OFF”. I 15A fuse FA
2. Disconnect cooling fan relay-2. I Harness continuity
3. Turn ignition switch “ON”. between cooling fan
4. Check voltage between cooling fan relay-2 and fuse
SEF574V
relay-2 terminals q2 ,q5 and ground I Harness continuity
RA
with CONSULT or tester. between cooling fan
Voltage: Battery voltage relay-2 and battery
If NG, repair harness or BR
OK
connectors.
H
ST
E
2. Disconnect cooling fan motor-2 harness harness or connectors.
RS
connector.
3. Check harness continuity between cool-
SEF639V ing fan relay-2 terminal q
3 and cooling BT
fan motor-2 terminal q1 , cooling fan
motor-2 terminal q 2 and body ground.
Continuity should exist. HA
and short to power.
OK EL
H
q
D SE
SEF643V
IDX
EC-101
q
D
H
CHECK OUTPUT SIGNAL CIRCUIT-I. NG Check the following.
E
terminal q6 and cooling fan relay-2 ter- I Harness connectors
minal q1 . M52 , F7
If OK, check harness for short to ground between cooling fan
SEF644V and short to power. relay-2 and ECM
OK
nectors.
H
CHECK COMPONENT NG Replace cooling fan relay.
E
EC-104.
OK
H
CHECK COMPONENTS NG Replace cooling fan motor.
E
EC-104.
OK
H

H
Reconnect ECM harness connector and
retest.
H
INSPECTION END
EC-102
MAIN 12 CAUSES OF OVERHEATING GI
Engine Step Inspection item Equipment Standard Reference page
OFF 1 I Blocked radiator I Visual No blocking — MA
I Blocked condenser
I Blocked radiator grille
I Blocked bumper EM
2 I Coolant mixture I Coolant tester 30 - 50% coolant mixture See “RECOMMENDED
FLUIDS AND LUBRI-
CANTS” in MA section.
LC
3 I Coolant level I Visual Coolant up to MAX level See “Changing Engine
in reservoir tank and Coolant”, “ENGINE MAIN-
radiator filler neck TENANCE” in MA section.
4 I Radiator cap I Pressure tester 78 - 98 kPa See “System Check”,
(0.78 - 0.98 bar, 0.8 - 1.0 “ENGINE COOLING SYS- FE
kg/cm2, 11 - 14 psi) TEM” in LC section.
59 - 98 kPa (0.59 - 0.98
bar, 0.6 - 1.0 kg/cm2,
CL
9 - 14 psi) (Limit)
ON*2 5 I Coolant leaks I Visual No leaks See “System Check”, MT
“ENGINE COOLING SYS-
TEM” in LC section.
ON*2 6 I Thermostat I Touch the upper and Both hoses should be hot. See “Thermostat” and AT
lower radiator hoses “Radiator”, “ENGINE
COOLING SYSTEM” in
LC section. TF
ON*1 7 I Cooling fan I Visual Operating See “TROUBLE DIAGNO-
SIS FOR OVER HEAT PD
(DTC 28)”, EC-92.
OFF 8 I Combustion gas leak I Color checker chemical Negative —
tester 4 gas analyzer FA
ON*3 9 I Coolant temperature I Visual Gauge less than 3/4 —
gauge when driving RA
I Coolant overflow to res- I Visual No overflow during driving See “Changing Engine
ervoir tank and idling Coolant”, “ENGINE MAIN-
TENANCE” in MA section. BR
OFF*4 10 I Coolant return from res- I Visual Should be initial level in See “ENGINE MAINTE-
ervoir tank to radiator reservoir tank NANCE” in MA section.
ST
OFF 11 I Cylinder head I Straight gauge feeler 0.1 mm (0.004 in) Maxi- See “Inspection”, “CYLIN-
gauge mum distortion (warping) DER HEAD” in EM sec-
tion. RS
12 I Cylinder block and pis- I Visual No scuffing on cylinder See “Inspection”, “CYLIN-
tons walls or piston DER BLOCK” in EM sec-
tion. BT
*1: Engine running at idle.
*2: Engine running at 3,000 rpm for 10 minutes. HA
*3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes.
*4: After 60 minutes of cool down time.
For more information, refer to “OVERHEATING CAUSE ANALYSIS” in LC section.
EL
SE
IDX
EC-103
Cooling fan relay-1 and -2
Check continuity between terminals q
3 and q
5 .
Conditions Continuity
12V direct current supply between terminals q
1
Yes
and q
2
No current supply No
SEF684P
Cooling fan motor-1

1. Disconnect cooling fan motor-1 harness connector.
2. Supply cooling fan motor terminals with battery voltage and
check operation as shown in the figure.
Terminals
(!) (@)
Cooling fan motor-1 q
1 ,q
3 2 ,q
q 4
SEF645V Cooling fan motor-1 should operate.

If NG, replace cooling fan motor.
Cooling fan motor-2

M/T models only
1. Disconnect cooling fan motor-2 harness connector.
check operation.
Terminals
(!) (@)
Cooling fan motor-2 q
1 q
2
SEF646V
Cooling fan motor should operate.
EC-104
TROUBLE DIAGNOSIS FOR “KNOCK SENSOR” (DTC 34) TB45E
Knock Sensor (KS) GI

The knock sensor is attached to the cylinder block under the intake
manifold. It senses engine knocking using a piezoelectric element. MA
A knocking vibration from the cylinder block is sensed as vibrational
pressure. This pressure is converted into a voltage signal and sent
to the ECM. EM
LC
SEF598K

FE
TER-
WIRE DATA
MINAL
COLOR
ITEM CONDITION
(DC voltage)
CL
NO.
Engine is running.
23 W Knock sensor Approximately 2.5V MT
Idle speed
AT
Diagnostic TF
Check Items
(Possible Cause)
No.
PD
34 I An excessively low or high voltage from the knock I Harness or connectors
sensor is sent to ECM. (The knock sensor circuit is open or shorted.)
I Knock sensor FA
RA
PROCEDURE
BR
mode with CONSULT.
2) Start engine and run it for at least 5 seconds at idle ST
speed.
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
1) Start engine and run it for at least 5 seconds at idle RS
speed.
SEF647V then turn “ON”. BT
3) Perform “Diagnostic Test Mode II” (Self-diagnostic
results) with ECM.
HA
EL
SE
IDX
EC-105
Knock Sensor (KS) (Cont’d)
TEC364
EC-106
Knock Sensor (KS) (Cont’d)
INSPECTION START
MA
H
Loosen and retighten engine ground
screws. EM
H
CHECK INPUT SIGNAL CIRCUIT. NG Repair open circuit, short to LC
E
SEF558V 2. Disconnect ECM harness connector and harness or connectors.
knock sensor harness connector.
3. Disconnect sub-harness connectors
F27 , EC1 .
nal q 2 and ECM terminal q 23 . FE
and short to power. CL
OK
H
CHECK SUB-HARNESS CIRCUIT. NG Repair open circuit, short to MT
E
1. Disconnect knock sensor harness con- ground or short to power in
SEF575V
nector. harness or connectors.
2. Check harness continuity between knock
sensor harness connector terminal q 2
AT
and knock sensor sub-harness connec-
tor terminal q
2 .
Continuity should exist. TF
and short to power.
OK PD
H
CHECK COMPONENT NG Replace knock sensor.
E
(Knock sensor).
FA
below.
SEF576V OK RA
H
BR
H
check the connection of ECM harness con- ST
and retest.
H
RS
INSPECTION END
SEF577V BT
Knock sensor HA
I Use an ohmmeter which can measure more than 10 MΩ.
1. Disconnect knock sensor harness connector. EL
2. Check resistance between terminal q
2 and ground.
Resistance: 500 - 620 kΩ [at 25°C (77°F)]
CAUTION: SE
Do not use any knock sensors that have been dropped or
physically damaged. Use only new ones.
AEC719
IDX
EC-107
TROUBLE DIAGNOSIS FOR “THROTTLE POSI SEN” (DTC 43) TB45E
Throttle Position Sensor

The throttle position sensor responds to the accelerator pedal movement. This sensor is a kind of potentiom-
eter which transforms the throttle position into output voltage, and emits the voltage signal to the ECM. In
addition, the sensor detects the opening and closing speed of the throttle valve and feeds the voltage signal
to the ECM.
Idle position of the throttle valve is determined by the ECM receiving the signal from the throttle position sen-
sor. This one controls engine operation such as fuel cut.
A/T models
SEF964T
M/T models
SEF520Q

I Ignition switch: ON Throttle valve: fully closed 0.4 - 0.6V

THRTL POS SEN
(Engine stopped) Throttle valve: fully opened Approx. 4.0V
I Ignition switch: ON Throttle valve: Idle position ON

CLSD THL/POSI
(Engine stopped) Throttle valve: Slightly open OFF
EC-108
Throttle Position Sensor (Cont’d)
TER-
WIRE DATA MA
COLOR (DC voltage)
NO.
Ignition switch “ON” (Warm-up condition) EM
0.4 - 0.6V
Throttle position sensor Accelerator pedal released
38 W
signal Ignition switch “ON” LC
Approximately 4.0V
Accelerator pedal fully depressed
48 OR Ignition switch “ON” Approximately 5V
power supply
Engine is running. (Warm-up condition) FE

30 B Sensors’ ground Approximately 0V
Idle speed
CL
MT
Diagnostic
Check Items
(Possible Cause)
Code No. AT
43 I An excessively low or high voltage from the sensor is I Harness or connectors
sent to ECM.* (The sensor circuit is open or shorted.)
I Throttle position sensor TF
PD
Engine operating condition in fail-safe mode Condition Driving condition
Throttle position will be determined based on the When engine is idling Normal
FA
amount of mass air flow and the engine speed.
Therefore, acceleration will be poor. When accelerating Poor acceleration
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-109
OVERALL FUNCTION CHECK
Use this procedure to check the overall function of the throttle
position sensor circuit. During this check, a DTC might not be con-
firmed.
1) Start engine and warm it up to normal operating tem-
perature.
2) Turn ignition switch “OFF” and wait at least 5 seconds.
4) Select “THRTL POS SEN” in “DATA MONITOR” mode
with CONSULT.
SEF578V 5) Read “THRTL POS SEN” signal and check the follow-
ing:
I The voltage when accelerator pedal fully released is
approximately 0.4 - 0.6V.
I The voltage when accelerator pedal fully depressed
is approximately 4.0V.
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
perature.
2) Turn ignition switch “OFF” and wait at least 5 seconds.
4) Check the voltage between ECM terminals q 38 and q 30
(ground) and check the following:
SEF579V
I The voltage when accelerator pedal fully released is
approximately 0.4 - 0.6V.
I The voltage when accelerator pedal fully depressed
is approximately 4.0V.
SEF580V
EC-110
GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC365
EC-111
INSPECTION START
H
screws.
OK
H
SEF558V
ADJUST THROTTLE POSITION SEN-
SOR.
Perform BASIC INSPECTION, EC-45.
OK
H
NG
Check the following.
1. Turn ignition switch “OFF”. I Harness for open or
2. Disconnect throttle position sensor har- short between throttle
ness connector. position sensor and ECM
3. Turn ignition switch “ON”. If NG, repair harness or
4. Check voltage between terminal q 3 and connectors.
SEF581V ground with CONSULT or tester.
Voltage: Approximately 5V
OK
H
NG
CHECK GROUND CIRCUIT. E
2. Check harness continuity between ter- E106 , M88 (A/T models)
minal q1 and engine ground. M51 , F6 (A/T models)
If OK, check harness for short to short between throttle
ground and short to power. position sensor and ECM
SEF582V OK short between throttle
position sensor and TCM
nectors.
H
NG
1. Disconnect ECM harness connector. I Harness for open or
2. Check harness continuity between ECM short between throttle
terminal q
38 and terminal q2 . position sensor and ECM
SEF583V
If OK, check harness for short to short to ground or short to
nectors.
OK
H
q
A
SEF584V
EC-112
q
A GI
H
NG MA
CHECK COMPONENT E Replace throttle position
(Throttle position sensor). sensor. To adjust it, per-
Refer to “COMPONENT INSPECTION” form BASIC INSPECTION,
below. EC-45. EM
OK
H
NG
CHECK SHIELD CIRCUIT. E Check the following. LC
2. Check the following. I Joint connector-5 F25
I Continuity between joint connector I Harness for open or
terminal q1 and ground short between joint con-
I Joint connector nector-6 and engine
(Refer to “HARNESS LAYOUT” in EL ground
section.) If NG, repair harness or FE
ground and short to power. Then recon-
nect joint connector. CL
OK
H
MT
Trouble is not fixed. AT

H
check the connection of ECM harness TF
connector.
retest.
PD
H
INSPECTION END FA
RA
Throttle position sensor BR
1. Start engine and warm it up to normal operating temperature.
3. Disconnect throttle position sensor harness connector. ST
4. Make sure that resistance between terminals q 2 and q 3
changes when opening throttle valve manually.
RS
Throttle valve conditions Resistance at 25°C (77°F)
Completely closed Approximately 0.6 kΩ
SEF965T BT
Partially open 0.6 - 4.0 kΩ
Completely open Approximately 4 kΩ
HA
If NG, replace throttle position sensor.
To adjust throttle position sensor, perform “BASIC
INSPECTION”, EC-45. EL
SE
IDX
EC-113
TROUBLE DIAGNOSIS FOR “A/T COMM LINE” (DTC 54) TB45E
A/T Control
These circuit lines are used to control the smooth shifting up and
down of A/T during the hard acceleration/deceleration.
Voltage signals are exchanged between ECM and TCM (Transmis-
sion control module).
Diagnostic
Check Item
(Possible Cause)
Code No.
54 I Harness or connectors
I ECM receives incorrect voltage from TCM continu-
(The circuit between ECM and TCM is open or
ously.
shorted.)
This DTC can be detected only by “DATA MONITOR (AUTO TRIG)” with CONSULT.

Use this procedure to check the overall function of the A/T control.
2) Start engine.
3) Check voltage between ECM terminal q 5 or q 14 and ground.
Voltage: Approximately 7V
SEF585V
EC-114
A/T Control (Cont’d)
GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC366
EC-115
INSPECTION START
H
CHECK INPUT SIGNAL CIRCUIT. NG Check the following.
E
2. Disconnect ECM harness connector E106 , M88
and TCM harness connector. I Harness connectors
SEF811V
3. Check harness continuity between ECM M51 , F6
terminal q5 and terminal q 5 , ECM ter- I Harness for open or
minal q14 and terminal q6 , ECM termi- short between ECM and
nal q
15 and terminal q 7 . TCM
nectors.
OK
H
CHECK INPUT SIGNAL CIRCUIT. NG Check the harness for
E
Check harness continuity between ECM open or short between
terminal q
5 and ground, ECM terminal q 14 ECM and TCM.
SEF586V
and ground, ECM terminal q15 and ground. If NG, repair harness.
Continuity should not exist.
OK
H

H
Check ECM pin terminals and TCM pin
terminals for damage and check the con-
nection of ECM harness connector.
SEF587V Reconnect ECM harness connector and
retest.
H
INSPECTION END
EC-116
TROUBLE DIAGNOSIS FOR NON-DETECTABLE ITEMS TB45E
Vehicle Speed Sensor (VSS) GI

The vehicle speed sensor is installed in the transmission. It con- MA
tains a pulse generator which provides a vehicle speed signal to the
speedometer. The speedometer then sends a signal to the ECM.
EM
LC
AEC110

FE
TER-
WIRE DATA
COLOR (DC voltage)
NO. CL
Varies from approximately
Engine stopped and gear position is “Neutral” 0 to BATTERY VOLTAGE MT
position. (11 - 14V)
While rotating drive wheel by hand
5 - 7V★ AT
53 L/OR Vehicle speed sensor

Engine is running. TF
Lift up the vehicle.
Suitable gear position PD
10 km/h (6 MPH)
SEF541V FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-117
Vehicle Speed Sensor (VSS) (Cont’d)
TEC367
EC-118
INSPECTION START
MA
H EM
CHECK OVERALL FUNCTION. OK INSPECTION END
E
1. Lift up the vehicle.
2. Start engine. LC
3. Perform “VEHICLE SPEED SEN
MEF559D CKT” in “FUNCTION TEST”
mode with CONSULT.
------------------------------------------------------------------- OR -------------------------------------------------------------------
2. Start engine.
3. Read “VHCL SPEED SE” signal FE
in “DATA MONITOR” mode with
CONSULT.
The vehicle speed on CON-
SULT should be able to CL
exceed 10 km/h (6 MPH) when
rotating wheels with suitable
gear position. MT
------------------------------------------------------------------- OR -------------------------------------------------------------------
SEF941N 2. Turn ignition switch “ON”.
3. Rotate drive wheel by hand. AT
4. Check voltage between ECM
terminal q 53 and ground.
Voltage should vary between TF
approx. 0 - 5V.
NG
PD
H FA
NG
SEF588V 2. Disconnect ECM harness connector M52 , F7 RA
and combination meter harness con- I Joint connector-1 M79
nector. I Harness for open or
3. Check harness continuity between ECM short between ECM and BR
terminal q53 and terminal q
26 . combination meter
ground and short to power. power in harness or con- ST
nectors.
OK
H RS
CHECK SPEEDOMETER FUNCTION. NG Check the following.
E
Make sure that speedometer functions I Harness for open or
SEF589V properly. short between combina- BT
tion meter and vehicle
OK speed sensor
If NG, repair harness or HA
connectors.
I Vehicle speed sensor
and its circuit EL
(Refer to EL section.)
H
q
A SE
IDX
EC-119
q
A
H

H
nector and retest.
H
INSPECTION END
EC-120
Oxygen Sensor (O2S) GI

The oxygen sensor is placed into the front exhaust tube. It detects MA
the amount of oxygen in the exhaust gas compared to the outside
air. The oxygen sensor has a closed-end tube made of ceramic
zirconia. The zirconia generates voltage from approximately 1V in EM
richer conditions to 0V in leaner conditions. The oxygen sensor
signal is sent to the ECM. The ECM adjusts the injection pulse
duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio LC
occurs near the radical change from 1V to 0V.
SEF288D

Remarks: Specification data are reference values. FE
O2 SEN I Engine: After warming up Maintaining engine speed at 2,000 rpm 0 - 0.3V ) 0.6 - 1.0V CL
MT
TER-
WIRE DATA
MINAL
COLOR
ITEM CONDITION
(DC voltage)
AT
NO.
Approximately 0 - 1.0V*
(periodically change)
TF
Engine is running. PD
29 W Oxygen sensor After warming up to normal operating tempera-
ture and engine speed is 2,000 rpm. FA
RA
SEF540V
*: Actual pulse signal can be confirmed by oscilloscope.

BR
ST
RS
BT
HA
EL
SE
IDX
EC-121
Oxygen Sensor (O2S) (Cont’d)
TEC369
EC-122
INSPECTION START
MA
H
CHECK OXYGEN SENSOR CIRCUIT. OK INSPECTION END EM
E
1. Start engine and warm it up to normal
operating temperature.
2. Perform “MIXTURE RATIO LC
TEST” in “FUNCTION TEST”
SEF515VA mode with CONSULT.
------------------------------------------------------------------- OR -------------------------------------------------------------------
2. Make sure that “M/R F/C MNT”
in “DATA MONITOR” mode indi-
cates “RICH” and “LEAN” peri- FE
odically more than 5 times dur-
ing 10 seconds at 2,000 rpm.
------------------------------------------------------------------- OR ------------------------------------------------------------------- CL
2. Stop engine and set ECM Diag-
nostic Test Mode II (Oxygen
sensor monitor). MT
3. Restart engine and run it at
SEF815L about 2,000 rpm for about 2
minutes under no-load. AT
4. Keep engine speed at 2,000
rpm and make sure that the
malfunction indicator lamp on
TF
the instrument panel comes on
more than 5 times during each
10 seconds.
PD
NG
H
q
A
FA
SEF052U
RA
BR
ST
RS
SEF051PA BT
HA
EL
SE
IDX
EC-123
q
A
H
screws.
OK
H
NG
SEF558V 2. Disconnect oxygen sensor harness con- F5 , M50
nector and ECM harness connector. I Harness connectors
3. Check harness continuity between ECM M86 , E104 (RHD mod-
terminal q29 and terminal q1 . els)
Continuity should exist. I Harness connectors
4. Check harness continuity between ECM M21 , E127 (LHD mod-
terminal q29 (or terminal q
1 ) and els)
ground. I Harness for open or
Continuity should not exist. short between ECM and
If OK, check harness for short to oxygen sensor
ground and short to power. If NG, repair open circuit,
OK power in harness or con-
SEF590V nectors.
H
NG
CHECK SHIELD CIRCUIT. E
Repair open circuit, short
1. Disconnect harness connectors M21 to ground or short to power
(LHD models), M86 (RHD models), in harness or connectors
E127 (LHD models), E104 (RHD mod-
els).
2. Check the following.
I Continuity between harness connec-
tor M21 (LHD models), M86 (RHD
models) terminal q
1 and ground
F5 , M50
ground and short to power. Then recon-
nect harness connectors M21 (LHD
models), M86 (RHD models), E127
(LHD models), E104 (RHD models).
OK
H

H
Check ECM pin terminals for damage and NG Replace oxygen sensor.
E
nector and retest.
OK
H
INSPECTION END
EC-124
Idle Air Control Valve (IACV) — Auxiliary Air GI

Control (AAC) Valve
SYSTEM DESCRIPTION MA
Engine speed
Camshaft position sensor E
EM
Amount of intake air
LC
Start signal
Ignition switch E FE
Neutral position switch Neutral position

E ECM E IACV-AAC valve CL
Air conditioner operation

Air conditioner switch E MT
Power steering load signal

Power steering oil pressure switch E AT
Battery voltage TF
Battery E
Vehicle speed sensor

Vehicle speed
E
PD
FA
This system automatically controls engine idle speed to a specified level. Idle speed is controlled through fine RA
adjustment of the amount of air which by-passes the throttle valve via IACV-AAC valve. The IACV-AAC valve
repeats ON/OFF operation according to the signal sent from the ECM. The camshaft position sensor detects
the actual engine speed and sends a signal to the ECM. The ECM then controls the ON/OFF time of the BR
IACV-AAC valve so that engine speed coincides with the target value memorized in ECM. The target engine
speed is the lowest speed at which the engine can operate steadily. The optimum value stored in the ECM is
determined by taking into consideration various engine conditions, such as during warm up, deceleration, and ST
engine load (air conditioner and power steering operation).
RS
BT
IACV-ACC valve
The IACV-AAC valve is moved by ON/OFF pulses from the ECM.
The longer the ON pulse, the greater the amount of air that will flow HA
through the valve. The more air that flows through the valve, the
higher the idle speed.
EL
SE
SEF040E
IDX
EC-125
Idle Air Control Valve (IACV) — Auxiliary Air
Control (AAC) Valve (Cont’d)
I Engine: After warming up Idle 20 - 40%

IACV-AAC/V
I No-load 2,000 rpm —

TER-
WIRE DATA
COLOR (DC voltage)
NO.
Engine is running.
7 - 10V
Idle speed
Engine is running.
4 L IACV-AAC valve
Steering wheel is being turned.
5 - 10V
Air conditioner is operating.
Rear window defogger switch is “ON”.
Lighting switch is “ON”.
EC-126
Control (AAC) Valve (Cont’d) GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC368
EC-127
Control (AAC) Valve (Cont’d)
INSPECTION START
H
E
2. Perform “IACV-AAC/V SYSTEM”
SEF591V in “FUNCTION TEST” mode with
CONSULT.
------------------------------------------------------------------- OR -------------------------------------------------------------------
2. Perform “IACV-AAC/V OPEN-
ING” in “ACTIVE TEST” mode
with CONSULT.
3. Check engine speed varies cor-
responding to IACV-AAC VALVE
opening percent.
------------------------------------------------------------------- OR -------------------------------------------------------------------
2. Check idle speed.
650±50 rpm
If NG, adjust idle speed.
3. Stop engine and disconnect
MEF176E throttle position sensor harness
connector.
4. Restart engine and let it idle
after revving it to 2,000 - 3,000
rpm a few times.
5. Check idle speed again.
600±50 rpm
NG
H
E
1. Stop engine. I 10A fuse
2. Disconnect IACV-AAC valve harness I Harness connectors
SEF164U connector. M52 , F7
2 and between IACV-AAC valve
ground with CONSULT or tester. and fuse
Voltage: Battery voltage If NG, repair harness or
connectors.
OK
H
q
A
SEF534V
SEF592V
EC-128
Control (AAC) Valve (Cont’d) GI
q
A
MA
H
CHECK OUTPUT SIGNAL CIRCUIT. NG Repair open circuit, short to
E
ground or short to power in EM
3. Check harness continuity between ECM
terminal q4 and terminal q1 . LC
SEF593V If OK, check harness for short to ground
and short to power.
OK
H
NG
CHECK COMPONENT
E
Replace IACV-AAC valve. FE
(IACV-AAC valve).
below.
CL
OK
H
Disconnect and reconnect harness connec- MT

H
AT
and retest.
TF
H
INSPECTION END
PD
FA
RA
IACV-AAC valve BR
Disconnect IACV-AAC valve harness connector.
I Check IACV-AAC valve resistance.
Resistance: ST
Approximately 10Ω at 25°C (77°F)
I Check plunger for seizing or sticking.
I Check for broken spring. RS
SEF594V BT
HA
EL
SE
IDX
EC-129
Park/Neutral Position Switch

When the gear position is in “Neutral”, neutral position is “ON”.
ECM detects the position because the continuity of the line (the
“ON” signal) exists.
SEF595V

Shift lever: Neutral position ON

Except above OFF

TER-
WIRE DATA
COLOR (DC voltage)
NO.
Approximately 0V
Park/neutral position sig- Gear position is “N” or “P”.
44 P/L
nal Ignition switch “ON”
Approximately 5V
Except the above gear position
EC-130
Park/Neutral Position Switch (Cont’d)
GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC371
EC-131
Neutral position switch (M/T mod-
els)
INSPECTION START
H
E
SEF595V 1. Turn ignition switch “ON”.
2. Perform “PARK/NEUT POSI SW
CKT” in “FUNCTION TEST”
mode with CONSULT.
------------------------------------------------------------------- OR -------------------------------------------------------------------
2. Select “P/N POSI SW” in “DATA
MONITOR” mode with CON-
SULT.
3. Check the “P/N POSI SW” sig-
nal under the following condi-
tions.
Neutral position: ON
SEF165U Except above position: OFF
------------------------------------------------------------------- OR -------------------------------------------------------------------
terminal q 44 and ground with
CONSULT or tester under the
following conditions.
Voltage:
Neutral position
Approximately 0V
Except above position
Approximately 5V
NG
SEF963N
H
E
2. Disconnect neutral position switch har- E202 , E69
ness connector. I Harness for open or short
3. Check harness continuity between termi- between neutral position
nal q
2 and body ground. switch and body ground
nectors.
OK
H
SEF596V
q
A
SEF162S
EC-132
q
A
GI
H MA
E
2. Check harness continuity between ECM F7 , M52 EM
44 and terminal q
terminal q 1 . I Harness connectors
Continuity should exist. M21 , E127
If OK, check harness for short to I Harness connectors LC
ground and short to power. E70 , E201
SEF597V
I Harness for open or short
OK
between ECM and neutral
position switch
short to ground or short to FE
nectors.
H
CL
CHECK COMPONENT NG Replace neutral position
E
(Neutral position switch). switch.
Refer to MT section.
MT
OK
H
AT

TF
H
check the connection of ECM harness con- PD
and retest.
FA
H
INSPECTION END
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-133
Inhibitor switch (A/T models)
INSPECTION START
H
E
2. Perform “PARK/NEUT POSI SW
CKT” in “FUNCTION TEST”
MEC731B mode with CONSULT.
------------------------------------------------------------------- OR -------------------------------------------------------------------
SULT.
3. Check “P/N POSI SW” signal
under the following conditions.
“N” or “P” position: ON
Except above position: OFF
------------------------------------------------------------------- OR -------------------------------------------------------------------
1. Make sure that inhibitor switch
circuit functions properly. (Refer
SEF963N to AT section.)
terminal q 44 and ground under
the following conditions.
Voltage:
“N” or “P” position
Approximately 0V
Except above position
Approximately 5V
NG
H
SEF596V NG
CHECK POWER SUPPLY. Check the following.
E
1. Turn ignition switch “OFF”. I 7.5A fuse
2. Disconnect inhibitor switch harness con- I Harness for open or short
nector. between inhibitor switch
3. Turn ignition switch “ON”. and fuse
4. Check voltage between terminal q 3 and If NG, repair harness or
ground with CONSULT or tester. connectors.
Voltage: Battery voltage
OK
H
CHECK OUTPUT SIGNAL CIRCUIT-I. NG Check the following.
E
SEF598V 1. Turn ignition switch “OFF”. I Diode E103
2. Disconnect TCM harness connector. I Harness for open or short
3. Check harness continuity between TCM between inhibitor switch
terminal q36 and inhibitor switch termi- and TCM
nals q
7 ,q 9 . If NG, repair open circuit,
Continuity should exist. short to ground or short to
If OK, check harness for short to ground power in harness or con-
and short to power. nectors.
OK
H
q
B
SEF599V
EC-134
q
B GI
H
MA
E
EM
2. Check harness continuity between ECM F7 , M52
terminal q
44 and TCM terminal q 14 . I Harness connectors
LC
If OK, check harness for short to ground I Harness for open or short
SEF600V and short to power. between ECM and TCM
OK
nectors. FE
H
CHECK COMPONENT NG Replace inhibitor switch.
(Inhibitor switch).
E CL
Refer to AT section.
OK MT
H
tors in the circuit. Then retest. AT
H
TF
PD
and retest.
H FA
INSPECTION END
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-135
Injector
The fuel injector is a small, precise solenoid valve. When the ECM
supplies a ground to the injector circuit, the coil in the injector is
energized. The energized coil pulls the ball valve back and allows
fuel to flow through the injector into the intake manifold. The
amount of fuel injected depends upon the injection pulse duration.
Pulse duration is the length of time the injector remains open. The
ECM controls the injection pulse duration based on engine fuel
needs.
SEF812J

TER-
WIRE DATA
COLOR (DC voltage)
NO.
BATTERY VOLTAGE
(11 - 14V)★
Idle speed
101 BR/W Injector No. 1

103 BR/Y Injector No. 3
SEF546V
105 GY/L Injector No. 2
110 BR Injector No. 5 BATTERY VOLTAGE
112 GY Injector No. 6 (11 - 14V)★
114 GY/R Injector No. 4
Engine is running.
SEF547V
EC-136
Injector (Cont’d)
GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC372
EC-137
Injector (Cont’d)
INSPECTION START
H
E
1. Start engine.
2. Perform “POWER BALANCE” in
SULT.
3. Make sure that each circuit pro-
SEF968Q duces a momentary engine
speed drop.
------------------------------------------------------------------- OR -------------------------------------------------------------------
2. Listen to each injector operating
sound.
Clicking noise should be
heard.
NG
H
E
2. Disconnect each injector harness con- M52 , F7
nector. I 10A fuse
SEF730L 3. Turn ignition switch “ON”. I Harness for open or short
4. Check voltage between each terminal between injector and fuse
q2 and ground with CONSULT or tester. block
Voltage: Battery voltage If NG, repair harness or
connectors.
OK
H
CHECK OUTPUT SIGNAL CIRCUIT. NG Repair open circuit, short to
E
3. Check harness continuity between each
terminal q1 and ECM terminals 101 ,
103 , 105 , 110 , 112 , 114 .
and short to power.
OK
H
CHECK COMPONENT NG Replace injector.
E
(Injector).
next page.
OK
H
AEC755 Trouble is not fixed.

H
and retest.
H
INSPECTION END
SEF326SB
EC-138
Injector (Cont’d)
Injector
1. Disconnect injector harness connector. MA
2. Check resistance between terminals as shown in the figure.
Resistance: 10 - 14Ω at 25°C (77°F)
If NG, replace injector. EM
LC
AEC559
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-139
Start Signal
TEC373
EC-140
Start Signal (Cont’d)
INSPECTION START
MA
H
E EM
2. Perform “START SIGNAL CKT”
in “FUNCTION TEST” mode with
CONSULT. LC
------------------------------------------------------------------- OR -------------------------------------------------------------------
SEF191L 1. Turn ignition switch “ON”.
2. Check “START SIGNAL” in
CONSULT.
IGN “ON” OFF

FE
IGN “START” ON
------------------------------------------------------------------- OR ------------------------------------------------------------------- CL
1. Turn ignition switch to “START”.
terminal q 43 and ground. MT
Voltage:
SEF153U
Battery voltage
Except above
AT
Approximately 0V
H
NG TF
Check if 7.5A fuse is OK. NG Replace 7.5A fuse.
E
OK PD
H
E
I Harness connectors FA
2. Disconnect ECM harness connector and M52 , F7
7.5A fuse. I Harness for open or short
SEF602V
3. Check harness continuity between ECM between ECM and fuse RA
terminal q43 and fuse block. block
If OK, check harness for short to ground short to ground or short to BR
and short to power. power in harness or con-
nectors.
OK
H ST
Trouble is not fixed. RS

H
SEF603V check the connection of ECM harness con- BT
and retest.
HA
H
INSPECTION END
EL
SE
IDX
EC-141
Fuel Pump
SYSTEM DESCRIPTION
Camshaft position sensor Engine speed
E Fuel
ECM E pump
Ignition switch Start signal relay
E
The ECM activates the fuel pump for several sec-

Condition Fuel pump operation
onds after the ignition switch is turned on to improve
engine startability. If the ECM receives a 120° sig- Ignition switch is turned to ON.
Operates for
nal from the camshaft position sensor, it knows that 5 seconds.
the engine is rotating, and causes the pump to oper- Engine running and cranking Operates.
ate. If the 120° signal is not received when the igni-
tion switch is on, the engine stalls. The ECM stops When engine is stopped Stops in 1 second.
pump operation and prevents battery discharging, Except as shown above Stops.
thereby improving safety. The ECM does not directly
drive the fuel pump. It controls the ON/OFF fuel
pump relay, which in turn controls the fuel pump.
The fuel pump with a fuel damper is an in-tank type (the pump and
damper are located in the fuel tank).
SEF609V

I Ignition switch is turned to ON (Operates for 5 seconds).

I Engine running and cranking ON
FUEL PUMP RLY I When engine is stopped (Stops in 1 second)
Except as shown above OFF
EC-142
Fuel Pump (Cont’d)
TER-
WIRE DATA MA
COLOR (DC voltage)
NO.
EM
For 5 seconds after turning ignition switch 0 - 1.0V LC

“ON”
8 R/Y Fuel pump relay Engine is running.
Ignition switch “ON” BATTERY VOLTAGE

5 seconds after turning ignition switch “ON” (11 - 14V)
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-143
TEC374
EC-144
INSPECTION START
MA
H
CHECK OVERALL FUNCTION. OK INSPECTION END EM
E
2. Pinch fuel feed hose with fingers.
Fuel pressure pulsation should be felt LC
on the fuel feed hose for 5 seconds
SEF610V after ignition switch is turned “ON”.
NG
H
E
I 15A fuse FE
2. Disconnect fuel pump relay. I Harness for open or short
3. Turn ignition switch “ON”. between fuse and fuel
1 , pump relay CL
q3 and ground with CONSULT or tester. If NG, repair harness or
Voltage: Battery voltage connectors.
OK MT
H
SEF611V
NG
CHECK GROUND CIRCUIT-I.
E
Check the following. AT
2. Disconnect fuel pump harness connec- C1 , B35 (LHD models)
tor. I Harness connectors
3. Check harness continuity between termi- C1 , B123 (RHD mod-
TF
nal q6 and body ground. els)
If OK, check harness for short to between fuel pump and PD
ground and short to power. body ground
OK short to ground or short to FA
nectors.
SEF612V
RA
H
CHECK GROUND CIRCUIT-II. NG Check the following.
E
1. Turn ignition switch “OFF”. I Harness connectors BR
2. Disconnect fuel pump (fuel tank gauge M20 , B19 (LHD models)
unit) harness connector. I Harness connectors
3. Check harness continuity between relay M97 , B103 (RHD mod-
terminal q5 and terminal q4 . els) ST
Continuity should exist. I Harness connectors
If OK, check harness for short to C1 , B35 (LHD models)
ground and short to power. I Harness connectors RS
C1 , B123 (RHD mod-
OK els)
SEF479P I Harness for open or short BT
between fuel pump and
fuel pump relay
HA
nectors.
H EL
q
A
(Go to next page.)
SE
SEF608V
IDX
EC-145
q
A
H
E
8 and terminal q
terminal q 2 . I Harness for open or short
Continuity should exist. between ECM and fuel
If OK, check harness for short to pump relay
SEF604V OK power in harness or con-
nectors.
H
CHECK COMPONENT NG Replace fuel pump relay.
E
(Fuel pump relay).
1. Reconnect fuel pump relay, fuel
pump harness connector and
ECM harness connector.
3. Turn fuel pump relay “ON” and
“OFF” in “ACTIVE TEST” mode
with CONSULT and check oper-
SEF605V ating sound.
------------------------------------------------------------------- OR -------------------------------------------------------------------
Refer to “COMPONENT INSPEC-
TION” on next page.
OK
H
CHECK COMPONENT NG Replace fuel pump.
E
(Fuel pump).
next page.
OK
H
SEF606V tors in the circuit. Then retest.

H
and retest.
H
INSPECTION END
SEF168U
EC-146
Fuel pump relay
3 and q
5 . MA
12V direct current supply
Yes
EM
between terminals q 1 and q
2
LC
If NG, replace relay.
SEF511P
Fuel pump
1. Disconnect fuel pump harness connector.
2. Check resistance between terminals q 4 and q
6 . FE
Resistance: 0.2 - 5.0Ω at 25°C (77°F)
If NG, replace fuel pump.
CL
MT
SEF607V
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-147
Power Steering Oil Pressure Switch

The power steering oil pressure switch is attached to the power
steering high-pressure tube and detects a power steering load.
When a power steering load is detected, it signals the ECM. The
ECM adjusts the IACV-AAC valve to increase the idle speed and
adjust for the increased load.
SEF569V

Steering wheel in neutral position

I Engine: After warming up, idle the OFF
PW/ST SIGNAL (forward direction)
engine
The steering wheel is turned. ON

TER-
WIRE DATA
COLOR (DC voltage)
NO.
Engine is running.
0V
Power steering oil pres- Steering wheel is being turned.
34 OR/L
sure switch Engine is running.
Approximately 5V
Steering wheel is not being turned.
EC-148
Power Steering Oil Pressure Switch (Cont’d)
GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC376
EC-149
INSPECTION START
H
E
2. Perform “PW/ST SIGNAL CIR-
MEF023E mode with CONSULT.
------------------------------------------------------------------- OR -------------------------------------------------------------------
1. Start engine.
2. Check “PW/ST SIGNAL” in
CONSULT.
Steering is neutral position: OFF
Steering is turned: ON
------------------------------------------------------------------- OR -------------------------------------------------------------------
1. Start engine.
SEF591I Voltage:
When steering wheel is
turned quickly
Approximately 0V
Except above
Approximately 5V
NG
H
E
1. Turn ignition switch “OFF”. I Joint connector-5 F25
2. Disconnect power steering oil pressure I Harness for open or short
SEF613V
switch harness connector. between power steering
3. Check harness continuity between termi- oil pressure switch and
nal q
2 and engine ground. engine ground
If OK, check harness for short to ground short to ground or short to
nectors.
OK
H
q
A
(Go to next page.)
SEF569V
SEF614V
EC-150
q
A
GI
MA
H
E
1. Disconnect ECM harness connector. I Harness for open or short EM
2. Check harness continuity between ECM between ECM and power
terminal q
34 and terminal q1 . steering oil pressure
Continuity should exist. switch LC
If OK, check harness for short to ground If NG, repair open circuit,
SEF615V
and short to power. short to ground or short to
OK
nectors.
H
FE
CHECK COMPONENT NG Replace power steering oil
E
(Power steering oil pressure switch). pressure switch.
Refer to “COMPONENT INSPECTION” CL
below.
OK
H
MT
AT
H
Check ECM pin terminals for damage and TF
and retest. PD
H
FA
INSPECTION END
RA
Power steering oil pressure switch BR
1. Disconnect power steering oil pressure switch harness connec-
tor then start engine.
2. Check continuity between terminals q 1 and q 2 . ST
Steering wheel is being turned Yes RS
Steering wheel is not being turned No
SEF616V If NG, replace power steering oil pressure switch. BT
HA
EL
SE
IDX
EC-151
IACV-FICD Solenoid Valve

The idle air adjusting (IAA) unit is made up of the IACV-AAC valve,
IACV-FICD solenoid valve and idle adjusting screw. It receives the
signal from the ECM and controls the idle speed at the preset
value.
SEF591V

Remarks: Specification data are reference values and are measured between each terminal and q
TER-
WIRE DATA
COLOR (DC voltage)
NO.
Engine is running.
Both air conditioner switch and blower switch 0 - 1.0V
9 Y/L Air conditioner relay are “ON”. (Compressor operates.)

Air conditioner switch is “OFF”. (11 - 14V)
Engine is running.
Both air conditioner switch and blower switch Approximately 0V
46 LG/B Air conditioner switch are “ON”. (Compressor operates.)

EC-152
IACV-FICD Solenoid Valve (Cont’d)
GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC377
EC-153
INSPECTION START
H
screws.
H
SEF558V OK
CHECK OVERALL FUNCTION. E INSPECTION END
2. Check idle speed.
650±50 rpm
If NG, adjust idle speed.
3. Turn air conditioner switch and blower
fan switch “ON”.
4. Recheck idle speed.
750 rpm or more (RHD models)
950 rpm or more (LHD models)
NG
H
NG
MEF634E Check if air conditioner compressor func- E Refer to HA section.
tions normally.
OK
H
NG
CHECK POWER SUPPLY. E Check the following.
2. Disconnect IACV-FICD solenoid valve M50 , F5
harness connector. I Harness connectors
3. Restart engine and turn air conditioner E104 , M86 (LHD mod-
switch and blower fan switch “ON”. els)
4. Check voltage between terminal q 2 and I Harness connectors
ground with CONSULT or tester. E127 , M21 (RHD mod-
Voltage: Battery voltage els)
SEF617V I Harness for open or
OK short between IACV-
FICD solenoid valve and
air conditioner relay
connectors.
H
NG
CHECK GROUND CIRCUIT. E Check the following.
1. Turn ignition switch “OFF”. I Joint connector-5 F25
2. Check harness continuity between ter- I Harness for open or
minal q1 and body ground. short between IACV-
Continuity should exist. FICD solenoid valve and
If OK, check harness for short to engine ground
SEF618V
nectors.
H
NG
CHECK COMPONENT E Replace IACV-FICD sole-
(IACV-FICD solenoid valve). noid valve.
next page.
H OK
q
A
(Go to next page.)
EC-154
q
A
GI
H
MA

EM
H
LC
nector. Then retest.
H
INSPECTION END
FE
CL
MT
AT
IACV-FICD solenoid valve TF
Disconnect IACV-FICD solenoid valve harness connector.
I Check for clicking sound when applying 12V direct current to
terminals. PD
FA
SEF619V
RA
I Check plunger for seizing or sticking.
I Check for broken spring.
BR
ST
RS
SEF199S BT
HA
EL
SE
IDX
EC-155
MIL & Data Link Connectors
TEC378
EC-156
ENGINE AND EMISSION CONTROL OVERALL SYSTEM TB42S
Component Parts Location GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
SEF424V
EC-157
System Diagram
SEF432GA
EC-158
Circuit Diagram GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC379
EC-159
Vacuum Hose Drawing
SEF439V
q
1 Distributor to vacuum gallery q
4 Air cleaner to BCDD q
7 Vacuum gallery to EVAP canister
q
2 Vacuum gallery to vacuum con- q
5 Vacuum connector to idle compen- (purge line)
nector sator
q
3 Vacuum gallery to carburetor q
6 Vacuum gallery to EVAP canister
(throttle vacuum port) (vacuum line)
For altitude compensator, refer to EC-179.
EC-160
CARBURETOR TB42S
Construction GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
SEF652V
EC-161
CARBURETOR TB42S
Construction (Cont’d)
SEF649G
EC-162
CARBURETOR TB42S
Major Service Operation GI

The perfectly adjusted carburetor delivers the proper fuel and air
ratios at all speeds for the particular engine for which it was MA
designed.
The carburetor should be maintained in its original condition and
will continue to deliver the proper ratios. EM
To maintain accurate carbureting through passages and discharge
holes, extreme care must be taken in cleaning.
Use only carburetor solvent and compressed air to clean all pas- LC
sages and discharge holes. Never use wire or other pointed instru-
ment to clean or carburetor calibration will be affected.
REMOVAL
Remove carburetor from engine, taking sufficient care to the follow-
ing: FE
PRECAUTIONS:
a. When disconnecting fuel lines, do not spill fuel from fuel
pipe.
CL
b. When removing carburetor, do not drop any nut or bolt into
intake manifold. MT
c. Be careful not to bend or scratch any part.
CLEANING AND INSPECTION AT

Dirt, gum, water or carbon contamination in or on exterior moving
parts of a carburetor often results in unsatisfactory performance.
For this reason, efficient carbureting depends upon careful clean- TF
ing and inspection while servicing.
Before assembling and installing the carburetor, blow all passages
and castings with compressed air and blow off all parts until dry. PD
Do not pass drills or wires through calibrated jets or passages
as this may enlarge orifice and seriously affect carburetor cali-
bration. FA
RA
Disassembling Carburetor Harness Connector
When replacing fuel cut solenoid valve, automatic choke heater BR
(choke chamber assembly) or BCDD control solenoid valve, it will
be necessary to disassemble carburetor harness connector.
1. Remove rear clip. ST
RS
SEF099H BT
2. With a small screwdriver, tilt lock tongue and, at the same time,
push out terminal. HA
CAUTION:
I When extracting terminal, do not pull wire harness. Always
push the top of terminal. EL
I Take care not to damage seal boot at the bottom of termi-
nal.
I Do not let oil or gasoline adhere to seal boot. SE
SEF425V
IDX
EC-163
CARBURETOR TB42S
Checking and Adjusting Idle Speed, Ignition

Timing and Mixture Ratio
CAUTION:
I Idle mixture ratio is adjusted at factory and requires no
further adjustment. If it becomes necessary to adjust it,
proceed with the following steps.
I Do not attempt to screw the idle adjusting screw down
completely. Doing so could cause damage to tip, which in
turn will tend to cause malfunctions.
I After adjusting idle speed and mixture ratio, be sure to
check items below, and if necessary, adjust them.
(1) Fast idle adjustment
(2) FICD adjustment
PREPARATION
1. Make sure that the following parts are in good order.
I Battery
I Ignition system
I Engine oil and coolant levels
I Fuses
I Vacuum hoses
I Air intake system
(Oil filler cap, oil level gauge, etc.)
I Engine compression
I Throttle valve
2. On air conditioner equipped models, checks should be car-
ried out while the air conditioner is “OFF”.
3. When measuring “CO” percentage, insert probe more than
40 cm (15.7 in) into tail pipe.
4. Turn off headlamps, heater blower, rear window defogger.
5. Keep front wheels pointed straight ahead.
6. Use idle adjusting screwdriver (KV10108300) when adjust-

ing idle adjusting screw.
WARNING:
Depress brake pedal while revving the engine to prevent for-
ward surge of vehicle.
SMA075C
EC-164
CARBURETOR TB42S
Checking and Adjusting Idle-rpm, Ignition GI

Timing and Mixture Ratio
MA
START
H EM
Start engine and warm it up until engine coolant temperature indicator
points to normal operating temperature.
LC
H
SEF442G
Open engine hood.
H
Rev engine (2,000 - 3,000 rpm) 2 or 3 times under no-load, and then FE
run engine at idle speed. F
H CL
Check idle speed.
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Idle speed:
650±50 rpm MT
OK NG
SEM947B
H
AT
Adjust idle speed by turning throttle adjusting
screw. E
TF
H
Check ignition timing at idle speed. PD
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Ignition timing: degree BTDC (in “N” position)
10±1
OK NG
FA
H
SEF426V
Adjust ignition timing by turning distributor. RA
H
q
A
BR
ST
RS
BT
HA
EL
SE
IDX
EC-165
CARBURETOR TB42S
Checking and Adjusting Idle-rpm, Ignition
Timing and Mixture Ratio (Cont’d)
q
A
H
Rev engine (2,000 - 3,000 rpm) 2 or 3 F F
times under no-load, and then run
engine at idle speed.
H
Adjust idle speed by turning throttle Repair or replace
adjusting screw. distributor, vacuum con-
SEF442G troller or vacuum hoses.
-------------------------------------------------------------------------------------------------------------------------------------------------
Idle speed: rpm (in “N” position) G
650±50
H
Rev engine (2,000 - 3,000 rpm) 2 or 3
times under no-load, and then run
engine at idle speed.
H
NG
Confirm idle speed and ignition timing. E Check distributor and
------------------------------------------------------------------------------------------------------------------------------------------------- vacuum hoses.
SEM947B Idle speed: rpm (in “N” position)
650±50
Ignition timing: degree BTDC
(in “N” position)
10±1
OK
E Without “CO”-meter.
H
H
q
B
With “CO”-meter
SEF441G
H
NG
Check “CO”% at idle speed. E Adjust idle “CO”% to
------------------------------------------------------------------------------------------------------------------------------------------------- 1.5±0.5% by turning idle
Idle “CO”: % adjusting screw.
1.5±0.5
OK
H
END
EC-166
CARBURETOR TB42S
Checking and Adjusting Idle-rpm, Ignition
Timing and Mixture Ratio (Cont’d) GI
q
B
MA
H
Turn out idle adjusting screw approxi-
mately two turns, starting from fully closed EM
position.
CAUTION:
Do not attempt to screw the idle adjust- LC
ing screw down completely. Doing so
SEF441G could cause damage to tip, which in
turn will tend to cause malfunctions.
H
FE
Adjust engine speed by turning throttle
F
adjusting screw.
-------------------------------------------------------------------------------------------------------------------------------------------------------- CL
Engine speed: rpm (in “N” position)
650±50
MT
H
SEF442G Turn idle adjusting screw until engine runs Engine speed rises.
smoothly at highest speed.
AT
Engine speed
does not rise. TF
H
Adjust engine speed by turning in idle
adjusting screw. PD
--------------------------------------------------------------------------------------------------------------------------------------------------------
Idle speed: rpm (in “N” position)
650±50 FA
H
SEF441G
END
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-167
CARBURETOR TB42S
Fuel Level
INSPECTION
Disconnect ignition wire between distribu-
tor and ignition coil.
H
Disconnect fuel cut solenoid valve con-
nector of carburetor.
H
Check primary main nozzle to ensure that NG Check needle valve for
E
no fuel is discharging while cranking looseness or sticking. If
engine for approximately 3 seconds. necessary, repair or
replace.
OK
Adjust fuel level.
G
H
Check that acceleration pump nozzle NG
injects fuel when throttle valve is opened.
SEF547G
OK
H
END
SEF548G
If necessary, use Tool to visually check fuel level as follows:

1. Disconnect inlet fuel hose from carburetor, and plug opening.
2. Start engine and wait for it to stop.
3. Install Tool on carburetor, as shown.
Be careful not to spill fuel.
4. Connect inlet hose to carburetor.
5. Start engine. Visually check fuel level.
If out of specification, adjust by bending float seat and float
stopper.
SEF453G
EC-168
CARBURETOR TB42S
Fuel Level (Cont’d)
ADJUSTMENT GI
1. Remove carburetor from engine.
2. Remove float chamber cover from float chamber.
3. Turn carburetor upside down, and fix it horizontally. MA
4. Raise float fully, then lower it slowly until float seat contacts
needle valve, and in this position, check height “H1”.
Height “H1”: EM
9.5 - 10.5 mm (0.374 - 0.413 in)
I If out of specification, adjust by bending float seat. Make
sure needle valve slides smoothly on float seat.
LC
FE
CL
MT
SEF537GA
AT
5. Lower float slowly until float stopper contacts carburetor, and in
this position, check height “H2”.
Height “H2”: TF
47.5 - 48.5 mm (1.870 - 1.909 in)
If out of specification, adjust by bending float stopper.
6. Install choke chamber and then place carburetor on engine. PD
7. Perform “FUEL LEVEL INSPECTION”.
FA
SEF674G
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-169
CARBURETOR TB42S
Automatic Choke
TEC380
EC-170
CARBURETOR TB42S
Automatic Choke (Cont’d)
MECHANICAL CHECK GI
1. Before starting engine, fully open throttle valve and ensure that
choke valve closes properly.
2. Push choke valve with your finger to check for smooth move- MA
ment.
EM
LC
3. Make sure bimetal cover index mark is aligned with center of

choke housing index mark.
4. Check wiring connection, and start engine.
5. After warming up engine, ensure that choke valve is fully open. FE
If not, check automatic choke circuit and heater.
CL
MT
SMA855A
AT
ENTIRE SYSTEM
Do not attach test leads of a circuit tester to those other than
designated. TF
1. Disconnect carburetor harness connector.
2. Start engine.
PD
FA
RA
3. Check voltage between terminal q 2 and ground, with engine
running.
Voltage: Approximately 9 - 12V BR
If no voltage appears, check the following items.
I Automatic choke circuit
I Automatic choke relay ST
I Automatic choke heater
RS
SEF427V BT
AUTOMATIC CHOKE CIRCUIT
1. Disconnect automatic choke relay and then connect a suitable HA
jumper wire between terminals q 3 and q
4 .
3. Turn ignition switch “ON”. EL
4. Check voltage between carburetor harness connector terminal
q2 and body ground.
Voltage: Battery voltage SE
If NG, check or repair the harness.
SEF428V
IDX
EC-171
CARBURETOR TB42S
Automatic Choke (Cont’d)
AUTOMATIC CHOKE RELAY
3 and q
4 .
12V direct current supply between
No
terminals q
1 and q 2
No current supply Yes
SEF621V
AUTOMATIC CHOKE HEATER

2. Check continuity between choke heater connector terminal q
2
and choke housing.
SEF429V
Fast Idle
1. Warm up engine.
2. Set fast idle arm on 2nd step of fast idle cam.
3. Check fast idle speed.
Fast idle speed (at 2nd cam step):
1,800±200 rpm
Make sure that engine is completely adjusted (idle speed, igni-
tion timing, etc.) before checking or adjusting fast idle speed.
SEF483C
4. If out of specification, remove carburetor and make fast idle

adjustments as follows:
1) Place fast idle arm on 2nd step of fast idle cam, in the same
manner as in step 2. above.
2) Adjust clearance “A” between primary throttle valve and inner
carburetor wall by turning fast idle adjusting screw.
Clearance “A”:
1.37±0.14 mm (0.0539±0.0055 in)
5. After adjusting clearance “A”, install carburetor on engine and
check engine speed.
Following installation, do not attempt further adjustment of
EF109A
clearance “A” even if fast idle speed is incorrect.
Vacuum Break
1. When engine is cold, close choke valve completely.
2. Apply vacuum to vacuum break diaphragm with a handy
vacuum pump.
Approximately −53.3 kPa
(−533 mbar, −400 mmHg, −15.75 inHg)
SEF550D
EC-172
CARBURETOR TB42S
Vacuum Break (Cont’d)
3. Lightly push piston rod in the direction that closes choke valve GI
and check clearance “R1”.
Clearance “R1”:
3.25±0.25 mm (0.1280±0.0098 in) MA
If out of specification, adjust “R1” by bending tongue.
EM
LC
SEF314D
4. Lightly push piston rod toward diaphragm and check clearance

“R2”.
Clearance “R2”:
5.0±0.5 mm (0.197±0.020 in) FE
If out of specification, recheck and adjust clearance “R1”.
CL
MT
SEF315D
AT
Accelerator Pump
1. With engine stopped, make a visual check of the accelerator
pump connecting rod and lever. TF
If they are bent or twisted, replace them.
PD
FA
RA
2. Turn the throttle lever and make sure that fuel is smoothly
injected from the pump nozzle located in the primary port.
If the accelerator pump is not functioning properly, check the BR
pump piston.
Replace it if necessary.
ST
RS
SEF316D BT
HA
EL
SE
IDX
EC-173
CARBURETOR TB42S
Fuel Cut Control System
TEC382
EC-174
CARBURETOR TB42S
Fuel Cut Control System (Cont’d)
COMPONENT DESCRIPTION GI
Fuel cut solenoid valve
The fuel cut solenoid valve is attached to the carburetor with its MA
needle valve facing the fuel passage of the primary slow system.
When current flows through the fuel cut solenoid valve, the needle
valve retracts, allowing the current to flow through the primary slow EM
system. When current does not flow through this system, the fuel
will be shut off.
LC
SEF673G
INSPECTION
1. Connect solenoid valve connector to battery. FE
2. Check “click” sound from solenoid valve when battery is con-
nected and disconnected.
CL
MT
SEF430V
AT
3. If no sound is heard from fuel cut solenoid valve, replace with
a new one.
1) Disconnect harness from harness connector. Refer to “Disas- TF
sembling Carburetor Harness Connector”, EC-163.
PD
FA
SEF462D
RA
2) Remove fuel cut solenoid valve from carburetor.
3) Install new fuel cut solenoid valve.
I Always use a new washer. BR
Fuel cut solenoid valve:
: 12 - 26 N⋅m (1.2 - 2.7 kg-m, 9 - 20 ft-lb)
I After replacement, start engine and check that fuel cut ST
solenoid is in good condition.
RS
SEF463D BT
HA
EL
SE
IDX
EC-175
CARBURETOR TB42S
ISC-FI Pot
TEC384
EC-176
CARBURETOR TB42S
ISC-FI Pot (Cont’d)
ISC-FI POT ACTUATOR ADJUSTMENT GI
1. Warm up engine to normal operating temperature.
2. Check idle speed and mixture ratio.
Idle speed: rpm (in “N” position) MA
650±50
Idle “CO”:
1.5±0.5% EM
3. Turn air conditioner switch “ON”, and check idle speed.
Idle speed: rpm (in “N” position)
1,100±50 LC
4. If out of specification, adjust idle speed by turning adjusting
SEF460GA screw.
ISC-FI POT CONTROL SOLENOID VALVE INSPECTION

1. Disconnect ISC-FI pot control solenoid valve harness connec-
tors and vacuum hoses. FE
2. Connect solenoid valve connector to battery and adequate
vacuum hoses to the solenoid valve as shown in the figure.
3. Check air passage continuity. CL
Battery voltage supplied: Air should flow.
No supply: Air should not flow.
If NG, replace ISC-FI pot control solenoid valve. MT
Always replace O-ring.
AT
TF
PD
FA
SEF011UA
RA
ENGINE COOLANT TEMPERATURE SWITCH-2
1. Drain about one liter of coolant. BR
2. Remove engine coolant temperature switch.
3. Check engine coolant temperature switch for proper operation.
Operating temperature: ST
OFF → ON approximately 100°C (212°F)
If NG, replace engine coolant temperature switch.
RS
SLC007B BT
AIR CONDITIONER CUT RELAY
3 and q
4 . HA
EL
YES
terminals q
1 and q 2
No current supply NO SE
SEF649V
IDX
EC-177
ALTITUDE COMPENSATION SYSTEM TB42S
SEF325
System Description
The higher the altitude, the thinner the density of air. At a higher
altitude, therefore, the carburetor produces too rich of an air-fuel
mixture.
The altitude compensator automatically corrects air-fuel mixture to
an optimum ratio. It operates in the following sequence in high alti-
tudes.
1. The bellows in the altitude compensator extend.
2. The lever attached to the bellows then pushes up the needle.
3. When the needle is pushed up, the air passage becomes wider,
allowing a larger amount of air to flow from the altitude com-
pensator to the carburetor.
4. With this additional air in the carburetor, the air-fuel mixture
thins to a proper ratio.
SEF444G
EC-178
ALTITUDE COMPENSATION SYSTEM TB42S
System Inspection GI
a. The altitude compensator is set to operate above an alti-
tude of approximately 500 m (1,641 ft). It should be care- MA
fully checked.
b. When making this check, ensure that all other parts are
working properly. EM
c. The altitude compensator cannot be adjusted; if it is found
to be functioning unsatisfactorily, it must be replaced as an
assembly. LC
d. The hoses are color-coded. When connecting them, be
sure to align them with the proper color marks on the unit.
COMPENSATOR AT LOW ALTITUDES
If compensator operates at low altitudes:
When compensator is malfunctioning, check it by sucking or blow- FE
ing air through the inlet and outlet hoses. If air flows through
smoothly, replace the unit as an assembly.
CL
MT
SEF297A
AT
COMPENSATOR AT HIGH ALTITUDES
If compensator does not operate at high altitudes:
When compensator is malfunctioning, check it by sucking or blow- TF
ing air through the inlet and outlet hoses. If air does not flow
through smoothly, replace the unit as an assembly.
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-179
MECHANICAL FUEL PUMP TB42S
Component Description
The fuel pump is a mechanical type and is mounted on the cylin-
der block. The end of the pump lever rests on the oil pump. When
the cam rotates, the lever moves in a reciprocating motion to
deliver fuel from the fuel tank to the carburetor.
SEF438G
Operation Check
1. Flush pump by immersing it in a fuel bath and operating rocker
arm several times.
2. Drain fuel from fuel pump. Then plug up inlet port with fingers
and check that pump arm does not move.
3. Remove your finger from the inlet port and listen for a suction
sound which will confirm that sufficient suction was produced.
SEF461G
4. Plug up outlet port and return port. Once again operate rocker
arm. After air pressure has been built up, confirm that pressure
remains for two or three seconds after.
5. Put a finger over outlet port and again build up pressure in
pump. Then submerse pump in a fuel bath and check for air
leaks.
WARNING:
Before starting to work on any part of fuel system, disconnect
ground cable from battery. When disconnecting fuel hoses,
use a container to catch fuel remaining in hoses.
SEF462G
Fuel Pressure
1. Disconnect fuel return hose and plug with a suitable blind plug.
2. Disconnect fuel feed outlet hose and connect fuel pressure
gauge between fuel pump and carburetor.
3. Check fuel pressure with engine running at various speeds.
Fuel pressure:
25.5 - 32.4 kPa
(0.255 - 0.324 bar, 0.26 - 0.33 kg/cm2, 3.7 - 4.7 psi)
If out of specification, check for fuel filter clogging or improper
fuel pump operation.
SEF463G
EC-180
IGNITION CONTROL SYSTEM TB42S
Wiring Diagram — IGN — GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC383
EC-181
System Description
Ignition timing is controlled by two systems built into the distributor
to meet varying conditions during engine operation:
1) Governor advance system
Advances ignition timing in response to engine speed.
2) Vacuum advance system
Advances ignition timing by compensating for combustion
speed delay when intake vacuum is high.
Component Parts Inspection

IGNITION COIL
1. Disconnect ignition coil harness connector.
2. Check resistance as shown in the figure.
Terminal Resistance [at 20°C (68°F)]
q
1 -q
2 (Primary coil) Approximately 1Ω
q
1 -q
3 (Secondary coil) Approximately 10 kΩ
SEF434V If NG, replace ignition coil.

Distributor Component Check
The distributor is not repairable and must be replaced as an assem-
bly except for the distributor cap.
CAP AND ROTOR HEAD

1. Check cap and rotor head for dust, carbon deposits and cracks.
2. Measure insulation resistance between electrodes on ignition
coil and spark plug sides on cap.
Insulation resistance:
More than 50 MΩ
SEL435E Less than specified value ... Replace.
CHECKING AIR GAP
Check air gap between reluctor and stator.
Air gap:
0.25 - 0.5 mm (0.0098 - 0.0197 in)
SEF431V
VACUUM ADVANCE
1. Connect vacuum pump gauge to vacuum controller and gradu-
ally draw a vacuum while watching breaker plate movement.
Check for smooth operation with no evidence of binding.
2. Turn breaker plate right and left to check for freedom of move-
ment.
SEF432V
EC-182
Distributor Component Check (Cont’d)
GOVERNOR ADVANCE GI
Turn head of cam assembly counterclockwise, release it, then
check that it returns smoothly to the original position.
MA
EM
LC
SEF433V
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-183
IDLE COMPENSATOR TB42S
Component Description
The idle compensator is basically a thermostatic valve which intro-
duces air directly from the air cleaner to the intake manifold to
compensate for abnormal enrichment of mixture in high idle tem-
peratures and to stabilize the engine. The idle compensator is
installed on the air cleaner.
SEF861A
Inspection
1. Remove air cleaner.
2. Suck on hose to make sure neither idle compensator opens.
SEF475G
3. Direct warm air to idle compensator with a heat gun.

And measure operating temperature of idle compensator.
I Place thermometer as close as possible to idle compensa-
tor sensor.
4. Idle compensator is in good condition if airflow opens idle com-
pensator when it reaches operating temperature.
I Take care not to bend or damage bimetals of idle compen-
sator.
Idle compensator opening temperature
Intake air temperature
SEF476G Bimetal function
°C (°F)
Below 65 (149) Fully closed
65 - 74 (149 - 165) Closed or open
Above 74 (165) Fully open
EC-184
AUTOMATIC TEMPERATURE CONTROL (ATC)
AIR CLEANER SYSTEM TB42S
System Description GI
The Automatic Temperature Control (ATC) system maintains the
temperature of air sucked in the carburetor within the constant MA
range, thereby enabling lean setting for carburetor calibration. In
addition to this, ATC system is effective to improve the warm-up
characteristics of the engine and to prevent carburetor from icing. EM
LC
SEC551AB
The ATC system is controlled by the inlet air temperature and the
load condition of the engine. The inlet air temperature is detected
by ATC temperature sensor, installed in the air cleaner, and the
vacuum motor is actuated by the intake manifold vacuum. FE
When the engine is not warmed up to normal operating
temperature, ATC temperature sensor passes the intake manifold
vacuum to the vacuum motor. Then the motor actuates to introduce
CL
hot air into the air cleaner. In this step, the higher the intake mani-
fold vacuum is, the wider the air control valve opens. MT
When the engine is warmed up, the ATC temperature sensor
releases to the atmosphere the vacuum line to the vacuum motor.
SEC552AB
Therefore, the vacuum motor deactivates. In this step, the air con- AT
trol valve shuts off hot air, allowing normal temperature air to flow
to the air cleaner.
TF
PD
FA
RA
System Inspection
I Engine stall or hesitation BR
I Increase in fuel consumption
I Lack of power
If these phenomena occur, check ATC system before carrying out ST
inspection of carburetor.
1. Check hoses for cracks, distortion and improper position.
2. Check ATC system for proper function while engine is cool. RS
Check air control valve position.
Air control valve is correct if it is in lower position.
SEF471G BT
3. Start engine and immediately check air control valve position.
If it rises, it is correct. HA
4. Make sure that air control valve moves up and down when
engine speed is quickly increased and decreased.
5. Make sure that air control valve partially rises when engine EL
warm-up advances.
If the above test reveals any problem in the operation of air control
valve, carry out the following test: SE
SEF472G
IDX
EC-185
AUTOMATIC TEMPERATURE CONTROL (ATC)
AIR CLEANER SYSTEM TB42S
Vacuum Motor
Disconnect inlet vacuum hose of vacuum motor, and connect
another hose to the inlet to apply vacuum to vacuum motor. Then,
confirm that air control valve moves.
Air control valve operating vacuum:
kPa (mbar, mmHg, inHg)
Opening starts
−9.6 (−96, −72, −2.83)
Full opening
Over −19.5 (−195, −146, −5.75)
SEF473G
Temperature Sensor
While engine is cool and idling, disconnect inlet vacuum hose of
vacuum motor and make sure that intake manifold vacuum is
present at the end of the vacuum hose. If vacuum is weak or is
nonexistent, check vacuum hose for leakage.
Replace temperature sensor if vacuum hoses are in good condi-
tion. After engine warms up, make sure no vacuum exists. If
necessary, replace temperature sensor.
SEF474G
EC-186
COOLING FAN MOTOR ELECTRICAL CIRCUIT TB42S
Wiring Diagram — COOL/F — GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC385
EC-187
System Description
Cooling fan motor is controlled by engine coolant temperature
switch and air conditioner signal. When engine coolant temperature
is high or air conditioner is operating, cooling fan motor operates.
OPERATION
Air conditioner switch Cooling fan motor
ture
ON — ON
Lower than 90°C (194°F) OFF
OFF
Higher than 90°C (194°F) ON
Inspection
ENTIRE SYSTEM
For air conditioner signal
2. Disconnect cooling fan motor harness connector.
3. Turn ignition switch and air conditioner switch “ON”.
4. Check voltage between terminals q 1 ,q3 and ground.
Battery voltage should exist.
If OK, check cooling fan motor ground circuit.
SEF622V If NG, check following.
I 10A and 30A fuses
I Power supply circuit to cooling fan motor
I Cooling fan relay and circuit
I Air conditioner relay and circuit
For engine coolant temperature switch signal

2. Disconnect cooling fan motor and engine coolant temperature
switch harness connectors.
3. Connect suitable jumper wire between engine coolant tempera-
ture switch harness connector terminals.
5. Check voltage between cooling fan motor terminals q
1 ,q3 and
ground.
Battery voltage should exist.
SEF623V
EC-188
If OK, check cooling fan motor ground circuit and engine cool- GI
ant temperature switch.
If NG, check following.
I 10A and 30A fuses MA
I Power supply circuit to cooling fan motor
I Cooling fan relay and circuit
I Engine coolant temperature switch and circuit EM
LC
Electrical Components Inspection

FE
1. Remove engine coolant temperature switch.
2. Check engine coolant temperature switch for proper operation.
CL
Operating temperature °C (°F) Operation
Increase to 87 - 93 (189 - 199) OFF , ON
Decrease to 82 - 84 (180 - 183) ON , OFF MT
OFF: Continuity does not exit.
SLC007B ON: Continuity exits.
AT
COOLING FAN MOTOR
1. Disconnect cooling fan motor harness connectors.
2. Supply cooling fan motor terminals with battery voltage and TF
check operation.
Cooling fan motor should operate.
If NG, replace cooling fan motor. PD
FA
SEF624V
RA
COOLING FAN RELAY
3 and q
5 . BR
Condition Continuity
Between terminals q
1 and q
2 Yes ST
No current supplied No
If NG, replace cooling fan relay. RS
SLC002B BT
AIR CONDITIONER RELAY
3 and q
5 . HA
Between terminals q
1 and q
2 Yes
EL
No current supplied No
If NG, replace air conditioner relay. SE
SEC202B
IDX
EC-189
EVAPORATIVE EMISSION CONTROL SYSTEM TB42S
System Description
SEF833MA
The evaporative emission control system is used to reduce hydro-

carbons emitted into the atmosphere from the fuel system. This
reduction of hydrocarbons is accomplished by activated charcoals
in the EVAP canister.
The fuel vapor from sealed fuel tank is led into the EVAP canister
when the engine is off. The fuel vapor is then stored in the EVAP
canister. The EVAP canister retains the fuel vapor until the EVAP
canister is purged by air.
When the engine is running, the air is drawn through the bottom of
the EVAP canister. The fuel vapor will then be led to the intake
manifold.
Inspection
EVAP CANISTER
Check EVAP canister as follows:
A and ensure that there is no leakage.
2.
I Apply vacuum to port q A . [Approximately −13.3 to −20.0 kPa
(−133 to −200 mbar, −100 to −150 mmHg, −3.94 to −5.91
inHg)]
I Cover port q D with hand.
I Blow air in port qC and ensure free flow out of port q
B .
SEF312N
EC-190
EVAPORATIVE EMISSION CONTROL SYSTEM TB42S
FUEL TANK VACUUM RELIEF VALVE GI
1. Wipe clean valve housing.
2. Check valve opening pressure and vacuum.
Pressure (Models with sub tank system only): MA
15.3 - 20.0 kPa (0.1530 - 0.2001 bar, 0.156 - 0.204
kg/cm2, 2.22 - 2.90 psi)
Vacuum (All models): EM
−6.0 to −3.3 kPa (−0.0598 to −0.0333 bar, −0.061 to
−0.034 kg/cm2, −0.87 to −0.48 psi)
3. If out of specification, replace fuel filler cap as an assembly.
LC
SEF427NA CAUTION:
Use only a genuine fuel filler cap as a replacement.
FE
CL
MT
SEC308AA
AT
FUEL CHECK VALVE
1. Blow air through connector on fuel tank side.
A considerable resistance should be felt at the mouth and a TF
portion of air flow be directed toward the engine.
2. Blow air through connector on engine side.
Air flow should be smoothly directed toward fuel tank. PD
3. If fuel check valve is suspected of not being properly function-
ing in steps 1 and 2 above, replace.
FA
EC090A
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-191
CRANKCASE EMISSION CONTROL SYSTEM TB42S
System Description
SEF445GA
This system returns blow-by gas to both the intake manifold and air cleaner.
The positive crankcase ventilation (PCV) valve is provided to conduct crankcase blow-by gas to the intake
manifold.
During partial throttle operation of the engine, the intake manifold sucks the blow-by gas through the PCV
valve.
Normally, the capacity of the valve is sufficient to handle any blow-by and a small amount of ventilating air.
The ventilating air is then drawn from the air cleaner, through the hose connecting air cleaner to rocker cover,
into the crankcase.
Under full-throttle condition, the manifold vacuum is insufficient to draw the blow-by flow through the valve,
and its flow goes through the hose connection in the reverse direction.
On vehicles with an excessively high blow-by some of the flow will go through the hose connection to the air
cleaner under all conditions.
SEC559A
Inspection
PCV (Positive Crankcase Ventilation) VALVE
With engine running at idle, remove ventilation hose from rocker
cover. A properly working valve makes a hissing noise as air
passes through it. A strong vacuum should be felt immediately
when a finger is placed over hose inlet.
SMA887BB
EC-192
CRANKCASE EMISSION CONTROL SYSTEM TB42S
PCV HOSE GI
2. Disconnect all hoses and clean with compressed air. If any
hose cannot be freed of obstructions, replace. MA
EM
LC
SEF484G
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-193
EXHAUST EMISSION CONTROL SYSTEM TB42S
Boost Controlled Deceleration Device (BCDD)
TEC381
EC-194
(Cont’d) GI
MA
EM
LC
FE
CL
MT
AT
TF
SEF672GA PD
DESCRIPTION
The BCDD serves to reduce HC emission during coasting. FA
The high manifold vacuum during coasting prevents the complete combustion of the mixture gas due to the
reduce amount of mixture gas available.
As a result, an excess amount of HC is emitted into the atmosphere. RA
When manifold vacuum exceeds the set value, this BCDD operates to supply additional mixture gas of opti-
mum mixture ratio.
Complete combustion of fuel is assisted by this additional mixture, and HC emission are thereby reduced.
BR
OPERATION WITHOUT BCDD CONTROL SOLENOID VALVE ST

Intake manifold vacuum
BCDD operation
kPa (mbar, mmHg, inHg)
RS
Below −76.0 (−760, −570, −22.44) Not actuated
Above −76.0 (−760, −570, −22.44) Actuated
BT
HA
EL
SE
IDX
EC-195
(Cont’d)
INSPECTION AND ADJUSTMENT
1. Disconnect BCDD control solenoid connector.
2. Fully loosen dash pot adjusting screw, if equipped.
After inspection and adjustment have been made, readjust
dash pot touch speed. Refer to EC-177.
SEF477GB
3. Connect vacuum gauge to intake manifold.
SEF478G
4. Start engine and observe vacuum gauge while engine revving.

5. If BCDD is in good condition, vacuum gauge will follow the
pattern shown in the figure at left.
Set pressure is shown in step 6.
EC502-A
6. If it does not react as described above, adjust operating pres-

sure.
1) Remove rubber cap on BCDD.
2) Revving engine, turn adjusting screw until the specified set
pressure is obtained.
BCDD set pressure (at sea level):
−76.0±0.7 kPa (−760±7 mbar,
−570±5 mmHg, −22.44±0.20 inHg)
SEF479G
a. Turning adjusting screw one quarter rotation will cause a

change in operation pressure of about 2.7 kPa (27 mbar, 20
mmHg, 0.79 inHg).
b. Do not fit tip of screwdriver tightly into screw slot.
ET037
EC-196
Circuit Check GI
2. Turn ignition switch “ON” and check voltage between terminals MA
of BCDD control solenoid valve at main harness side connec-
tor.
Battery voltage should exist. EM
LC
SEF435V
3. Jack up the rear of the vehicle, support with safety stands,

block front wheels, and set parking brake.
4. Start engine and drive rear wheels until speedometer indicates
20 km/h (12 MPH) by putting transmission in 1st gear and FE
depressing accelerator pedal.
WARNING:
For safety, do not drive rear wheels, at higher speeds than
CL
necessity.
MT
SEF481G
AT
5. Disengage clutch and slowly decelerate without braking.
6. Ensure that voltmeter indicates as follows:
Below 10 km/h (6 MPH): Battery voltage TF
Above 10 km/h (6 MPH): 0 [V]
If out of specification, check harness continuity between BCDD
control solenoid valve and ignition switch. PD
FA
SEF482G
RA
BCDD Control Solenoid Valve
Check function of BCDD control solenoid valve after disconnecting BR
its connector. Listen for clicking sound of solenoid valve, applying
battery voltage to solenoid valve.
ST
RS
SEF436V BT
HA
EL
SE
IDX
EC-197
PRECAUTIONS AND PREPARATION RD28ETi
Engine Fuel & Emission Control System
SEF656V
EC-198
Precautions GI
I Before connecting or disconnecting the ECM harness
connector, turn ignition switch OFF and disconnect nega- MA
tive battery terminal. Failure to do so may damage the ECM
because battery voltage is applied to ECM even if ignition
switch is turned off. EM
LC
SEF289H
I When connecting ECM harness connector, tighten secur-

ing bolt until the gap between orange indicators disap-
pears.
: 3.0 - 5.0 N⋅m (0.3 - 0.5 kg-m, 26 - 43 in-lb) FE
CL
MT
SEF308Q
AT
I When connecting or disconnecting pin connectors into or
from ECM, take care not to damage pin terminals (bend or
break). TF
Make sure that there are not any bends or breaks on ECM
pin terminal, when connecting pin connectors.
PD
FA
SEF291H
RA
I Before replacing ECM, perform Terminals and Reference
Value inspection and make sure ECM functions properly.
Refer to EC-247. BR
ST
RS
MEF040D BT
I If MIL illuminates or blinks irregularly when engine is
running, water may have accumulated in fuel filter. Drain HA
water from fuel filter. If this does not correct the problem,
perform specified trouble diagnostic procedures.
I After performing each TROUBLE DIAGNOSIS, perform EL
“OVERALL FUNCTION CHECK” or “DTC (Diagnostic
Trouble Code) CONFIRMATION PROCEDURE”.
The DTC should not be displayed in the “DTC CONFIRMA- SE
TION PROCEDURE” if the repair is completed. The “OVER-
ALL FUNCTION CHECK” should be a good result if the
SEF051P
repair is completed. IDX
EC-199
Precautions (Cont’d)
I When measuring ECM signals with a circuit tester, never
allow the two tester probes to contact.
Accidental contact of probes will cause a short circuit and
damage the ECM power transistor.
SEF348N
EC-200
ENGINE AND EMISSION CONTROL OVERALL SYSTEM RD28ETi
ECCS-D Component Parts Location GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
SEF657V
EC-201
ECCS-D Component Parts Location (Cont’d)
SEF658V
EC-202
ECCS-D Component Parts Location (Cont’d)
GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
SEF659V
EC-203
Circuit Diagram
TEC420
EC-204
System Diagram GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
SEF660V
EC-205
Vacuum Hose Drawing
SEF661V
q
1 Charge air cooler to vacuum gal- q
5 3-way connector to throttle control q
8 3-way connector to EGRC-sole-
lery solenoid valve noid valve B
q
2 Throttle control valve to throttle q
6 3-way connector to EGRC-sole- q
9 EGR valve and 3-way connector
control solenoid valve noid valve A
q
3 Vacuum pump to 3-way connector q
7 3-way connector to EGRC-sole-
q
4 Vacuum gallery to wastegate valve noid valve A
actuator
Refer to “System Diagram”, EC-205 for vacuum control system.
EC-206
System Chart GI
MA
Camshaft position sensor (PUMP) E Fuel injection control E Electric governor
EM
Crankshaft position sensor (TDC) E
LC
Control sleeve position sensor E Fuel injection timing control E Injection timing control valve
Fuel temperature sensor E
FE
Engine coolant temperature sensor E Fuel cut control E Fuel cut solenoid valve
CL
Needle lift sensor E
MT
Accelerator position sensor E Glow control system E Glow relay & glow lamp
AT
Accelerator position switch E
TF
Accelerator switch (F/C) E ECM Malfunction indicator lamp
On board diagnostic system E (On the instrument panel)
PD
Neutral position switch E
FA
Ignition switch E
EGR valve & throttle control E EGRC-solenoid valve A, B &
valve control throttle control solenoid valve
RA
Battery voltage E
BR
Cooling fan control E Cooling fan relay

ST
RS
Air conditioning cut control E Air conditioner relay

BT
Charge air temperature sensor E
HA
Heat up switch E
Charge air cooler fan control E Charge air cooler fan relay
EL
SE
IDX
EC-207
DESCRIPTION RD28ETi
Fuel Injection System

SYSTEM DESCRIPTION
Three types of fuel injection control are provided to accommodate engine operating conditions; normal control,
idle control and start control. The ECM determines the appropriate fuel injection control. Under each control,
the amount of fuel injected is compensated to improve engine performance. The ECM performs duty control
on the electric governor (built into the fuel injection pump) according to sensor signals to compensate the
amount of fuel injected to the preset value.
START CONTROL
Input/output signal line
Engine speed
ECM Electric
E governor
Start signal
Ignition switch E
Control sleeve position

Control sleeve position sensor E
When the ECM receives a start signal from the ignition switch, the
ECM adapts the fuel injection system for the start control. The
amount of fuel injected at engine starting is a preset program value
in the ECM. The program is determined by the engine speed and
engine coolant temperature.
For better startability under cool engine conditions, the lower the
coolant temperature becomes, the greater the amount of fuel
injected. The ECM ends the start control when the engine speed
reaches 400 rpm (for M/T models), 600 rpm (for A/T models) and
shifts the control to the normal or idle control.
SEF648S
EC-208
DESCRIPTION RD28ETi
Fuel Injection System (Cont’d)
IDLE CONTROL GI
MA
Engine speed EM
Gear position LC
Battery voltage
Battery E
ECM
Control sleeve position Electric
Control sleeve position sensor E E governor FE
Idle position
Accelerator position switch E
CL
Vehicle speed
Air conditioner signal

MT
Heat up switch
Heat up switch signal AT
E
When the ECM determines that the engine speed is at idle, the fuel injection system is adapted for the idle TF
control. The ECM regulates the amount of fuel injected corresponding to changes in load applied to the engine
to keep engine speed constant. The ECM also provides the system with a fast idle control in response to the
engine coolant temperature and heat up switch signal. PD
NORMAL CONTROL
FA
Engine speed RA

Control sleeve position sensor E BR
ECM Electric
E governor
Accelerator position
Accelerator position sensor E
ST
Vehicle speed
RS
BT
The amount of fuel injected under normal driving conditions is
determined according to sensor signals. The crankshaft position HA
sensor (TDC) detects engine speed and the accelerator position
sensor detects accelerator position. These sensors send signals to
the ECM. EL
The fuel injection data, predetermined by correlation between vari-
ous engine speeds and accelerator positions, are stored in the
ECM memory, forming a map. The ECM determines the optimal SE
amount of fuel to be injected using the sensor signals in compari-
son with the map.
IDX
SEF649S
EC-209
DESCRIPTION RD28ETi
Fuel Injection System (Cont’d)
FUEL TEMPERATURE COMPENSATION
Fuel temperature
Fuel temperature sensor E
Engine speed ECM Electric

Crankshaft position sensor (TDC) E E governor

Control sleeve position sensor E
The amount of fuel leaking at or around high-pressure parts inside fuel injection pump varies with fuel tem-
perature and engine speed. This will result in a difference between the target amount of fuel injected and the
actual amount. The ECM compensates for the actual amount depending on the signal from the fuel tempera-
ture sensor which detects fuel temperature.
DECELERATION CONTROL
Accelerator switch (F/C) E
Electric
ECM E governor
Engine speed
Camshaft position sensor (PUMP) E
The ECM cuts power supply delivery to the electric governor during deceleration for better fuel efficiency. The
ECM determines the time of deceleration according to signals from the accelerator switch (F/C) and camshaft
position sensor (PUMP).
EC-210
DESCRIPTION RD28ETi
Fuel Injection Timing System GI

SYSTEM DESCRIPTION
The fuel injection timing system provides the optimal fuel injection timing for the target amount of fuel injected MA
according to engine speed. The timing is compensated when the vehicle is being driven or when starting
depending on the engine coolant temperature.
The ECM performs duty control on the timing control valve, allowing the valve to provide optimal fuel injection EM
timing. The ECM also performs feedback control on the timing control valve using the signal from the needle
lift sensor which detects the actual fuel injection timing.
LC
BASIC CONTROL
Engine speed
Crankshaft position sensor (TDC) E Injection FE
ECM E timing con-
Injection timing trol valve
CL
The optimal fuel injection timing data, predetermined in proportion
to engine speeds and amount of fuel injected, are stored in the MT
ECM memory. The ECM uses the data to control the fuel injection
timing.
AT
TF
PD
SEF650S
FA
ENGINE COOLANT TEMPERATURE COMPENSATION (When starting)
Input/output signal line RA
Engine speed
BR
Engine coolant temperature sensor E Injection
ECM timing con- ST
E
Ignition timing trol valve
Start signal RS
Ignition switch E
BT
For better startability under cool engine conditions, the fuel injec-
tion timing is compensated according to the engine coolant tem- HA
perature.
EL
SE
IDX
SEF651S
EC-211
DESCRIPTION RD28ETi
Fuel Injection Timing System (Cont’d)
ENGINE COOLANT TEMPERATURE COMPENSATION (During driving)
Engine speed
Engine coolant temperature Injection

Engine coolant temperature sensor E ECM timing con-
E
trol valve
Injection timing
For better exhaust efficiency under cool engine conditions, the fuel
injection timing is controlled within a compensation range depend-
ing on the engine speed, engine coolant temperature and amount
of fuel injected.
SEF652S
Air Conditioning Cut Control

Accelerator valve opening angle

Accelerator position sensor E
Air
ECM E conditioner
Vehicle speed relay

SYSTEM DESCRIPTION
This system improves acceleration when the air conditioner is used.
When the accelerator pedal is fully depressed, the air conditioner is turned off for a few seconds.
When engine coolant temperature becomes excessively high, the air conditioner is turned off. This continues
until the coolant temperature returns to normal.
EC-212
DESCRIPTION RD28ETi
Fuel Cut Control (at no load & high engine GI

speed)
INPUT/OUTPUT SIGNAL LINE MA
Vehicle speed
Vehicle speed sensor E EM
Neutral position
LC
Accelerator position switch or Accelerator E
ECM E
Electric
switch (F/C)
governor

FE
Engine speed
CL
If the engine speed is above 3,000 rpm with no load (for example,
in neutral and engine speed over 3,000 rpm) fuel will be cut off after MT
some time. The exact time when the fuel is cut off varies based on
engine speed.
Fuel cut will operate until the engine speed reaches 1,500 rpm, AT
then fuel cut is cancelled.
NOTE:
This function is different from deceleration control and fuel cut TF
solenoid valve control listed under “Fuel Injection System”,
EC-208 and “TROUBLE DIAGNOSIS FOR DTC 36, 37, 38”,
EC-323. PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-213
CRANKCASE VENTILATION SYSTEM RD28ETi
Description
In this system, blow-by gas is sucked into the air inlet pipe through
the control valve after oil separation by oil separator in the rocker
cover.
SEF456HA
Inspection
BLOW-BY CONTROL VALVE
Check control valve for clogging and abnormalities.
SEC586B
VENTILATION HOSE
2. Disconnect all hoses and clean with compressed air.
If any hose cannot be freed of obstructions, replace.
SEC692
EC-214
INJECTION NOZZLE RD28ETi
CAUTION: GI
I Do not disassemble No. 1 nozzle (with needle lift sensor
built-in). If NG, replace No. 1 injection nozzle.
I Plug flare nut with a cap or rag so that no dust enters the MA
nozzle. Cover nozzle tip for protection of needle.
EM
LC
Removal and Installation

1. Remove fuel injection tube and spill tube.
2. Remove injection nozzle assembly. FE
Also remove gasket from nozzle end.
3. Install injection nozzle in the reverse order of removal.
Injection nozzle to engine: CL
: 59 - 69 N⋅m (6.0 - 7.0 kg-m, 43 - 51 ft-lb)
Injection nozzle to tube:
: 22 - 25 N⋅m (2.2 - 2.5 kg-m, 16 - 18 ft-lb) MT
Spill tube:
SEF939S : 39 - 49 N⋅m (4.0 - 5.0 kg-m, 29 - 36 ft-lb)
a. Always clean the nozzle holes. AT
b. Always use new injection nozzle gasket.
c. Note that small washer should be installed in specified
direction. TF
d. Bleed air from fuel system.
PD
FA
SEF662V
RA
Disassembly (No. 2 - 4 nozzles)
Do not disassemble No. 1 nozzle (with needle lift sensor). BR
1. Loosen nozzle nut while preventing nozzle top from turning.
ST
RS
SEF669A BT
2. Arrange all disassembled parts in the order shown at left.
HA
EL
SE
SEF670A
IDX
EC-215
Inspection (No. 2 - 4 nozzles)

Thoroughly clean all disassembled parts with fresh kerosene or
solvent.
I If nozzle needle is damaged or fused, replace nozzle assem-
bly with a new one.
I If end of nozzle needle is seized or excessively discolored,
replace nozzle assembly.
I Check nozzle body and distance piece for proper contact. If
excessively worn or damaged, replace nozzle assembly or dis-
tance piece.
I Check distance piece and nozzle holder for proper contact. If
excessively worn or damaged, replace distance piece or nozzle
holder.
I Check nozzle spring for excessive wear or damage. If exces-
sively worn or damaged, replace it with a new spring.
Cleaning (No. 2 - 4 nozzles)

a. Do not touch the nozzle mating surface with your fingers.
b. To wash the nozzles, use a wooden stick and brass brush
with clean diesel fuel.
1. Remove any carbon from exterior of nozzle body (except wrap-
ping angle portion) by using Tool.
SEF830
2. Clean oil sump of nozzle body using Tool.
SEF831
3. Clean nozzle seat by using Tool.

This job should be performed with extra precautions, since
efficiency of nozzle depends greatly on a good nozzle seat.
SEF832
EC-216
Cleaning (No. 2 - 4 nozzles) (Cont’d)
4. Clean spray hole of nozzle body by using Tool. GI
To prevent spray hole from canting, always clean it by start-
ing with inner side and working towards outside.
MA
EM
LC
SEF833
5. Decarbonate nozzle needle tip by using Tool.
FE
CL
MT
SEF834
AT
6. Check needle sinking.
(1) Pull needle about halfway out from body and then release it.
(2) Needle should sink into body very smoothly from just its own TF
weight.
(3) Repeat this test and rotate needle slightly each time.
If needle fails to sink smoothly from any position, replace both PD
needle and body as a unit.
FA
SEF835
RA
Assembly (No. 2 - 4 nozzles)
Assemble in the reverse order of disassembly, observing the fol- BR
lowing.
ST
RS
SEF671A BT
If nozzle body is not installed properly, Tool cannot be
removed and nozzle body may be damaged. HA
Holder to nozzle nut:
: 78 - 98 N⋅m (8.0 - 10.0 kg-m, 58 - 72 ft-lb)
EL
SE
IDX
EC-217
Test and Adjustment

WARNING:
When using nozzle tester, be careful not to allow diesel fuel
sprayed from nozzle to contact your hands or body, and make
sure your eyes are properly protected with goggles.
INJECTION PRESSURE TEST

1. Install nozzle to injection nozzle tester and bleed air from flare
nut.
EF791A
2. Pump the tester handle slowly (one time per second) and watch
the pressure gauge.
3. Read the pressure gauge when the injection pressure just
starts dropping.
Initial injection pressure:
Used
14,220 kPa (142.2 bar, 145 kg/cm2, 2,062 psi)
New
14,711 - 15,495 kPa (147.1 - 155.0 bar,
150 - 158 kg/cm2, 2,133 - 2,247 psi)
SEF672A
Always check initial injection pressure using a new nozzle.
4. To adjust injection pressure, change adjusting shims (No. 2 - 4

nozzles).
a. Increasing the thickness of adjusting shims increases ini-
tial injection pressure. Decreasing thickness reduces ini-
tial pressure.
b. A shim thickness of 0.04 mm (0.0016 in) corresponds
approximately to a difference of 471 kPa (4.71 bar, 4.8
kg/cm2, 68 psi) in initial injection pressure.
Refer to SDS for adjusting shim (EC-430).
SEF673A
LEAKAGE TEST
1. Maintain the pressure at about 981 to 1,961 kPa (9.8 to 19.6
bar, 10 to 20 kg/cm2, 142 to 284 psi) below initial injection
pressure.
2. Check that there is no dripping from the nozzle tip or around the
body.
SEF674A
EC-218
Test and Adjustment (Cont’d)
3. If there is leakage, clean, overhaul or replace nozzle. GI
MA
EM
LC
SPRAY PATTERN TEST

1. Check spray pattern by pumping tester handle one full stroke
per second. FE
I If main spray angle is within 30 degrees as shown, injec-
tion nozzle is good.
I It is still normal even if a thin stream of spray deviates from CL
the main spray (pattern B).
2. If the spray pattern is not correct, disassemble and clean
nozzle. MT
3. Test again and if spray pattern is not corrected, replace nozzle.
SEF079S
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-219
ELECTRONIC FUEL INJECTION PUMP RD28ETi
SEF663V
Removal
1. Remove battery.
Disconnect electronic injection pump harness connectors.
2. Set No. 1 piston at TDC on its compression stroke.

TDC: Crankshaft pulley notch without painted mark
3. Remove fuel hoses (supply, return and spill) and injection
tubes.
4. Remove air duct and injection pump timing belt cover.
5. Remove injection pump timing belt.
Refer to EM section (“Injection Pump Timing Belt”).
SEF664V
6. Remove injection pump sprocket with Tool.

I Remove key from injection pump shaft and store safely.
SEF665V
EC-220
Removal (Cont’d)
7. Remove injection pump assembly. GI
MA
EM
LC
SEF666V
Installation
1. Install key on injection pump shaft, then install injection pump
sprocket. FE
I Use alignment mark on sprocket.
2. Install injection pump timing belt.
Refer to EM section (“Injection Pump Timing Belt”). CL
MT
SEF667V
AT
3. Adjust injection timing.
Refer to “Basic Inspection”, EC-239.
4. Install all parts removed. TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-221
SEF668V
Disassembly and Assembly

CAUTION:
I Do not disassemble the parts not shown in the illustration
above.
I Before installing injection timing control valve, liberally
apply a coat of diesel fuel to O-ring and its mating area.
Insert injection timing control valve straight into bore in
fuel pump body. After properly positioning injection timing
control valve, visually check that fuel does not leak.
I After assembling the parts, erase Diagnostic Trouble Code
(DTC), and perform DTC CONFIRMATION PROCEDURE (or
OVERALL FUNCTION CHECK).
EC-222
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION RD28ETi
DTC and MIL Detection Logic GI

When a malfunction is detected for the first time, the malfunction (DTC) is stored in the ECM memory.
The MIL will light up each time the ECM detects malfunction. However, if the same malfunction is experienced MA
in two consecutive driving patterns and the engine is still running, the MIL will stay lit up. For diagnostic items
causing the MIL to light up, refer to “DIAGNOSTIC TROUBLE CODE INDEX”, EC-2.
EM
Diagnostic Trouble Code (DTC)
HOW TO READ DTC LC
The diagnostic trouble code can be read by the following methods.
1. The number of blinks of the malfunction indicator lamp in the Diagnostic Test Mode II (Self-Diagnostic
Results) Examples: 11, 13, 14, etc.
These DTCs are controlled by NISSAN.
2. CONSULT Examples: “CAM POS SEN (PUMP)”, etc.
FE
I Output of the trouble code means that the indicated circuit has a malfunction. However, in the Mode
II it does not indicate whether the malfunction is still occurring or occurred in the past and returned
to normal. CL
CONSULT can identify them. Therefore, using CONSULT (if available) is recommended.
HOW TO ERASE DTC
The diagnostic trouble code can be erased by the following methods.
MT
Selecting “ERASE” in the “SELF-DIAG RESULTS” mode with CONSULT.
AT
Changing the diagnostic test mode from Diagnostic Test Mode II to Mode I. (Refer to EC-225.)
I If the battery terminal is disconnected, the diagnostic trouble code will be lost within 24 hours.
I When you erase the DTC, using CONSULT is easier and quicker than switching the diagnostic test TF
modes.
HOW TO ERASE DTC (With CONSULT)
PD
5 seconds and then turn it “ON” (Engine stopped) again.
2. Turn CONSULT “ON” and touch “ENGINE”. FA
3. Touch “SELF-DIAG RESULTS”.
4. Touch “ERASE”. (The DTC in the ECM will be erased.)
RA
BR
ST
RS
SEF691S
BT
HOW TO ERASE DTC (No Tools)
5 seconds and then turn it “ON” again. HA
2. Change the diagnostic test mode from Mode II to Mode I. (Refer to EC-225.)
EL
SE
IDX
EC-223
Malfunction Indicator Lamp (MIL)

1. The malfunction indicator lamp will light up when the ignition
switch is turned ON without the engine running. This is a bulb
check.
I If the malfunction indicator lamp does not light up, refer to EL
section (“WARNING LAMPS AND CHIME”) or see EC-381.
2. When the engine is started, the malfunction indicator lamp
should go off.
If the lamp remains on, the on board diagnostic system has
detected an engine system malfunction.
SEF051P If MIL illuminates or blinks irregularly after starting engine,
water may have accumulated in fuel filter. Drain water from
fuel filter.
ON BOARD DIAGNOSTIC SYSTEM FUNCTION
The on board diagnostic system has the following three functions.
1. BULB CHECK : This function checks the MIL bulb for damage (blown, open circuit,
etc.).
2. MALFUNCTION : This is a usual driving condition. When a malfunction is detected, the
WARNING MIL will light up to inform the driver that a malfunction has been
detected.
3. SELF-DIAGNOSTIC : This function allows diagnostic trouble codes to be read.
RESULTS
Refer to “HOW TO SWITCH DIAGNOSTIC TEST MODES” on next page.

Diagnostic Diagnostic
Condition
Test Mode I Test Mode II
Engine
stopped SELF-DIAGNOSTIC
BULB CHECK
Ignition switch RESULTS
in “ON” posi-
tion Engine
running MALFUNCTION
—
WARNING
EC-224
HOW TO SWITCH DIAGNOSTIC TEST MODES GI
Turn ignition switch “ON”.
(Do not start engine.) MA
EM
H
NG NG
Check MIL circuit. E
Repair harness or
E
Diagnostic Test Mode I — BULB CHECK. (See EC-381.) connectors. LC
Refer to previous page.
MIL should come on. OK OK
E H
F
OK
FE
E
G E
Diagnostic Test
Mode I
Start engine. — MALFUNC-
TION WARN- CL
ING.
Refer to previ-
ous page. MT
H
NG AT
E
Check MIL circuit and data link connector for
CONSULT circuit. (See EC-381.)
OK NG TF
H PD
Data link connector for CONSULT Repair harness or
(Connect CHK and IGN terminals with a suitable connectors.
harness.) FA
MIL should go off. OK
H RA
Wait at least 2 seconds. F H
H BR
ST
RS
(Disconnect the suitable harness between CHK
and IGN terminals.) BT
H
DIAGNOSTIC TEST MODE II HA
— SELF-DIAGNOSTIC RESULTS
EL
H
q
B q
A SE
IDX
EC-225
q
B q
A
G
H
I Switching the modes is not possible when the engine

is running.
I When ignition switch is turned off during diagnosis,
power to ECM will drop after approx. 5 seconds.
Data link connector for CONSULT The diagnosis will automatically return to Diagnostic
(Connect CHK and IGN terminals with a suit- Test Mode I.
able harness.)
H
Wait at least 2 seconds.

H
If the suitable harness is disconnected at this
time, the diagnostic trouble code will be
erased from the backup memory in the ECM.
EC-226
DIAGNOSTIC TEST MODE I—BULB CHECK GI
In this mode, the MALFUNCTION INDICATOR LAMP on the instrument panel should stay ON. If it remains
OFF, check the bulb. Refer to EL section (“WARNING LAMPS AND CHIME”) or see EC-381.
MA
DIAGNOSTIC TEST MODE I—MALFUNCTION WARNING
MALFUNCTION
Condition EM
INDICATOR LAMP
When the malfunction is detected or the ECM’s CPU is malfunctioning. (Refer to “MIL Illumination” of the
ON
“DIAGNOSTIC TROUBLE CODE INDEX”, EC-2.) LC
OFF No malfunction.
I These Diagnostic Trouble Code Numbers are clarified in Diagnostic Test Mode II (SELF-DIAGNOSTIC
RESULTS).
DIAGNOSTIC TEST MODE II—SELF-DIAGNOSTIC RESULTS
In this mode, a diagnostic trouble code is indicated by the number of blinks of the MALFUNCTION INDICA-
FE
TOR LAMP as shown below.
CL
MT
AT
TF
SEF212NA
Long (0.6 second) blinking indicates the number of ten digits, and short (0.3 second) blinking indicates the PD
number of single digits. For example, the malfunction indicator lamp blinks 4 times for 5 seconds (0.6 sec x
4 times) and then it blinks three times for about 1 second (0.3 sec x 3 times). This indicates the DTC “43” and
refers to the malfunction of the accelerator position sensor circuit. FA
In this way, all the detected malfunctions are classified by their diagnostic trouble code numbers. The DTC
“55” refers to no malfunction. (See DIAGNOSTIC TROUBLE CODE INDEX, EC-2.)
RA
HOW TO ERASE DIAGNOSTIC TEST MODE II (Self-diagnostic results)
The diagnostic trouble code can be erased from the backup memory in the ECM when the diagnostic test mode
is changed from Diagnostic Test Mode II to Diagnostic Test Mode I. (Refer to “HOW TO SWITCH DIAGNOS- BR
TIC TEST MODES” on previous page.)
I If the battery terminal is disconnected, the diagnostic trouble code will be lost from the backup
memory within 24 hours.
ST
I If the MIL blinks or “NATS MALFUNCTION” is displayed on RS
“SELF-DIAG RESULTS” screen, perform self-diagnostic
results mode with CONSULT using NATS program card
(NATS-E940). Refer to EL section. BT
I Confirm no self-diagnostic results of NATS is displayed
before touching “ERASE” in “SELF-DIAG RESULTS” mode
with CONSULT. HA
I When replacing ECM, initialisation of NATS V2.0 system
and registration of all NATS V2.0 ignition key IDs must be
carried out with CONSULT using NATS program card EL
(NATS-E940).
SEF288Q
Therefore, be sure to receive all keys from vehicle owner.
Regarding the procedures of NATS initialisation and NATS SE
ignition key ID registration, refer to CONSULT operation
manual, NATS V2.0.
IDX
EC-227
RELATIONSHIP BETWEEN MIL, DTC, CONSULT AND DRIVING PATTERNS
SEF659S
*1: When a malfunction is detected, MIL will light up. *5: The DTC will not be displayed any longer after vehicle is
*2: When the same malfunction is detected in two consecutive driven 40 times without the same malfunction.
driving patterns, MIL will stay lit up. (The DTC still remain in ECM.)
*3: MIL will go off after vehicle is driven three times without *6: Other screens except SELF-DIAGNOSTIC RESULTS &
any malfunctions. DATA MONITOR (AUTO TRIG) cannot display the mal-
*4: When a malfunction is detected for the first time, the DTC function. DATA MONITOR (AUTO TRIG) can display the
will be stored in ECM. malfunction at the moment it is detected.
EC-228
CONSULT GI
CONSULT INSPECTION PROCEDURE
1. Turn ignition switch OFF. MA
2. Connect “CONSULT” to data link connector for CONSULT.
(Data link connector for CONSULT is located under the hood
opener.) EM
LC
SEF669V
3. Turn ignition switch ON.

4. Touch “START”.
5. Touch “ENGINE”.
6. Perform each diagnostic test mode according to each service FE
procedure.
For further information, see the CONSULT Operation Manual.
CL
MT
SEF895K
AT
TF
PD
FA
SEF660S
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-229
CONSULT (Cont’d)
ENGINE CONTROL COMPONENT PARTS/CONTROL SYSTEMS APPLICATION
DIAGNOSTIC TEST MODE
Item SELF-DIAG-
DATA ACTIVE
NOSTIC
MONITOR TEST
RESULTS
Camshaft position sensor (PUMP) X X
Engine coolant temperature sensor X X
Control sleeve position sensor X X
Fuel temperature sensor X X
Vehicle speed sensor X X
Accelerator position sensor X X X
ENGINE CONTROL COMPONENT PARTS
Accelerator position switch X X

Accelerator switch (F/C) X X
INPUT Crankshaft position sensor (TDC) X X
Needle lift sensor X
Ignition switch (start signal) X
Neutral position switch X
Battery voltage X
Air conditioner switch X
Heat up switch X
Mass air flow sensor X X
Charge air temperature sensor X
Injection timing control valve X X X
Fuel cut solenoid valve X X X
Glow relay X X
OUTPUT
EGRC-solenoid valve A, B & throttle control solenoid valve X X
Cooling fan relay X X
Charge air cooler fan relay X
X: Applicable
EC-230
CONSULT (Cont’d)
SELF-DIAGNOSTIC MODE GI
Regarding items detected in “SELF-DIAG RESULTS” mode, refer to “DIAGNOSTIC TROUBLE CODE
INDEX”, EC-2.
MA
DATA MONITOR MODE
Monitored item ECM
[Unit] input
Main
Description Remarks
EM
signals
signals
CKPS⋅RPM I The engine speed computed from the
(TDC) [rpm] q q crankshaft position sensor (TDC) signal
is displayed.
LC
CKPS⋅RPM I The engine speed [determined by the

(REF) [rpm]
q q time between pulses from the crankshaft
position sensor (TDC) signal] is dis-
played.
FE
CMPS⋅RPM - I The engine speed computed from the
PUMP [rpm] q q camshaft position sensor (PUMP) signal
is displayed.
CL
COOLAN TEMP/S I The engine coolant temperature (deter- I When the engine coolant temperature
[°C] or [°F] mined by the signal voltage of the engine sensor is open or short-circuited, ECM
q q coolant temperature sensor) is displayed. enters fail-safe mode. The engine coolant
temperature determined by the ECM is MT
displayed.
VHCL SPEED SE
[km/h] or [mph] q q I The vehicle speed computed from the
vehicle speed sensor signal is displayed. AT
FUEL TEMP SEN I The fuel temperature (determined by the
[°C] or [°F] q q signal voltage of the fuel temperature
sensor) is displayed.
TF
ACCEL POS SEN [V]
q q I The accelerator position sensor signal
voltage is displayed. PD
FULL ACCEL SW
accelerator position switch signal.
FA
ACCEL SW (FC)
[OPEN/CLOSE] q q I Indicates [OPEN/CLOSE] condition from
the accelerator switch (FC) signal.
OFF ACCEL SW
accelerator position switch signal.
RA
C/SLEEV POS/S [V]
q q I The control sleeve position sensor signal
voltage is displayed. BR
BATTERY VOLT [V]
q q I The power supply voltage of ECM is dis-
played.
ST
P/N POSI SW
park/neutral position switch signal.
START SIGNAL
starter signal.
I After starting the engine, [OFF] is dis-
played regardless of the starter signal. RS
NOTE:
Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically. BT
HA
EL
SE
IDX
EC-231
CONSULT (Cont’d)
Monitored item ECM
Main
[Unit] input Description Remarks
signals
signals
I Indicates [ON/OFF] condition of the air
q q
AIR COND SIG
[ON/OFF] conditioner switch as determined by the
air conditioner signal.
IGN SW
[ON/OFF] q q I Indicates [ON/OFF] condition from igni-
tion switch signal.
MAS AIR/FL SE [V]
q q I The signal voltage of the mass air flow
sensor is displayed.
I When the engine is stopped, a certain
value is indicated.
ACT INJ TIMG [°] I The actual injection timing angle deter-
q q mined by the ECM (an approximate aver-

age angle between injection start and
end from TDC) is displayed.
INJ TIMG C/V [%] I Indicates the duty ratio of fuel injection
timing control valve.
I Indicates [ON/OFF] condition from decel- I When the accelerator pedal is released
q
DECELER F/CUT
[ON/OFF] eration fuel cut signal. quickly with engine speed at 3,000 rpm
or more, “ON” is displayed.
FUEL CUT S/V I The control condition of the fuel cut sole- I When the fuel cut solenoid valve is not
[ON/OFF] noid valve (determined by ECM accord- operating, fuel is not supplied to injection
q
ing to the input signal) is indicted. nozzles.
I OFF ... Fuel cut solenoid valve is not
operating.
ON ... Fuel cut solenoid valve is operat-
ing.
I The glow relay control condition (deter-
q
GLOW RLY [ON/OFF]
mined by ECM according to the input
signal) is displayed.
COOLING FAN I Indicates the control condition of the
[LOW/HI/OFF] cooling fans (determined by ECM accord-
q ing to the input signal).

I LOW ... Operates at low speed.
HI ... Operates at high speed.
OFF ... Stopped.
I Indicates the control condition of the
q
I/C FAN RLY
[ON/OFF] charge air cooler fan (determined by
ECM according to the input signals).
EGRC SOL/V A I The control condition of the EGRC-sole-
[ON/OFF] noid valve A (determined by ECM
according to the input signal) is indicated.
I OFF ... EGRC-solenoid valve A is not
operating.
ON ... EGRC-solenoid valve A is operat-
ing.
EGRC SOL/V B I The control condition of the EGRC-sole-
[ON/OFF] noid valve B (determined by ECM
I OFF ... EGRC-solenoid valve B is not
operating.
ON ... EGRC-solenoid valve B is operat-
ing.
THROT RLY I The control condition of the throttle con-
[ON/OFF] trol solenoid valve (determined by ECM
I OFF ... Throttle control solenoid valve is
not operating.
ON ... Throttle control solenoid valve is
operating.
EC-232
CONSULT (Cont’d)
ACTIVE TEST MODE GI
TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY)
I Ignition switch: ON MA
I Operate the cooling fan at Cooling fan moves at “LOW”, “HI” I Harness and connector
COOLING FAN
“LOW”, “HI” speed and turn speed and stops. I Cooling fan motor
“OFF” using CONSULT.
EM
OFF ACCEL PO I Clears the self-learning fully closed accelerator position, detected by accelerator position sensor, from the
SIG ECM.
I Ignition switch: ON LC
I Turn solenoid valve “ON” and Solenoid valve makes an operating I Harness and connector
FUEL CUT SOL/V
“OFF” with the CONSULT and sound. I Solenoid valve
listen to operating sound.
EGRC SOL/V A
“OFF” with the CONSULT and sound. I Solenoid valve
listen to operating sound. FE
EGRC SOL/V B
“OFF” with the CONSULT and sound. I Solenoid valve CL
THROT CONT I Turn solenoid valve “ON” and Solenoid valve makes an operating I Harness and connector MT
SOL/V “OFF” with the CONSULT and sound. I Solenoid valve
I Ignition switch: ON (Engine AT
stopped)
Glow relay makes the operating I Harness and connector
GLOW RLY I Turn the glow relay “ON” and
sound. I Glow relay
“OFF” using CONSULT and listen
to operating sound. TF
I Engine: Return to the original
trouble condition If trouble symptom disappears, see
INJ TIMING I Adjust initial injection timing
I Retard the injection timing using CHECK ITEM. PD
CONSULT.
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-233
CONSULT (Cont’d)
REAL TIME DIAGNOSIS IN DATA MONITOR MODE
CONSULT has two kinds of triggers and they can be selected by touching “SETTING” in “DATA MONITOR”
mode.
1. “AUTO TRIG” (Automatic trigger):
I The malfunction will be identified on the CONSULT screen in real time.
In other words, the malfunction item will be displayed at the moment the malfunction is detected by
ECM.
DATA MONITOR can be performed continuously until a malfunction is detected. However, DATA
MONITOR cannot continue any longer after the malfunction detection.
2. “MANU TRIG” (Manual trigger):
I The malfunction item will not be displayed automatically on CONSULT screen even though a malfunc-
tion is detected by ECM.
DATA MONITOR can be performed continuously even though a malfunction is detected.
Use these triggers as follows:
1. “AUTO TRIG”
I While trying to detect the DTC by performing the “DTC CONFIRMATION PROCEDURE”, be sure to
select to “DATA MONITOR (AUTO TRIG)” mode. You can confirm the malfunction at the moment it is
detected.
I While narrowing down the possible causes, CONSULT should be set in “DATA MONITOR (AUTO
TRIG)” mode, especially in case the incident is intermittent.
Inspect the circuit by gently shaking (or twisting) suspicious connectors, components and harness in
the “DTC CONFIRMATION PROCEDURE”. The moment a malfunction is found the malfunction item
will be displayed. (Refer to GI section, “Incident Simulation Tests” in “HOW TO PERFORM EFFICIENT
DIAGNOSIS FOR AN ELECTRICAL INCIDENT”.)
2. “MANU TRIG”
I If the malfunction is displayed as soon as “DATA MONITOR” is selected, reset CONSULT to “MANU
TRIG”. By selecting “MANU TRIG” you can monitor and store the data. The data can be utilized for
further diagnosis, such as a comparison with the value for the normal operating condition.
SEF529Q
EC-234
TROUBLE DIAGNOSIS — Introduction RD28ETi
Introduction GI
The engine has an ECM to control major systems such as fuel
injection control, fuel injection timing control, glow control system, MA
etc. The ECM accepts input signals from sensors and instantly
drives electronic fuel injection pump. It is essential that both input
and output signals are proper and stable. At the same time, it is EM
important that there are no problems such as vacuum leaks, or
other problems with the engine.
It is much more difficult to diagnose a problem that occurs intermit- LC
tently rather than continuously. Most intermittent problems are
SEF858S caused by poor electric connections or improper wiring. In this
case, careful checking of suspected circuits may help prevent the
replacement of good parts.
A visual check only may not find the cause of the problems. A road
test with CONSULT or a circuit tester connected should be per- FE
formed. Follow the “Work Flow”, EC-237.
Before undertaking actual checks, take a few minutes to talk with
a customer who approaches with a driveability complaint. The cus- CL
tomer can supply good information about such problems, especially
intermittent ones. Find out what symptoms are present and under
what conditions they occur. A “Diagnostic Worksheet” like the MT
example on next page should be used.
SEF233G Start your diagnosis by looking for “conventional” problems first.
This will help troubleshoot driveability problems on an electronically AT
controlled engine vehicle.
TF
PD
FA
SEF234G
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-235
TROUBLE DIAGNOSIS — Introduction RD28ETi
Diagnostic Worksheet
There are many operating conditions that lead to the malfunction
of engine components. A good grasp of such conditions can make
troubleshooting faster and more accurate.
In general, each customer feels differently about a problem. It is
important to fully understand the symptoms or conditions for a
customer complaint.
Utilize a diagnostic worksheet like the one shown below in order to
organize all the information for troubleshooting.
SEF907L
WORKSHEET SAMPLE
Customer name MR/MS Model & Year VIN
Engine # Trans. Mileage
Incident Date Manuf. Date In Service Date
l Impossible to start l No combustion l Partial combustion
l Partial combustion when engine is warm
l Startability
l Partial combustion when engine is cool
l Possible but hard to start l Others [ ]
l No fast idle l Unstable l High idle l Low idle
l Idling
Symptoms l Others [ ]
l Stumble l Surge l Knock l Lack of power
l Driveability
l Others [ ]
l At the time of start l While idling
l Engine stall l While accelerating l While decelerating
l Just after stopping l While loading
l Just after delivery l Recently
Incident occurrence
l In the morning l At night l In the daytime
Frequency l All the time l Under certain conditions l Sometimes
Weather conditions l Not affected
Weather l Fine l Raining l Snowing l Others [ ]
Temperature l Hot l Warm l Cool l Cold l Humid °F
l Cold l During warm-up l After warm-up
Engine conditions Engine speed
Road conditions l In town l In suburbs l Highway l Off road (up/down)

l Not affected
l At starting l While idling l At racing
l While accelerating l While cruising
Driving conditions l While decelerating l While turning (RH/LH)
Vehicle speed
Malfunction indicator lamp l Turned on l Not turned on
EC-236
TROUBLE DIAGNOSIS — Work Flow RD28ETi
Work Flow GI
CHECK IN
MA
H
CHECK INCIDENT CONDITIONS. ................................................. STEP I EM
Listen to customer complaints. (Get symptoms.)
H LC
Check and PRINT OUT (write down) Diagnostic Trouble Code (DTC).
Then clear. Also check related service bulletins for information. ........................................... STEP II
Symptoms No symptoms, except MIL

collected. lights up, or Malfunction
Code exists at STEP II. FE
H
Verify the symptom by driving in the condition the cus-
*1
tomer described. ............................................................................................. STEP III CL
Normal Code Malfunction Code
(at STEP II) (at STEP II) MT
H H
INCIDENT CONFIRMATION *1
........................................... STEP IV AT
Verify the DTC by performing the “DTC CONFIRMATION PROCEDURE”.
H TF
Choose the appropriate action. ...........................................
E STEP V
*2
Malfunction Code (at STEP II or IV) Normal Code (at both STEP II and IV)
H PD
BASIC INSPECTION
SYMPTOM BASIS (at STEP I or III) FA

................................................................E
H
Perform inspections RA
according to Symptom
Matrix Chart.
BR
H H
TROUBLE DIAGNOSIS FOR DTC XX. STEP VI
ST
H
REPAIR/REPLACE RS
H
NG FINAL CHECK BT
Confirm that the incident is completely fixed by performing BASIC INSPECTION and
........................................... STEP VII
DTC CONFIRMATION PROCEDURE (or OVERALL FUNCTION CHECK). Then,
erase the unnecessary (already fixed) DTCs in ECM.
HA
OK
H
EL
CHECK OUT
*1: If the incident cannot be duplicated, refer to GI section (“Incident Simulation Tests”, “HOW TO PERFORM EFFICIENT
SE
DIAGNOSIS FOR AN ELECTRICAL INCIDENT”).
*2: If the on board diagnostic system cannot be performed, check main power supply and ground circuit. Refer to
“TROUBLE DIAGNOSIS FOR POWER SUPPLY”, EC-256.
IDX
EC-237
TROUBLE DIAGNOSIS — Work Flow RD28ETi
Description for Work Flow

STEP DESCRIPTION
Get detailed information about the conditions and the environment when the incident/symptom occurred using the
STEP I
“DIAGNOSTIC WORKSHEET” as shown on EC-236.
Before confirming the concern, check and write down (print out using CONSULT) the Diagnostic Trouble Code
(DTC), then erase the code. Refer to EC-223.
STEP II
Study the relationship between the cause, specified by DTC, and the symptom described by the customer. (The
“Symptom Matrix Chart” will be useful. Refer to EC-241.)
Try to confirm the symptom and under what conditions the incident occurs.
The “DIAGNOSTIC WORK SHEET” is useful to verify the incident. Connect CONSULT to the vehicle in DATA
STEP III MONITOR (AUTO TRIG) mode and check real time diagnosis results.
If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. Refer to GI section.
If the malfunction code is detected, skip STEP IV and perform STEP V.
Try to detect the Diagnostic Trouble Code (DTC) by driving in (or performing) the “DTC CONFIRMATION PROCE-
DURE”. Check and read the DTC by using CONSULT.
During the DTC verification, be sure to connect CONSULT to the vehicle in DATA MONITOR (AUTO TRIG) mode
and check real time diagnosis results.
STEP IV
If the incident cannot be verified, perform INCIDENT SIMULATION TESTS. Refer to GI section.
In case the “DTC CONFIRMATION PROCEDURE” is not available, perform the “OVERALL FUNCTION CHECK”
instead. The DTC cannot be displayed by this check, however, this simplified “check” is an effective alternative.
The “NG” result of the “OVERALL FUNCTION CHECK” is the same as the DTC detection.
Take the appropriate action based on the results of STEP I through IV.
If the malfunction code is indicated, proceed to TROUBLE DIAGNOSIS FOR DTC XX.
STEP V
If the normal code is indicated, proceed to the BASIC INSPECTION. Refer to EC-239. Then perform inspections
according to the Symptom Matrix Chart. Refer to EC-241.
Identify where to begin diagnosis based on the relationship study between symptom and possible causes. Inspect
the system for mechanical binding, loose connectors or wiring damage using (tracing) “Harness Layouts”.
Gently shake the related connectors, components or wiring harness with CONSULT set in “DATA MONITOR
(AUTO TRIG)” mode.
Check the voltage of the related ECM terminals or monitor the output data from the related sensors with CON-
STEP VI
SULT. Refer to EC-247.
The “DIAGNOSTIC PROCEDURE” in EC section contains a description based on open circuit inspection. A short
circuit inspection is also required for the circuit check in the DIAGNOSTIC PROCEDURE. For details, refer to GI
section (“Circuit Inspection”, “HOW TO PERFORM EFFICIENT DIAGNOSIS FOR AN ELECTRICAL INCIDENT”).
Repair or replace the malfunction parts.
Once you have repaired the circuit or replaced a component, you need to run the engine in the same conditions
and circumstances which resulted in the customer’s initial complaint.
Perform the “DTC CONFIRMATION PROCEDURE” and confirm the normal code (Diagnostic trouble code No. 55)
STEP VII is detected. If the incident is still detected in the final check, perform STEP VI by using a different method from the
previous one.
Before returning the vehicle to the customer, be sure to erase the unnecessary (already fixed) DTC in ECM. (Refer
to EC-223.)
EC-238
TROUBLE DIAGNOSIS — Basic Inspection RD28ETi
Basic Inspection GI
Precaution:
Perform Basic Inspection without electrical or mechanical MA
loads applied;
I Headlamp switch is OFF,
I Air conditioner switch is OFF, EM
I Rear defogger switch is OFF,
I Steering wheel is in the straight-ahead position, etc.
LC
BEFORE STARTING
SEF142I
1. Check service records for any recent
repairs that may indicate a related
problem, or the current need for sched-
uled maintenance.
2. Open engine hood and check the fol- FE
lowing:
I Harness connectors for improper con-
nections CL
I Vacuum hoses for splits, kinks, or
improper connections
I Wiring for improper connections,
pinches, or cuts
MT
3. Using priming pump, bleed air from fuel
SEF670V system. Refer to “DRAINING WATER”,
“Checking and Replacing Fuel Filter AT
and Draining Water” of “ENGINE MAIN-
TENANCE” in MA section.
TF
H
CONNECT CONSULT TO THE VEHICLE. PD
Connect “CONSULT” to the data link con-
nector for CONSULT and select “ENGINE”
from the menu. Refer to EC-229. FA
H
SEF669V
DOES ENGINE START?
No Turn ignition switch OFF,
RA
E
wait 5 seconds and then
Yes start engine. If engine fails
to start, check diagnostic BR
trouble code (DTC).
H
ST
Run engine for 10 minutes.
RS
H
CHECK IDLE SPEED.
SEF714V
-------------------------------------------------------------------------------------------------------------------------------------------------------- BT
Read engine idle speed in “DATA
MONITOR” mode with CONSULT.
------------------------------------------------------------------- OR -------------------------------------------------------------------
Check idle speed using tachom-
HA
eter tester.
--------------------------------------------------------------------------------------------------------------------------------------------------------
775±25 rpm EL
H
(Go to q
A on next page.) SE
SEF671V
IDX
EC-239
TROUBLE DIAGNOSIS — Basic Inspection RD28ETi
Basic Inspection (Cont’d)
q
A
H
OK
CHECK INJECTION TIMING. E I Bleed air from fuel sys-
1. Set No. 1 piston at TDC on its com- tem.
pression stroke. I After this inspection,
2. Remove injection tubes and air bleeder unnecessary diagnostic
on the back of injection pump. trouble code No. might
3. Set dial gauge so its indicator points to be displayed.
somewhere between 1.0 and 2.0 mm Erase the stored memory
(0.039 and 0.079 in) on the scale. in ECM.
4. Turn crankshaft 1 turn clockwise and Refer to “ON BOARD
SEF672V check that dial gauge indicates the DIAGNOSTIC SYSTEM
same value again. DESCRIPTION” (EC-
5. Turn crankshaft counterclockwise about 223) and “HOW TO
100 degrees, then turn crankshaft ERASE DTC” (EC-223).
clockwise slowly, and set dial gauge
indicator to 0 mm at the position it OK
stops. H
6. Turn crankshaft clockwise and set the INSPECTION END
injection timing mark on the crankshaft
pulley to the timing indicator.
7. Read plunger lift.
Plunger lift:
0.92±0.04 mm (0.0362±0.0016 in)
I When repeating the checking, start
with step 5.
SEF664V
NG
H
ADJUSTING E Go to .
1. If plunger lift is not within the specified
value, adjust by turning injection pump.
I If indication is smaller than the speci-
fied value, turn pump body away
from engine.
I If indication is larger than the speci-
fied value, turn pump body towards
engine.
SEF673V
2. Tighten injection pump securing bolts
and nuts.
Nut:
: 16 - 21 N⋅m
(1.6 - 2.1 kg-m, 12 - 15 ft-lb)
Bolt:
: 22 - 29 N⋅m
(2.2 - 3.0 kg-m, 16 - 22 ft-lb)
3. Remove dial gauge and install air
bleeder with new washer.
4. Install injection tubes.
Flare nut:
: 22 - 25 N⋅m
(2.2 - 2.5 kg-m, 16 - 18 ft-lb)
5. Bleed air from fuel system.
SEF666V Refer to “DRAINING WATER”, “Check-
ing and Replacing Fuel Filter and
Draining Water” of “ENGINE MAINTE-
NANCE” in MA section.
EC-240
TROUBLE DIAGNOSIS — General Description RD28ETi
Symptom Matrix Chart GI

SYMPTOM
MA

EM
LC
ENGINE STALL
ABNORMAL SMOKE COLOR

OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE
SYSTEM FE
— Basic engine
control system
HARD TO START WHEN ENGINE IS COLD
HARD TO START WHEN ENGINE IS HOT
CL
DEAD BATTERY (UNDER CHARGE)


MT
Malfunction indicator lamp illuminates.

NO START (without first firing)

NO START (with first firing)
Feature of symptom, Check point

Can be detected by CONSULT?
ROUGH IDLE/HUNTING
WHEN DECELERATING
POOR ACCELERATION
KNOCK/DETONATION
AT
IDLING VIBRATION
DURING DRIVING
LACK OF POWER
BLACK SMOKE
WHITE SMOKE
TF
LOW IDLE
Reference page
AT IDLE
HI IDLE
PD
Fuel cut
Warranty symptom
AA AB AC AD AE AF AG AH AJ AK AL AM AP HA
code
Injection Advanced q q I I q I q q I q EC-239 FA

timing
Retarded q q I I q I q q I q EC-239
Electric injection pump

I I I I q q q q q I q q q I I q q I q q q q — *1 RA
mainframe
Injection nozzle q q q q q q q I q q q I I I EC-215 *2
Glow system q q I I I I EC-344

BR
Engine body EM sec-
q q I I q q q I q q q I I q q q I tion
*3
ST
EGR system I I I EC-349
Air cleaner and ducts MA sec-

I I I q
tion
*4
RS
I ; High Possibility Item
q ; Low Possibility Item
*1: Insufficient or excess amount. Governor malfunction may be the cause. BT
*2: Depends on open-valve pressure and spray pattern.
*3: Caused mainly by insufficient compression pressure.
*4: Symptom varies depending on off-position of air duct, etc.
HA
EL
SE
IDX
EC-241
SYMPTOM
HI IDLE
Fuel cut
LOW IDLE
ENGINE STALL
HARD/NO START/
LACK OF POWER
IDLING VIBRATION
RESTART (EXCP. HA)

KNOCK/DETONATION
POOR ACCELERATION
ROUGH IDLE/HUNTING

AT IDLE
page
SYSTEM
Malfunction
Reference
Check point
DURING DRIVING
Feature of symptom
— ENGINE CONTROL system

WHEN DECELERATING


WHITE SMOKE
BLACK SMOKE

Warranty symptom code AA AB AC AD AE AF AG AH AJ AK AL AM AP HA
Camshaft position sensor (PUMP) cir- open, short q q Tachometer malfunction
cuit EC-262
noise q q q q q q
open, ground short q q q q
Mass air flow sensor circuit EC-267
short q q q
Compensation according to
EC-242
Engine coolant temperature sensor open, short q q q q q q q q EC-272 engine coolant temperature does
circuit not function.
Vehicle speed sensor circuit open, short q q EC-276
Control sleeve position sensor circuit open, short q q q q q q EC-280
Adjustment resistor circuit open, short q q q q q q q q EC-285
open, ground short q q q q q q q
Electric governor circuit EC-289
short q q
open, short q q q Injection timing cannot be con-
Injection timing control valve circuit EC-294 trolled.
ground short q q
open, short q q q
Accelerator switch (FC) circuit EC-299
ground short q q
ENGINE CONTROL
Charge air temperature sensor circuit open, short q EC-315
Needle lift sensor circuit open, short q q q EC-319
TROUBLE DIAGNOSIS — General Description
open, ground short q q q q q

Fuel cut solenoid valve circuit EC-323 Engine runs on after turning igni-
short q q q tion switch OFF.
Compensation for amount of fuel
Fuel temperature sensor circuit open, short q q q q q q q q q q EC-328 injected according to fuel tem-
perature does not function.
Accelerator position sensor circuit open, short q q q q q EC-332
Crankshaft position sensor (TDC) cir- open, short q q q q
cuit EC-337
noise q q q q q
RD28ETi
SYMPTOM
HI IDLE
Fuel cut
LOW IDLE
ENGINE STALL
HARD/NO START/
LACK OF POWER
IDLING VIBRATION
RESTART (EXCP. HA)

KNOCK/DETONATION
POOR ACCELERATION
ROUGH IDLE/HUNTING

AT IDLE
SYSTEM
Malfunction
Check point
Reference page
DURING DRIVING
Feature of symptom
— ENGINE CONTROL system

WHEN DECELERATING


WHITE SMOKE
BLACK SMOKE

Warranty symptom code AA AB AC AD AE AF AG AH AJ AK AL AM AP HA
Start signal circuit open, short q q EC-356 Start control does not function.
open, short q q q
Neutral position switch circuit EC-363
ground short q q
open, ground short q q q
Accelerator position switch (Idle) cir- EC-358
cuit short q q q q q Accelerator position sensor NG
EC-243
signal is output.
Accelerator position switch (Full) cir-
cuit open, short q q q q q EC-358
open q q q q
Ignition switch circuit EC-256
short Engine does not stop.
open q q q
Power supply for ECM circuit EC-256
short q q
open, short Does not operate.
Throttle control solenoid valve circuit EC-349
ground short q q q Does not stop operating.
open, short
EGRC-solenoid valve A, B circuit EC-349
ground short q Does not stop operating.
open q q q q q Glow lamp does not turn on.
ENGINE CONTROL
Glow relay circuit EC-344
short Glow lamp does not turn off.
open q q q q
ECCS relay (Self-shutoff) circuit EC-256 Ground short makes engine
short q q
TROUBLE DIAGNOSIS — General Description
unable to stop.
ECM, Connector circuit open, short q q q q q q q q q q q q q q q q q q q q q q q q q EC-304
open Air conditioner does not operate.
Air conditioner relay circuit EC-380 Air conditioner does not stop
short
operating.
Air conditioner does not stop
open, ground short operating.
Air conditioner switch circuit EC-380
short Air conditioner does not work.
RD28ETi
GI
TF
AT
EL
FE
ST
FA
SE
BT
CL
LC
RS
RA
PD
HA
BR
MT
EM
MA
IDX

Mode
Remarks:
I Specification data are reference values.
I Specification data are output/input values which are detected or supplied by the ECM at the connector.
* Specification data may not be directly related to their components signals/values/operations.
CKPS⋅RPM (TDC)
I Tachometer: Connect Almost the same speed as the CON-
CKPS⋅RPM (REF)
I Run engine and compare tachometer indication with the CONSULT value. SULT value.
CMPS⋅RPM-PUMP
COOLAN TEMP/S I Engine: After warming up More than 70°C (158°F)
Almost the same speed as

VHCL SPEED SE I Turn drive wheels and compare speedometer indication with the CONSULT value
the CONSULT value
FUEL TEMP SEN I Engine: After warming up More than 40°C (104 °F)
I Ignition switch: ON Accelerator pedal: released 0.40 - 0.60V

ACCEL POS SEN
(Engine stopped) Accelerator pedal: depressed Approx. 4.0V
I Ignition switch: ON Accelerator pedal: depressed ON

FULL ACCEL SW
(Engine stopped) Except above OFF
I Ignition switch: ON Accelerator pedal: released CLOSE

ACCEL SW (FC)
(Engine stopped) Accelerator pedal: slightly open OPEN
I Ignition switch: ON Accelerator pedal: released ON

OFF ACCEL SW
(Engine stopped) Accelerator pedal: slightly open OFF
C/SLEEV POS/S I Engine: After warming up 1.0 - 3.5V
BATTERY VOLT I Ignition switch: ON (Engine stopped) 11 - 14V
Shift lever: Neutral/Park ON

Except above OFF
START SIGNAL I Ignition switch: ON , START , ON OFF , ON , OFF
Air conditioner switch: OFF OFF

AIR COND SIG Air conditioner switch: ON
engine ON
IGN SW I Ignition switch: ON , OFF ON , OFF
Heat up switch: ON ON
WARM UP SW I Ignition switch: ON
Heat up switch: OFF OFF

I Air conditioner switch: OFF
MAS AIR/FL SE Idle 1.6 - 2.0V
I Shift lever: “N”
I No-load
I Engine: After warming up Idle −9.5 to −12.0°

ACT INJ TIMG
I No-load 2,000 rpm −10.0 to −15.5°
INJ TIMG C/V I Engine: After warming up, idle the engine. Approx. 50%
Idle OFF
DECELER F/CUT I Engine: After warming up When accelerator pedal is released

quickly with engine speed at 3,000 rpm ON
or more.
FUEL CUT S/V I Ignition switch: ON , OFF ON , OFF
GLOW RLY I Refer to EC-344.
EC-244
Mode (Cont’d) GI
I When cooling fan is stopped. OFF

MA
COOLING FAN
I When cooling fan operates. ON
I When charge air cooler fan is stopped. OFF EM

I/C FAN RLY
I When charge air cooler fan operates. ON
I Engine: After warming up Idle ON LC

EGRC SOL/V A
I No-load Revving engine from idle to 3,750 rpm OFF
I Engine: After warming up Idle ON

EGRC SOL/V B
I No-load Revving engine from idle to 2,600 rpm OFF FE
THROT RLY
I Shift lever: “N” CL
I No-load Revving engine from idle to 2,500 rpm OFF
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-245

Mode
The following are the major sensor reference graphs in “DATA MONITOR” mode.
(Select “HI SPEED” in “DATA MONITOR” with CONSULT.)
ACCEL POS SEN, C/SLEEV POS/S, ACT INJ TIMG

Below is the data for “ACCEL POS SEN”, “C/SLEEV POS/S” and “ACT INJ TIMG” when revving engine quickly
up to 3,000 rpm under no load after warming up engine sufficiently.
Each value is for reference, the exact value may vary.
SEF663S
EC-246
ECM Terminals and Reference Value GI

PREPARATION
1. ECM is located behind the instrument lower panel. For this MA
inspection, remove the driver’s side instrument lower cover.
EM
LC
SEF519V
2. Remove ECM harness protector.
FE
CL
MT
AEC913
AT
3. Perform all voltage measurements with the connector con-
nected. Extend tester probe as shown to perform tests easily.
I Open harness securing clip to make testing easier. TF
I Use extreme care not to touch 2 pins at one time.
I Data is for comparison and may not be exact.
PD
FA
RA
BR
ST
RS
SEF367I BT
Be sure ECM unit is properly grounded before checking.
HA
EL
SE
SEF665S
IDX
EC-247
ECM HARNESS CONNECTOR TERMINAL LAYOUT
SEF064P
ECM INSPECTION TABLE

43 (ECM
ground) with a voltmeter.
TER- DATA
WIRE
MINAL ITEM CONDITION (DC Voltage and Pulse
COLOR
NO. Signal)

Approximately 0.4V
Throttle control solenoid Idle speed
1 W
valve Engine is running. (Warm-up condition) BATTERY VOLTAGE
Revving engine from idle to 2,500 rpm (11 - 14V)


BATTERY VOLTAGE
switch “OFF”
Approximately 1.0 - 2.0V
Idle speed
SEF715V
5 Y/B Tachometer
Approximately 1.0 - 2.0V
SEF716V
EC-248
TER- DATA
GI
WIRE
COLOR
NO. Signal)
MA
(11 - 14V)
Charge air cooler fan Charge air cooler fan is not operating. EM
8 G/OR
relay Engine is running.
0 - 1V
Charge air cooler fan is operating. LC
Approximately 0 - 4.8V
10 P Fuel temperature sensor Engine is running. Output voltage varies with
fuel temperature.
Engine is running. BATTERY VOLTAGE FE

14 L Cooling fan relay
Engine is running. CL
0 - 1V
Engine is running.
MT
BATTERY VOLTAGE
AT
15 Y/L Air conditioner relay Engine is running.
Both air conditioner switch and blower fan 0 - 1V

switch are “ON”.
TF
(Compressor is operating.)
Ignition switch “ON” PD

0 - 1.5V
Glow lamp is “ON”.
16 L/W Glow lamp FA
Glow lamp is “OFF”. (11 - 14V)
RA
Ignition switch “ON” 0 - 1.5V
18 G Malfunction indicator lamp Engine is running. BATTERY VOLTAGE BR

Idle speed (11 - 14V)
Approximately 0 - 4.8V ST
Engine coolant tempera- Output voltage varies with
19 LG/R Engine is running.
ture sensor engine coolant tempera-
ture. RS
Ignition switch “ON” Approximately 0V
20 R/W Start signal BT
BATTERY VOLTAGE
(11 - 14V)
Engine is running.
HA
BATTERY VOLTAGE
EL
21 LG/B Air conditioner switch Engine is running.
Both air conditioner switch and blower fan Approximately 0V

switch are “ON”. SE
IDX
EC-249
TER- DATA
WIRE
COLOR
NO. Signal)

Approximately 0V
Gear position is “N” or “P” (A/T models).
Inhibitor switch/Neutral Gear position is “Neutral” (M/T models).
22 P/B
position switch
Except the above gear position (11 - 14V)

0.4 - 0.6V
Accelerator position sen- Accelerator pedal fully released
23 W
sor Ignition switch “ON”
Approximately 4.3V
Engine is running.
24 PU/W A/T signal No. 1 6 - 8V
Idle speed
0 - BATTERY VOLTAGE
(11 - 14V)
Engine is running.
26 L/OR Vehicle speed sensor Lift up the vehicle.

In 1st gear position
Vehicle speed is 40 km/h.
SEF717V
28 Camshaft position sensor Engine is running. (Warm-up condition)

B Approximately 0V
33 (PUMP) ground Idle speed

Accelerator pedal fully released (11 - 14V)
29 R/L Accelerator switch (F/C)
Approximately 0V
Accelerator pedal depressed
Engine is running.
30 P A/T signal No. 3 Approximately 0V
Idle speed

Accelerator position switch
31 R/L
(Idle) Ignition switch “ON”
Approximately 0V

Approximately 0V
Accelerator position switch Accelerator pedal released
32 W/G
(Full) Ignition switch “ON” BATTERY VOLTAGE
Accelerator pedal fully depressed (11 - 14V)
EC-250
TER- DATA
GI
WIRE
COLOR
NO. Signal)
MA
Approximately 0V
EM
Idle speed
LC
SEF718V
34 W Needle lift sensor
Approximately 0V FE
Engine is running. (Warm-up condition) CL

MT
SEF719V
AT
35 R Mass air flow sensor 1.6 - 2.0V
Idle speed
TF
Charge air temperature
36 LG Engine is running. Output voltage varies with
sensor
charge air temperature. PD
Engine is running.
37 P/B A/T signal No. 2 6 - 8V FA
Idle speed
Ignition switch “OFF” 0V

RA
38 B/Y Ignition switch BATTERY VOLTAGE
(11 - 14V)
BR
Engine ground
39 Engine is running. (Probe this terminal with
B ECM ground
43 Idle speed @ tester probe when ST
measuring.)
RS
BT
HA
EL
SE
IDX
EC-251
TER- DATA
WIRE
COLOR
NO. Signal)
Approximately 0V
Idle speed
SEF720V
40 Crankshaft position sensor
L
44 (TDC) Approximately 0V
SEF721V
Approximately 0V
Idle speed
SEF722V
W
45 (PUMP) Approximately 0V
SEF723V
42 L/G Approximately 0V
Engine is running.
Data link connector for
64 Y/G Idle speed (CONSULT is connected and Approximately 0 - 12V
CONSULT
turned on)
65 Y/R Approximately 0 - 9V
(Voltage varies with part
46 Y Adjustment resistor Ignition switch “ON”
number of adjustment
resistor.)
47 Crankshaft position sensor Engine is running. (Warm-up condition)

B/W Approximately 0V
52 (TDC) ground Idle speed
Accelerator position sen-

48 G/R Ignition switch “ON” Approximately 5V
sor power supply
EC-252
TER- DATA
GI
WIRE
COLOR
NO. Signal)
MA
Sensor’s power signal to
TCM
EM
Idle speed LC
Accelerator position sen- Engine is running. (Warm-up condition)
51 L/W Approximately 0V
Approximately 2.6V
FE
53 Control sleeve position Engine is running.

57
W
sensor power supply
CL
Idle speed
MT
SEF724V
56 BATTERY VOLTAGE AT
W Power supply for ECM Ignition switch “ON”
61 (11 - 14V)
Ignition switch “ON” TF

0V
Heat up switch is “OFF”.
59 BR/W Heat up switch
PD
Heat up switch is “ON”. (11 - 14V)
Approximately 2.6V
FA
RA
B
66 sensor ground Idle speed BR
SEF725V ST
Approximately 2.6V
RS

R BT
67 sensor Idle speed
HA
SEF726V
Ignition switch “ON” EL

0.4 - 0.6V
68 B/W SE
sor signal to TCM Ignition switch “ON”
Approximately 4.3V
IDX
EC-253
TER- DATA
WIRE
COLOR
NO. Signal)
BATTERY VOLTAGE
70 BR Power supply (Back-up) Ignition switch “OFF”
(11 - 14V)
101 Engine is running. BATTERY VOLTAGE

R/B Electric governor
107 Idle speed (11 - 14V)
Approximately 10V
Engine is running.
Idle speed
SEF727V
102
G/Y Electric governor ground
108 Approximately 10V
Engine is running.
SEF728V

0 - 1V
Idle speed
103 L/Y EGRC-solenoid valve A
Engine is running. (Warm-up condition) BATTERY VOLTAGE
Engine is revving from idle up to 3,750 rpm. (11 - 14V)
BATTERY VOLTAGE
(11 - 14V)
Idle speed
SEF729V
104 Injection timing control
L/W
110 valve BATTERY VOLTAGE
(11 - 14V)
SEF730V
EC-254
TER- DATA
GI
WIRE
COLOR
NO. Signal)
MA
106 Engine is running.
112 B ECM ground Approximately 0V
118 Idle speed EM
0 - 1V LC
Idle speed
109 BR/Y EGRC-solenoid valve B
Engine is revving from idle up to 2,600 rpm. (11 - 14V)
111 LG/B Glow relay Refer to “Glow Control System”, EC-344. FE

Ignition switch “OFF” Approximately 0V
113
115
R/W Fuel cut solenoid valve BATTERY VOLTAGE CL
(11 - 14V)
116 BATTERY VOLTAGE MT

117 (11 - 14V)
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-255
TROUBLE DIAGNOSIS FOR POWER SUPPLY RD28ETi

43 (ECM
TER- DATA
WIRE
COLOR
NO. Signal)


BATTERY VOLTAGE
switch “OFF”
Ignition switch “OFF” 0V

38 B/Y Ignition switch BATTERY VOLTAGE
(11 - 14V)
Engine ground
39 Engine is running. (Probe this terminal with
B ECM ground
43 Idle speed @ tester probe when
measuring.)
56 BATTERY VOLTAGE
61 (11 - 14V)
BATTERY VOLTAGE
70 BR Power supply (Back-up) Ignition switch “OFF”
(11 - 14V)
106 Engine is running.

112 B ECM ground Approximately 0V
118 Idle speed
116 BATTERY VOLTAGE

117 (11 - 14V)
EC-256
(Cont’d) GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC421
EC-257
(Cont’d)
TEC422
EC-258
(Cont’d) GI
INSPECTION START
MA
H
No
Start engine. CHECK POWER SUP-
Is engine running?
E
PLY-I. EM
Yes “ON”.
2. Check voltage between LC
ECM terminal q38 and
ground with CONSULT
SEF065P or tester.
Voltage: Battery volt-
age
If NG, check the following.
M51 , F6
I 10A fuse
FE
fuse CL
connectors.
H
OK MT
Go to “CHECK
SEF056R GROUND CIRCUIT” on
EC-261. AT
H
NG
CHECK POWER SUPPLY-II. E Check the following. TF
2. Check voltage between ECM terminal E127 , M21
q
70 and ground with CONSULT or tester. I Harness connectors
Voltage: Battery voltage M52 , F7
I 7.5A fuse
PD
OK I Harness for open or
battery
FA
connectors.
SEF566S
H RA
OK
CHECK POWER SUPPLY-III. E Go to “CHECK
1. Turn ignition switch “ON” and then GROUND CIRCUIT” on
“OFF”. EC-261. BR
q56 , q
61 , 116 , 117 and ground with
CONSULT or tester.
Voltage: Case-1: Battery voltage does ST
After turning ignition switch “OFF”, not exist.
battery voltage will exist for a few Case-2: Battery voltage exists
seconds, then drop to approximately for more than a few
0V. seconds. RS
NG
SEF567S Case-2 BT
Case-1 E Go to “CHECK ECCS
RELAY” on next page.
H
q
A HA
EL
SE
IDX
EC-259
(Cont’d)
q
A
H
CHECK HARNESS CONTINUITY NG Check the following.
E
BETWEEN ECCS RELAY AND ECM. I Harness connectors
2. Disconnect ECCS relay. I Harness connectors
terminals q56 , q
61 and relay terminal q
7 , I Harness for open or
SEF513V and ECM terminals 116 , 117 and short between ECM and
relay terminal q 5 . ECCS relay
Continuity should exist. If NG, repair open circuit or
nectors.
OK
H
CHECK VOLTAGE BETWEEN ECCS NG Check the following.
E
RELAY AND GROUND. I Harness connectors
Check voltage between relay terminals E127 , M21
q1 ,q3 ,q6 and ground with CONSULT or I 15A fuse
SEF569S tester. I Harness for open or
Voltage: Battery voltage short between ECCS
relay and battery
OK
connectors.
H
E
Check harness continuity between ECM I Harness connectors
terminal q
4 and relay terminal q 2 . M52 , F7
If OK, check harness for short to ground short between ECM and
SEF030S and short to power. ECCS relay
If NG, repair open circuit or
OK
nectors.
H
CHECK ECCS RELAY. NG Replace ECCS relay.
E
1. Apply 12V direct current between relay
terminals q
1 and q 2 .
2. Check continuity between relay termi-
nals q
3 and q 5 ,q7 and q 6 .
SEC202B 12V (q1 -q 2 ) applied:
Continuity exists.
No voltage applied:
No continuity
OK
H
q
B
EC-260
(Cont’d) GI
q
B
MA
H
E
1. Turn ignition switch “OFF”. I Joint connector F18 EM
2. Disconnect ECM harness connector. I Harness for open or
terminals q39 , q
43 , 106 , 112 , 118 and ground LC
engine ground. If NG, repair open circuit or
SEF570S Continuity should exist. short to ground or short to
If OK, check harness for short to power in harness or con-
ground and short to power. nectors.
OK
H FE
connector. CL
H
MT
INSPECTION END
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-261
TROUBLE DIAGNOSIS FOR “CAM POS SEN (PUMP)”
(DTC 11) RD28ETi
Camshaft Position Sensor (CMPS) (PUMP)

The camshaft position sensor (PUMP) is located on the electronic
fuel injection pump.
The sensor consists of a permanent magnet, core and coil.
When engine is running, gap between sensor and drive shaft rotat-
ing plate will periodically change. Permeability near the sensor also
changes.
Due to the permeability change, the magnetic flux near the core is
changed. Therefore, the voltage signal generated in the coil is
changed.
SEF674V The ECM receives the voltage signal (6 pulses/2 engine revolu-
tions).
These signals are used for tachometer indication.

CKPS⋅RPM (REF) I Tachometer: Connect

Almost the same speed as the
I Run engine and compare tachometer indication with the CONSULT
CKPS⋅RPM-PUMP CONSULT value.
value.

43 (ECM
TER- DATA
WIRE
COLOR
NO. Signal)
28 Camshaft position sensor Engine is running. (Warm-up condition)

B Approximately 0V
33 (PUMP) ground Idle speed
Approximately 0V
Idle speed
SEF722V
W
45 (PUMP) Approximately 0V
SEF723V
EC-262
(DTC 11) RD28ETi
(Cont’d) GI
Diagnostic
MA
Check Items
(Possible cause)
No.
11 I An improper signal from the sensor is detected by I Harness or connectors
EM
ECM during engine running. [The camshaft position sensor (PUMP) circuit is open
or shorted.]
I Camshaft position sensor (PUMP) LC

PROCEDURE
1) Turn ignition switch “ON” and select “DATA MONITOR” FE
mode with CONSULT.
speed. CL
---------------------------------------------------------------------------------------------------------------------------- OR ---------------------------------------------------------------------------------------------------------------------------- MT
SEF714V speed.
(If engine does not run, turn ignition switch to “START” AT
then “ON”. TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-263
(DTC 11) RD28ETi
(Cont’d)
TEC423
EC-264
(DTC 11) RD28ETi
(Cont’d) GI
INSPECTION START MA
EM
H
NG
Repair open circuit or short
1. Turn ignition switch “OFF”. to ground or short to power LC
2. Disconnect electronic fuel injection in harness or connectors.
SEF675V pump harness connector and ECM har-
ness connector.
minal q1 and ECM terminals q 41 , q
45 .
If OK, check harness for short to FE
OK CL
H
NG
CHECK GROUND CIRCUIT-I. E
Repair open circuit or short MT
2. Check harness continuity between ter- in harness or connectors.
SEF731V minal q2 and ECM terminals q 28 , q
33 .
AT
TF
OK
H PD
NG
CHECK GROUND CIRCUIT-II. E
1. Loosen and retighten engine ground I Joint connector F19
screws. I Harness for open or FA
2. Check harness continuity between ter- short between electronic
minal q3 and engine ground. fuel injection pump and
Continuity should exist. engine ground
SEF732V
If OK, check harness for short to If NG, repair harness or
RA
ground and short to power. connectors.
OK BR
H
NG
CHECK COMPONENT E
Replace camshaft position
[Camshaft position sensor (PUMP)]. sensor (PUMP). ST
next page.
OK RS
H
SEF676V tors in the circuit. Then retest. BT
H
HA
retest. EL
H
INSPECTION END
SE
SEF733V
IDX
EC-265
(DTC 11) RD28ETi
(Cont’d)
Camshaft position sensor (PUMP)
1. Disconnect electronic fuel injection pump harness connector.
2. Loosen the camshaft position sensor (PUMP).
3. Remove the sensor.
4. Visually check the sensor for chipping.
SEF573S
5. Check resistance between terminals q 1 and q2 .

Resistance:
Approximately 1,360 - 1,840Ω [at 25°C (77°F)]
If NG, replace camshaft position sensor (PUMP).
SEF677V
EC-266
TROUBLE DIAGNOSIS FOR “MASS AIR FLOW SEN”
(DTC 12) RD28ETi
Mass Air Flow Sensor (MAFS) GI

The mass air flow sensor is placed in the stream of intake air. It MA
measures the intake air flow rate by measuring a part of the entire
intake air flow. It consists of a hot wire that is supplied with electric
current from the ECM. The temperature of the hot wire is controlled EM
by the ECM a certain amount. The heat generated by the hot wire
is reduced as the intake air flows around it. The more air, the
greater the heat loss. LC
Therefore, the ECM must supply more electric current to the hot
SEF734V wire as air flow increases. This maintains the temperature of the hot
wire. The ECM detects the air flow by means of this current change.

MONITOR ITEM CONDITION SPECIFICATION CL
MAS AIR/FL SE Idle 1.6 - 2.0V
I Shift lever: “N” MT
I No-load
AT
43 (ECM
TF
TER-
MINAL
WIRE
ITEM CONDITION
DATA PD
COLOR (DC voltage)
NO.
Engine is running. (Warm-up condition) FA
35 R Mass air flow sensor 1.6 - 2.0V
Idle speed
Engine is running. (Warm-up condition) RA
Idle speed
BR
ST
Diagnostic
Check Items
(Possible Cause)
Code No. RS
sent to ECM. (The sensor circuit is open or shorted.)
I Mass air flow sensor BT
HA
EL
SE
IDX
EC-267
(DTC 12) RD28ETi
PROCEDURE
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
then turn “ON”.
EC-268
(DTC 12) RD28ETi
GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC424
EC-269
(DTC 12) RD28ETi
INSPECTION START
H
NG
2. Disconnect mass air flow sensor har- M52 , F7
ness connector. I Harness for open or
3. Turn ignition switch “ON”. short between mass air
4. Check voltage between terminal q1 and flow sensor and ECM
SEF713V ground with CONSULT or tester. I Harness for open or
Voltage: Battery voltage short between mass air
flow sensor and ECCS
OK relay
connector.
H
NG
2. Loosen and retighten engine ground E106 , M88
screws. I Harness connectors
3. Check harness continuity between ter- M51 , F6
minal q2 and engine ground. I Harness for open or
SEF736V Continuity should exist. short between mass air
If OK, check harness for short to flow sensor and ECM
ground and short to power. I Harness for open or
short between mass air
OK flow sensor and TCM
nectors.
H
NG
CHECK INPUT SIGNAL CIRCUIT. E Repair open circuit or short
1. Disconnect ECM harness connector. to ground or short to power
2. Check harness continuity between ter- in harness or connectors.
SEF676V
minal q3 and ECM terminal q 35 .
OK
H
NG
CHECK COMPONENT E Replace mass air flow sen-
(Mass air flow sensor). sor.
next page.
OK
H
SEF737V nectors in the circuits. Then retest.

H
nector and retest.
H
INSPECTION END
SEF738V
EC-270
(DTC 12) RD28ETi
1. Start engine and warm it up to normal operating temperature. MA
2. Check voltage between ECM terminal q 35 and ground under the
following condition.
EM
Conditions Voltage V
Ignition switch “ON” (Engine stopped.) Less than 1.0
Idle (Engine is warmed-up to normal operating tem-
LC
1.0 - 1.7
perature.)
SEF739V
2,500 rpm Approximately 2.1
Idle to about 4,000 rpm* 1.0 - 1.7 to Approx. 4.0
*: Check for linear voltage rise in response to increase to about 4,000 rpm in engine
speed. FE
3. If NG, remove mass air flow sensor from air duct. Check hot
wire for damage and dust. CL
MT
SEF740V
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-271
TROUBLE DIAGNOSIS FOR “COOLANT TEMP SEN”
(DTC 13) RD28ETi
Engine Coolant Temperature (ECT) Sensor

The engine coolant temperature sensor is used to detect the engine
coolant temperature. The sensor modifies a voltage signal from the
ECM. The modified signal returns to the ECM as the engine cool-
ant temperature input. The sensor uses a thermistor which is sen-
sitive to the change in temperature. The electrical resistance of the
thermistor decreases as temperature increases.
SEF594K
<Reference data>
Voltage* Resistance
ture
(V) (kΩ)
°C (°F)
−10 (14) 4.4 7.0 - 11.4
20 (68) 3.5 2.1 - 2.9
50 (122) 2.3 0.68 - 1.00
90 (194) 1.0 0.236 - 0.260
SEF012P *: These data are reference values and measured between ECM terminal q 19
(Engine coolant temperature sensor) and ECM terminal q
43 (ECM ground).
Diagnostic
Check Items
(Possible Cause)
No.
entered to ECM. (The sensor circuit is open or shorted.)

PROCEDURE
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
then turn “ON”.
SEF741V results)” with ECM.
EC-272
(DTC 13) RD28ETi
(Cont’d) GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC425
EC-273
(DTC 13) RD28ETi
(Cont’d)
INSPECTION START
H
NG
2. Disconnect engine coolant temperature E202 , E69
sensor harness connector. I Harness connectors
SEF678V 3. Turn ignition switch “ON”. E127 , M21
2 and I Harness connectors
ground with CONSULT or tester. M51 , F6
Voltage: I Harness for open or
Approximately 5V short between ECM and
OK ture sensor
connectors.
H
NG
2. Check harness continuity between ter- E202 , E69
minal q1 and engine ground. I Harness connectors
SEF541P
Continuity should exist. E127 , M21
ground and short to power. M50 , F5
OK F6 , M51
M88 , E106
ture sensor
SEF542P ture sensor
nectors.
H
NG
CHECK COMPONENT E Replace engine coolant
(Engine coolant temperature sensor). temperature sensor.
on next page.
OK
H

H
nector and retest.
H
INSPECTION END
EC-274
(DTC 13) RD28ETi
(Cont’d) GI
Engine coolant temperature sensor MA

EM
20 (68) 2.1 - 2.9
50 (122) 0.68 - 1.0 LC
SEF152P 90 (194) 0.236 - 0.260
If NG, replace engine coolant temperature sensor.
FE
CL
MT
SEF012P
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-275
TROUBLE DIAGNOSIS FOR “VEHICLE SPEED SEN”
(DTC 14) RD28ETi
Vehicle Speed Sensor (VSS)

The vehicle speed sensor is installed in the transaxle. It contains a
pulse generator which provides a vehicle speed signal to the
speedometer. The speedometer then sends a signal to the ECM.
AEC110

43 (ECM
TER- DATA
WIRE
COLOR
NO. Signal)
0 - BATTERY VOLTAGE
(11 - 14V)
Engine is running.
26 L/OR Vehicle speed sensor Lift up the vehicle.

In 1st gear position
Vehicle speed is 40 km/h (25 MPH).
SEF717V

Diagnostic
Check Items
(Possible Cause)
No.
14 I The almost 0 km/h (0 MPH) signal from vehicle speed I Harness or connector
sensor is sent to ECM even when vehicle is being (The vehicle speed sensor circuit is open or shorted.)
driven. I Vehicle speed sensor
EC-276
(DTC 14) RD28ETi
OVERALL FUNCTION CHECK GI
Use this procedure to check the overall function of the vehicle
speed sensor circuit. During this check, a DTC might not be con-
firmed. MA
1) Jack up drive wheels.
2) Start engine.
3) Read vehicle speed sensor signal in “DATA MONITOR” EM
mode with CONSULT.
The vehicle speed on CONSULT should be able to
exceed 10 km/h (6 MPH) when rotating wheels with suit-
LC
SEF941N able gear position.
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
1) Jack up drive wheels.
2) Start engine.
3) Rotate drive wheel by hand. FE
4) Check voltage between ECM terminal q 26 and ground
with tester.
Voltage should vary between 0V - battery voltage. CL
MT
SEF811R
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-277
(DTC 14) RD28ETi
TEC426
EC-278
(DTC 14) RD28ETi
INSPECTION START
MA
H EM
E
2. Disconnect ECM harness connector M52 , F7 LC
and combination meter harness con- I Joint connector M79
SEF742V nector. I Harness for open or
terminal q26 and meter terminal q
26 . combination meter
If OK, check harness for short to short to ground or short to FE
nectors.
OK
CL
H
CHECK SPEEDOMETER FUNCTION. NG Check the following.
E
Make sure that speedometer functions I Harness connectors MT
properly. M86 , E104 (LHD mod-
els)
OK
I Harness connectors AT
M21 , E127 (RHD mod-
els)
I Harness connectors TF
E70 , E201
short between combina- PD
tion meter and vehicle
speed sensor
If NG, repair open circuit or FA
nectors. RA
Check vehicle speed sen-
sor and its circuit.
Refer to EL section. BR
H
Disconnect and reconnect harness con- ST

H
check the connection of ECM harness BT
nector and retest.
HA
H
INSPECTION END EL
SE
IDX
EC-279
TROUBLE DIAGNOSIS FOR “CONT SLEEV POS SEN”
(DTC 15) RD28ETi
Control Sleeve Position Sensor (CSPS)

The control sleeve position sensor is installed on the electric gov-
ernor. It senses the position of control sleeve (rotor angle) while the
control sleeve is being driven by the electric governor, and feeds it
back to the ECM.
SEF743V

C/SLEEV POS/S I Engine: After warming up 1.0 - 3.5V

43 (ECM
TER- DATA
WIRE
COLOR
NO. Signal)
Approximately 2.6V

W
57 sensor power supply Idle speed
SEF724V
Approximately 2.6V

B
66 sensor ground Idle speed
SEF725V
Approximately 2.6V

R
67 sensor Idle speed
SEF726V
EC-280
(DTC 15) RD28ETi
Control Sleeve Position Sensor (CSPS) (Cont’d)
ON BOARD DIAGNOSIS LOGIC GI
Diagnostic
Check Items
Trouble Code Malfunction is detected when .... MA
(Possible cause)
No.
detected by ECM. (The control sleeve position sensor circuit is open or EM
........................................................................................... shorted.)
I An improper voltage signal from the sensor is detected I Control sleeve position sensor
by ECM during engine running. LC

PROCEDURE
1) Turn ignition switch “ON” and select “DATA MONITOR” FE
mode with CONSULT.
speed. CL
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
speed. MT
SEF714V then “ON”.
3) Perform “Diagnostic Test Mode II (Self-diagnostic AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-281
(DTC 15) RD28ETi
TEC427
EC-282
(DTC 15) RD28ETi
INSPECTION START
MA
H
CHECK POWER SUPPLY CIRCUIT. NG Repair open circuit or short EM
E
2. Disconnect ECM harness connector in harness or connectors.
and electronic fuel injection pump har- LC
ness connector.
SEF679V 3. Check harness continuity between ter-
minal q2 and ECM terminals q 53 , q
57 .
ground and short to power. FE
OK
H CL
CHECK INPUT SIGNAL CIRCUIT. NG Repair open circuit or short
E
Check harness continuity between sensor to ground or short to power
terminal q
3 and ECM terminals q 63 , q
67 . in harness or connectors. MT
and short to power.
AT
OK
H
TF
CHECK GROUND CIRCUIT-I. NG Repair open circuit or short
E
Check harness continuity between sensor to ground or short to power
PD
terminal q
6 and ECM terminals q 62 , q
66 . in harness or connectors.
If OK, check harness for short to ground FA
and short to power.
OK
SEF745V
RA
H
CHECK GROUND CIRCUIT-II. NG Check the following.
E
1. Loosen and retighten engine ground I Joint connector F19 BR
screws. I Harness for open or
2. Check harness continuity between ter- short between control
minal q4 and engine ground. sleeve position sensor ST
Continuity should exist. and engine ground
If OK, check harness for short to If NG, repair open circuit or
ground and short to power. short to ground or short to RS
OK
nectors.
SEF746V H BT
q
A
HA
EL
SE
SEF676V
IDX
EC-283
(DTC 15) RD28ETi
q
A
H
CHECK COMPONENT NG Take proper action.
E
(Control sleeve position sensor).
below.
OK
H
SEF747V tors in the circuit. Then retest.
H
and retest.
H
INSPECTION END
Control sleeve position sensor
2. Check continuity between terminals q 2 and q3 ,q
2 and q 6 .
Resistance: Approximately 5.9Ω [at 23°C (73°F)]
If NG, take proper action.
SEF680V
EC-284
TROUBLE DIAGNOSIS FOR “ADJUST RESISTOR” (DTC 17) RD28ETi
Adjustment Resistor GI
The adjustment resistor is used to achieve uniform pump charac-
teristics. MA
EM
LC
SEF681V

43 (ECM
FE
TER- DATA CL
WIRE
COLOR
NO. Signal)
MT
(Voltage varies with part
46 Y Adjustment resistor Ignition switch “ON”
number of adjustment AT
resistor.)

50 B Sensors’ ground Approximately 0V TF
Idle speed
PD
Diagnostic FA
Check Items
(Possible Cause)
No.
17 I An excessively high or low voltage from the resistor is I Harness or connectors RA
detected by ECM. (The adjustment resistor circuit is open or shorted.)
I Adjustment resistor
BR
ST
RS
BT
PROCEDURE HA
3) Wait at least 5 seconds. EL
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
2) Turn ignition switch “OFF”, wait at least 5 seconds and SE
then turn “ON”.
SEF748V results)” with ECM. IDX
EC-285
Adjustment Resistor (Cont’d)
TEC428
EC-286
INSPECTION START
MA
H
CHECK POWER SUPPLY. NG Repair harness or connec- EM
E
2. Disconnect electronic fuel injection
pump harness connector. LC
SEF682V
4. Check voltage between terminal q 2 and
ground.
Voltage:
Approximately 5V
FE
OK
H
CL
E
2. Check harness continuity between ter- F6 , M51
MT
SEF749V
If OK, check harness for short to I Harness for open or AT
ground and short to power. short between ECM and
adjustment resistor
OK
I Harness for open or TF
adjustment resistor
If NG, repair open circuit or PD
nectors. FA
H
SEF750V
CHECK COMPONENT NG Replace adjustment resis- RA
E
(Adjustment resistor). tor.
next page. BR
OK
H
ST

H
check the connection of ECM harness BT
connector.
retest. HA
H
INSPECTION END EL
SE
IDX
EC-287
Adjustment resistor
Check resistance between terminals q 2 and q 6 .
Resistance: Approximately 0.2 - 15.0 kΩ [at 25°C
(77°F)]
Resistance value varies with adjustment sensor num-
bers.
If NG, replace adjustment resistor.
Always replace adjustment resistor with a new one which has same
number on label.
SEF683V
EC-288
TROUBLE DIAGNOSIS FOR “F/INJ F/B 2” (DTC 18),
“F/INJ F/B” (DTC 22), “ELECTRIC GOV” (DTC 25) RD28ETi
Electric Governor GI
The electric governor is built into the electronic fuel injection pump.
It moves the control sleeve to increase or decrease the amount of MA
fuel injected.
When current flows through the coil, a magnetic force is produced,
rotating the rotor. The rotor shaft is installed to the control sleeve EM
via a ball pin which is eccentrically situated in relation to the rotor
shaft. With this arrangement, the control sleeve can be moved in
relation to rotor rotation. LC
The rotor’s rotating angle is determined by a balanced condition of
magnetic force (generated by current flow regulated by means of
the ECM) and tension of return spring (installed to rotor). The larger
the current flow through the coil, the greater the rotor’s rotating
angle. This means that the control sleeve moves to the right,
increasing the amount of fuel injected. FE
The ECM regulates the current flow through the coil by changing
the duty ratio which controls the ON-OFF operation of the electric
governor grounding circuit. CL
MT
SEF632S
AT
TF
PD
FA
SEF633S
RA
ECM TERMINALS AND REFERENCE VALUE BR

43 (ECM
ST
TER- DATA
WIRE
COLOR
NO. Signal) RS
BT
4 B/Y ECCS relay (Self-shutoff) “OFF” HA
BATTERY VOLTAGE
A few seconds passed after turning ignition EL
(11 - 14V)
switch “OFF”
101 Engine is running. BATTERY VOLTAGE SE

R/B Electric governor
107 Idle speed (11 - 14V)
IDX
EC-289
Electric Governor (Cont’d)
TER- DATA
WIRE
COLOR
NO. Signal)
Approximately 10V
Engine is running.
Idle speed
SEF727V
102
G/Y Electric governor ground
108 Approximately 10V
Engine is running.
SEF728V
116 BATTERY VOLTAGE

117 (11 - 14V)

Diagnostic
Check Items
(Possible cause)
No.
18, 22, 25 I Fuel injection feedback system does not operate prop- I Main power supply circuit (ECM terminals 116 , 117 )
erly. (This system consists essentially of ECM, electric and fuse
governor and control sleeve position sensor.) I Harness or connectors
(Electric governor and control sleeve position sensor
circuit)
I Electric governor
I Electronic fuel injection pump
I ECM
EC-290
DIAGNOSTIC TROUBLE CODE CONFIRMATION GI
PROCEDURE
Note: If DTC 18, 22, 25 and DTC 15 are displayed, perform
TROUBLE DIAGNOSIS FOR DTC 15. (See EC-280.)
MA
mode with CONSULT.
EM
perature.
3) Run engine for 2 seconds at 3,000 rpm. Return engine LC
speed to idle, then increase to 3,000 rpm under no load.
SEF751V ---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
perature.
2) Run engine for 2 seconds at 3,000 rpm. Return engine
speed to idle, then increase to 3,000 rpm under no load. FE
then turn “ON”.
4) Perform “Diagnostic Test Mode II (Self-diagnostic CL
Note: If a malfunction occurs intermittently, conduct suitable
driving pattern for 10 minutes. This makes it possible to MT
determine DTC.
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-291
TEC429
EC-292
INSPECTION START
MA
H
CHECK POWER SUPPLY.
Refer to EC-256. EM
H LC
NG
CHECK POWER SUPPLY CIRCUIT. E
SEF679VA
2. Disconnect ECM harness connector in harness or connectors.
and electronic fuel injection pump har-
ness connector.
3. Check harness continuity between ter- FE
minal q 1 and ECM terminals 101 ,
107 .
If OK, check harness for short to CL
OK MT
H
SEF752V NG
Check harness continuity between termi- to ground or short to power AT
nal q
5 and ECM terminals 102 , 108 . in harness or connectors.
If OK, check harness for short to ground TF
and short to power.
OK
H PD
NG
CHECK COMPONENT E
Take proper action.
(Electric governor).
Refer to “COMPONENT INSPECTION” FA
below.
OK
SEF753V
H RA
BR
H
check the connection of ECM harness con- ST
and retest.
RS
H
INSPECTION END
BT
Electric governor HA
2. Check continuity between terminals q 1 and q5 . EL
Resistance: Approximately 0.68Ω [at 23°C (73°F)]
SE
SEF684V
IDX
EC-293
TROUBLE DIAGNOSIS FOR “F/INJ TIMG F/B” (DTC 21) RD28ETi
Injection Timing Control Valve

The injection timing control valve is built into the electronic fuel
injection pump. It controls the timer piston to change the fuel injec-
tion timing.
The timing control valve is a solenoid valve located in the line
between high-pressure chamber and low-pressure chamber. It
changes fuel pressure in the high-pressure chamber.
When current flows through the solenoid (the solenoid turns ON),
the timing control valve opens, advancing fuel injection timing.
When current does not flow through it, the timing control valve
SEF638S closes, retarding injection timing.
The ECM emits an ON-OFF duty signal. The longer the OFF-
duration, the greater the advance angle. The longer the
ON-duration, the greater the retard angle. This means that chang-
ing the ON-OFF duty ratio makes it possible to achieve an optimal
advance angle and accurately control fuel injection timing.
I Engine: After warming up Idle −9.5 to −12.0°
ACT INJ TIMG
I No-load 2,000 rpm −10.0 to −15.5°
INJ TIMG C/V I Engine: After warming up, idle the engine. Approx. 50%

43 (ECM
TER- DATA
WIRE
COLOR
NO. Signal)
BATTERY VOLTAGE
(11 - 14V)
Idle speed
SEF729V
104 Injection timing control
L/W
110 valve BATTERY VOLTAGE
(11 - 14V)
SEF730V
EC-294
Injection Timing Control Valve (Cont’d)
Diagnostic
Check Items
Trouble Code Malfunction is detected when .... MA
(Possible cause)
No.
21 I Injection timing feedback system does not operate I Harness or connectors
properly. (This system consists essentially of ECM, [Injection timing control valve, needle lift sensor, crank- EM
injection timing control valve and needle lift sensor.) shaft position sensor (TDC) circuits]
I Injection timing control valve
I Needle lift sensor LC
I Crankshaft position sensor (TDC)
I Air in fuel line

PROCEDURE FE
Note: If both DTC 21 and 34 or 47 are displayed, perform
TROUBLE DIAGNOSIS FOR DTC 34 or 47. (See EC-319
or EC-337.) CL
mode with CONSULT.
2) Start engine and warm it up to normal operating tem- MT
perature.
SEF751V speed to idle, then increase to 3,000 rpm under no load. AT
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
perature. TF
speed to idle, then increase to 3,000 rpm under no load.
3) Turn ignition switch “OFF”, wait at least 5 seconds and PD
then turn “ON”.
results)” with ECM. FA
Note: If a malfunction occurs intermittently, conduct suitable
driving pattern for 10 minutes. This makes it possible to
determine DTC.
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-295
TEC430
EC-296
INSPECTION START
MA
H
OK
CHECK FOR AIR IN FUEL FILTER. E
INSPECTION END EM
1. Move priming pump up and down to
purge air from fuel filter.
2. Perform “DIAGNOSTIC TROUBLE LC
CODE CONFIRMATION PROCE-
SEF670V DURE”.
NG
H
NG
CHECK POWER SUPPLY. Check the following.
E
FE
2. Disconnect injection timing control valve M51 , F6
harness connector. I Electronic fuel injection
3. Turn ignition switch “ON”. pump harness connector CL
4. Check harness continuity between ter- F3
minal q 2 and ground with CONSULT or I 10A fuse
tester. I Harness for open or MT
Voltage: Battery voltage short between injection
SEF685V
timing control valve and
OK fuse AT
connectors.
TF
H
NG
CHECK OUTPUT SIGNAL CIRCUIT. E
1. Turn ignition switch “OFF”. I Electronic fuel injection PD
2. Disconnect ECM harness connector. pump harness connector
3. Check harness continuity between ter- F3
minal q 1 and ECM terminals 104 , I Harness for open or
110 . short between injection
FA
Continuity should exist. timing control valve and
If OK, check harness for short to ECM
SEF754V
ground and short to power. If NG, repair open circuit or RA
nectors. BR
H
NG
CHECK COMPONENT E
Replace injection timing
(Injection timing control valve). control valve. ST
next page.
RS
OK
H
SEF755V tors in the circuit. Then retest. BT
H
Check ECM pin terminals for damage and HA
and retest. EL
H
INSPECTION END SE
IDX
EC-297
Injection timing control valve
1. Reconnect injection timing control valve harness connector.
Resistance: Approximately 11Ω [at 20°C (68°F)]
If NG, replace injection timing control valve.
SEF686V
EC-298
TROUBLE DIAGNOSIS FOR “ACCEL POS SW (F/C)”
(DTC 23) RD28ETi
Accelerator Switch (F/C) GI

The accelerator switch is installed to the accelerator pedal assem-
bly. The switch senses accelerator position and sends an ON-OFF MA
signal to the ECM. The ECM uses the signal to control the fuel cut
operation at deceleration for better fuel efficiency.
EM
LC
SEF687V

Accelerator pedal: released CLOSE
CL
ACCEL SW (FC)
(Engine stopped) Accelerator pedal: slightly open OPEN
Idle OFF MT
DECELER F/CUT I Engine: After warming up When accelerator pedal is
released quickly with engine ON
speed at 3,000 rpm or more. AT
TF
43 (ECM
ground) with a voltmeter. PD
TER- DATA
WIRE
MINAL
COLOR
ITEM CONDITION (DC Voltage and Pulse FA
NO. Signal)
Ignition switch “ON” BATTERY VOLTAGE RA

29 R/L Accelerator switch (F/C)
Ignition switch “ON” BR
Approximately 0V
ST
Diagnostic
RS
Check Items
(Possible cause)
No.
BT
23 I The OFF signal (short) is sent to the ECM for a cer- I Harness or connectors
tain period of time even when the accelerator pedal is (The switch circuit is shorted.)
not being depressed. I Accelerator switch (F/C) HA
EL
SE
IDX
EC-299
(DTC 23) RD28ETi
Accelerator Switch (F/C) (Cont’d)
PROCEDURE
mode with CONSULT.
2) Depress and release accelerator pedal once for 15 sec-
onds.
3) Repeat step 2 for 26 times.
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
2) Depress and release accelerator pedal once for 15 sec-
SEF756V onds.
3) Repeat step 2 for 26 times.
then turn “ON”.
EC-300
(DTC 23) RD28ETi
GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC431
EC-301
(DTC 23) RD28ETi
INSPECTION START
H
OK
CHECK OVERALL FUNCTION. E
INSPECTION END
2. Check “ACCEL SW (F/C)” in
CONSULT.
Accelerator pedal released:
OFF
SEF688V Accelerator pedal depressed:
ON
------------------------------------------------------------------- OR -------------------------------------------------------------------
Voltage:
Accelerator pedal released
Battery voltage
Approximately 0V
NG
H
NG
SEF589S 1. Turn ignition switch “OFF”. I Harness connectors
2. Loosen and retighten engine ground M51 , F6 (RHD mod-
screws. els)
3. Disconnect accelerator switch (F/C) har- I Joint connector F18
4. Check harness continuity between termi- short between accelera-
nal q
3 and engine ground. tor switch (F/C) and
Continuity should exist. engine ground
If OK, check harness for short to ground If NG, repair open circuit or
and short to power. short to ground or short to
OK nectors.
H
NG
SEF590S 1. Disconnect ECM harness connector. I Harness connectors
2. Check harness continuity between ECM F6 , M51 (RHD mod-
terminal q
29 and terminal q1 . els)
If OK, check harness for short to ground between ECM and accel-
and short to power. erator switch (F/C)
OK short to ground or short to
nectors.
H
NG
CHECK COMPONENT E
Replace accelerator pedal
[Accelerator switch (F/C)]. assembly.
on next page.
SEF591S
OK
H
H
and retest.
H
INSPECTION END
SEF592S
EC-302
(DTC 23) RD28ETi
Accelerator switch (F/C)
1. Disconnect accelerator switch (F/C) harness connector. MA
2. Check continuity between terminals q1 and q 3 .
EM
Accelerator pedal released No
Accelerator pedal depressed Yes
LC
If NG, replace accelerator pedal assembly.
SEF689V
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-303
TROUBLE DIAGNOSIS FOR “ECM 1” (DTC 27),
“ECM 2” (DTC 31) RD28ETi
Engine Control Module (ECM)-ECCS-D Control

Module
The ECM consists of a microcomputer and connectors for signal
input and output and for power supply. The unit controls the engine.
SEC220B
Diagnostic
Check Item
(Possible Cause)
No.
27, 31 I ECM calculation function is malfunctioning. I ECM
(ECCS-D control module)

PROCEDURE
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
then turn “ON”.
EC-304
TROUBLE DIAGNOSIS FOR “ECM 1” (DTC 27),
“ECM 2” (DTC 31) RD28ETi
Engine Control Module (ECM)-ECCS-D Control
Module (Cont’d) GI
MA
INSPECTION START
H EM
2) Select “SELF DIAG RESULTS”
mode with CONSULT. LC
3) Touch “ERASE”.
------------------------------------------------------------------- OR -------------------------------------------------------------------
2) Erase the Diagnostic Test Mode
II (Self-diagnostic results)
memory.
FE
CL
H
PERFORM SELF-DIAGNOSIS.
Select “SELF DIAG RESULTS” MT
mode with CONSULT.
------------------------------------------------------------------- OR -------------------------------------------------------------------
PERFORM “Diagnostic Test Mode AT
II” (SELF-DIAGNOSTIC
RESULTS).
TF
H
Is the DTC 27, 31 displayed again? Yes Replace ECM.
E PD
No
H
INSPECTION END FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-305
TROUBLE DIAGNOSIS FOR “OVER HEAT” (DTC 28) RD28ETi
Cooling Fan (Overheat)

SYSTEM DESCRIPTION
Vehicle speed sensor Vehicle speed
E
Engine coolant temperature sensor Engine coolant temperature Cooling fan

E ECM E
relay
Air conditioner switch Air conditioner “ON” signal

E
The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, air condi-
tioner system pressure and air conditioner ON signal. The control system has 2-step control [ON/OFF].
Operation
SEF757V

Air conditioner switch: OFF OFF
I Engine: After warming up, idle
AIR COND SIG Air conditioner switch: ON
the engine ON
I When cooling fan is stopped. OFF
COOLING FAN
I When cooling fan operates. ON

43 (ECM
TER- DATA
WIRE
COLOR
NO. Signal)

14 L Cooling fan relay
Engine is running.
0 - 1V
EC-306
Cooling Fan (Overheat) (Cont’d)
TER- DATA
GI
WIRE
COLOR
NO. Signal)
MA
(11 - 14V)
Air conditioner switch is “OFF”. EM
15 Y/L Air conditioner relay Engine is running.
Both air conditioner switch and blower fan 0 - 1V

LC
switch are “ON”.
ON BOARD DIAGNOSIS LOGIC FE

This diagnosis continuously monitors the engine coolant temperature.
If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will
rise. CL
When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is
indicated.
MT
Diagnostic Trouble Check Items
Code No. (Possible Cause)
28 I Cooling fan does not operate properly (Overheat). I Harness or connectors AT
I Cooling fan system does not operate properly (Over- (The cooling fan circuit is open or shorted.)
heat). I Cooling fan
I Engine coolant was not added to the system using I Radiator hose
the proper filling method. I Radiator TF
I Radiator cap
I Water pump
I Thermostat PD
I Fan belt
For more information, refer to “MAIN 12
CAUSES OF OVERHEATING”, EC-313. FA
CAUTION:
When a malfunction is indicated, be sure to replace the coolant following the procedure in the MA RA
section (“Changing Engine Coolant”, “ENGINE MAINTENANCE”). Also, replace the engine oil.
a. Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure to
use coolant with the proper mixture ratio. Refer to MA section (“Anti-freeze Coolant Mixture Ratio”, BR
“RECOMMENDED FLUIDS AND LUBRICANTS”).
b. After refilling coolant, run engine to ensure that no water-flow noise is emitted.
ST
RS
BT
HA
EL
SE
IDX
EC-307
Use this procedure to check the overall function of the cooling fan.
WARNING:
Never remove the radiator cap when the engine is hot. Serious
burns could be caused by high pressure fluid escaping from
the radiator.
Wrap a thick cloth around the cap. Carefully remove the cap
by turning it a quarter turn to allow built-up pressure to
escape. Then turn the cap all the way off.
AEC640 1) Check the coolant level in the reservoir tank and radiator.
Allow engine to cool before checking coolant level.
If the coolant level in the reservoir tank and/or radiator is below
the proper range, skip the following steps and go to “DIAGNOS-
TIC PROCEDURE”, EC-310.
2) Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to “DIAGNOS-
TIC PROCEDURE”, EC-310.
4) Perform “COOLING FAN” in “ACTIVE TEST” mode with
CONSULT and make sure that cooling fan operates
when touching “ON”.
SEF758V
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
3) Disconnect engine coolant temperature sensor harness
connector.
4) Connect 150Ω resistor to engine coolant temperature
5) Start engine and make sure that cooling fan operates.
Be careful not to overheat engine.
SEF979S
EC-308
GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC432
EC-309
INSPECTION START
H
CHECK COOLING FAN OPERATION. OK Go to “CHECK COOL-
E
1. Turn ignition switch “OFF”. ING SYSTEM FOR LEAK”,
2. Turn ignition switch “ON”. EC-312.
SEF758V SULT and make sure that cooling
fan operates when touching
“ON”.
------------------------------------------------------------------- OR -------------------------------------------------------------------
2. Disconnect engine coolant tem-
perature sensor harness connec-
tor.
3. Connect 150Ω resistor to engine
coolant temperature sensor har-
ness connector.
4. Start engine and make sure that
cooling fan operates.
SEF979S NG
H
E
2. Disconnect cooling fan relay-1. I 30A fusible link
2 , between cooling fan
q5 and ground with CONSULT or tester. relay-1 and fuse
between cooling fan
OK
relay-1 and battery
SEF690V
connectors.
H
CHECK GROUND CIRCUIT. NG Repair open circuit or short
E
2. Disconnect cooling fan motor harness in harness or connectors.
connector.
relay terminal q
3 and motor termi-
nals q1 ,q3 .
SEF759V 4. Check harness continuity between
motor terminals q2 ,q4 and body
ground.
OK
H
q
A
SEF691V
EC-310
q
A
GI
H
MA
E
EM
terminal q
14 and terminal q1 . I Harness connectors
Continuity should exist. M52 , F7
LC
If OK, check harness for short to ground I Harness for open or short
SEF760V and short to power. between cooling fan
relay-1 and ECM
OK
power in harness or con- FE
nectors.
H
CHECK COMPONENT NG Replace cooling fan relay. CL
E
EC-314. MT
OK
SEF761V H
CHECK COMPONENT NG Replace cooling fan motor.
AT
E
EC-314.
TF
OK
H PD

FA
H
SEF762V
check the connection of ECM harness con- RA
and retest.
BR
H
INSPECTION END
ST
RS
BT
HA
EL
SE
IDX
EC-311
CHECK COOLING SYSTEM FOR LEAK. NG Check the following for

E
Apply pressure to the cooling system with leak.
a tester, and check if the pressure drops. I Hose
Testing pressure: I Radiator
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi) I Water pump
Pressure should not drop. Refer to LC section (“Water
CAUTION: Pump”).
Higher than the specified pressure may
cause radiator damage.
SLC754AA
OK
H
CHECK RADIATOR CAP. NG Replace radiator cap.
E
Apply pressure to cap with a tester.
Radiator cap relief pressure:
78 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0
kg/cm2, 11 - 14 psi)
OK
H
CHECK THERMOSTAT. NG Replace thermostat.
E
1. Check valve seating condition at normal
room temperatures.
It should seat tightly.
SLC755AB 2. Check valve opening temperature and
valve lift.
Valve opening temperature:
82°C (180°F) [standard]
Maximum valve lift:
More than 10 mm/95°C
(0.39 in/203°F)
3. Check if valve is closed at 5°C (9°F)
below valve opening temperature.
For details, refer to LC section (“Thermo-
stat”).
OK
H
SLC343 Check engine coolant temperature sensor. NG Replace engine coolant
E
Refer to “COMPONENT INSPECTION”, temperature sensor.
EC-275.
OK
H
If the cause cannot be isolated, go to
“MAIN 12 CAUSES OF OVERHEATING”
on next page.
H
INSPECTION END
Perform FINAL CHECK by the following procedure after repair

is completed.
1. Warm up engine. Run the vehicle for at least 20 minutes. Pay
attention to engine coolant temperature gauge on the instrument
panel. If the reading shows an abnormally high temperature,
another part may be malfunctioning.
2. Stop vehicle and let engine idle. Check the intake and exhaust
systems for leaks by listening for noise or visually inspecting the
components.
3. Allow engine to cool and visually check for oil and coolant leaks.
Then, perform “OVERALL FUNCTION CHECK”.
EC-312
MAIN 12 CAUSES OF OVERHEATING GI
Engine Step Inspection item Equipment Condition Reference page
OFF 1 I Blocked radiator I Visual No blocking — MA
I Blocked radiator grille
I Blocked bumper
2 I Coolant mixture I Coolant tester 50 - 50% coolant mixture See “RECOMMENDED
EM
FLUIDS AND LUBRI-
CANTS” in MA section.
LC
3 I Coolant level I Visual Coolant up to MAX level See “Changing Engine
in reservoir tank and Coolant”, “ENGINE MAIN-
radiator filler neck TENANCE” in MA section.
4 I Radiator cap I Pressure tester 78 - 98 kPa See “System Check”
(0.78 - 0.98 bar, 0.8 - 1.0 “ENGINE COOLING SYS-
kg/cm2, 11 - 14 psi) TEM” in LC section. FE
ON*2 5 I Coolant leaks I Visual No leaks See “System Check”
“ENGINE COOLING SYS- CL
TEM” in LC section.
ON*2 6 I Thermostat I Touch the upper and Both hoses should be hot See “Thermostat” and
lower radiator hoses “Radiator”, “ENGINE MT
COOLING SYSTEM” in
LC section.
AT
ON*1 7 I Cooling fan I CONSULT Operating See “TROUBLE DIAGNO-
SIS FOR DTC 28”,
EC-306. TF
OFF 8 I Combustion gas leak I Color checker chemical Negative —
tester 4 Gas analyzer
ON*3 9 I Coolant temperature I Visual Gauge less than 3/4 —
PD
gauge when driving
I Coolant overflow to res- I Visual No overflow during driving See “Changing Engine FA
ervoir tank and idling Coolant”, “ENGINE MAIN-
TENANCE” in MA section.
OFF*4 10 I Coolant return from res- I Visual Should be initial level in See “ENGINE MAINTE-
RA
ervoir tank to radiator reservoir tank NANCE” in MA section.
OFF 11 I Cylinder head I Straight gauge feeler 0.1mm (0.004 in) Maxi- See “Inspection”, “CYLIN- BR
gauge mum distortion (warping) DER HEAD” in EM sec-
tion.
12 I Cylinder block and pis- I Visual No scuffing on cylinder See “Inspection”, “CYLIN- ST
tons walls or piston DER BLOCK” in EM sec-
tion.
RS
*1: Turn the ignition switch ON.
*2: Engine running at 3,000 rpm for 10 minutes.
*3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes.
*4: After 60 minutes of cool down time. BT
For more information, refer to “OVERHEATING CAUSE ANALYSIS” in LC section.
HA
EL
SE
IDX
EC-313
Cooling fan relay-1
3 and q
5 .
Yes
1 and q
terminals q 2
SEF511P
Cooling fan motor-1

check operation.
Terminals
(!) (@)
Cooling fan motor q
1 ,q
3 q
2 ,q
4
SEF763V Cooling fan motor should operate.

EC-314
TROUBLE DIAGNOSIS FOR “I/C INT/A TEMP SEN”
(DTC 33) RD28ETi
Charge Air Temperature Sensor GI

The charge air temperature sensor is used to detect the charge air
temperature. The sensor modifies a voltage signal from the ECM. MA
The modified signal returns to the ECM as the charge air tempera-
ture input. The sensor uses a thermistor which is sensitive to the
change in temperature. The electrical resistance of the thermistor EM
decreases as temperature increases.
The ECM uses this signal for the charge air cooler control.
LC
SEF594K
<Reference data>
Charge air temperature Voltage Resistance
°C (°F) (V) (kΩ) FE
−10 (14) 4.4 7.0 - 11.4
20 (68) 3.5 2.1 - 2.9 CL
50 (122) 2.3 0.68 - 1.00
90 (194) 1.0 0.236 - 0.260
MT
110 (230) 0.64 0.143 - 0.153
SEF012P 150 (302) 0.30 0.050 - 0.065
AT
43 (ECM TF
TER- DATA
MINAL
WIRE
ITEM CONDITION (DC Voltage and Pulse
PD
COLOR
NO. Signal)
Charge air temperature

Approximately 0 - 4.8V FA
36 LG Engine is running. Output voltage varies with
sensor
charge air temperature.
RA
Idle speed
BR
Diagnostic
ST
Check Items
(Possible Cause)
No.
RS
entered to ECM. (The sensor circuit is open or shorted.)
I Charge air temperature sensor BT

HA
PROCEDURE
2) Select “DATA MONITOR” mode with CONSULT. EL
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
1) Turn ignition switch “ON” and wait at least 5 seconds. SE
then turn “ON”.
3) Perform “Diagnostic Test Mode II (Self-diagnostic IDX
EC-315
(DTC 33) RD28ETi
Charge Air Temperature Sensor (Cont’d)
TEC438
EC-316
(DTC 33) RD28ETi
INSPECTION START
MA
H
NG EM
Repair harness or connec-
2. Disconnect charge air temperature sen-
sor harness connector. LC
SEF710V 4. Check voltage between terminal q2 and
Voltage:
Approximately 5V
OK FE
H
NG
Check the following. CL
MT
If OK, check harness for short to I Harness for open or
SEF764V ground and short to power. short between ECM and
charge air temperature AT
OK sensor
short between TCM and TF
charge air temperature
sensor
If NG, repair open circuit or PD
nectors.
FA
H
NG
SEF765V CHECK COMPONENT E
Replace charge air tem- RA
(Charge air temperature sensor). perature sensor.
on next page. BR
OK
H ST

RS
H
Check ECM pin terminals for damage and BT
nector and retest. HA
H EL
INSPECTION END
SE
IDX
EC-317
(DTC 33) RD28ETi
Charge air temperature sensor

20 (68) 2.1 - 2.9
50 (122) 0.68 - 1.0
90 (194) 0.236 - 0.260
SEF152P
If NG, replace charge air temperature sensor.
SEF012P
EC-318
TROUBLE DIAGNOSIS FOR “NEEDLE LIFT SEN” (DTC 34) RD28ETi
Needle Lift Sensor (NLS) GI

The needle lift sensor is built into the No. 1 injection nozzle. Its
piezoelectric element senses changes in fuel injection timing MA
caused by fuel temperature, etc. This change of fuel injection tim-
ing is sent as a pulse signal to the ECM.
EM
LC
SEF604S

43 (ECM
FE
TER- DATA CL
WIRE
COLOR
NO. Signal)
MT
Approximately 0V
AT
Idle speed TF
SEF718V PD
34 W Needle lift sensor
Approximately 0V
FA

RA
BR
SEF719V
ST
RS
Diagnostic
Check Items
(Possible Cause)
No. BT
34 I An improper signal from the sensor is sent to ECM. I Harness or connectors
(The sensor circuit is open or shorted.)
I Needle lift sensor HA
I Air in fuel line
I Clogging No. 1 injection nozzle
EL
SE
IDX
EC-319
Needle Lift Sensor (NLS) (Cont’d)
PROCEDURE
mode with CONSULT.
speed.
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
speed.
SEF714V then turn “ON”.
EC-320
GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC433
EC-321
INSPECTION START
H
CHECK FOR AIR IN FUEL FILTER. OK INSPECTION END
E
1. Move priming pump up and down to
purge air from fuel filter.
2. Perform “DIAGNOSTIC TROUBLE
CODE CONFIRMATION PROCEDURE”.
SEF670V NG
H
Loosen and retighten engine ground
screws.
H
CHECK INPUT SIGNAL CIRCUIT. NG Repair open circuit or short
E
2. Disconnect ECM harness connector and in harness or connectors.
needle lift sensor harness connector.
nal q
1 and ECM terminal q 34 .
SEF676V Continuity should exist.
and short to power.
OK
H
CHECK GROUND CIRCUIT. NG Repair open circuit or short
E
Check resistance between terminal q 2 and to ground or short to power
engine ground. in harness or connectors.
and short to power.
OK
SEF692V H
CHECK NO. 1 INJECTION NOZZLE FOR NG Replace No. 1 injection
E
CLOGGING. nozzle.
Refer to “SPRAY PATTERN TEST”, “Test
and Adjustment”, “INJECTION NOZZLE”,
EC-219.
OK
H

H
SEF766V
and retest.
H
INSPECTION END
SEF767V
EC-322
TROUBLE DIAGNOSIS FOR “FUEL CUT S/V 1” (DTC 36),
“FCV SHORT” (DTC 37), “FUEL CUT S/V 2” (DTC 38) RD28ETi
Fuel Cut Solenoid Valve GI

When the ignition switch is OFF, the ECM turns the fuel cut sole-
noid valve OFF (under this condition, no current flows through the
fuel cut solenoid valve), shutting off fuel supply. MA
When the engine is not operating due to trouble, the fuel cut sole-
noid valve may or may not be OFF even when the ignition switch
is ON. EM
LC
SEF667S

Idle OFF
CL
DECELER F/CUT I Engine: After warming up When accelerator pedal is released
quickly with engine speed at 3,000 ON MT
rpm or more.
FUEL CUT S/V I Ignition switch: ON , OFF ON , OFF
AT
ECM TERMINALS AND REFERENCE VALUE TF

43 (ECM
TER- DATA
PD
WIRE
COLOR
NO. Signal)
FA

RA
4 B/Y ECCS relay (Self-shutoff) “OFF” BR
BATTERY VOLTAGE
A few seconds passed after turning ignition (11 - 14V) ST
switch “OFF”
56 BATTERY VOLTAGE
61
(11 - 14V)
RS
Ignition switch “OFF” Approximately 0V
113
R/W Fuel cut solenoid valve
BT
115 BATTERY VOLTAGE
(11 - 14V)
116 BATTERY VOLTAGE HA

117 (11 - 14V)
EL
SE
IDX
EC-323
Fuel Cut Solenoid Valve (Cont’d)
Diagnostic
Check Items
(Possible Cause)
Code No.
36, 37, 38 I Fuel cut solenoid valve circuit is malfunctioning. I Main power supply circuit (ECM terminals 116 , 117 )
and fuse
I Harness or connectors
(The solenoid valve circuit is open or shorted.)
I Fuel cut solenoid valve
I ECM

PROCEDURE
3) Start engine.
then turn “ON”.
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
1) Start engine.
SEF748V then turn “ON”.
EC-324
GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC434
EC-325
INSPECTION START
H
CHECK POWER SUPPLY FOR ECM.
Check power supply circuit. Refer to
EC-256.
OK
H
SEF860S NG
CHECK OUTPUT SIGNAL CIRCUIT. Repair open circuit or short
E
1. Turn ignition switch “ON”. to ground or short to power
2. Select “FUEL CUT SOL/V” in in harness or connectors.
“ACTIVE TEST” mode with
CONSULT.
3. Touch “ON” and “OFF” alter-
nately.
4. Check that operating sound is
emitted.
------------------------------------------------------------------- OR -------------------------------------------------------------------
2. Disconnect ECM harness con-
SEF682VA
nector and electronic fuel injec-
tion pump harness connector.
3. Check harness continuity
between terminal q 4 and ECM
terminals 113 , 115 .
OK
H
CHECK COMPONENT NG Replace fuel cut solenoid
E
(Fuel cut solenoid valve). valve.
SEF768V
next page.
OK
H

H
nector and retest.
H
INSPECTION END
EC-326
1. Remove fuel cut solenoid valve. MA
2. Check shaft to see if it is lifted when applying 12V direct cur-
rent to terminals.
If NG, replace fuel cut solenoid valve. EM
LC
SEF859S
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-327
TROUBLE DIAGNOSIS FOR “FUEL TEMP SENSOR”
(DTC 42) RD28ETi
Fuel Temperature Sensor (FTS)

The fuel temperature sensor is used to detect the fuel temperature
in the injection pump. The sensor modifies a voltage signal from the
ECM. The modified signal returns to the ECM as the fuel tempera-
ture input. The sensor uses a thermistor which is sensitive to the
change in temperature. The electrical resistance of the thermistor
decreases as temperature increases.
SEF666S
<Reference data>
Voltage Resistance
ture
(V) (kΩ)
°C (°F)
−20 (−4) 4.6 13.67 - 16.37
20 (68) 3.5 2.306 - 2.568
60 (140) 1.8 0.538 - 0.624
80 (176) 1.2 0.289 - 0.344
SEF012P

43 (ECM
TER- DATA
WIRE
COLOR
NO. Signal)
10 P Fuel temperature sensor Engine is running. Output voltage varies with
fuel temperature.

Idle speed

Diagnostic
Check Items
(Possible Cause)
No.
detected by ECM. (The sensor circuit is open or shorted.)
I Fuel temperature sensor

PROCEDURE
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
then turn “ON”.
EC-328
(DTC 42) RD28ETi
Fuel Temperature Sensor (FTS) (Cont’d)
GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC435
EC-329
(DTC 42) RD28ETi
INSPECTION START
H
CHECK POWER SUPPLY. NG Repair harness or connec-
E
2. Disconnect electronic fuel injection
pump harness connector.
SEF682VB
4. Check voltage between terminal q 1 and
Voltage:
Approximately 5V
OK
H
E
SEF769V If OK, check harness for short to I Harness for open or
ground and short to power. short between ECM and
electronic fuel injection
OK
pump
electronic fuel injection
pump
nectors.
SEF770V
H
CHECK COMPONENT NG Take proper action.
E
(Fuel temperature sensor).
next page.
OK
H

H
nector and retest.
H
INSPECTION END
EC-330
(DTC 42) RD28ETi
Fuel temperature sensor
Wait until fuel temperature sensor reaches room temperature. MA
Temperature °C (°F) Resistance kΩ EM

20 (68) 2.306 - 2.568
60 (140) 0.538 - 0.624
LC
80 (176) 0.289 - 0.344
SEF693V
FE
CL
MT
SEF012P
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-331
TROUBLE DIAGNOSIS FOR “ACCEL POS SENSOR”
(DTC 43) RD28ETi
Accelerator Position Sensor

The accelerator position sensor is installed on the upper end of the
accelerator pedal assembly. The sensor detects the accelerator
position and sends a signal to the ECM. The ECM uses the signal
to determine the amount of fuel to be injected.
SEF861SA

I Ignition switch: ON Accelerator pedal: released 0.40 - 0.60V

ACCEL POS SEN
(Engine stopped) Accelerator pedal: depressed Approx. 4.0V

43 (ECM
TER- DATA
WIRE
COLOR
NO. Signal)

0.4 - 0.6V
23 W
sor Ignition switch “ON”
Approximately 4.3V
Accelerator position sen-

sor power supply
Accelerator position sen- Engine is running. (Warm-up condition)

51 L/W Approximately 0V
EC-332
(DTC 43) RD28ETi
Accelerator Position Sensor (Cont’d)
Diagnostic
Check Items
Trouble Malfunction is detected when ... MA
(Possible Cause)
Code No.
43 I An excessively low or high voltage from the sensor is I Harness or connectors
detected by the ECM. (The sensor circuit is open or shorted.) EM
I Accelerator position sensor
I Accelerator position switch
I Accelerator switch (F/C) LC

PROCEDURE
1) Turn ignition switch “ON”. FE
---------------------------------------------------------------------------------------------------------------------------- OR ---------------------------------------------------------------------------------------------------------------------------- CL
then turn “ON”. MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-333
(DTC 43) RD28ETi
TEC436
EC-334
(DTC 43) RD28ETi
INSPECTION START
MA
H
NG
CHECK POWER SUPPLY. E Check the following. EM
2. Disconnect accelerator position sensor F7 , M52 (RHD mod-
harness connector. els)
3. Turn ignition switch “ON”. I Harness for open or LC
4. Check voltage between terminal q 1 and short between ECM and
SEF694V ground with CONSULT or tester. accelerator position sen-
Voltage: Approximately 5V sor
OK connectors.
FE
H
NG
1. Turn ignition switch “OFF”. I Harness connectors CL
2. Loosen and retighten engine ground F7 , M52 (RHD mod-
screw. els)
3. Check harness continuity between ter- I Harness for open or
minal q3 and engine ground. short between ECM and MT
Continuity should exist. accelerator position sen-
If OK, check harness for short to sor
SEF771V ground and short to power. If NG, repair open circuit or
AT
nectors.
TF
H
NG
CHECK INPUT SIGNAL CIRCUIT. E Check the following.
1. Disconnect ECM harness connector. I Harness connectors PD
2. Check harness continuity between ECM F7 , M52 (RHD mod-
terminal q
23 and terminal q2 . els)
Continuity should exist. I Harness for open or FA
If OK, check harness for short to short between ECM and
ground and short to power. accelerator position sen-
sor
SEF676V
OK If NG, repair open circuit or RA
nectors. BR
H
NG
CHECK COMPONENT E Replace accelerator pedal
(Accelerator position sensor). assembly. ST
next page.
OK RS
H
SEF772V nectors in the circuit. Then retest. BT
H
HA
nector and retest. EL
H
INSPECTION END SE
SEF773V
IDX
EC-335
(DTC 43) RD28ETi
Accelerator position sensor
1. Disconnect accelerator position sensor harness connector.
2. Make sure that resistance between terminals q 2 and q 3
changes when depressing accelerator pedal manually.
Accelerator pedal conditions Resistance [at 25°C (77°F)]
Completely released Approximately 0.5 kΩ
Partially depressed 0.5 - 4 kΩ
SEF695V Completely depressed Approximately 4 kΩ
CAUTION:
If accelerator position sensor or ECM connector is
disconnected, perform the following procedures:
Select “OFF ACCEL PO SIG” in “ACTIVE TEST” mode.
Touch CLEAR.
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
Start and warm up engine. After engine has warmed up,
idle for 10 minutes.
EC-336
TROUBLE DIAGNOSIS FOR “CRANK POS SEN (TDC)”
(DTC 47) RD28ETi
Crankshaft Position Sensor (TDC) GI

The crankshaft position sensor (TDC) monitors engine speed by
means of signals from the sensing plate (with three protrusions) MA
installed to the crankshaft pulley. The datum signal output is
detected at ATDC 70° and sent to the ECM. The sensor signal is
used for fuel injection control and fuel injection timing control. EM
LC
SEF615S

I Tachometer: Connect CL
Almost the same speed as the
CKPS⋅RPM (TDC) I Run engine and compare tachometer indication with the CONSULT
CONSULT value.
value.
MT
43 (ECM
AT
TER- DATA
WIRE TF
COLOR
NO. Signal)
Approximately 0V
PD
Engine is running. (Warm-up condition) FA

Idle speed
RA
40 Crankshaft position sensor SEF720V
L BR
44 (TDC) Approximately 0V
ST

RS
SEF721V
BT
47 Crankshaft position sensor Engine is running. (Warm-up condition)
B/W Approximately 0V
52 (TDC) ground Idle speed HA
ON BOARD DIAGNOSIS LOGIC EL

Diagnostic
Check Items
(Possible Cause) SE
No.
47 I An improper signal from the sensor is detected by I Harness or connectors
ECM during engine running and cranking. (The sensor circuit is open.)
I Crankshaft position sensor (TDC)
IDX
EC-337
(DTC 47) RD28ETi
Crankshaft Position Sensor (TDC) (Cont’d)
PROCEDURE
Before performing the following procedure, confirm that bat-
tery voltage is more than 10V.
mode with CONSULT.
2) Crank engine for at least 1 second.
speed.
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
SEF714V 1) Crank engine for at least 1 second.
speed.
then turn “ON”.
EC-338
(DTC 47) RD28ETi
GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC437
EC-339
(DTC 47) RD28ETi
INSPECTION START
H
NG
2. Disconnect crankshaft position sensor F13 , EC4
(TDC) harness connector and ECM har- I Harness for open or
ness connector. short between ECM and
SEF696V 3. Check harness continuity between ECM crankshaft position sen-
terminals q40 , q
44 and terminal q
1 . sor (TDC)
nectors.
OK
H
NG
CHECK GROUND CIRCUIT-I. E
Check harness continuity between termi- I Harness connectors
2 and ECM terminals q
nal q 47 , q
52 . F13 , EC4
If OK, check harness for short to ground short between crankshaft
SEF774V and short to power. position sensor (TDC)
and ECM
OK If NG, repair open circuit or
nectors.
H
NG
CHECK GROUND CIRCUIT-II. E
1. Loosen and retighten engine ground I Joint connector F19
screws. I Harness for open or
2. Disconnect harness connectors F13 , short between harness
EC4 . connector F13 and
3. Check harness continuity between ter- engine ground
SEF775V
minal q3 and engine ground. If NG, repair open circuit or
Continuity should exist. short to ground or short to
If OK, check harness for short to power in harness or con-
ground and short to power. nectors.
OK
H
NG
CHECK COMPONENT E
Replace crankshaft posi-
[Crankshaft position sensor (TDC)]. tion sensor (TDC).
next page.
OK
H
SEF676V

H
and retest.
H
INSPECTION END
SEF776V
EC-340
(DTC 47) RD28ETi
Crankshaft position sensor (TDC)
1. Disconnect crankshaft position sensor (TDC) harness connec- MA
tor.
2. Loosen the fixing bolt of the sensor.
3. Remove the sensor. EM
4. Visually check the sensor for chipping.
LC
SEF620S

Resistance: Approximately 0.8 - 1.2 kΩ
[at 25°C (77°F)]
If NG, replace crankshaft position sensor (TDC). FE
CL
MT
SEF697V
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-341
TROUBLE DIAGNOSIS FOR “GOV CUT CIRCUIT” (DTC 48) RD28ETi
Governor Cut Circuit

This diagnostic procedure checks whether or not fuel cut is being performed during deceleration.
Signals from the accelerator switch and camshaft position sensor (PUMP) are sent to the ECM. The ECM uses
these signals to control the electric governor operation.
Accelerator switch (F/C) E
ECM Electric
E
Engine speed governor
Camshaft position sensor (PUMP) E
Diagnostic
Check Item
(Possible Cause)
No.
48 I Accelerator switch circuit is shorted. I Harness or connectors
I Crankshaft position sensor (PUMP) or ECM is mal- [Accelerator switch (F/C) and camshaft position sen-
functioning. sor (PUMP) circuits]
I Accelerator switch (F/C)
I Camshaft position sensor (PUMP)
I ECM

PROCEDURE
Note: If both DTC 48 and 11 or 23 are displayed, perform
TROUBLE DIAGNOSIS FOR DTC 11 or 23 (See EC-262 or
299).
3) Start engine and run it to 3,000 rpm, then quickly release
accelerator pedal.
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
1) Start engine and run it to 3,000 rpm, then quickly release
accelerator pedal.
then turn “ON”.
results)”.
EC-342
TROUBLE DIAGNOSIS FOR “GOV CUT CIRCUIT” (DTC 48) RD28ETi
Governor Cut Circuit (Cont’d)
INSPECTION START
MA
H
1) Turn ignition switch “ON”. EM
2) Select “SELF DIAG RESULTS”
mode with CONSULT.
3) Touch “ERASE”.
------------------------------------------------------------------- OR ------------------------------------------------------------------- LC
2) Erase the diagnostic test mode
II (Self-diagnostic results)
memory.
H FE
PERFORM DIAGNOSTIC TROUBLE
CODE CONFIRMATION PROCEDURE.
See previous page. CL
H
Is the DTC 48 displayed again?
Yes
Replace ECM.
MT
E
No
H AT
INSPECTION END
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-343
TROUBLE DIAGNOSES FOR NON-DETECTABLE ITEMS RD28ETi
Glow Control System

SYSTEM DESCRIPTION
Engine speed
Crankshaft position sensor (TDC) Glow relay Glow plugs
E E E
ECM
Engine coolant temperature sensor Glow lamp
E E
When engine coolant temperature is more than 90°C (194°F), the glow relay turns off, inactivating the quick-
glow control until coolant temperature drops below 70°C (158°F).
When coolant temperature is lower than 90°C (194°F):
I Ignition switch ON
After ignition switch has turned to ON, the glow relay turns ON for a certain period of time in relation to
engine coolant temperature, allowing current to flow through glow plug.
I Cranking
The glow relay turns ON, allowing current to flow through glow plug.
I Starting
After engine has started, current continues to flow through glow plug (after-glow mode) for a certain period
in relation to engine coolant temperature.
When engine speed exceeds 2,400 rpm, current flow through glow plug is interrupted.
The glow lamp turns ON for a certain period of time in relation to engine coolant temperature at the time glow
relay is turned ON.
Glow plug
The glow plug is provided with a ceramic heating element to obtain
a high-temperature resistance. It glows in response to a signal sent
from the ECM, allowing current to flow through the glow plug via the
glow relay.
SEF857S

43 (ECM
TER- DATA
WIRE
COLOR
NO. Signal)

0 - 1.5V
Glow lamp is “ON”.
16 L/W Glow lamp
Glow lamp is “OFF”. (11 - 14V)
111 LG/B Glow relay Refer to “SYSTEM DESCRIPTION”.
EC-344
Glow Control System (Cont’d)
GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC441
EC-345
INSPECTION START
H
Check fuel level, fuel supplying system, NG Correct.
E
starter motor, etc.
OK
H
NG
Check that all glow plug connecting plate E
Install properly.
SEF698V
nuts are installed properly.
OK
H
OK
CHECK COMPONENT
Check entire glow control system. (Refer (Glow plug).
to “System Operation Check” on next See page EC-348.
page.)
NG
H
NG
CHECK VOLTAGE BETWEEN GLOW E
RELAY AND GROUND. I 100A fusible link
SEF699V 1. Turn ignition switch “OFF”. I Harness for open or
2. Disconnect glow relay. short between glow
1 , relay and battery
q3 and ground with CONSULT or If NG, repair harness or
tester. connectors.
OK
H
E
terminal 111 and terminal q 2 . I Harness connectors
SEF777V
ground and short to power. short between glow
relay and ECM
OK If NG, repair open circuit or
nectors.
H
CHECK HARNESS CONTINUITY NG Check the following.
E
BETWEEN GLOW RELAY AND GLOW I Harness connectors
PLUG. E65 , E204
SEF778V
1. Disconnect glow plug harness connec- I Harness for open or
tor. short between glow
2. Check harness continuity between glow relay and glow plug
relay terminal q
5 and glow plug har- If NG, repair open circuit or
ness connector. short to ground or short to
Continuity should exist. power in harness or con-
If OK, check harness for short to nectors.
H
OK
q
A
SEF779V
EC-346
q
A
GI
H
NG
MA
CHECK COMPONENTS Replace malfunctioning
E
(Glow relay, Glow plug). component(s).
Refer to “COMPONENT INSPECTION”, EM
EC-348.
OK
H LC

H
FE
and retest.
CL
H
INSPECTION END MT
AT
SYSTEM OPERATION CHECK
Set voltmeter between glow plug and engine body.
TF
PD
FA
SEF700V
RA
1. Quick-glow (Pre-glow) system
a. Turn ignition switch “ON”.
b. Read voltage. BR
Voltage:
Battery voltage for about 20* seconds
* Engine coolant temperature is lower than 90°C ST
(194°F). [It is lower than 70°C (158°F) after
warm-up.]
* Repeating ignition switch “ON” and “OFF” may RS
change the time.
2. Quick-glow (Cranking) system
SEF780V
a. Disconnect “S” terminal for starter motor to prevent engine from BT
cranking.
b. Read voltage when ignition switch is turned to “START”.
Voltage:
HA
Battery voltage*
* For about 20 seconds after returning ignition EL
switch to “ON”.
SE
IDX
EC-347
3. After-glow system
a. Connect “S” terminal to starter motor.
b. Start engine and read voltage.
Voltage:
Battery voltage for 5* minutes
* Engine coolant temperature is lower than 50°C
(122°F).
SEF781V
Glow relay
1. Check relay for coil continuity.
2. Check relay for proper operation.
Coil voltage Continuity Contact point

0V No OFF
12V Yes ON
SEC564B
Glow plug
1. Remove glow plug connecting plate.
2. Check each glow plug for continuity.
Continuity should exist:
Approximately 0.8Ω [at 25°C (77°F)]
I If NG, replace glow plug.
SEF701V
3. Install glow plug connecting plate securely.

I Do not bump glow plug heating element. If it is bumped,
replace glow plug with new one. (If glow plug is dropped
from a height of 10 cm (3.94 in), replace with new one.)
I If glow plug installation hole is contaminated with carbon,
remove using a reamer or suitable tool.
I Hand-tighten glow plug by turning it two to three times,
then tighten using a tool to specified torque.
: 15 - 20 N⋅m (1.5 - 2.0 kg-m, 11 - 14 ft-lb)
SEC565B
EC-348
EGRC-Solenoid Valve A, B and Throttle Control GI

Solenoid Valve
SYSTEM DESCRIPTION MA
Engine speed
Camshaft position sensor (TDC) EGRC-solenoid valve A
E E
EM
Accelerator position sensor
E
LC
Engine coolant temperature sensor EGRC-solenoid valve B
E ECM E
Start signal
Ignition switch
E

Amount of intake air
E E
Throttle control solenoid valve FE
The ECM receives signals sent from the engine coolant tempera- CL
ture sensor, crankshaft position sensor (TDC), ignition switch, mass
air flow sensor and accelerator position sensor to determine engine
speed and operating conditions. Based on these signals, the ECM MT
controls EGR control solenoid valve (A and B) operation and
throttle control solenoid valve operation.
AT
Engine coolant EGRC-solenoid valve Throttle control Throttle control Amount of EGR
temperature Load EGR valve
solenoid valve valve gas
°C (°F) A B TF
OFF OFF OFF
Below 70 (158) Any Fully closed Fully open —
(Closed) (Closed) (Closed)
Low load
ON ON ON
Fully open Closed Large
PD
(Open) (Open) (Open)
ON ON OFF
Medium load-1 Fully open Fully open Medium
Above 70 (158)
(Open) (Open) (Closed) FA
ON OFF OFF
Medium load-2 Half open Fully open Small
(Open) (Closed) (Closed)
High load
OFF
(Closed)
OFF
(Closed)
OFF
(Closed)
Fully closed Fully open — RA
BR
ST
RS
BT
The EGRC-solenoid valves A and B control vacuum pressure act- HA
ing on the EGR valve. The EGR control valve will then be fully
opened, half-opened or fully closed, as required.
The throttle control solenoid valve controls vacuum pressure acting EL
on the throttle chamber. Thus, intake air passages are opened or
closed in relation to exhaust gas and intake air. Utilizing the rela-
tionship between exhaust gas pressure and intake air pressure SE
control, the amount of EGR (exhaust gas recirculated) is regulated
in three stages — large, medium, small.
IDX
SEF784V
EC-349
EGRC-Solenoid Valve A, B and Throttle Control
Solenoid Valve (Cont’d)
EGRC SOL/V A
I Shift lever: “N” Revving engine from idle to 3,750
OFF
I No-load rpm
EGRC SOL/V B
OFF
I No-load rpm
THROT RLY
OFF
I No-load rpm

43 (ECM
TER- DATA
WIRE
COLOR
NO. Signal)

Approximately 0.4V
Throttle control solenoid Idle speed
1 W
valve Engine is running. (Warm-up condition) BATTERY VOLTAGE
Revving engine from idle to 2,500 rpm (11 - 14V)

0 - 1V
Idle speed
103 L/Y EGRC-solenoid valve A
Revving engine from idle up to 3,750 rpm. (11 - 14V)

0 - 1V
Idle speed
109 BR/Y EGRC-solenoid valve B
Revving engine from idle up to 2,600 rpm. (11 - 14V)
EC-350
Solenoid Valve (Cont’d) GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC442
EC-351
INSPECTION START
H
E
SEF702V 2. Perform diagnostic test mode II (Self-
diagnostic results).
Make sure that diagnostic trouble code
No. 55 is displayed.
3. Make sure that EGR valve spring
moves up and down (Use your finger)
At idle:
Spring moves up and down.
Revving engine from idle to 3,800
rpm:
Spring does not move.
SEF703V 4. Make sure that throttle control valve rod
moves up and down under the following
conditions.
At idle:
Rod moves up and down.
rpm:
Rod does not move.
NG
H
CHECK VACUUM SOURCES TO EGR OK CHECK COMPONENTS
E
SEF704V VALVE AND THROTTLE CONTROL (EGR valve and throttle
VALVE. control valve).
1. Disconnect vacuum hose to EGR valve. (See page EC-355.)
2. Make sure that vacuum exists under
NG
At idle:
Vacuum should exist.
rpm:
Vacuum should not exist.
3. Disconnect vacuum hose to throttle
H
control valve.
SEF705V 4. Make sure that vacuum exists under Replace malfunctioning
the following conditions. component(s).
At idle:
Vacuum should exist.
rpm:
Vacuum should not exist.
NG
H
q
A
EC-352
q
A
MA
H
CHECK CONTROL FUNCTION. OK CHECK VACUUM HOSE.
1. Stop engine.
E
Check vacuum hose for
EM
2. Turn ignition switch “ON”. clogging, cracks or
3. Turn EGRC-solenoid valve A, B improper connection.
and throttle control solenoid
LC
SEF682S valve “ON” and “OFF” in
“ACTIVE TEST” mode with
CONSULT and check operating
sound.
------------------------------------------------------------------- OR -------------------------------------------------------------------
FE
terminal 103 and ground under
the following conditions. CL
Voltage:
At idle
0 - 1V MT
Revving engine from idle to
3,800 rpm
SEF683S
Battery voltage AT
terminal 109 and ground under
the following conditions. TF
Voltage:
At idle
0 - 1V PD
2,600 rpm
Battery voltage FA
SEF816F
the following conditions. RA
Voltage:
At idle
0 - 1V BR
2,500 rpm
Battery voltage ST
NG
H
q
B
RS
BT
HA
EL
SE
IDX
EC-353
q
B
H
E
2. Disconnect EGRC-solenoid valve A, B M21 , E127
and throttle control solenoid valve har- I 10A fuse
SEF706V 3. Turn ignition switch “ON”. short between EGRC-
4. Check voltage between terminal q 1 and solenoid valve A, B and
ground with CONSULT or tester. fuse
short between throttle
OK
control solenoid valve
and fuse
connectors.
H
E
SEF782V 1. Turn ignition switch “OFF”. I Harness connectors
2. Disconnect ECM harness connector. E127 , M21
3. Check harness continuity between I Harness connectors
ECM terminal q 1 and terminal q 2 , M50 , F5
ECM terminal 103 and terminal q 2 , I Harness for open or
ECM terminal 109 and terminal q 2 . short between EGRC-
Continuity should exist. solenoid valve A, B and
If OK, check harness for short to ECM
ground and short to power. I Harness for open or
short between throttle
OK
control solenoid valve
and ECM
SEF783V If NG, repair open circuit or
nectors.
H
CHECK COMPONENTS NG Replace malfunctioning
E
(EGRC-solenoid valve A, B and throttle component(s).
control solenoid valve).
next page.
OK
H

H
retest.
H
INSPECTION END
EC-354
EGR valve MA
Apply vacuum to EGR vacuum port with a hand vacuum pump.
EGR valve spring should lift.
If NG, replace EGR valve. EM
LC
MEF137D
Throttle control valve

Apply vacuum to throttle control valve vacuum port with a hand
vacuum pump. FE
Throttle control valve should close.
If NG, replace throttle control valve.
CL
MT
SEF707V
AT
EGRC-solenoid valve A, B and throttle control solenoid
valve
Check air passage continuity. TF
Air passage Air passage
Condition continuity continuity PD
between qA and q
B between qA and q
C
12V direct current supply FA

between terminals q 1 Yes No
and q
2
MEC488B
No supply No Yes RA
If NG, replace solenoid valve(s).

BR
ST
RS
BT
HA
EL
SE
IDX
EC-355
Start Signal
TEC443
EC-356
Start Signal (Cont’d)
INSPECTION START
MA
H
E EM
2. Check “START SIGNAL” in
CONSULT. LC
SEF625S
IGN “ON” OFF
IGN “START” ON
------------------------------------------------------------------- OR -------------------------------------------------------------------
1. Turn ignition switch to “START”. FE
Voltage: CL
Battery voltage
Except above MT
Approximately 0V
SEF109P NG
H
AT
E
2. Disconnect ECM harness connector and M52 , F7
TF
ignition switch harness connector. I 7.5A fuse
3. Check harness continuity between ECM I Fuse block M3 , E112
6 . I Harness for open or short PD
Continuity should exist. between ECM and igni-
If OK, check harness for short to ground tion switch
and short to power. If NG, repair open circuit or FA
nectors.
SEF785V
RA
H
tors in the circuit. Then retest. BR
H
Check ECM pin terminals for damage and ST
and retest.
RS
H
INSPECTION END BT
HA
EL
SE
IDX
EC-357
Accelerator Position Switch

The accelerator position switch detects OFF-accelerator switch sig-
nal and Full-accelerator switch signal and send these signals to the
ECM. The ECM will then determine engine idle conditions. These
signals are also used for diagnosing the accelerator position sen-
sor.
SEF708V

I Ignition switch: ON Accelerator pedal: depressed ON

FULL ACCEL SW
(Engine stopped) Except above OFF
I Ignition switch: ON Accelerator pedal: released ON

OFF ACCEL SW
(Engine stopped) Accelerator pedal: slightly open OFF

43 (ECM
TER- DATA
WIRE
COLOR
NO. Signal)

31 R/L
(Idle) Ignition switch “ON”
Approximately 0V

Approximately 0V
Accelerator position switch Accelerator pedal released
32 W/G
(Full) Ignition switch “ON” BATTERY VOLTAGE
Accelerator pedal fully depressed (11 - 14V)
EC-358
Accelerator Position Switch (Cont’d)
GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC444
EC-359
INSPECTION START
H
OK
INSPECTION END
2. Select “FULL ACCEL SW” and
“OFF ACCEL SW” in “DATA
SEF626S SULT.
3. Check “FULL ACCEL SW” and
“OFF ACCEL SW” signal under
OFF ACCEL SW:
ON
Accelerator pedal
depressed OFF
FULL ACCEL SW:
OFF
Accelerator pedal fully
SEF627S depressed ON
------------------------------------------------------------------- OR -------------------------------------------------------------------
Voltage:
Battery voltage
Accelerator pedal
depressed
Approximately 0V
SEF708V
Voltage:
Approximately 0V
Accelerator pedal fully
depressed
Battery voltage
NG
H
NG
SEF786V 2. Disconnect accelerator position switch M52 , F7 (LHD mod-
harness connector. els)
3. Turn ignition switch “ON”. I Harness for open or
4. Check voltage between terminal q 5 and short between accelera-
ground with CONSULT or tester. tor position switch and
Voltage: Battery voltage ECCS relay
OK short between accelera-
tor position switch and
ECM
connectors.
H
q
A
EC-360
q
A GI
H MA
CHECK INPUT SIGNAL CIRCUIT-I. NG Check the following.
E
2. Disconnect ECM harness connector. M52 , F7 (RHD mod- EM
3. Check harness continuity between ter- els)
minal q6 and ECM terminal q 31 . I Harness for open or
Continuity should exist. short between ECM and LC
If OK, check harness for short to accelerator position
SEF787V
ground and short to power. switch
OK
nectors. FE
H
CHECK INPUT SIGNAL CIRCUIT-II. NG Check the following.
CL
E
Check harness continuity between termi- I Harness connectors
nal q
4 and ECM terminal q 32 . M52 , F7 (RHD mod-
Continuity should exist. els)
MT
If OK, check harness for short to ground I Harness for open or
SEF788V and short to power. short between ECM and
accelerator position
AT
OK
switch
TF
nectors. PD
H
NG
CHECK COMPONENT
E
Replace accelerator pedal FA
(Accelerator position switch). assembly.
next page. RA
OK
H
Disconnect and reconnect harness con- BR
Trouble is not fixed. ST

H
check the connection of ECM harness RS
nector and retest.
BT
H
INSPECTION END
HA
EL
SE
IDX
EC-361
1. Disconnect accelerator position switch harness connector.
2. Check continuity between terminals q 5 and q6 .
Accelerator pedal released Yes
Accelerator pedal depressed No
3. Check continuity between terminals q

4 and q
5 .
SEF709V
Accelerator pedal released No
Accelerator pedal fully depressed Yes
CAUTION:
If accelerator position sensor or ECM connector is
disconnected, perform the following procedures:
Select “OFF ACCEL PO SIG” in “ACTIVE TEST” mode.
Touch CLEAR.
---------------------------------------------------------------------------------------------------------------------------- OR ----------------------------------------------------------------------------------------------------------------------------
Start and warm up engine. After engine has warmed up,
idle for 10 minutes.
EC-362
Park/Neutral Position Switch GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC445
EC-363
When the gear position is in “P” or “N”, neutral position switch is
“ON”. The ECM detects the position because the continuity of the
line (the “ON” signal) exists.
Shift lever: Neutral/Park ON
Except above OFF

43 (ECM
TER- DATA
WIRE
COLOR
NO. Signal)
Approximately 0V
Gear position is “N” or “P” (A/T models).
Inhibitor switch/Neutral Gear position is “Neutral” (M/T models).
22 P/B
position switch
Except the above gear position (11 - 14V)
M/T models
INSPECTION START
H
E
SEF963N
SULT.
Neutral position: ON
Except neutral position: OFF
------------------------------------------------------------------- OR -------------------------------------------------------------------
Voltage:
Neutral position
SEF622S
Approximately 0V
Except neutral position
Battery voltage
NG
H
q
A
SEF789V
EC-364
q
A GI
H MA
E
2. Disconnect neutral position switch har- E202 , E69
EM
ness connector. I Harness for open or short
3. Check harness continuity between termi- between neutral position
nal q
2 and body ground. switch and body ground
LC
AEC750
nectors.
OK
FE
H
E
1. Disconnect ECM harness connector. I Harness connectors CL
2. Check harness continuity between ECM F7 , M52
22 and terminal q
terminal q 1 . I Harness connectors
Continuity should exist. M21 , E127 MT
SEF624S
ground and short to power. E70 , E201
OK
I Harness for open or short AT
between ECM and neutral
position switch
If NG, repair open circuit or TF
nectors. PD
H
CHECK COMPONENT NG Replace neutral position
(Neutral position switch).
E
switch. FA
Refer to MT section.
OK RA
H
tors in the circuit. Then retest. BR
H
Check ECM pin terminals for damage and ST
and retest. RS
H
INSPECTION END
BT
HA
EL
SE
IDX
EC-365
A/T models
INSPECTION START
H
E
SEF963N
SULT.
“P” or “N” position: ON
Except above positions: OFF
------------------------------------------------------------------- OR -------------------------------------------------------------------
Voltage:
“P” or “N” position
Approximately 0V
SEF622S
Except above positions
Battery voltage
NG
H
E
1. Turn ignition switch “OFF”. I 7.5A fuse
2. Disconnect inhibitor switch harness con- I Harness for open or short
nector. between inhibitor switch
3. Turn ignition switch “ON”. and fuse
4. Check voltage between terminal q 3 and If NG, repair harness or
SEF790V
OK
H
q
A
SEF791V
SEF792V
EC-366
q
A
GI
H
MA
E
1. Turn ignition switch “OFF”. I Diode E103 EM
2. Disconnect TCM harness connector. I Harness continuity
3. Check harness continuity between TCM between inhibitor switch
terminal q36 and terminals q7 ,q
9 . and TCM LC
SEF793V If OK, check harness for short to ground short to ground or short to
OK nectors.
H FE
E
2. Check harness continuity between ECM F7 , M52 CL
terminal q
22 and TCM terminal q 14 . I Harness connectors
If OK, check harness for short to ground I Harness for open or short MT
and short to power. between ECM and TCM
SEF794V If NG, repair open circuit or
OK
short to ground or short to AT
nectors.
TF
H
CHECK COMPONENT NG Replace inhibitor switch.
E
(Inhibitor switch). PD
Refer to AT section.
OK
H FA
RA
H
BR
retest.
ST
H
INSPECTION END RS
BT
HA
EL
SE
IDX
EC-367
A/T Control
These circuit lines are used to control the smooth shifting up and
down of A/T during the hard acceleration/deceleration.
Voltage signals are exchanged between ECM and TCM.
43 (ECM
TER- DATA
WIRE
COLOR
NO. Signal)
Engine is running.
24 PU/W A/T signal No. 1 6 - 8V
Idle speed
Engine is running.
30 P A/T signal No. 3 Approximately 0V
Idle speed
Engine is running.
37 P/B A/T signal No. 2 6 - 8V
Idle speed
EC-368
GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC440
EC-369
INSPECTION START
H
E
1. Start engine and let it idle.
q
24 , q
30 , q
37 and ground with CONSULT
or tester.
SEF792V
Terminal Voltage
q
24 and ground 6 - 8V
q
30 and ground Approximately 0V
q
37 and ground 6 - 8V
NG
H
E
SEF795V 2. Disconnect ECM harness connector M51 , F6
and TCM harness connector. I Harness connectors
3. Check harness continuity between E106 , M88
ECM terminal q 24 and terminal q
5 , I Harness continuity
7 , between ECM and TCM
6 . If NG, repair harness or
OK
H
E
Check harness continuity between ECM I Harness connectors
SEF796V terminal q
24 and ground, ECM terminal q 30 E106 , M88
and ground, ECM terminal q 37 and ground. I Harness connectors
Continuity should not exist. M51 , F6
If OK, check harness for short to power. I Harness for short
between ECM and TCM
OK
If NG, repair short to
ground or short to power in
harness or connectors.
H
SEF797V Trouble is not fixed.

H
nector and retest.
H
INSPECTION END
EC-370
Charge Air Cooler Fan Control GI

SYSTEM DESCRIPTION
Engine speed MA
Crankshaft position sensor (TDC)
E
Charge air temperature sensor Charge air temperature ECM E Charge air cooler fan relay EM
E
Ignition switch Start signal

E
LC
The ECM controls the charge air cooler fan operation corresponding to the engine speed, the charge air tem-
perature and the start signal. The control system has 2-step control [ON/OFF]. The ECM does not directly drive
the charge air cooler fan. It controls the ON/OFF charge air cooler fan relay, which in turn controls the charge
air cooler fan. FE
When the charge air temperature is above 67°C (153°F) and engine speed is more than 1,600 rpm, the charge
air cooler fan operates.
CL
MT
I When charge air cooler fan is stopped. OFF
I/C FAN RLY AT
I When charge air cooler fan operates. ON
ECM TERMINALS AND REFERENCE VALUE TF

43 (ECM
PD
TER- DATA
WIRE
COLOR
NO. Signal) FA
Charge air cooler fan Charge air cooler fan is not operating. (11 - 14V) RA
8 G/OR
relay Engine is running.
0 - 1V BR
Charge air cooler fan is operating.
ST
RS
BT
HA
EL
SE
IDX
EC-371
Charge Air Cooler Fan Control (Cont’d)
TEC439
EC-372
INSPECTION START
MA
H
CHECK OVERALL FUNCTION. OK INSPECTION END EM
E
2. Disconnect charge air temperature sen-
sor harness connector. LC
3. Connect 150Ω resistor to charge air
SEF710V
temperature sensor harness connector.
4. Start engine and keep engine speed at
2,000 rpm.
5. Make sure that charge air cooler fan
operates.
FE
NG
CL
H
E
1. Stop engine. I Harness connectors MT
2. Disconnect charge air cooler fan relay. M21 , E127
SEF798V 3. Turn ignition switch “ON”. I 10A fuse

4. Check voltage between terminals q 2 , I 15A fuse AT
q5 and ground with CONSULT or I Fuse block M2
tester. I Harness for open or
Voltage: Battery voltage short between charge air TF
cooler fan relay and
OK
fuses
If NG, repair harness or PD
connectors.
FA
H
E
SEF712V 1. Turn ignition switch “OFF”. I Harness connectors RA
2. Disconnect charge air cooler fan motor E127 , M21
harness connector. I Harness connectors
3. Check harness continuity between relay M50 , F5 BR
terminal q3 and motor terminal q 1 , I Harness for open or
motor terminal q2 and engine ground. short between charge air
Continuity should exist. cooler fan relay and ST
If OK, check harness for short to charge air cooler fan
ground and short to power. motor
OK
I Harness for open or RS
short between charge air
cooler fan motor and
SEF799V engine ground BT
power in harness or con- HA
nectors.
H
q
A
EL
SE
SEF711V
IDX
EC-373
q
A
H
E
terminal q
8 and relay terminal q 1 . I Harness connectors
SEF800V ground and short to power. short between ECM and
charge air cooler fan
OK
relay
nectors.
H
CHECK COMPONENT NG Replace charge air cooler
E
(Charge air cooler fan relay). fan relay.
next page.
SEF801V
OK
H
CHECK COMPONENT NG Replace charge air cooler
E
(Charge air cooler fan motor). fan motor.
next page.
OK
H

H
nector and retest.
H
INSPECTION END
EC-374
Charge air cooler fan relay
3 and q
5 . MA
EM
Yes
1 and q
terminals q 2
No current supply No LC
SEF511P If NG, replace relay.
Charge air cooler fan motor
1. Disconnect charge air cooler fan motor harness connector.
2. Supply charge air cooler fan motor terminals with battery volt- FE
age and check operation.
Charge air cooler fan motor should operate.
If NG, replace charge air cooler fan motor. CL
MT
SEF802V
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-375
Heat Up Switch
The heat up switch is located on the lower side of the instrument
panel. This switch is used to speed up the heater’s operation when
the engine is cold.
When the ECM received the heat up switch “ON” signal, the ECM
increases the engine idle speed to 1,100 - 1,200 rpm to warm up
engine quickly.
This system works when all conditions listed below are met.
Heat up switch ON
SEF803V
Engine coolant temperature Below 70°C (158°F)
Shift lever “P” or “N”
Accelerator pedal Fully released
Vehicle speed Below 4 km/h (2 MPH)

Heat up switch: ON ON
WARM UP SW I Ignition switch: ON
Heat up switch: OFF OFF

43 (ECM
TER- DATA
WIRE
COLOR
NO. Signal)

0V
Heat up switch is “OFF”.
59 BR/W Heat up switch
Heat up switch is “ON”. (11 - 14V)
EC-376
Heat Up Switch (Cont’d)
GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC447
EC-377
INSPECTION START
H
E
2. Check “WARM UP SW” signal in
CONSULT.
SEF804V
Heat up switch is “ON”: ON
Heat up switch is “OFF”: OFF
------------------------------------------------------------------- OR -------------------------------------------------------------------
the following condition.
Voltage:
Heat up switch is “ON”
Battery voltage
Heat up switch is “OFF”
Approximately 0V
SEF805V NG
H
E
1. Turn heat up switch “OFF”. I Fuse block M3
3. Disconnect heat up switch harness con- I Harness for open or
nector. short between heat up
4. Turn ignition switch “ON”. switch and fuse
5. Check voltage between terminal q6 and If NG, repair harness or
SEF806V OK
H
E
3. Check harness continuity between ECM I Harness for open or
5 . short between heat up
Continuity should exist. switch and ECM
If OK, check harness for short to If NG, repair open circuit or
ground and short to power. short to ground or short to
OK
SEF807V nectors.
H
q
A
EC-378
q
A GI
H
CHECK COMPONENT NG Replace heat up switch.
MA
E
(Heat up switch).
below.
EM
OK
H LC

H
Check ECM pin terminals for damage or FE
retest. CL
H
INSPECTION END MT
AT
Heat up switch TF
1. Disconnect heat up switch harness connector.
5 and q
2. Check continuity between terminals q 6 .
PD
Heat up switch “ON” Yes
FA
Heat up switch “OFF” No
If NG, replace heat up switch.

SEF808V
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-379
Air Conditioner Control
TEC446
EC-380
MIL & Data Link Connectors GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC448
EC-381
INJECTION SYSTEM TD
CAUTION:
I Disassembly and assembly of the injection pumps should be done only in service shops autho-
rized by NISSAN or by the pump manufacturer.
I The pump tester is required for servicing the pump.
I Before removing fuel injection pump from vehicle, check closely to make sure that it is definitely
malfunctioning.
Fuel System
SEF382F
EC-382
INJECTION SYSTEM TD
Fuel System (Cont’d)
GI
MA
EM
LC
FE
CL
MT
AT
TF
SEF383FA
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
SEF381F
IDX
EC-383
INJECTION PUMP TD
Inspection
PLUNGER LIFT INSPECTION
1. Remove injection tubes.
2. Remove plug bolt from distributor head and install dial gauge.
3. Plunger lift measurement
(1) Turn crankshaft counterclockwise 20 to 25 degrees from No. 1
piston at TDC.
(2) Find dial gauge’s needle rest position at step (1) set position,
then set the gauge to zero.
(3) Turn crankshaft clockwise until No. 1 piston is set at TDC.
SEF065K
(4) Read dial gauge indication.
0.626±0.05 mm (0.0246±0.0020 in)
(5) If it is not within the above range, adjust it within adjustment
standard range.
Refer to EC-388.
4. Disconnect dial gauge and reinstall plug bolt with new washer.
: 14 - 20 N⋅m (1.4 - 2.0 kg-m, 10 - 14 ft-lb)
5. Connect injection tubes.
Flare nut:
: 20 - 25 N⋅m (2.0 - 2.5 kg-m, 14 - 18 ft-lb)
Refer to EC-396.
SEF616G
INJECTION PUMP CALIBRATION

Calibrate injection pump on injection pump tester.
Refer to “Injection Pump Calibration Standard” in SDS,
EC-433.
EC-384
INJECTION PUMP TD
Removal GI
1. Disconnect air duct and cleaner.
MA
EM
LC
2. Remove injection tube.

Cover the injection nozzle assembly with a plug to prevent
dust entry.
FE
CL
MT
SEM895D
AT
3. Disconnect fuel cut solenoid wire connector.
TF
PD
FA
DEM072
RA
4. Remove accelerator wire and disconnect overflow hose, fuel
inlet hose and fuel return hose.
BR
ST
RS
SEF334F BT
5. Remove injection pump drive gear cover.
HA
EL
SE
DEF012
IDX
EC-385
INJECTION PUMP TD
Removal (Cont’d)
6. Loosen injection pump drive gear nut and remove drive gear by
using puller.
DEM062
7. Remove vacuum pump.

I Remove the eye bolt securing the oil tube. Remove the vacuum
pump. Be careful not to bend the oil tube during vacuum pump
removal.
8. Remove injection pump fixing nuts and bolts.
SEF063K
9. Remove injection pump with injection tubes.

Disconnect injection tube from pump once it is removed.
SEF064K
EC-386
INJECTION PUMP TD
Installation and Adjustment GI

1. Confirm that No. 1 piston is set at TDC on its compression
stroke. MA
EM
LC
DEM102
FE
CL
MT
DEM089
AT
2. Install injection pump.
(1) Temporarily set injection pump so that the flange of pump is
aligned with aligning mark on front cover. TF
(2) Install injection drive gear over the key.
: 59 - 69 N⋅m (6 - 7 kg-m, 43 - 51 ft-lb)
Coat key with grease to prevent it from falling into the front PD
cover. Make sure that “Z” marks are aligned.
(3) Install drive gear cover while applying a continuous bead of
liquid gasket. FA
SEF337F
RA
I Be sure liquid gasket is 2.5 to 3.5 mm (0.098 to 0.138 in)
wide.
I Attach timing gear case cover to timing gear case within 5 BR
minutes after coating.
I Wait at least 30 minutes before refilling engine oil.
I Use Genuine Liquid Gasket or equivalent. ST
RS
SEF626I BT
HA
EL
SE
IDX
EC-387
INJECTION PUMP TD
Installation and Adjustment (Cont’d)
PLUNGER LIFT ADJUSTMENT
1. Loosen injection pump mounting nuts and mounting bracket
bolt.
2. Remove plug bolt from distributor head and install dial gauge.
3. Plunger lift measurement and adjustment
(1) Turn crankshaft counterclockwise 20 to 25 degrees from No. 1
piston at TDC.
(2) Find dial gauge’s needle rest position at step (1) set position,
then set the gauge to zero.
(3) Turn crankshaft clockwise until No. 1 piston is set at TDC.
SEF065K (4) Read dial gauge indication.
0.626±0.02 mm (0.0246±0.0008 in)
(5) If it is not within the above range, turn pump body until it comes
within standard range.
a. If indication is smaller than the specified value, turn pump
body counterclockwise.
b. If indication is larger than the specified value, turn pump
body clockwise.
4. Tighten injection pump securely.
Injection pump fixing bolt:
: 20 - 25 N⋅m (2.0 - 2.5 kg-m, 14 - 18 ft-lb)
Injection pump to mounting bracket:
: 30 - 41 N⋅m (3.1 - 4.2 kg-m, 22 - 30 ft-lb)
5. Disconnect dial gauge and reinstall plug bolt with new washer.
: 14 - 20 N⋅m (1.4 - 2.0 kg-m, 10 - 14 ft-lb)
6. Connect injection tubes.
Flare nut:
: 20 - 25 N⋅m (2.0 - 2.5 kg-m, 14 - 18 ft-lb)
Refer to EC-396.
SEF616G
IDLE AND MAXIMUM SPEED ADJUSTMENT

CAUTION:
I Do not remove sealing wires unless absolutely necessary.
I Disturbing full-load adjusting screw will change fuel flow
characteristics, resulting in an improperly adjusted engine.
Readjustment of fuel injection pump should be done using
a pump tester.
I If maximum speed adjusting screw is turned in direction
that increases control lever angle, engine damage may
result.
SEF066K
Idle adjustment
Refer to “Checking Idle Speed”, “ENGINE MAINTENANCE” in
MA section.
EC-388
INJECTION PUMP TD
Installation and Adjustment (Cont’d)
Maximum speed adjustment GI
Maximum speed adjusting screw is retained by sealing wire
and need not be adjusted under normal circumstances.
However, if it becomes necessary to adjust it, the following MA
procedure should be followed:
1. Start engine and warm it up until coolant temperature indicator
points to middle of gauge. EM
2. Connect tachometer’s pick-up to No. 1 fuel injection tube.
To obtain accurate reading of engine rpm, remove clamps that
secure No. 1 fuel injection tube.
LC
SEF068K 3. Depress accelerator pedal fully under no load and, at this point,
read the tachometer indication.
Maximum engine speed (Under no load):
+50
4,600-150 rpm
FE
CL
MT
AT
4. If indication is lower than specified maximum engine speed,
turn maximum speed adjusting screw counterclockwise 1 or 2
rotations. Then depress accelerator pedal to floor under no load TF
and, at this point, read indication.
5. If indication is still lower than specified speed, repeat step 4
above until specified engine speed is reached. PD
6. After adjustment, tighten lock nut securely.
7. Seal with a sealing wire or install a sealing cap.
FA
SEF627I
RA
Disassembly
Refer to “VE INJECTION PUMP” in EF & EC section of Service BR
Manual for Model Y60 series Pub. No. SM8E-0Y60G0.
ST
RS
BT
Load Timer Adjustment
1. After adjusting the timer stroke, find the control lever position HA
where the injection quantity is as specified and then fix the
control lever using the adjusting device (KV11282617).
EL
SE
MEF451B
IDX
EC-389
INJECTION PUMP TD
Load Timer Adjustment (Cont’d)
2. Run the injection pump at the specified speed and then adjust
the governor shaft installation position so that the timer stroke
is as specified.
Refer to “Injection Pump Calibration Standard” in SDS for the
timer stroke.
MEF450B
EC-390
INJECTION NOZZLE TD
Removal and Installation GI

1. Remove injection tube assembly.
2. Remove spill tube assembly. MA
To prevent spill tube from breaking, remove it by gripping
nozzle holder.
EM
LC
SEM895D
3. Remove injection nozzle assembly using deep socket wrench.

4. Install injection nozzle in the reverse order of removal.
Injection nozzle to cylinder head:
: 54 - 64 N⋅m (5.5 - 6.5 kg-m, 40 - 47 ft-lb) FE
Spill tube nut:
: 29 - 39 N⋅m (3.0 - 4.0 kg-m, 22 - 29 ft-lb) CL
Injection tube flare nut:
: 20 - 25 N⋅m (2.0 - 2.5 kg-m, 14 - 18 ft-lb)
a. Nozzle gaskets should always be replaced. MT
b. To prevent spill tube from breaking later, spill tube nuts
DEM075 should be tightened gradually in sequence.
5. Bleed air from fuel system. AT
Refer to “Bleeding Fuel System”, EC-396.
TF
PD
FA
RA
Disassembly
1. Loosen inlet connector while keeping nozzle top from turning. BR
ST
RS
SEF785 BT
2. Arrange all disassembled parts in order shown at left.
HA
EL
SE
SEF425F
IDX
EC-391
INJECTION NOZZLE TD
Inspection
Thoroughly clean all disassembled parts with fresh kerosene or
solvent.
I If nozzle needle is damaged or fused, replace nozzle assem-
bly with a new one.
I If end of nozzle needle is seized or excessively discolored,
replace nozzle assembly.
I Check nozzle body and distance piece for proper contact. If
excessively worn or damaged, replace nozzle assembly or
nozzle holder assembly.
I Check spacer and nozzle holder for proper contact. If exces-
sively worn or damaged, replace spacer or nozzle holder.
I Check nozzle spring for excessive wear or damage. If exces-
sively worn or damaged, replace it with a new spring.
Cleaning
a. Do not touch the nozzle mating surface with your fingers.
b. To wash the nozzles, use a wooden stick and brass brush
with clean diesel fuel.
1. Clean nozzle assembly using the Nozzle Cleaning Kit.
SEF828
2. Portions which should be cleaned are indicated in the left fig-

ure.
SEF426F
3. Remove any carbon from exterior of nozzle body (except wrap-

ping angle portion) by using Tool.
SEF830
EC-392
INJECTION NOZZLE TD
Cleaning (Cont’d)
4. Clean fuel sump of nozzle body using Tool. GI
MA
EM
LC
SEF831-A
5. Clean nozzle seat by using Tool.

This job should be performed with extra precautions, since
efficiency of nozzle depends greatly on a good nozzle seat.
FE
CL
MT
SEF832-A
AT
6. Clean spray hole of nozzle body by using Tool.
To prevent spray hole from canting, always clean it by start-
ing with inner side and working towards outside. TF
PD
FA
SEF833
RA
7. Decarbon nozzle needle tip by using Tool.
BR
ST
RS
SEF834 BT
8. Check needle for proper position.
(1) Pull needle about halfway out from body and then release it. HA
(2) Needle should sink into body very smoothly from just its own
weight.
(3) Repeat this test and rotate needle slightly each time. EL
If needle fails to sink smoothly from any position, replace both
needle and body as a unit.
SE
SEF835
IDX
EC-393
INJECTION NOZZLE TD
Assembly
Assemble in the reverse order of disassembly.
Inlet connector to nozzle holder:
: 29 - 49 N⋅m (3.0 - 5.0 kg-m, 22 - 36 ft-lb)
SEF967
Test and Adjustment

WARNING:
When using nozzle tester, be careful not to allow diesel fuel
sprayed from nozzle to contact your hand or body, and make
sure your eyes are properly protected with goggles.
INJECTION PRESSURE TEST

1. Install nozzle to injection nozzle tester and bleed air from flare
nut.
EF791A
2. Pump the tester handle slowly (one time per second) and watch
the pressure gauge.
3. Read the pressure gauge when the injection pressure just
starts dropping.
Initial injection pressure:
Used 9,807 - 10,297 kPa
(98.1 - 103.0 bar, 100 - 105 kg/cm2,
1,422 - 1,493 psi)
New 10,297 - 11,278 kPa
(103.0 - 112.8 bar, 105 - 115 kg/cm2,
1,493 - 1,635 psi)
SEF672A
Always check initial injection pressure using a new nozzle.
4. To adjust injection pressure, change adjusting shims.
a. Increasing the thickness of adjusting shims increases ini-
tial injection pressure. Decreasing thickness reduces ini-
tial pressure.
b. A shim thickness of 0.04 mm (0.0016 in) corresponds
approximately to a difference of 471 kPa (4.71 bar, 4.8
kg/cm2, 68 psi) in initial injection pressure.
Refer to “Injection Nozzle” in SDS for adjusting shims, EC-432.
SEF427F
EC-394
INJECTION NOZZLE TD
Test and Adjustment (Cont’d)
LEAKAGE TEST GI
1. Maintain the pressure at about 981 to 1,961 kPa (9.8 to 19.6
bar, 10 to 20 kg/cm2, 142 to 284 psi) below initial injection
pressure. MA
2. Check that there is no dripping from the nozzle tip or around the
body.
3. If there is leakage, clean, overhaul injection nozzle or replace EM
it.
LC
SEF674A
SPRAY PATTERN TEST

1. Check spray pattern by pumping tester handle one full stroke
per second. FE
a. If main spray angle is within 30 degrees as shown, injec-
tion nozzle is good.
b. It is still normal even if a thin stream of spray deviates from CL
main spray (pattern B).
2. If injection nozzle is not normal, adjust or clean injection nozzle
or replace it. MT
SEF079S
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-395
FUEL SYSTEM CHECK TD
Bleeding Fuel System

Air should be bled out of fuel system when injection pump is
removed or fuel system is repaired.
Protect pump and engine mounts from fuel splash with rags.
If engine will not start after bleeding air, loosen injection tubes
at nozzle side and crank engine until fuel overflows from injec-
tion tube. Tighten injection tube flare nuts.
If the engine does not operate smoothly after it has started, race it
two or three times.
CAUTION:
Wipe up any fuel discharged while bleeding air during each
step.
I Step 1: Fuel filter and injection pump bleeding
1. Loosen air bleeder screw to injection pump.
2. Move fuel filter priming pump up and down until no further air
comes out of air bleeder screw.
3. Tighten air bleeder screw.
SEF083K
DEC001
I Step 2: Fuel injection tube and spill tube air bleeding

1. Loosen injection tube nuts on nozzle holder side.
2. Move the priming pump up and down until no further air comes
out of the injection tube nuts.
3. Tighten the injection tube nuts.
: 20 - 25 N⋅m (2.0 - 2.5 kg-m, 14 - 18 ft-lb)
DEC002
EC-396
FUEL SYSTEM CHECK TD
Bleeding Fuel Filter GI

1. Move the priming pump up and down to bleed air from the fuel
filter. MA
2. When air is completely bled from the fuel pump, priming pump
operation becomes noticeably heavy. Stop pump operation.
EM
LC
Checking Priming Pump

Before checking priming pump, make sure that fuel filter is
filled with fuel. FE
1. Disconnect fuel return hose.
Place a suitable container beneath hose end.
2. Pump priming pump and check that the fuel overflows from the CL
hose end. If not, replace priming pump.
MT
DEC003
AT
Checking Fuel Filter Switch
1. Remove the connector from filter and fuel filter switch.
2. Turn the key switch “ON”. Lift the float to ensure that the warn- TF
ing lamp turns on.
Fuel filter switch tightening torque:
: 3.9 - 5.9 N⋅m (0.4 - 0.6 kg-m, 35 - 52 in-lb) PD
Discard the old O-ring and replace it with a new one.
FA
SEF122U
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-397
POSITIVE CRANKCASE VENTILATION TD
Description
The closed-type crankcase ventilation system is utilized as a crank-
case emission control system.
The closed-type crankcase emission control system prevents
blow-by gas from entering the atmosphere and keeps the internal
crankcase pressure constant.
During the valve operation, the blow-by gas is fed into the intake
manifold by the air control valve.
This is activated by the internal rocker cover pressure. When the
intake air flow is restricted by the throttle body, the internal rocker
cover pressure decreases. At this point, the crankcase emission
control valve keeps the internal rocker cover pressure constant so
that air or dust is not sucked in around the crankshaft oil seal.
SEF432F
Inspection
AIR CONTROL VALVE
1. Remove rocker cover.
2. Remove control valve from rocker cover.
3. After plugging the center hole with adhesive tape, check that air
flows from inlet by blowing air from outlet and that air does not
flow by inhaling air.
SEF060B
VENTILATION HOSE
2. Disconnect all hoses and clean with compressed air.
If any hose cannot be freed of obstructions, replace.
SEC692
EC-398
QUICK-GLOW SYSTEM TD
Component Parts Location GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
DEC004 BT
HA
EL
SE
IDX
EC-399
Circuit Diagram
EXCEPT FOR COLD AREAS
TEC449
EC-400
Circuit Diagram (Cont’d)
FOR COLD AREAS GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC450
EC-401
Description
SEL337JB
When the ignition switch is turned on, the relay is turned on and the electric current flows through the glow
plugs and heats them up quickly. After T1 seconds have passed, the control unit turns off the glow indicator
but the relay remains on. The relay chops intermittently the electric current when the ignition switch turns to
“START” from “ON”.
The relay chops intermittently the electric current for T3 seconds after the ignition switch has returned to “ON”
from “START”. When not cranking, the relay chops intermittently the electric current while T4 - T2 seconds after
the ignition switch has turned to “ON” from “OFF”.
T1: approx. 2 - 6 [sec.] (Varies with coolant temperature.)
T3, T4: 15 [sec.] [When coolant temperature is below 50°C (122°F).]
2 [sec.] [When coolant temperature is over 50°C (122°F).]
I When the ignition switch is repeatedly turned “ON” and “OFF”, T2 becomes shorter.
EC-402
Description (Cont’d)
GI
MA
EM
LC
FE
CL
MT
AT
TF
SEL983NC
When coolant temperature is lower than 50°C (122°F), the relay-1 and the relay-2 are turned on at the same PD
time that the ignition switch is turned on. From this time, the electric current flows through the glow plugs and
heats them up quickly. After T1 seconds have passed, the control unit turns off the indicator. The relay-1 auto-
matically turns off after it has been on for T2 seconds or the cranking time, whichever is longer. FA
The solenoid timer (for advance injection timing) is turned on at the time that the ignition switch is turned to
“ON”. The relay-2 remains on for T3 seconds and the solenoid timer remains on for T4 seconds after the igni-
tion switch has returned to “ON” from “START”. The solenoid timer advances injection timing. These features RA
improve the combustion performance of the engine after it has started.
When the coolant temperature is higher than 50°C (122°F), the relay-2 is turned on only during engine crank-
ing.
BR
When the coolant temperature is higher than 10°C (50°F), the solenoid timer is turned on only during engine
cranking. ST
T2: approx. 4 - 8 [sec.] (Varies with coolant temperature.) RS
T3: 360 [sec.] [When coolant temperature is below 50°C (122°F).]
0 [sec.] [When coolant temperature is over 50°C (122°F).] BT
T4, T5: 30 [sec.] [When coolant temperature is below 10°C (50°F).]
0 [sec.] [When coolant temperature is over 10°C (50°F).] HA
T5: 30 [sec.] [When coolant temperature is below 50°C (122°F).]
5 [sec.] [When coolant temperature is over 50°C (122°F).] EL
I When the ignition switch is repeatedly turned “ON” and “OFF”, T2 becomes shorter.
SE
IDX
EC-403
Wiring Diagram
EXCEPT FOR COLD AREAS
TEC451
EC-404
Wiring Diagram (Cont’d)
EXCEPT FOR COLD AREAS GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC452
EC-405
FOR COLD AREAS
TEC453
EC-406
FOR COLD AREAS GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC454
EC-407
FOR COLD AREAS
TEC455
EC-408
FOR COLD AREAS GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC456
EC-409
Glow Control Unit Circuit Inspection (Except

for Cold Areas)
Roll up the floor sheet. Check the glow control unit.
DEC005
POWER SUPPLY CIRCUIT

Turn ignition switch ON and check voltage between terminal q
7
and body ground.
Voltage: approx. 12V
SEF694R
GROUND CIRCUIT
Check continuity between terminal q
4 and body ground.
SEF695R
COOLANT TEMPERATURE SENSOR CIRCUIT

5 and q
4 .
Measure resistance to temperature approximately as shown in
“COOLANT TEMPERATURE SENSOR”, “Component Inspection”,
EC-415.
SEF696R
START SIGNAL INPUT CIRCUIT

2. Disconnect harness connector from the starter motor’s “S” ter-
minal.
3. Check terminal voltage between terminals q
1 and q4 when the
ignition switch is at “START”.
SEF697R
EC-410
for Cold Areas) (Cont’d) GI
GLOW INDICATOR CONTROL CIRCUIT
1. Turn ignition switch OFF. MA
2. Leave harness connector joined to glow control unit.
3. Connect test lamp to glow control unit as shown.
4. Turn ignition switch to ON and measure the time the test lamp EM
stays lit.
Time the test lamp should stay lit:
Approx. 2 - 6 seconds LC
(The time will vary according to coolant tempera-
SEF698R ture.)
FE
CL
MT
SEF699R
AT
GLOW CONTROL CIRCUIT
Pre-glow control TF
3. Connect test lamp to glow control unit as shown. PD
4. Turn ignition switch ON and measure terminal voltage and the
times the test lamp turns on and off.
1) At coolant temperature below 50°C (122°F) the battery voltage FA
appears for 15 seconds.
I Battery voltage should appear for 4 to 8 seconds*, and
SEF169U
then be chopped intermittently for the rest time. RA
* Pre-glow time (Varies with coolant temperature)
BR
ST
RS
BT
I The time will be shortened if ignition switch is OFF for only
a brief period. HA
Therefore, when measuring the time, leave ignition switch
OFF for more than 1 minute, and then turn ignition switch
ON. EL
The test lamp turns on and off approx. 1 - 3 times after it stayed
lit.
2) At coolant temperature over 50°C (122°F) the battery voltage SE
appears for approximately 3 seconds.
SEF701R
IDX
EC-411
for Cold Areas) (Cont’d)
After-glow control
3. Connect test lamp to glow control unit as shown in “Pre-glow
control”.
4. Turn ignition switch to START and return to ON. Measure ter-
minal voltage and count the times the test lamp turns on and
off.
1) At coolant temperature below 50°C (122°F) the battery voltage
SEF177U appears intermittently for 15 seconds. Test lamp turns on and
off approx. 3 times.
2) At coolant temperature over 50°C (122°F) the battery voltage
appears for 2 seconds.
Glow Control Unit Circuit Inspection (For Cold

Areas)
Roll up the floor sheet. Check the glow control unit.
DEC005
POWER SUPPLY CIRCUIT

Turn ignition switch ON and check voltage between terminal q
10
and body ground.
SEF683R
GROUND CIRCUIT
Check continuity between terminal q
13 and body ground.
SEF684R
EC-412
Areas) (Cont’d) GI
SPEED SENSOR SIGNAL CIRCUIT
While running vehicle or lifting rear wheels in 2WD position, check MA
that voltage between terminal q 11 and body ground fluctuates.
Voltage: approx. 5V
EM
LC
SEF685R
COOLANT TEMPERATURE SENSOR CIRCUIT

12 and q
13 .
Measure resistance to temperature approximately as shown in FE
“COOLANT TEMPERATURE SENSOR”, “Component Inspection”,
EC-415.
CL
MT
SEF686R
AT
ALTERNATOR’S “L” TERMINAL CIRCUIT
2. Leave harness connector joined to glow control unit. TF
15 and q13 when the
ignition switch is turned to ON.
Voltage: approx. 12V PD
FA
DEC009
RA
START SIGNAL INPUT CIRCUIT
1. Turn ignition switch OFF. BR
2. Disconnect harness connector from the starter motor’s “S” ter-
minal.
16 and q
13 when the ST
ignition switch is at “START”.
RS
SEF688R BT
HA
EL
SE
IDX
EC-413
Areas) (Cont’d)
GLOW INDICATOR CONTROL CIRCUIT
4. Turn ignition switch to ON and measure the time the test lamp
stays lit.
Approx. 2 - 6 seconds
(The time will vary according to coolant tempera-
SEF689R ture.)
DEF031
PRE-GLOW CONTROL CIRCUIT

4. Turn ignition switch ON and measure terminal voltage and the
time the test lamp stays lit.
Battery voltage should appear for 4 to 8 seconds*.
* (Varies with coolant temperature)
SEF170U
I The time will be shortened if ignition switch is OFF for only

a brief period.
Therefore, when measuring the time, leave ignition switch
OFF for more than 1 minute, and then turn ignition switch
ON.
I When the coolant temperature is below 10°C (50°F), the
battery voltage should appear for 30 seconds.
SEF692R
AFTER-GLOW CONTROL CIRCUIT

2. Turn ignition switch to START and run engine, then measure
glow plug terminal voltage and the time the test lamp stays lit.
SEF171U
EC-414
Areas) (Cont’d) GI
Battery voltage should continue for 6 minutes at coolant tem-
perature below 50°C (122°F).
[If vehicle speed is above 20 km/h (12 MPH), glow plug termi- MA
nal voltage should drop to 0V. If the speed drops below 10
km/h (6 MPH), the battery voltage should appear.]
The voltage should not appear at coolant temperature over EM
50°C (122°F).
LC
SEL486MB
Component Inspection
GLOW PLUG CONNECTING PLATE NUTS
FE
Check that all glow plug connecting plate nuts and harness nut are
installed securely.
CL
MT
SEL681KA
AT
GLOW PLUG
Remove glow plug connecting plate and perform continuity test
between each glow plug and cylinder head. TF
No continuity ... Replace glow plug.
PD
FA
SEL682K
RA
GLOW RELAY
The glow relay is normally open. BR
ST
RS
SEF680R BT
COOLANT TEMPERATURE SENSOR
Disconnect coolant temperature harness connector and measure HA
resistance.
Coolant temp. °C (°F) Resistance kΩ
EL
−25 (−13) 19
0 (32) 5.6
SE
20 (68) 2.5
40 (104) 1.2
DEF020
IDX
EC-415
Component Inspection (Cont’d)
DROPPING RESISTOR
Measure resistance between terminals.
Resistance: approx. 0.19 - 0.23Ω at 20°C (68°F)
DEC007
EC-416
SOLENOID TIMER TD
Description GI
To improve startability, a solenoid timer is used on models for cold
areas. Its purpose is to advance fuel injection timing in relation to MA
coolant temperature for a certain period after starting the engine.
This timer is controlled by the signal from the glow control unit. The
glow control unit sends a signal to activate the advance mechanism EM
of the fuel injection pump during cold starting.
Refer to “Circuit Diagram”, “QUICK-GLOW SYSTEM”, EC-401.
LC
FE
CL
MT
SEF419F
AT
Operation
Part of the fuel in the return line returns to the fuel injection pump
inlet, when the solenoid timer is OFF. When cold starting, the sole- TF
noid timer comes ON to stop the return of fuel to the inlet. This
increases the fuel pressure in the fuel injection pump so that fuel
injection timing advances. The duration of fuel injection timing PD
advance varies with changes in coolant temperature.
FA
SEF914H
RA
The advance duration of fuel injection timing is 30 seconds (con-
stant) when coolant temperature is below 10°C (50°F). Above 10°C
(50°F), fuel injection timing does not advance. BR
Refer to “Description”, “QUICK-GLOW SYSTEM”, EC-403.
ST
RS
SEF421F BT
TIMER CHARACTERISTICS
The figures show the differences in fuel injection timing in relation HA
to engine speed when the solenoid timer is both ON and OFF.
When the solenoid timer turns ON, fuel injection timing advances
by approximately 2°. Thus, cold engine starting in cold weather is EL
greatly improved.
SE
DEC008
IDX
EC-417
SOLENOID TIMER TD
Wiring Diagram
TEC457
EC-418
SOLENOID TIMER TD
Inspection GI
SOLENOID TIMER CONTROL CIRCUIT
1. Connect test lamp to glow control unit as shown. MA
2. Disconnect the harness connector from starter motor “S” termi-
nal.
3. Make sure that test lamp comes on when ignition switch is EM
turned to START.
4. Measure the time the test lamp stays lit when ignition switch is
turned to ON from START. LC
SEL361M
Approx. 30 seconds at coolant temperature below
10°C (50°F)
0 second at coolant temperature over 10°C (50°F)
FE
CL
MT
AT
SOLENOID TIMER
1. Disconnect solenoid timer harness and check for “clicking”
sound from solenoid when battery is connected and discon- TF
nected.
If solenoid has malfunction, replace it.
After checking, reconnect the connector. PD
FA
RA
BR
ST
RS
SEF423F BT
HA
EL
SE
IDX
EC-419
SOLENOID TIMER TD
2. Disconnect coolant temperature sensor harness connector.
3. Start engine and check voltage between terminal q 2 and
ground.
Battery voltage should exist for 30 seconds after starting
engine.
If not, check harness and glow control unit.
SEF424F
TIMER PISTON STROKE (Using pump tester)

Measure timer piston strokes at specified fuel injection pump speed
when solenoid timer is on and off.
Refer to “Injection Pump Calibration Standard” in SDS, EC-433.
EC-420
FUEL CUT SYSTEM TD
Wiring Diagram GI
MA
EM
LC
FE
CL
MT
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
TEC458
EC-421
FAST IDLE CONTROL CIRCUIT TD
Wiring Diagram
TEC459
EC-422
FAST IDLE CONTROL CIRCUIT TD
Electrical Components Inspection GI

IACV-FICD SOLENOID VALVE
1. Disconnect IACV-FICD solenoid valve harness connectors and MA
vacuum hoses.
2. Connect solenoid valve connector to battery and adequate
vacuum hoses to the solenoid valve as shown in the figure. EM
3. Blow air into hoses.
If air flows: OK
If air does not flow: NG LC
If NG, replace IACV-FICD solenoid valve.
DEC010
AIR CONDITIONER RELATED COMPONENTS

Refer to “Electrical Components Inspection”, “TROUBLE DIAG-
NOSES” in HA section. FE
CL
MT
AT
TF
PD
FA
DEC011
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-423
ENGINE ROOM FAN MOTOR ELECTRICAL CIRCUIT TD
Wiring Diagram
TEC460
EC-424
Cooling Fan (Motor driven) GI
MA
EM
LC
FE
CL
MT
DEC012
AT
Electrical Components Inspection
TF
COOLING FAN MOTOR
PD
FA
RA
DEC013

check operation. BR
Terminal
Cooling fan motor
! @ ST
q
a q
d
Operated
q
b q
c RS
BT
SEF422N
COOLING FAN RELAY HA
EL
SE
IDX
DEC014
EC-425
Electrical Components Inspection (Cont’d)
3 and q
4 .
Yes
terminals q
1 and q 2
SEF440N

1. Disconnect engine coolant temperature switch-1 harness con-
nector.
DEC015
2. Check operation as shown in the figure.

Coolant temperature
Operation Continuity
°C (°F)
Increased to 87 - 93
OFF , ON ON: Exists.
(189 - 199)
Decreased to 82 - 84
ON , OFF OFF: Does not exist.
(180 - 183)
SEF643Q
AIR CONDITIONER RELAY

For inspection of this relay, refer to HA section (“AIR CONDI-
TIONER RELAY”, “Electrical Components Inspection”).
EC-426
SERVICE DATA AND SPECIFICATIONS (SDS) TB45E
General Specifications GI
PRESSURE REGULATOR
MA
Fuel pressure
kPa (bar, kg/cm2, psi)
At idle
Approximately EM
245 (2.45, 2.5, 36)
A few seconds after ignition Approximately
switch is turned OFF to ON 294 (2.94, 3.0, 43) LC
Inspection and Adjustment

ENGINE COOLANT TEMPERATURE
Idle speed rpm Base idle speed*2 600±50
SENSOR FE
No-load*1
Target idle speed 650±50
(in “N” position) Temperature °C (°F) Resistance
Air conditioner: ON 750 or more (RHD models) 20 (68) 2.1 - 2.9 kΩ CL
(in “N” position) 950 or more (LHD models)
50 (122) 0.68 - 1.00 kΩ
Ignition timing 5°±2° BTDC
90 (194) 0.236 - 0.260 kΩ MT
Throttle position touch
900±150
speed rpm
*1: Under the following conditions: AT
I Air conditioner switch: OFF
I Steering wheel: Kept in straight-ahead position FUEL PUMP
I Electrical load: OFF (Lights, heater fan & rear window defog-
ger) Resistance [at 25°C (77°F)] Ω 0.2 - 5.0 TF
*2: Throttle position sensor connector is disconnected.
PD
IGNITION COIL IACV-AAC VALVE
Resistance [at 25°C (77°F)] Ω Approximately 10.0
Primary voltage V Battery voltage (11 - 14) FA
Primary resistance
Less than 1.0
[at 25°C (77°F)] Ω
Secondary resistance RA
[at 25°C (77°F)] kΩ
7 - 13 INJECTOR
Resistance [at 25°C (77°F)] Ω 10 - 14
BR
RESISTOR
ST
Resistance [at 25°C (77°F)] kΩ Approximately 2.2 THROTTLE POSITION SENSOR
Throttle valve conditions Resistance [at 25°C (77°F)]
Completely closed Approximately 0.6 kΩ

RS
MASS AIR FLOW SENSOR Partially open 0.6 - 4.0 kΩ
Completely open Approximately 4.0 kΩ BT

Supply voltage V Battery voltage (11 - 14)
1.3 - 1.8 at idle*

Output voltage at idle V
2.1 - 2.5 at 2,500 rpm* HA
*: Engine is warmed up to normal operating temperature and running
under no-load.
EL
SE
IDX
EC-427
SERVICE DATA AND SPECIFICATIONS (SDS) TB42S
General Specifications
CARBURETOR
Carburetor model 21J360-51
P 36 (1.42)
Throttle body bore mm (in)
S 40 (1.57)
P 32 (1.26)
Venturi diameter mm (in)
S 36 (1.42)
P #140
Main jet
S #225
P #60
Main air bleed
S #80
P #52
Slow jet
S #130
P #180
Slow air bleed
S #60
Power jet #120
Choke type Automatic choke
Fast idle adjustment
Fast idle speed

1,800±200
(A/T model in “N” position) rpm
Clearance “A”
1.37±0.14 (0.0539±0.0055)
(at 2nd cam step) mm (in)
Vacuum break adjustment mm (in)
Clearance “R1” 3.25±0.25 (0.1280±0.0098)
Clearance “R2” 5.0±0.5 (0.197±0.020)
Normal 650±50
Idle speed rpm
Air conditioner: ON 1,100±50
Ignition timing 10°±1°

Idle CO% 1.5
P: Primary S: Secondary #: 1/100 mm
Main jets for high altitude Vacuum motor kPa (mbar, mmHg, inHg)
Elevation m (ft) P S Opening starts −9.6 (−96, −72, −2.83)
1,000 (3,300) #138 #220 Fully open Over −19.5 (−195, −146, −5.75)
2,000 (6,600) #134 #212
3,000 (9,900) #130 #205
4,000 (13,200) #126 #200
Replacement of main jets is not necessary for models equipped with

altitude compensation system.
EC-428
SERVICE DATA AND SPECIFICATIONS (SDS) TB42S
Inspection and Adjustment GI

ATC AIR CLEANER Distributor spark advance curve
Atmospheric temperature
MA
Intake manifold vacuum °C (°F)
kPa (mbar, mmHg, inHg) Below Above
38 (100) 48 (118)
EM
Below 10.7 (107, 80, 3.15) Cool air Cool air
Above 22.7 (227, 170, 6.69) Hot air Cool air LC
IDLE COMPENSATOR
Unit: °C (°F)
Idle compensator partially opens 65 - 74 (149 - 165)
FE
Idle compensator fully opens Above 74 (165)
SEF437V
CL
FUEL PUMP MT
Fuel pump capacity
m (Imp fl oz)/minute More than 2,600 (91.5)
at 1,000 rpm AT
Fuel pressure 25.5 - 32.4 (0.255 - 0.324,
kPa (bar, kg/cm2, psi) 0.26 - 0.33, 3.7 - 4.7)
TF
BCDD PD
BCDD set pressure (at sea level) −76.0±0.7 (−760±7,
kPa (mbar, mmHg, inHg) −570±5, −22.44±0.20)
FA
DISTRIBUTOR SEF438V RA
Firing order 1-5-3-6-2-4
Rotating direction Counterclockwise IGNITION COIL BR

Air gap mm (in) 0.25 - 0.5 (0.0098 - 0.0197)
Primary resistance
Approximately 1
[at 20°C (68°F)] Ω
Cap insulation resistance MΩ More than 50
ST
Rotor head insulation resistance Secondary resistance
More than 50 Approximately 10
MΩ [at 20°C (68°F)] kΩ
RS
BT
HA
EL
SE
IDX
EC-429
SERVICE DATA AND SPECIFICATIONS (SDS) RD28ETi
General Specifications
Unit: rpm Injection pump numbers
Engine RD28ETi
Pump assembly
Engine Part number
Idle speed 775±25 number
Maximum engine speed 5,400 RD28ETi 16700 VB300 104721-2000
Injection Nozzle
INSPECTION AND ADJUSTMENT Adjusting shims
Injection nozzle assembly Thickness mm (in) Parts No.
Unit: kPa (bar, kg/cm2, psi) 0.50 (0.0197) 16613-V0700
Initial injection pressure 0.54 (0.0213) 16613-V0702
Used 14,220 (142.2, 145, 2,062) 0.58 (0.0228) 16613-V0704
14,711 - 15,495 (147.1 - 155.0, 0.62 (0.0244) 16613-V0706
New
150 - 158, 2,133 - 2,247)
0.66 (0.0260) 16613-V0708
0.70 (0.0276) 16613-V0710
0.74 (0.0291) 16613-V0712
0.78 (0.0307) 16613-V0714
0.82 (0.0323) 16613-V0716
0.86 (0.0339) 16613-V0718

0.90 (0.0354) 16613-V0720
0.94 (0.0370) 16613-V0722
0.98 (0.0386) 16613-V0724
1.00 (0.0394) 16613-V0760
Inspection and Adjustment

0.92±0.04 (0.0362±0.0016)
ENGINE COOLANT TEMPERATURE
Plunger lift mm (in) SENSOR
(at 9.75° ATDC)
20 (68) 2.1 - 2.9

CAMSHAFT POSITION SENSOR (PUMP) 50 (122) 0.68 - 1.00
Resistance [at 25°C (77°F)] Ω 1,360 - 1,840 90 (194) 0.236 - 0.260
CONTROL SLEEVE POSITION SENSOR

Resistance [at 23°C (73°F)] Ω 5.9
EC-430
SERVICE DATA AND SPECIFICATIONS (SDS) RD28ETi
Inspection and Adjustment (Cont’d)
ADJUSTMENT RESISTOR ACCELERATOR POSITION SENSOR GI
Resistance [at 25°C (77°F)] kΩ 0.2 - 15.0 Resistance kΩ
Throttle valve conditions
[at 25°C (77°F)]
MA
Completely closed Approximately 0.5
Partially open 0.5 - 4

INJECTION TIMING CONTROL VALVE
Completely open Approximately 4
EM
Resistance [at 20°C (68°F)] Ω Approximately 11
LC
FUEL TEMPERATURE SENSOR
ELECTRIC GOVERNOR
−20 (−4) 13.67 - 16.37
20 (68) 2.306 - 2.568

FE
60 (140) 0.538 - 0.624
CRANKSHAFT POSITION SENSOR (TDC)
80 (176) 0.289 - 0.344
Resistance [at 25°C (77°F)] kΩ Approximately 0.8 - 1.2 CL
MT
GLOW PLUG
AT
TF
PD
FA
RA
BR
ST
RS
BT
HA
EL
SE
IDX
EC-431
SERVICE DATA AND SPECIFICATIONS (SDS) TD
VE-type Injection Pump

APPLICATION
Destination Part No. Pump assembly No. Remarks
16700 VB503 104760-4770 For standard models

General areas
16700 VB504 104760-4780 With high altitude compensator (ACS)
Russia 16700 VB505 104760-4790 With solenoid timer
Australia 16700 VB511 104760-4800
INSPECTION AND ADJUSTMENT

Plunger lift Maximum engine speed
Plunger lift at TDC Maximum engine speed
mm (in) Pump assembly (Under no load) rpm
Part No.
No.
+50
Inspection Adjustment 4,600−150
16700 VB503 104760-4770

0.626±0.05 0.626±0.02 16700 VB504 104760-4780
(0.0246 (0.0246
±0.0020) ±0.0008) 16700 VB505 104760-4790
16700 VB511 104760-4800
SEF065K
Injection Nozzle
INSPECTION AND ADJUSTMENT Adjusting shims
Injection nozzle assembly Thickness mm (in) Part No.
Unit: kPa (bar, kg/cm2, psi) 0.1 (0.004) 16613-43G00
0.2 (0.008) 16613-43G01
Initial injection pressure
0.3 (0.012) 16613-43G02
9,807 - 10,297 0.4 (0.016) 16613-43G03
Used
(98.1 - 103.0, 100 - 105, 1,422 - 1,493) 0.5 (0.020) 16613-43G04
0.52 (0.0205) 16613-43G05
10,297 - 11,278 0.54 (0.0213) 16613-43G06
New
(103.0 - 112.8, 105 - 115, 1,493 - 1,635) 0.56 (0.0220) 16613-43G07
0.58 (0.0228) 16613-43G08
0.8 (0.031) 16613-43G09
EC-432
Injection Pump Calibration Standard GI
Pump rotation: Clockwise—viewed from drive side MA

Injection pump assembly No. 104760-4770
Part No. 16700 VB503
EM
1. Test conditions
1 - 1 Nozzle: 105780-0060 (NP-DN0SD1510) 1 - 4 Injection pipe: 2 dia. x 6 dia. x 450 mm (0.08 dia. x 0.24 dia. x 17.72 in)
1 - 2 Nozzle holder: 105780-2150 1 - 5 Fuel oil temperature: 45+5
0 °C (113+90 °F) LC
+0.3
1 - 3 Nozzle opening pressure: 13.000 MPa 0 1 - 6 Supply pump pressure: 20 kPa (0.20 bar, 0.2 kg/cm2, 2.8 psi)
+3.0
(130.0 bar,0
133+30 kg/cm2,
1,891+43
0 psi)
2. Setting Pump speed Settings

Charge air press
kPa Difference in delivery FE
rpm (mbar, mmHg, inHg) m (Imp fl oz)
2 - 1 Timing device travel 1,000 2.9±0.2 mm (0.114±0.008 in) —

422±20 kPa (4.22±0.20 bar, CL
2 - 2 Supply pump pressure 1,000 4.3±0.2 kg/cm2, 61±2.8 psi) —
2 - 3 Full-load delivery 1,000 46.9±0.5 m 3.5 (0.12)

(1.65±0.02 Imp fl oz)/1,000 st
10.1±2.0 m —
MT
2 - 4 Idle speed regulation 350 2.0 (0.07)
(0.36±0.07 Imp fl oz)/1,000 st
+20.0
60.0−10.0 m
2 - 5 Start (Full lever) 100 —
+0.70
(2.11−0.35 Imp fl oz)*/1,000 st AT
2 - 6 Full-load speed regulation 2,300 17.8±2.0 m 5.0 (0.18)
(0.63±0.07 Imp fl oz)/1,000 st
3. Test specifications Solenoid timer

TF
N = rpm 650 1,000 1,800 2,200
3 - 1 Timing device mm (in) 1.2±0.5 (0.047±0.020)* 2.9±0.3 (0.114±0.012) 6.6±0.5 (0.260±0.020)* +0.4
8.2−0.5 +0.016
(0.323−0.020)
N = rpm 1,000 1,800 PD
3 - 2 Supply pump kPa (bar, 422±29 686±39
kg/cm2, psi) (4.22±0.29, (6.86±0.39,
4.3±0.3, 61±4) 7.0±0.4, 100±6)
N = rpm 1,000 (O-ring less) FA
3 - 3 Overflow delivery m (Imp fl oz)/ 400±130
min. (14.1±4.6)
3-4 Fuel injection quantities RA

Speed control Pump speed Fuel delivery Charge air press Difference in
lever position rpm m (Imp fl oz)/ kPa (mbar, delivery
1,000 st
46.9±1.0
mmHg, inHg) m (Imp fl oz)
BR
1,000
(1.65±0.04)
4. Dimensions
600 45.4±2.5
(1.60±0.09)* K 3.3±0.1 mm (0.130±0.004 in) ST
2,000 44.9±2.5
(1.58±0.09)* KF 6.64±0.1 mm (0.2614±0.0039 in)
Max. speed — —
2,100 44.7±4.5
(1.57±0.16)* MS 1.0±0.1 mm (0.039±0.004 in) RS
2,300 17.8±2.5 BCS —
(0.63±0.09)
Below 5.0 Pre-stroke —
2,500 (0.18) BT
Switch OFF Control lever angle
Magnet valve 350 0 (0) — —
α 51.5 - 59.5 degree
10.1±2.5
Idling 350
(0.36±0.09)
— —
β 35.0 - 45.0 degree
HA
3-5 Solenoid Max. cut-in voltage: 8V
Test voltage: 12 - 14V γ —
*: Reference value EL
SE
IDX
EC-433
Injection Pump Calibration Standard (Cont’d)
Control lever angle measurement position
Measure the control lever angles (α, β).
DEF011
EC-434
GI
Pump rotation: Clockwise—viewed from drive side
Part No. 16700 VB504 MA
1. Test conditions
1 - 1 Nozzle: 105780-0060 (NP-DN0SD1510) 1 - 4 Injection pipe: 2 dia. x 6 dia. x 450 mm (0.08 dia. x 0.24 dia. x 17.72 in) EM
1 - 2 Nozzle holder: 105780-2150 1 - 5 Fuel oil temperature: 45+50 °C (113+90 °F)
1 - 3 Nozzle opening pressure: 13.000+0.3
0 MPa 1 - 6 Supply pump pressure: 20 kPa (0.20 bar, 0.2 kg/cm2, 2.8 psi)
(130.0+3.0
0 bar, LC
133+30 kg/cm2,
1,891+43
0 psi)
Pump speed Charge air press Difference in delivery

2. Setting rpm Settings kPa m (Imp fl oz)
(mbar, mmHg, inHg)
2 - 1 Timing device travel 1,000 2.9±0.2 mm (0.114±0.008 in) — —

FE
2 - 2 Supply pump pressure 1,000 422±20 kPa (4.22±0.20 bar,
4.3±0.2 kg/cm2, 61±2.8 psi) — —
2 - 3 Full-load delivery 1,000 46.9±0.5 m — 3.5 (0.12) CL

(1.65±0.02 Imp fl oz)/1,000 st
2 - 4 Idle speed regulation 350 10.1±2.0 m — 2.0 (0.07)
(0.36±0.07 Imp fl oz)/1,000 st
2 - 5 Start (Full lever) 100
+20.0
60.0−10.0 m
— —
MT
+0.70
(2.11−0.35 Imp fl oz)*/1,000 st
2 - 6 Full-load speed regulation 2,300 17.8±2.0 m — 5.0 (0.18)
(0.63±0.07 Imp fl oz)/1,000 st
38.4±1.5 m −21.9 AT
2 - 7 ACS adjustment 1,000 (1.35±0.05 Imp fl oz)/1,000 st (−219, −164, −6.46) —
3. Test specifications Solenoid timer TF

N = rpm 650 1,000 1,800 2,200
8.2−0.5 +0.016
(0.323−0.020)
N = rpm 1,000
422±29
1,800
686±39
PD
3 - 2 Supply pump kPa (bar,
kg/cm2, psi) (4.22±0.29, (6.86±0.39,
4.3±0.3, 61±4) 7.0±0.4, 100±6)
3 - 3 Overflow delivery
N = rpm
m (Imp fl oz)/
1,000
400±130
FA
min. (14.1±4.6)

Speed control Pump speed Fuel delivery Charge air press
lever position rpm m (Imp fl oz)/ kPa (mbar,
1,000 st mmHg, inHg)
1,000
46.9±1.0 BR
(1.65±0.04) 4. Dimensions
600 45.4±2.5 K 3.3±0.1 mm (0.130±0.004 in)

(1.60±0.09)*
44.9±2.5 KF 6.64±0.1 mm (0.2614±0.0039 in)
ST
2,000
Max. speed (1.58±0.09)* —
44.7±4.5 MS 1.0±0.1 mm (0.039±0.004 in)
2,100
(1.57±0.16)*
17.8±2.5
BCS — RS
2,300 (0.63±0.09) Pre-stroke —
2,500 Below 5.0 (0.18)
Switch OFF
Magnet valve 350 0 (0) —
Control lever angle BT
α 51.5 - 59.5 degree
Idling 350 10.1±2.5 —
(0.36±0.09) β 35.0 - 45.0 degree
3-5 Solenoid
Max. cut-in voltage: 8V HA
*: Reference value
ACS: High altitude compensator EL
SE
IDX
EC-435
DEF011
Full-load fuel injection quantity and ACS (high altitude compensator) adjusting procedure
at high altitudes
1. Full-load fuel injection quantity adjustment
(1)Remove the ACS cover, the bellows and the adjusting shims.
(2)Perform all adjustments as described in the adjusting specifications, except for ACS adjustment.
2. ACS adjustment
(1)Attach the ACS cover, the bellows and the adjusting shims.
(2)At a pump speed of 1,000 rpm and referring to the value below, use the shims to adjust the fuel injection
quantity decrease quantity according to the altitude.
Under the following conditions, adjust the ACS to value as specified.
Atmospheric pressure
Pump speed Altitude Fuel injection q’ty Increasing rate
kPa (mbar, mmHg, Remarks
rpm m (ft) m (Imp fl oz)/1,000 st (%)
inHg)
46.9±0.5
0 0 0 —
(1.65±0.02)
−5.9±3.3 (−59±33,
[500 (1,600)] Change point — —
−44±25, −1.73±0.98)
1,000
−21.9 (−219, −164, 38.4±1.5
2,000 (6,500) 18.1 —
−6.46) (1.35±0.05)
−39.7 (−397, −298,

4,000 (13,000) 31.4 (1.11)* 33.0 —
−11.73)
*: Reference value
EC-436
GI
1. Test conditions
1 - 2 Nozzle holder: 105780-2150 1 - 5 Fuel oil temperature: 45+5
0 °C (113+90 °F)
(130.0+3.0
0 bar, LC
133+30 kg/cm2,
1,891+43
0 psi)

(mbar, mmHg, inHg)
2 - 1 Timing device travel 1,000 OFF 2.9±0.2 mm (0.114±0.008 in) —

FE
OFF 422±20 kPa (4.22±0.20 bar,
2 - 2 Supply pump pressure 1,000 4.3±0.2 kg/cm2, 61±2.8 psi) —
2 - 3 Full-load delivery 1,000 46.9±0.5 m 3.5 (0.12) CL

(1.65±0.02 Imp fl oz)/1,000 st
10.1±2.0 m —
2 - 4 Idle speed regulation 350 2.0 (0.07)
(0.36±0.07 Imp fl oz)/1,000 st
+20.0
60.0−10.0 m
—
MT
+0.70
(2.11−0.35 Imp fl oz)*/1,000 st
(0.63±0.07 Imp fl oz)/1,000 st
AT
3. Test specifications Solenoid timer ON OFF
1,000 650 1,000 1,800
3 - 1 Timing device N = rpm 4.6±0.5 1.2±0.5 2.9±0.3 6.6±0.5 2,200 TF
mm (in) (0.181±0.020)* (0.047±0.020)* (0.114±0.012) (0.260±0.020)* 8.2+0.4 +0.016
−0.5 (0.323−0.020)
N = rpm 1,000 1,800

422±29 686±39
(4.22±0.29, (6.86±0.39, PD
kg/cm2, psi)
4.3±0.3, 61±4) 7.0±0.4, 100±6)
N = rpm 1,000 (O-ring)
3 - 3 Overflow delivery m (Imp fl oz)/ 400±130
min. (14.1±4.6) FA
3-4 Fuel injection quantities
Speed control Pump speed Fuel delivery Charge air press RA

46.9±1.0
1,000 (1.65±0.04)
4. Dimensions
BR
600 45.4±2.5
(1.60±0.09)* K 3.3±0.1 mm (0.130±0.004 in)
44.9±2.5
Max. speed
2,000 (1.58±0.09)*
—
KF 6.64±0.1 mm (0.2614±0.0039 in) ST
44.7±4.5
2,100 (1.57±0.16)* MS 1.0±0.1 mm (0.039±0.004 in)
17.8±2.5
2,300 (0.63±0.09)
BCS — RS
2,500 Below 5.0 Pre-stroke —
(0.18)
Control lever angle
Switch OFF
Magnet valve
350 0 (0) — BT
α 51.5 - 59.5 degree
Idling 350 10.1±2.5 —
(0.36±0.09) β 35.0 - 45.0 degree
3-5 Solenoid Max. cut-in voltage: 8V
HA
*: Reference value
ON: Solenoid timer is ON.
OFF: Solenoid timer is OFF. EL
If there is no designation in the specifications for the Solenoid Timer’s ON-OFF position, then the position should be regarded as OFF.
SE
IDX
EC-437
DEF011
EC-438
GI
1. Test conditions
1 - 2 Nozzle holder: 105780-2150 1 - 5 Fuel oil temperature: 45+50 °C (113+90 °F)
(130.0+3.0
0 bar, LC
133+30 kg/cm2,
1,891+43
0 psi)

(mbar, mmHg, inHg)
2 - 1 Timing device travel 1,000 2.9±0.2 mm (0.114±0.008 in) —

FE
2 - 2 Supply pump pressure 1,000 422±20 kPa (4.22±0.20 bar,
4.3±0.2 kg/cm2, 61±2.8 psi) —
2 - 3 Full-load delivery 1,000 50.3±0.5 m 3.5 (0.12) CL

(1.77±0.02 Imp fl oz)/1,000 st
2 - 4 Idle speed regulation 350 10.1±2.0 m 2.0 (0.07)
(0.36±0.07 Imp fl oz)/1,000 st —
+20.0
60.0−10.0 m
—
MT
+0.70
(2.11−0.35 Imp fl oz)*/1,000 st
(0.63±0.07 Imp fl oz)/1,000 st
35.0±1.0 m AT
2 - 7 Load timer adjustment 1,000 (1.23±0.04 Imp fl oz)/1,000 st) —
3. Test specifications TF
N = rpm 650 1,000 1,800 2,200
8.2−0.5 +0.016
(0.323−0.020)
N = rpm 1,000
422±29
1,800
686±39
PD
kg/cm2, psi) (4.22±0.29, (6.86±0.39,
4.3±0.3, 61±4) 7.0±0.4, 100±6)*
3 - 3 Overflow delivery
N = rpm
m (Imp fl oz)/
1,000
400±130
FA
min. (14.1±4.6)

Speed control Pump speed Fuel delivery Charge air press
1,000
50.3±1.0 BR
(1.77±0.04) 4. Dimensions
600 48.8±2.5 K 3.3±0.1 mm (0.130±0.004 in)

(1.72±0.09)*
48.3±2.5 KF 6.64±0.1 mm (0.2614±0.0039 in) ST
2,000
Max. speed (1.70±0.09)* —
48.1±4.5 MS 1.0±0.1 mm (0.039±0.004 in)
2,100
(1.69±0.16)*
17.8±2.5
BCS — RS
2.300 (0.63±0.09) Pre-stroke —
2,500 Below 5.0 (0.18)
Control lever angle
Switch OFF
Magnet valve 350 0 (0) Idle — BT
α 51.5 - 59.5 degree
Idling 350 10.1±2.5 —
(0.36±0.09) β 35.0 - 45.0 degree
3-5 Solenoid
Max. cut-in voltage: 8V HA
*: Reference value
EL
SE
IDX
EC-439
DEF011
Load timer adjustment

1. Fix the control lever in the position satisfying the following conditions.
Pump speed: 1,000 rpm
Fuel injection quantity: 35.0±1.0 m (1.23±0.04 Imp fl oz)/1,000 st
2. With the control lever positioned as described in 1. above, adjust the governor sleeve so that the timer
stroke conforms to the specified values (item 2 - 7).
Control lever position Specified values
Timer stroke
Pump speed Fuel injection quantity Boost pressure Timer stroke
reduction value
rpm m (Imp fl oz)/1,000 st kPa (mbar, mmHg, inHg) mm (in)
mm (in)
32.0±1.0 3.4±0.3
1,200 — —
(1.13±0.04) (0.134±0.012)
23.0±2.5 2.9±0.6
1,200 — —
(0.81±0.09)* (0.114±0.024)*
*: Reference value
EC-440

Engine Control System

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Engine Control System

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ENGINE CONTROL SYSTEM

Alphabetical & Numerical Index for DTC

*: Refer to “NATS (Nissan Anti-Theft System)” in EL section.

Special Service Tools GI

FOR DIESEL ENGINE INJECTION PUMP

KV11102900 Removing injection pump

KV10111100 Removing injection pump RS

Engine Fuel & Emission Control System

I When connecting ECM harness connector, tighten secur-

Engine Control Component Parts Location GI

Vacuum Hose Drawing GI

Camshaft position sensor E Fuel injection &

Mass air flow sensor E

Engine coolant temperature sensor E

Distributor ignition system E Power transistor

Neutral position switch (M/T models) E

TCM (Transmission control module) (A/T E

Vehicle speed sensor E

Air conditioner switch E

Oxygen sensor monitor* & Malfunction indicator lamp

*: For Australia and specific areas

Multiport Fuel Injection (MFI) System GI

Amount of intake air EM

Engine coolant temperature sensor Engine coolant temperature LC

Oxygen sensor* Density of oxygen in exhaust gas

TCM (Transmission control module) (A/T mod- Gear position MT

Battery voltage Battery voltage PD

*: For Australia and specific areas FA

BASIC MULTIPORT FUEL INJECTION VARIOUS FUEL INJECTION RA

MIXTURE RATIO SELF-LEARNING CONTROL

Simultaneous multiport fuel injection system MA

Sequential multiport fuel injection system

Distributor Ignition (DI) System

Mass air flow sensor Amount of intake air

Engine coolant temperature sensor Engine coolant temperature

Vehicle speed sensor Vehicle speed

Intake air temperature sensor Intake air temperature

Neutral position switch (M/T models) Neutral position

TCM (Transmission control module) (A/T mod- Neutral position

Battery Battery voltage

Air Conditioning Cut Control GI

Air conditioner “ON” signal

Ignition switch Start signal

Engine coolant temperature sensor Engine coolant temperature

Fuel Cut Control (at no load & high engine TF

The evaporative emission system is used to reduce hydrocarbons

FUEL CUT VALVE

Fuel Pressure Release GI

Injector Removal and Installation

6. Push out any malfunctioning injector from fuel tube assembly.

8. Install injector to fuel tube assembly.

Fast Idle Cam (FIC) Inspection and Adjustment GI

Diagnostic Trouble Code (DTC)

A sample of CONSULT display is shown at left. The malfunction is

HOW TO ERASE DTC

Selecting “ERASE” in the SELF- DIAG RESULTS” mode with CONSULT

Malfunction Indicator Lamp (MIL)

ON BOARD DIAGNOSTIC SYSTEM FUNCTION

Diagnostic Test Mode I

Diagnostic Test Mode II

MIL Flashing without DTC

Data link connector for CONSULT ST

I Switching the modes is not possible when the