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GIM0059
ECM0010
ECM0012
EC-3 113
PREPARATION
ECM0013
ECM0014
ECM0015
ECM0016
Harness adapter
91H20-09040
(150-pin to 121-pin conversion adapter)
ECM0017
114 EC-4
DESCRIPTION
Electric throttle control actuator • Adopts electronic throttle control actuator with integrated throttle control motor to adjust
throttle valve opening optimally according to driving conditions or to improve safety and
operability by electronically controlled governor.
Fuel injection control • With SOFIS control, amounts of injected fuel are optimized to improve exhaust
performance and response.
• Using feedback control through learning of air-fuel ratio compensation, the system corrects
the ratio during transitional conditions, such as sudden sharp changes in the ratio, in order
to improve drivability.
Ignition timing control • Uses Hall IC crankshaft position sensor (POS) and camshaft position sensor (PHASE) to
perform controls so that optimum ignition timing is obtained for every operating condition.
Optimum ignition timing setup according to each fuel is also enabled at the time of a
combined use formula.
• Adopts electronic distribution system (NDIS) in which each cylinder is equipped with an
ignition coil incorporating a power transistor for better ignition performance.
Idle speed control • Adopts electronic throttle control actuator that continuously regulates intake air amount
required for idling.
Governor speed control • Performs maximum regulation of engine speed for oil pressure pump protection by engine
speed signal.
Maximum speed regulation control • Performs maximum speed regulation by vehicle speed sensor signal. Also, performs
variable control of maximum speed by changeover switch as an option.
Idling area torque up control • Performs torque up control in idling area by engine speed signal in order to also enable
cargo work at idling.
Overheat prevention control • Reduces engine heat generation by reducing maximum engine speed and regulating
maximum throttle opening when engine coolant temperature reaches approximately 110˚C.
• Prevents resulting in engine breakage by overheat by performing fuel cut at 1,000 rpm or
more when engine coolant temperature reaches approximately 135˚C.
Slow operation mode control • Changes throttle opening characteristic of throttle position by slow operation mode switch,
and then minute operation of engine speed is enabled.
Fuel pump control (gasoline) • Turns fuel pump relay ON/OFF depending on engine speed signal.
LPG interception valve control • Turns interception valve relay ON/OFF depending on engine speed signal and fuel
pressure sensor signal.
Fail-safe function • Ensures vehicle's safe operation and enables vehicle to be driven in an emergency when
any of the major system components (mass air flow sensor, engine coolant temperature
sensor, etc.) have malfunctioned.
Diagnostic system • Adopts self-diagnosis system for easier trouble diagnosis.
EC-5 115
DESCRIPTION
K-ENGINE ELECTRONICALLY CONTROLLED SYSTEM
DIAGRAM (GASOLINE)
ECM0018
116 EC-6
DESCRIPTION
K-ENGINE ELECTRONICALLY CONTROLLED SYSTEM
DIAGRAM (LPG)
ECM0019
EC-7 117
DESCRIPTION
K-ENGINE ELECTRONICALLY CONTROLLED SYSTEM
DIAGRAM (LPG AND GASOLINE)
ECM0020
118 EC-8
DESCRIPTION
Combined
Gasoline std std std std — std std std std opt opt std std
Fuel
Self-diagnosis
Fuel cut off
Fail-safe
⊕: Significant impact to control
♦: Impact to control
Crankshaft position sensor (POS,
⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ♦
PHASWE)
Mass air flow sensor ⊕ ⊕ ♦ ⊕ ♦ ♦
Intake air temperature sensor ♦ ⊕ ♦
Engine coolant temperature sensor ♦ ♦ ⊕ ♦ ♦ ♦ ♦
Heated oxygen sensor ⊕ ♦ ♦
Vehicle speed sensor ♦ ♦ ♦ ♦ ⊕ ♦
Throttle position sensor ♦ ♦ ⊕ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
Accelerator pedal position sensor ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
Sensors
Ignition switch ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕
P/N POSI SW ♦ ♦ ♦ ♦ ♦
Stop lamp switch ♦
Headlamp (electrical load) switch ♦
Slow mode switch (opt) ⊕
Battery voltage ♦ ♦ ♦ ♦ ♦ ♦
LPG fuel pressure sensor ♦ ⊕ ♦
LPG injector drive unit check signal ♦
Fuel changing switch ⊕ ⊕ ⊕ ⊕ ⊕
EC-9 119
DESCRIPTION
Combined
Gasoline std std std std — std std std std opt opt std std
Fuel
Self-diagnosis
Fuel cut off
Fail-safe
⊕: Significant impact to control
♦: Impact to control
Gasoline injector ⊕ ⊕ ⊕
Power transistor ⊕ ♦
Ignition
system Ignition coil ⊕
Throttle control motor relay ⊕ ⊕ ♦
Throttle control motor ⊕ ⊕ ♦ ♦
Gasoline fuel pump relay ⊕ ⊕
Gasoline fuel pump ⊕ ♦
Actuators
Ignition relay ⊕
ECM relay ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕
LPG injector drive unit ⊕ ⊕ ⊕
LPG injector ⊕ ⊕ ⊕ ♦
LPG assistance injector ⊕ ⊕ ⊕ ♦
LPG interception valve relay ⊕ ⊕ ♦
LPG interception valve ⊕ ♦
LPG PTC heater relay ♦ ⊕
LPG PTC heater ♦ ♦
120 EC-10
BASIC INSPECTION
CAUTION:
Perform “Idle Air Volume Learning” (on page EC-13) when idle
speed or ignition timing is outside the standard.
• Turn ignition switch ON, and then make sure that no
malfunction is detected by self-diagnosis.
• Make sure that engine is free of oil pressure pump loads and
any electrical loads. Perform the inspection with the shift lever
in the neutral or N position.
• Warm up engine and transaxle to the normal operating
temperature.
IDLE SPEED
With ST
1. Connect ST to VCM connector.
2. Indicate “Eng.rev” in ECM Input/Output monitor and make sure
that idle speed is 700 ±50 rpm.
CAUTION:
Perform “Idle Air Volume Learning” (on page EC-13) when idle
speed is outside the standard.
Without ST
1. Connect an induction type (current detection type) tachometer
to the primary wire of the 1 cylinder to check idle speed.
• The primary wire for the 1 cylinder is looped and longer than the
wires for other cylinders. It is used for detecting idle speed and
ignition timing.
2. Make sure that idle speed is 700 ±50 rpm.
CAUTION:
Perform “Idle Air Volume Learning” (on page EC-13) when idle
speed is outside the standard.
EC-11 121
BASIC INSPECTION
CAUTION:
Perform “Idle Air Volume Learning” (on page EC-13) when ignition
timing is outside the standard.
With ST
1. Indicate “O2 sensor rich” in ECM Input/Output monitor.
2. Keep engine speed at approximately 2,000 rpm, and make sure
that “ON” and “OFF” are alternately displayed.
ECM0024
Without ST
1. Check it with heated oxygen sensor monitor mode. (Refer to
EC-49, “DIAGNOSTIC TEST MODE II - HEATED OXYGEN
SENSOR MONITOR” for operation procedure.)
2. Keep engine speed at approximately 2,000 rpm, and make sure
that the MWL on the dash blinks at least 5 times within 10
seconds.
NOTE:
• Increase engine speed when inspecting while air-fuel ratio feed-
back control is activated during idle.
122 EC-12
BASIC INSPECTION
CAUTION:
Throttle valve closed position learning cannot be performed with ST.
CAUTION:
“IDLE AIR VOL LEARN (PLANT)” is the original setting on the
vehicle. Do not use it.
NOTE:
Battery voltage should be 12.3V or higher.
EC-13 123
BASIC INSPECTION
CAUTION:
It will take approximately 20 seconds to complete the idle air volume
learning. Do not turn OFF the ignition switch until completion.
• Confirm whether or not the learning has been completed by
checking the “TAS completion” in ECM Input/Output monitor.
Learning completed: ON
Learning not yet completed: OFF
• Make sure that idle speed and ignition timing are within the
ECM0027
standard.
• Perform “Idle Air Volume Learning” again if values are outside
the standard.
OPERATION PROCEDURE
1. Turn ignition switch ON and wait at least 2 seconds.
2. Turn ignition switch OFF and wait at least 10 seconds.
3. Then turn ignition switch ON again and wait at least 2 seconds
(learning completed).
CAUTION:
Relieve fuel pressure before removing fuel piping to secure safety.
124 EC-14
BASIC INSPECTION
Without ST
1. Disconnect fuel pump fuse.
2. Start engine.
3. Crank engine 2 or 3 times to consume the fuel in the fuel line
after it stalls.
4. Turn OFF the ignition switch, and install the fuel pump fuse.
CAUTION:
• Safely and securely remove and install fuel hose.
• Use the fuel pressure gauge for fuel pressure inspection.
• Do not inspect fuel pressure while other systems are operating.
Malfunctions may occur in fuel pressure value.
1. Release the fuel pressure.
2. Install fuel pressure gauge using fuel hose for fuel pressure
inspection.
3. Remove fuel hose, and then install fuel hose for fuel pressure
inspection.
CAUTION:
Usable period of fuel hose for fuel pressure inspection is 30 times or
less. (Fuel hoses that are damaged and allow fuel leakage are not
contained above.)
4. Turn ignition switch ON, and then make sure that there is no
fuel leakage.
5. Start engine, and check for fuel leakage.
6. Make sure that fuel pressure is within the standard.
At idle: 0.35MPa (3.6 kgf/cm2)
• If the vehicle shows poor starting, check fuel pressure with fuel
pump operating for approximately 1 second after ignition switch
is turned ON, and during cranking.
For 1 second after ignition switch is turned ON and
during cranking: 0.35Mpa (3.6 kgf/cm2)
CAUTION:
Also check fuel pressure at increased engine speed.
• Malfunctioning pressure regulator (integrated with fuel pump)
• Clogged fuel piping
• Clogged fuel filter (with fuel pump)
• Poor fuel pump discharge
EC-15 125
TROUBLE DIAGNOSIS
CAUTION:
Customers are not professionals. Do not assume “maybe the
customer means ...” or “maybe the customer mentioned this
ECM0032 symptom.”
126 EC-16
TROUBLE DIAGNOSIS
ECM0034
ECM0035
EC-17 127
TROUBLE DIAGNOSIS
ECM0036
128 EC-18
TROUBLE DIAGNOSIS
ECM0037
EC-19 129
TROUBLE DIAGNOSIS
Poor starting
Other
Symptoms Poor idle Poor driving control
Description/notable
Fast idle is not effective
No initial combustion
symptom
High idle rpm
Low idle rpm
After-burn
Knocking
Backfire
Driving
At Idle
Sensor malfunction
⊕: Highly possible
♦: Possible
130 EC-20
TROUBLE DIAGNOSIS
Poor starting
Other
Symptoms Poor idle Poor driving control
After-burn
Knocking
Backfire
Driving
At Idle
Sensor malfunction
⊕: Highly possible
♦: Possible
EC-21 131
TROUBLE DIAGNOSIS
RELATIONSHIPS BETWEEN MALFUNCTIONING SYMPTOMS
AND ACTUATOR CIRCUITS
The table below shows the possible symptoms caused by the
malfunction of each actuator circuit.
Poor starting
Other
Symptoms Poor idle Poor driving
After-burn
Knocking
Backfire
Driving
At Idle
Actuator malfunction
⊕: Highly possible
♦: Possible
Momentarily ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦
open
Ignition signal circuit OPEN ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • Slight shocks and surges may
be sensed depending on the
Momentarily ♦ ♦ ♦ duration of momentarily open
open circuit and the operating
conditions.
Ignition coil Power OPEN ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ¥
supply
circuit Momentarily ♦ ♦ ♦ • Engine stall may occur if
open duration of momentarily open
circuit is too long.
Momentarily ♦ ♦ ♦
open
ECM relay circuit OPEN ⊕ ♦ ⊕ ⊕ ⊕ ⊕
132 EC-22
TROUBLE DIAGNOSIS
Poor starting
Other
Symptoms Poor idle Poor driving
After-burn
Knocking
Backfire
Driving
At Idle
Actuator malfunction
⊕: Highly possible
♦: Possible
Tip OPEN
circuit
SHORT
PWM OPEN
circuit
SHORT
Power OPEN
supply
Ground OPEN
Coil OPEN
LO side OPEN
circuit
SHORT
Control unit
side short
Control unit
side short
EC-23 133
TROUBLE DIAGNOSIS
RELATIONSHIP BETWEEN MALFUNCTIONING SYMPTOM AND
THE ENGINE MAIN BODY/AUXILIARY COMPONENT
The table below shows the possible symptoms caused by the
malfunction of engine main body system. It will be helpful in
malfunction trouble diagnosis. (The table lists general symptoms
and some may not be applicable.)
Poor starting
Impossible
to start
Engine
Other
Symptoms Poor idle Poor driving
stall
Description/notable
No initial combustion
After-burn
Knocking
Backfire
Driving
At Idle
⊕: Highly possible
♦: Possible
∇: Not very possible
Air sucked from oil level gauge ♦ ∇ ♦ ♦ ∇ ∇ ∇ • Air-fuel ratio becomes LEAN.
• High air-fuel correction factor.
Air sucked from oil filler cap ♦ ∇ ♦ ♦ ∇ ∇ ∇ • Low suction power (vacuum pressure) of
intake manifold.
Air sucked from PCV hose ♦ ∇ ♦ ∇ ♦ ♦ ♦ ♦ ♦ ∇ ∇ ♦ ♦ ♦ ∇ * Check the suction using a pressure
(downstream of PCV) gauge.
* Generally applicable to air suction in air
Air sucked from intake manifold and ♦ ∇ ♦ ∇ ♦ ♦ ♦ ♦ ♦ ∇ ∇ ♦ ♦ ♦ ∇ intake system
gasket
PCV kept open ♦ ♦ ∇ ♦ ♦ ♦ ♦ ♦ • Noise (high hissing tone)
Improper LPG fuel (cold area and ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ∇ ♦ ♦ ♦ ♦ ∇ • Starting ability in cold area is changed
propane ratio) depending on propane ratio.
• Use LPG with proper propane ratio.
Malfunctioning LPG vaporizer ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • If the pressure is low, it is caused by poor
pressure adjusting valve output during high-speed or high load
operation.
• If the pressure is excessively high, relief
valve operates and engine stalls at rich.
134 EC-24
TROUBLE DIAGNOSIS
Poor starting
Impossible
to start
Engine
Other
Symptoms Poor idle Poor driving
stall
No initial combustion
After-burn
Knocking
Backfire
Driving
At Idle
⊕: Highly possible
♦: Possible
∇: Not very possible
Improper bulb contact ∇ ♦ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ ♦ ♦ ♦ • Symptom varies depending on contact
Compression
Low idle base speed ∇ ∇ ∇ ∇ ♦ ♦ ♦ ♦ • Engine stall may occur by power steering
load and cargo load during deceleration
or at idling.
∇ ∇ ♦ ∇ ♦
Other
High HYD PUMP load (PS, Cargo) ∇ ∇ ∇ ♦ ♦ ∇ ∇ ∇ ♦ • Malfunctioning oil pressure relief valve,
improper oil specification (This symptom
may especially occur in the cold.)
Foreign material in fuel tank (such ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • With low fuel, this may easily occur.
as dust)
Damaged fan, malfunctioning water ♦ • Noise
pump
Clogged/restricted radiator/ ♦ —
condenser
EC-25 135
TROUBLE DIAGNOSIS
Ignition coil
Gasoline injector
LPG injector
ECM0038
Specifications
Main component part Type Location
Gasoline LPG Combined
136 EC-26
TROUBLE DIAGNOSIS
ECM Component
Specifications NOTE
Component Location
Gasoline LPG Combined Actuator Sensor Other
EC-27 137
TROUBLE DIAGNOSIS
ECM0039
138 EC-28
TROUBLE DIAGNOSIS
ECM0040
EC-29 139
TROUBLE DIAGNOSIS
Circuit Diagram
K-ENGINE ELECTRONICALLY CONTROLLED ECM CIRCUIT
DIAGRAM (GASOLINE)
ECM0041
140 EC-30
TROUBLE DIAGNOSIS
ECM0042
EC-31 141
TROUBLE DIAGNOSIS
ECM0043
142 EC-32
TROUBLE DIAGNOSIS
ECM0044
EC-33 143
TROUBLE DIAGNOSIS
144 EC-34
TROUBLE DIAGNOSIS
108 —
119 Power supply for ECM
120 Power supply for ECM
104 Throttle control motor relay
3 Throttle control motor relay power supply
5 Throttle control motor (Open)
4 Throttle control motor (Close)
1 ECM ground
10 —
20 —
21 —
26 —
33 —
40 —
43 —
44 LPG injector drive intake
53 —
58 —
59 —
60 —
64 —
65 —
66 Sensor ground (Throttle position sensor)
71 —
72 LPG injector check
74 —
75 —
76 —
82 Accelerator pedal position sensor 1 ground
90 Accelerator pedal position sensor 1 power supply
93 —
96 —
97 —
103 —
112 LPG interception valve relay
114 —
117 —
118 —
EC-35 145
TROUBLE DIAGNOSIS
ECM0044
Terminal
Signal name Measurement condition Measured value
signal
146 EC-36
TROUBLE DIAGNOSIS
ECM0047
ECM0048
ECM0049
ECM0050
ECM0051
EC-37 147
TROUBLE DIAGNOSIS
85 (K LINE) K-line (ECM data transmit/receive) When connected to ST Approx. 6.6 - Battery voltage
When not connected to ST Approx. 6V
84 Headlamp switch Lighting switch OFF Approx. 0V
Lighting switch ON Battery voltage
67 Sensor ground Always Approx. 0V
115 ECM ground Always Approx. 0V
116
1
13 Crankshaft position sensor (POS) At cranking Approx. 2.6V
ECM0052
ECM0053
ECM0054
91 Accelerator pedal position sensor 2 Ignition switch ON, engine running Approx. 2.5V
power supply
48 Sensor power supply Ignition switch ON, engine running Approx. 5V
121 Power supply for ECM (Backup) Always Battery voltage
47 Electric throttle control actuator power Ignition switch ON, engine running Approx. 5V
supply
78 Heated oxygen sensor ground Always Approx. 0V
82 Accelerator pedal position sensor 1 Always Approx. 0V
ground
90 Accelerator pedal position sensor 1 Ignition switch ON, engine running Approx. 5V
power supply
148 EC-38
TROUBLE DIAGNOSIS
ECM0055
ECM0056
ECM0057
EC-39 149
TROUBLE DIAGNOSIS
ECM0058
ECM0059
73 Engine coolant temperature sensor Engine coolant temperature is approx. Approx. 3.5V
signal 20˚C.
Engine coolant temperature is approx. Approx. 1.2V
80˚C.
150 EC-40
TROUBLE DIAGNOSIS
ECM0060
ECM0061
ECM0062
119 Power supply for ECM Ignition switch ON, engine running Battery voltage
120
104 Throttle control motor relay Ignition switch ON, engine running Approx. 1V
3 Throttle control motor relay power supply Always Battery voltage
5 Throttle control motor (Open) At idle after warming up Approx. 0.1 - 0.15V
At approx. 2,000 rpm
4 Throttle control motor (Close) At idle after warming up Approx. 2 - 2.5V
At approx. 2,000 rpm
11 LPG assistance injector Other than above (Ignition switch ON, Battery voltage
engine running)
27 PTC heater relay Other than above (Ignition switch ON, Battery voltage
engine running)
32 Fuel changing switch 2 (Gasoline) Changing switch ON (At gasoline side) Approx. 5V
Changing switch ON (At LPG side or Approx. 0V
neutral)
49 Fuel changing switch power supply Changing switch ON Approx. 5V
Changing switch ON (At neutral) Approx. 0V
70 Fuel changing switch 1 (LPG) Changing switch ON (At LPG side) Approx. 5V
Changing switch ON (At LPG side or Approx. 0V
neutral)
112 LPG interception valve relay For approximately 10 seconds with Battery voltage
ignition switch ON and after ignition
switch OFF
Ignition switch OFF Approx. 0V
EC-41 151
TROUBLE DIAGNOSIS
OPERATION PROCEDURE
1. Turn ignition switch OFF.
2. Connect ST to VCM connector.
3. Turn ignition switch ON.
4. Touch “START.”
5. Touch “ENGINE.”
6. Perform the necessary trouble diagnosis mode.
Refer to “ST Operation Manual” for further information.
WORK SUPPORT
ST assists with idle adjustment work. With ST, it sends an operation
command to ECM, and adjustment control is performed accordingly.
However, inspector performs actual adjustment work.
FUEL PRESSURE RELEASE Shuts down the fuel pump and stops the engine. (While cranking, pressure in the fuel piping can be
released.)
IDLE AIR VOL LEARN Learns the minimum idle air flow amount required for idle speed control when predetermined conditions
are specified following replacement of electric throttle control actuator and ECM.
SELF-LEARNING CONT Clears air-fuel ratio feedback control correction coefficient.
152 EC-42
TROUBLE DIAGNOSIS
ST (Cont’d)
SELF-DIAGNOSTIC RESULTS
ECM0077
EC-43 153
TROUBLE DIAGNOSIS
ST (Cont’d)
ENGINE
Diagnosis item Malfunction Return Condition Display Warning Trip
lamp
Crankshaft position sensor • The crankshaft position sensor (POS) signal is not POS sensor fault ON 2
(POS) signal circuit detected for a predetermined time at the engine start or [E27]
during engine running (during camshaft position sensor
(PHASE) signal input).
• A crankshaft position sensor (POS) signal irregular
waveform is detected for a predetermined time during
engine running (during camshaft position sensor (PHASE)
signal input).
Camshaft position sensor • At start-up, no camshaft position sensor (PHASE) signal Phase sensor fault ON 2
(PHASE) signal circuit has been detected for more than a predetermined period. [E28]
• The camshaft position sensor (PHASE) signal is not
detected for a predetermined time during engine running
(during crankshaft position sensor (POS) signal input).
• A camshaft position sensor (PHASE) signal irregular
waveform is detected for a predetermined time during
engine running (during crankshaft position sensor (POS)
signal input).
Engine control module • CPU system or circuits in ECM have a malfunction. CCS C/U system ON* or 1 or 2
fault [E30] ON (Note)
ECM power supply circuit • Power is not supplied to ECM for some time. ECM BACKUP/ ON 2
CIRC [P1065]
Electric throttle control actuator • Because of mechanical malfunction of electric throttle Throttle control fault ON* or 1
control actuator, electric throttle control actuator does not [E31] ON
operate normally.
Electric throttle control function • When a malfunction occurred due to the correlation Throttle control fault ON* 1
between the target throttle position and the actual throttle [E31]
position.
• Over current flows into throttle motor control circuit.
Throttle control motor relay • When throttle control motor relay has been locked ON or Throttle control fault ON* 1
circuit OFF. [E31]
Overheat (STEP1) • Coolant temperature sensor output voltage has been Overheat (STEP1) ON* 1
approximately 0.35V or lower for a predetermined period [E32]
of time. (With the coolant temperature sensor normal)
Ignition signal • Ignition signal has not been continuously generated while Ignition system fault ON 2
the engine is running. [E34]
Brake switch • Brake switch signal circuit is open or shorted. Stop lamp SW fault ON* 1
[E41]
CAN communication system • Malfunction occurs in CAN communication transmit/ Communication ON* 1
receive data or in ECM, and data transmission/reception fault ECM [E03,
cannot be confirmed. E04,E05, E06, E07,
• CAN communication data is transmitted/received for E08]
predetermined period.
LPG injector control signal circuit • LPG injector control signal circuit is open or shorted. F/INJ disconn [E35] ON* 1
LPG vaporizer fuel pressure • LPG fuel pressure in vaporizer is excessively high. LPG result signal ON 1
fault [E38]
CAUTION:
Some DTC specified above may detect a malfunction related in
vehicle side self-diagnosis when the DTC detects some malfunction.
Check self-diagnosis except engine at this time.
154 EC-44
TROUBLE DIAGNOSIS
ST (Cont’d)
Trip 1: If a malfunction is detected by self-diagnosis between the
time ignition switch is turned ON (engine is running) and then turned
OFF (this is defined as “trip”), Multi-purpose warning lamp (MWL) is
lit. The corresponding DTC is recorded immediately after detection.
Trip 2: When a malfunction is detected by self-diagnosis for the first
time in the first trip, a tentative DTC is recorded. If the same
malfunction is detected again by self-diagnosis in the next trip
(second trip), MWL is lit and the corresponding final DTC is
recorded.
EC-45 155
TROUBLE DIAGNOSIS
“FU**1 / GY**0 / GZ**0” ---- Last 5 Digits of ECM part number
E-32 Overheat (STEP 1)
E-41 Stop lamp SW fault
Connect to GSE KIT
E-03 thru E-08 Communication fault ECM Hour meter display
< ! > + Code < ! > + Code and erase.
only
E-35 F/INJ disconn
E-29 Self-shut off system
signal faulty
E-23 Throttle sensor fault Hour meter display Connect to GSE KIT
< ! > + Code < ! > + Code
E-24 Accel sensor fault only and erase.
E-30 ECM C/U system fault Hour meter display Connect to GSE KIT
< ! > + Code < ! > + Code
E-31 Throttle control fault or < ! > + Code and erase.
DATA MONITOR
• Allows determination and identification of the possible source of
a malfunction based on self-diagnosis test results.
• Displays ECM input/output signal data in real time.
• Records the data before and after engine stalls, falters or
refuses to start intentionally.
156 EC-46
TROUBLE DIAGNOSIS
ST (Cont’d)
Display Item List
Monitor item Unit Description
Eng.rev rpm Engine speed computed from crankshaft angle sensor signal
Air flow meter mV Mass air flow sensor output voltage
Cly air ratio GAS % Average of cycles for air-fuel ratio feedback correction coefficient
Cly air ratio LPG
Eng.temp ˚C Value converted into temperature from the output voltage of the engine coolant temperature
sensor.
O2 sensor volt mV Output voltage of heated oxygen sensor
O2 sensor rich ON/OFF Air-fuel ratio is given as heated oxygen sensor output signal during air-fuel ratio feedback control.
ON: Heated oxygen sensor output is high. Controlling to lower the value for leaner ratio.
OFF: Heated oxygen sensor output is low. Controlling to raise the value for richer ratio.
Battery voltage mV ECM battery voltage
Accelerator % Value converted from the output voltage of accelerator pedal position sensor into accelerator
position
Throttle % Value converted from the output voltage of throttle position sensor into throttle position
Air temp sensor ˚C Value converted from the output power supply of intake air temperature sensor into intake air
temperature
Stater SW ON/OFF ON/OFF status as judged by each input signal
Idle SW
Air conditioner SW
Neutral SW
Mast high SW 1,2
Electric load SW
Chg fuel SW 1,2
Inching SW
Foot brake SW
Fuel jet pls GAS µs Value calculated by ECM
Fuel jet pls LPG
Spark timing deg
Fuel pump relay ON/OFF Status of each control as calculated by ECM.
Throttle relay
LPG relay
O2 sensor heater
TAS completion ON/OFF State of “Idle Air Volume Learning.”
Ratio date clr comp ON/OFF Status of each control as calculated by ECM.
TAS factory run
TAS general run
Spark correct run
Ratio correct run
Power balance run
Pressure clr run
Self chk clr comp
All shut update exp
Connect CONSULT-II
Cly air ratio GAS % Value converted from the output voltage of mass air flow sensor into filling efficiency.
Cly air ratio LPG
Fuel control GASOLINE/ Fuel changing switch connecting condition
LPG/NEUTRAL
LPG pres sensor kg/cm2 Value converted into pressure from the output voltage of LPG fuel pressure sensor.
EC-47 157
TROUBLE DIAGNOSIS
ST (Cont’d)
ACTIVE TEST
Use this mode to determine and identify the details of a malfunction,
based on self-diagnosis test results and data obtained from DATA
MONITOR mode. ST, instead of the ECM on the vehicle, sends a
drive signal to actuators to check their operation.
FUEL INJECTION • Can increase or decrease the amount of fuel injection ( ±25%).
• Can reproduce conditions resulting from air-fuel ratio related malfunctions (e.g. hesitation, poor acceleration,
poor racing, etc.) and can help solve these malfunctions by pinpointing the causes.
IGNITION TIMING • Allows setting a correction coefficient for retarding (-10 - 0˚)
POWER BALANCE • Stops operation of specified injector. Also, displays the condition at that time.
• Mainly used to inspect for misfiring cylinders.
OPERATION PROCEDURE
• Refer to the following for how to activate self-diagnosis mode or
erase heated oxygen sensor monitor and self-diagnostic
results.
CAUTION:
When a malfunction occurs in accelerator pedal position sensors,
self-diagnosis (without ST) cannot be activated. Thus, use ST to
perform self-diagnosis, and repair malfunctioning part.
158 EC-48
TROUBLE DIAGNOSIS
1. Turn ignition switch ON with accelerator pedal released and start the stopwatch simultaneously.
2. After 3 seconds, fully depress accelerator pedal and then release it. Quickly repeat this cycle 5 times within 5 seconds or faster if desired (end in
released position).
3. Wait until the stopwatch reads 15 seconds, then fully depress the accelerator pedal and keep that position at least 10 seconds (until MWL blinks).
Diagnostic test mode II self-diagnostic results starts.
1. Fully depress accelerator pedal in Diagnostic test mode II (self-diagnostic results), and keep the position at least 10 seconds. Self-diagnostic results
are erased.
䊶Release accelerator pedal. Make sure self-diagnostic results are erased.
䊶Turning ignition switch OFF returns to mode 1.
Ignition ON
switch OFF
Start diagnostic test mode II
5 times in (self-diagnostic results) 10 sec. Erase self-diagnostic result
5 seconds or longer
1 2 34 5
Fully-open
Accelerator pedal Hold for at least 10 seconds
Fully-closed
0 3 5 8 10 15 20 25 30
t=3s t=8s t=15s t=25s
EC-49 159
TROUBLE DIAGNOSIS
CAUTION:
Some DTC specified above may detect a malfunction related in
vehicle side self-diagnosis when the DTC detects some malfunction.
Check self-diagnosis except engine at this time.
Trip 1: If a malfunction is detected by self-diagnosis between the
time ignition switch is turned ON (engine is running) and then turned
OFF (this is defined as “trip”), MWL is lit. The corresponding DTC is
recorded immediately after detection.
Trip 2: When a malfunction is detected by self-diagnosis for the first
time in the first trip, a tentative DTC is recorded. If the same
malfunction is detected again by self-diagnosis in the next trip
(second trip), MWL is lit and the corresponding final DTC is
recorded. Even when 1st trip DTC is being memorized, the
appropriate malfunction code is displayed as self-diagnostic results
by MWL.
160 EC-50
TROUBLE DIAGNOSIS
EC-51 161
TROUBLE DIAGNOSIS
162 EC-52
TROUBLE DIAGNOSIS
EC-53 163
TROUBLE DIAGNOSIS
Mass air flow sensor Same as self-diagnosis • Selects fuel injection pulse width depending on engine speed and ON
malfunction detection throttle position so the vehicle can be driven. However, fuel injection
conditions. will be inhibited (fuel cut off) when engine speed exceeds
approximately 2,400 rpm.
• Idle speed is 800 rpm.
Engine coolant • Uses the estimated engine coolant temperature (varies with elapsed ON
temperature sensor time after start) to perform controls so the vehicle can be driven.
Accelerator pedal position • Fuel injection will be inhibited when 1 circuit is opened. Release ON
sensor valve mechanically until it can drive at low speed when disconnecting
connector.
Throttle position sensor • Fixes output to a preset value so the vehicle can be driven. However, ON
fuel injection will be inhibited (fuel cut off) when engine speed
exceeds approximately 2,500 rpm.
Malfunction indicator lamp • Fuel injector will be inhibited at approximately 2,500 rpm to prevent —
MWL malfunction if exhaust performance and driving performance
malfunctions are occurring.
164 EC-54
POWER SUPPLY AND GROUND SYSTEM
111 ECM & IGN coil relay For approximately 10 seconds with ignition switch Approx. 1V
ON and after ignition switch OFF
Approximately 10 seconds or more after ignition Battery voltage
switch OFF
109 Ignition switch Ignition switch ON
119
120 Power supply for ECM
121 Power supply for ECM (Backup) Always
115
116
1 Ground Approx. 0V
Circuit Diagram
ECM0081
EC-55 165
CRANKSHAFT POSITION SENSOR (POS) SYSTEM
Circuit Diagram
ECM0085
CAUTION:
Measurement values will vary depending on the measurement
range of circuit tester. Note that the higher the range is, the larger
the resistance is.
ECM0086
166 EC-56
CAMSHAFT POSITION SENSOR (PHASE) SYSTEM
14 Camshaft position Approx. 0.15V Fluctuates between approx. 1.5 - 2V. Approx. 2V
sensor (PHASE)
Circuit Diagram
ECM0090
CAUTION:
Measurement values will vary depending on the measurement
range of circuit tester. Note that the higher the range is, the larger
ECM0091
the resistance is.
EC-57 167
MASS AIR FLOW SENSOR SYSTEM
51 Mass air flow sensor Approx. 1.5V Approx. 1.3V Approx. 1.5V
67 Mass air flow sensor ground Approx. 0V
Circuit Diagram
ECM0092
CAUTION:
If air is blown from the air duct side, the voltage becomes lower.
ECM0093
168 EC-58
ENGINE COOLANT TEMPERATURE SENSOR SYSTEM
NOTE:
ECM0094 • If engine coolant temperature sensor has a malfunction, the
value of engine coolant temperature signal is changed along
with start-up time by fail-safe to enable normal operation.
Circuit Diagram
ECM0095
ECM0096
EC-59 169
HEATED OXYGEN SENSOR SYSTEM
HEATED OXYGEN SENSOR SYSTEM ST Data Monitor Display
Monitor item At idle after warming up At approx. 2,000 rpm
O2 sensor volt Changes between approx. 0.1 - 0.4V⇔ approx. 0.6 - 0.9V
O2 sensor rich ON and OFF alternate slowly. ON and OFF alternate at least 5 times in 10 seconds.
ECM0097 ECM0098
Circuit Diagram
ECM0099
170 EC-60
THROTTLE POSITION SENSOR SYSTEM
Circuit Diagram
ECM0100
CAUTION:
• Make sure that there is no moisture around connector when
removing and installing throttle position sensor connector. If
there are any water drops, completely wipe them off.
• Do not apply voltage to throttle position sensor terminal.
• Perform “Throttle Valve Closed Position Learning” if disconnect-
ing connector. Perform “Throttle Valve Closed Position Learning
ECM0101
and Idle Air Volume Learning” if replacing electric throttle control
actuator. (Refer to (EC-13), “Throttle Valve Closed Position
Learning and Idle Air Volume Learning”.)
• Do not disassemble electric throttle control actuator.
EC-61 171
ACCELERATOR PEDAL POSITION SENSOR SYSTEM
NOTE:
• When the accelerator pedal is depressed slowly from the fully-
closed position, the voltage must increase in proportion to the
opening of the throttle. [Ignition switch ON (engine stopped)]
Ignition switch ON, engine stopped Ignition switch ON, engine stopped
Terminal Signal name
Accelerator pedal is fully depressed Accelerator pedal is fully released
106 Accelerator pedal position sensor 1 Approx. 0.6V Approx. 4.2V
98 Accelerator pedal position sensor 2 Approx. 0.3V Approx. 2V
Circuit Diagram
ECM0102
CAUTION:
• Do not apply voltage to accelerator pedal position sensor termi-
nal.
• Do not disassemble accelerator work unit.
ECM0103
172 EC-62
INTAKE AIR TEMPERATURE SENSOR
34 Intake air temperature sensor signal Intake air temperature at 20˚C: approx. 3.5V
Intake air temperature at 80˚C: approx. 1.2V
Circuit Diagram
ECM0092
ECM0105
EC-63 173
PNP SWITCH SYSTEM
Neutral SW ON OFF
Circuit Diagram
ECM0106
174 EC-64
STOP LAMP SWITCH SYSTEM
Circuit Diagram
ECM0107
ECM0108
EC-65 175
ELECTRIC LOAD SWITCH SYSTEM
Circuit Diagram
ECM0109
176 EC-66
CAN COMMUNICATION SYSTEM
ECM0110
ECM0111
Circuit Diagram
ECM0112
EC-67 177
IGNITION SYSTEM
Circuit Diagram
ECM0116
CAUTION:
• Check terminals for looseness.
• Check insulator for cracks or damage.
• Check for contamination by oil, water, and dust.
• Make sure that the spark plug gap is normal, using a feeler
gauge.
Spark plug gap: 0.8 - 0.9 mm
ECM0117
178 EC-68
IGNITION SYSTEM
Ignition coil
Check the resistance between terminals of the power transistor by
applying and exchanging (+ and -) the inspection rods of an analog
circuit tester.
(+) - (-) Resistance (at room temperature)
1-2 : Not 0 Ω nor ∞ Ω
2-1 : Not 0 Ω nor ∞ Ω
3-1 : Except 0 Ω
1-3 : Except 0 Ω
3-2 : Except 0 Ω
2-3 : Except 0 Ω
ECM0118
CAUTION:
Do not use a digital circuit tester because the standard is different.
EC-69 179
FUEL INJECTOR SYSTEM
22 Injector drive signal Approx. 10.5V Battery voltage Relatively lower than battery voltage
23
41
42
Circuit Diagram
ECM0122
ECM0123
180 EC-70
FUEL PUMP SYSTEM
113 Fuel pump relay Approx. 1V (After approx. 1 second: Battery voltage) Approx. 1V
Circuit Diagram
ECM0124
EC-71 181
THROTTLE CONTROL MOTOR SYSTEM
Circuit Diagram
ECM0100
CAUTION:
• Make sure that there is no moisture around connector when
removing and installing throttle position sensor connector. Com-
pletely wipe off water drops if there are any.
• Do not apply voltage to electric throttle control motor terminal.
• Perform “Throttle Valve Closed Position Learning” if disconnect-
ing connector. Perform “Throttle Valve Closed Position Learning
ECM0126
and Idle Air Volume Learning” if replacing electric throttle control
actuator. (Refer to (EC-13), “Throttle Valve Closed Position
Learning and Idle Air Volume Learning.”)
• Do not disassemble electric throttle control actuator.
182 EC-72
HEATED OXYGEN SENSOR HEATER SYSTEM
24 Heated oxygen sensor heater open signal Approx. 0.3V Battery voltage
Circuit Diagram
ECM0099
ECM0128
EC-73 183
PCV GAS RECIRCULATION DEVICE
ECM0143
ECM0144
3. Check air flow through the PCV valve and sucking air to/from
the INT end.
Blowing air: No air flow
Sucking air: Air flow exists
ECM0145
184 EC-74
FUEL CUT FUNCTION
ECM0146
Without ST
1. Warm up the engine sufficiently.
2. Disconnect harness connector of the injector and connect a test
lamp.
3. Release the accelerator pedal at the engine speed of
approximately 2,500 rpm or more, and confirm test lamp goes
off for a moment.
ECM0147
EC-75 185
REMOVAL AND INSTALLATION OF ECM COMPONENTS
CAUTION:
Perform “Throttle Valve Closed Position Learning and Idle Air
Volume Learning” after installation if replacing ECM. (Refer to (EC-
12), “Throttle Valve Closed Position Learning and Idle Air Volume
Learning.”)
ECM0148
Removal and Installation of Crankshaft Position
Sensor (POS)
Removal
1. Remove fan.
2. Remove harness connector.
3. Remove crankshaft position sensor (POS).
Installation
NOTE:
• Make sure that there is no foreign material on sensor flange, O-
rings, and cylinder block.
• Keep away from magnetized objects.
ECM0149 • Make sure that the sensor is inserted securely into chain hous-
ing before tightening bolts.
Installation
NOTE:
• Make sure that there is no foreign material on sensor flange, O-
rings, and cylinder head.
• Keep away from magnetized objects.
ECM0150 • Make sure that the sensor is inserted securely into cylinder
head front cover before tightening bolts.
186 EC-76
REMOVAL AND INSTALLATION OF ECM COMPONENTS
ECM0151
CAUTION:
Make sure to drain when the coolant temperature is cold.
2. Remove harness connector.
3. Remove coolant temperature sensor using a socket specially
designed for removing and installing coolant temperature
sensors [commercially available: Thermosensor Socket
manufactured by KTC (part No.: B20T-19)] and similar parts.
ECM0152
Removal and Installation of Heated Oxygen
Sensor (with Heated Oxygen Sensor Heater)
1. Remove harness connector from heated oxygen sensor.
2. Remove heated oxygen sensor using a socket designed for
heated oxygen sensor removal and installation (ST).
ECM0153
CAUTION:
Handle it carefully and avoid impacts.
EC-77 187
REMOVAL AND INSTALLATION OF ECM COMPONENTS
188 EC-78
REMOVAL AND INSTALLATION OF ECM COMPONENTS
Installation
NOTE:
• Uniformly tighten bolts diagonally in several steps.
CAUTION:
• Make sure that there is no moisture around connector when
removing and installing each connector. Completely wipe off
water drops if there are any.
• Do not apply voltage to each terminal.
ECM0156
EC-79 189
SERVICE DATA AND SPECIFICATIONS (SDS)
190 EC-80