ACTIVE TEST MODE
TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY)
COOLING FAN+Ignition switch: ON
+Operate the cooling fan at
``LOW'', ``HI'' speed and turn
``OFF'' using CONSULT.Cooling fan moves at ``LOW'', ``HI''
speed and stops.+Harness and connector
+Cooling fan motor
OFF ACCEL PO
SIG+Clears the self-learning fully closed accelerator position, detected by accelerator position sensor, from the
ECM.
FUEL CUT SOL/V+Ignition switch: ON
+Turn solenoid valve ``ON'' and
``OFF'' with the CONSULT and
listen to operating sound.Solenoid valve makes an operating
sound.+Harness and connector
+Solenoid valve
EGRC SOL/V A+Ignition switch: ON
+Turn solenoid valve ``ON'' and
``OFF'' with the CONSULT and
listen to operating sound.Solenoid valve makes an operating
sound.+Harness and connector
+Solenoid valve
EGRC SOL/V B+Ignition switch: ON
+Turn solenoid valve ``ON'' and
``OFF'' with the CONSULT and
listen to operating sound.Solenoid valve makes an operating
sound.+Harness and connector
+Solenoid valve
THROT CONT
SOL/V+Ignition switch: ON
+Turn solenoid valve ``ON'' and
``OFF'' with the CONSULT and
listen to operating sound.Solenoid valve makes an operating
sound.+Harness and connector
+Solenoid valve
GLOW RLY+Ignition switch: ON (Engine
stopped)
+Turn the glow relay ``ON'' and
``OFF'' using CONSULT and
listen to operating sound.Glow relay makes the operating
sound.+Harness and connector
+Glow relay
INJ TIMING+Engine: Return to the original
trouble condition
+Retard the injection timing using
CONSULT.If trouble symptom disappears, see
CHECK ITEM.+Adjust initial injection timing
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTION
CONSULT (Cont'd)
EC-40
Introduction
The engine has an ECM to control major systems such as fuel
injection control, fuel injection timing control, glow control system,
etc. The ECM accepts input signals from sensors and instantly
drives electronic fuel injection pump. 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 such as vacuum leaks, or
other problems with the engine.
It is much more difficult to diagnose a problem that occurs intermit-
tently rather than continuously. Most intermittent problems are
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 ®nd the cause of the problems. A road
test with CONSULT or a circuit tester connected should be per-
formed. Follow the ``Work Flow'', EC-44.
Before undertaking actual checks, take a few minutes to talk with
a customer who approaches with a driveability complaint. The cus-
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
example on next page should be used.
Start your diagnosis by looking for ``conventional'' problems ®rst.
This will help troubleshoot driveability problems on an electronically
controlled engine vehicle.
SEF858S
SEF233G
SEF234G
TROUBLE DIAGNOSIS Ð Introduction
EC-42
Description for Work Flow
STEP DESCRIPTION
STEP IGet detailed information about the conditions and the environment when the incident/symptom occurred using the
``DIAGNOSTIC WORKSHEET'' as shown on EC-43.
STEP IIBefore con®rming the concern, check and write down (print out using CONSULT) the Diagnostic Trouble Code
(DTC), then erase the code. Refer to EC-30.
Study the relationship between the cause, speci®ed by DTC, and the symptom described by the customer. (The
``Symptom Matrix Chart'' will be useful. Refer to EC-48.)
STEP IIITry to con®rm 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
MONITOR (AUTO TRIG) mode and check real time diagnosis results.
If the incident cannot be veri®ed, perform INCIDENT SIMULATION TESTS. Refer to GI section.
If the malfunction code is detected, skip STEP IV and perform STEP V.
STEP IVTry 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 veri®cation, be sure to connect CONSULT to the vehicle in DATA MONITOR (AUTO TRIG) mode
and check real time diagnosis results.
If the incident cannot be veri®ed, 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 simpli®ed ``check'' is an effective alternative.
The ``NG'' result of the ``OVERALL FUNCTION CHECK'' is the same as the DTC detection.
STEP VTake 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.
If the normal code is indicated, proceed to the BASIC INSPECTION. Refer to EC-46. Then perform inspections
according to the Symptom Matrix Chart. Refer to EC-48.
STEP VIIdentify 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-
SULT. Refer to EC-54.
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.
STEP VIIOnce 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 con®rm the normal code (Diagnostic trouble code No. 55)
is detected. If the incident is still detected in the ®nal 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 ®xed) DTC in ECM. (Refer
to EC-30.)
TROUBLE DIAGNOSIS Ð Work Flow
EC-45
SYSTEM
Ð ECCS systemMalfunction
SYMPTOM
Reference
page Feature of symptom
Check point
HARD/NO START/
RESTART (EXCP. HA) ENGINE STALL HESITATION/SURGING/FLAT SPOT KNOCK/DETONATION
LACK OF POWER
POOR ACCELERATION
HI IDLE
LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION ABNORMAL SMOKE COLOR
DEAD BATTERY (UNDER CHARGE) Malfunction indicator lamp illuminates.
Can be detected by CONSULT?
Fuel cut
NO START (with ®rst ®ring) NO START (without ®rst ®ring)
HARD TO START WHEN ENGINE IS COLD
HARD TO START WHEN ENGINE IS HOT
AT IDLE
DURING DRIVING
WHEN DECELERATINGBLACK SMOKE WHITE SMOKE
Warranty symptom code AA AB AC AD AE AF AG AH AJ AK AL AM AP HAECCS
Camshaft position sensor (PUMP) cir-
cuitopen, shortjj
EC-69Tachometer malfunction
noisejjjj jj
Mass air ¯ow sensor circuitopen, ground shortjjj j
EC-74
shortjjj
Engine coolant temperature sensor
circuitopen, shortjjj jjj jjEC-79Compensation according to
engine coolant temperature does
not function.
Vehicle speed sensor circuit open, shortjjEC-83
Control sleeve position sensor circuit open, shortjjjjjjEC-87
Adjustment resistor circuit open, shortj j jjjj j jEC-92
Electric governor circuitopen, ground shortj jjjjjj
EC-96
shortjj
Injection timing control valve circuitopen, shortjjj
EC-101Injection timing cannot be con-
trolled.
ground shortjj
Accelerator switch (FC) circuitopen, shortjjj
EC-106
ground shortjj
Charge air temperature sensor circuit open, shortjEC-122
Needle lift sensor circuit open, shortjjjEC-126
Fuel cut solenoid valve circuitopen, ground shortj jjjj
EC-130
shortjjjEngine runs on after turning igni-
tion switch OFF.
Fuel temperature sensor circuit open, shortjj jj jj j jj jEC-135Compensation for amount of fuel
injected according to fuel tem-
perature does not function.
Accelerator position sensor circuit open, shortjjj jjEC-139
Crankshaft position sensor (TDC) cir-
cuitopen, shortjj jj
EC-144
noisejjjjj
TROUBLE DIAGNOSIS Ð General Description
Symptom Matrix Chart (Cont'd)
EC-49
SYSTEM
Ð ECCS systemMalfunction
SYMPTOM
Reference page Feature of symptom
Check point
HARD/NO START/
RESTART (EXCP. HA) ENGINE STALL HESITATION/SURGING/FLAT SPOT KNOCK/DETONATION
LACK OF POWER
POOR ACCELERATION
HI IDLE
LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEAT/HIGH ENGINE COOLANT TEMPERATURE
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION ABNORMAL SMOKE COLOR
DEAD BATTERY (UNDER CHARGE) Malfunction indicator lamp illuminates.
Can be detected by CONSULT?
Fuel cut
NO START (with ®rst ®ring) NO START (without ®rst ®ring)
HARD TO START WHEN ENGINE IS COLD
HARD TO START WHEN ENGINE IS HOT
AT IDLE
DURING DRIVING
WHEN DECELERATINGBLACK SMOKE WHITE SMOKE
Warranty symptom code AA AB AC AD AE AF AG AH AJ AK AL AM AP HAECCS
Start signal circuit open, shortjjEC-163 Start control does not function.
Neutral position switch circuitopen, shortjjj
EC-170
ground shortjj
Accelerator position switch (Idle) cir-
cuitopen, ground shortjj j
EC-165
shortjjj jjAccelerator position sensor NG
signal is output.
Accelerator position switch (Full) cir-
cuitopen, shortjjj jjEC-165
Ignition switch circuitopenj jjj
EC-63
shortEngine does not stop.
Power supply for ECM circuitopenjjj
EC-63
shortjj
Throttle control solenoid valve circuitopen, short
EC-156Does not operate.
ground shortjj jDoes not stop operating.
EGRC-solenoid valve A, B circuitopen, short
EC-156
ground shortjDoes not stop operating.
Glow relay circuitopenjjjjj
EC-151Glow lamp does not turn on.
shortGlow lamp does not turn off.
ECCS relay (Self-shutoff) circuitopenjjjj
EC-63
shortjjGround short makes engine
unable to stop.
ECM, Connector circuit open, shortjjjjjjjjjjjjj jjjjjjjjjjjjEC-111
Air conditioner relay circuitopen
EC-187Air conditioner does not operate.
shortAir conditioner does not stop
operating.
Air conditioner switch circuitopen, ground short
EC-187Air conditioner does not stop
operating.
shortAir conditioner does not work.
TROUBLE DIAGNOSIS Ð General Description
Symptom Matrix Chart (Cont'd)
EC-50
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.)
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
TROUBLE DIAGNOSIS Ð General Description
EC-53
TER-
MINAL
NO.WIRE
COLORITEM CONDITIONDATA
(DC Voltage and Pulse
Signal)
8 G/ORCharge air cooler fan
relayEngine is running.
Charge air cooler fan is not operating.BATTERY VOLTAGE
(11 - 14V)
Engine is running.
Charge air cooler fan is operating.0-1V
10 P Fuel temperature sensor Engine is running.
Approximately 0 - 4.8V
Output voltage varies with
fuel temperature.
14 L Cooling fan relayEngine is running.
Cooling fan is not operating.BATTERY VOLTAGE
(11 - 14V)
Engine is running.
Cooling fan is operating.0-1V
15 Y/L Air conditioner relayEngine is running.
Air conditioner switch is ``OFF''.BATTERY VOLTAGE
(11 - 14V)
Engine is running.
Both air conditioner switch and blower fan
switch are ``ON''.
(Compressor is operating.)0-1V
16 L/W Glow lampIgnition switch ``ON''
Glow lamp is ``ON''.0 - 1.5V
Ignition switch ``ON''
Glow lamp is ``OFF''.BATTERY VOLTAGE
(11 - 14V)
18 G Malfunction indicator lampIgnition switch ``ON''
0 - 1.5V
Engine is running.
Idle speedBATTERY VOLTAGE
(11 - 14V)
19 LG/REngine coolant tempera-
ture sensorEngine is running.
Approximately 0 - 4.8V
Output voltage varies with
engine coolant tempera-
ture.
20 R/W Start signalIgnition switch ``ON''
Approximately 0V
Ignition switch ``START''
BATTERY VOLTAGE
(11 - 14V)
21 LG/B Air conditioner switchEngine is running.
Air conditioner switch is ``OFF''.BATTERY VOLTAGE
(11 - 14V)
Engine is running.
Both air conditioner switch and blower fan
switch are ``ON''.
(Compressor is operating.)Approximately 0V
TROUBLE DIAGNOSIS Ð General Description
ECM Terminals and Reference Value (Cont'd)
EC-56
TER-
MINAL
NO.WIRE
COLORITEM CONDITIONDATA
(DC Voltage and Pulse
Signal)
22 P/BInhibitor switch/
Neutral position switchIgnition switch ``ON''
Gear position is ``N'' or ``P'' (A/T models).Gear position is ``Neutral'' (M/T models).Approximately 0V
Ignition switch ``ON''
Except the above gear positionBATTERY VOLTAGE
(11 - 14V)
23 WAccelerator position sen-
sorIgnition switch ``ON''
Accelerator pedal fully released0.4 - 0.6V
Ignition switch ``ON''
Accelerator pedal fully depressedApproximately 4.3V
24 PU/W A/T signal No. 1Engine is running.
Idle speed6-8V
26 L/OR Vehicle speed sensorEngine is running.
Lift up the vehicle.In 1st gear positionVehicle speed is 40 km/h.0 - BATTERY VOLTAGE
(11 - 14V)
SEF717V
28
33BCamshaft position sensor
(PUMP) groundEngine is running.(Warm-up condition)
Idle speedApproximately 0V
29 R/L Accelerator switch (F/C)Ignition switch ``ON''
Accelerator pedal fully releasedBATTERY VOLTAGE
(11 - 14V)
Ignition switch ``ON''
Accelerator pedal depressedApproximately 0V
30 P A/T signal No. 3Engine is running.
Idle speedApproximately 0V
31 R/LAccelerator position switch
(Idle)Ignition switch ``ON''
Accelerator pedal fully releasedBATTERY VOLTAGE
(11 - 14V)
Ignition switch ``ON''
Accelerator pedal depressedApproximately 0V
32 W/GAccelerator position switch
(Full)Ignition switch ``ON''
Accelerator pedal releasedApproximately 0V
Ignition switch ``ON''
Accelerator pedal fully depressedBATTERY VOLTAGE
(11 - 14V)
TROUBLE DIAGNOSIS Ð General Description
ECM Terminals and Reference Value (Cont'd)
EC-57