TROUBLE DIAGNOSIS FOR POWER SUPPLY.... 75
Main Power Supply and Ground Circuit .............. 75
TROUBLE DIAGNOSIS FOR ``CAMSHAFT
POSI SEN'' (DTC 11).............................................. 82
Camshaft Position Sensor (CMPS) ..................... 82
TROUBLE DIAGNOSIS FOR ``MASS AIR
FLOW SEN'' (DTC 12)............................................ 89
Mass Air Flow Sensor (MAFS) ............................ 89
TROUBLE DIAGNOSIS FOR ``COOLANT TEMP
SEN'' (DTC 13)........................................................ 95
Engine Coolant Temperature Sensor (ECTS) ..... 95
TROUBLE DIAGNOSIS FOR ``IGN SIGNAL-
PRIMARY'' (DTC 21)............................................... 99
Ignition Signal ...................................................... 99
TROUBLE DIAGNOSIS FOR ``OVER HEAT''
(DTC 28)................................................................. 106
Overheat ............................................................ 106
TROUBLE DIAGNOSIS FOR ``INT AIR TEMP
SEN'' (DTC 41)...................................................... 109
Intake Air Temperature Sensor ......................... 109
TROUBLE DIAGNOSIS FOR ``THROTTLE POSI
SEN'' (DTC 43)...................................................... 113
Throttle Position Sensor .................................... 113
TROUBLE DIAGNOSIS FOR
NON-DETECTABLE ITEMS.................................. 118
Vehicle Speed Sensor (VSS) ............................ 118
Heated Oxygen Sensor (HO2S)
- LHD Models - .................................................. 123
Heated Oxygen Sensor Heater
- LHD Models - .................................................. 127
Idle Air Control Valve (IACV) - Auxiliary Air
Control (AAC) Valve .......................................... 131
Neutral Position Switch ...................................... 136
EVAP Canister Purge Control Solenoid Valve .. 140
Injector ............................................................... 144
Start Signal ........................................................ 149
Fuel Pump.......................................................... 151
Power Steering Oil Pressure Switch ................. 157
Swirl Control Valve Control Solenoid Valve ...... 161
IACV-FICD Solenoid Valve ................................ 168
MIL & Data Link Connectors ............................. 173
TD
INJECTION SYSTEM............................................ 176
Fuel System ....................................................... 176
INJECTION PUMP................................................. 178
Inspection ........................................................... 178
Removal ............................................................. 178
Installation and Adjustment................................ 180
Disassembly ....................................................... 183
Load Timer Adjustment...................................... 183
Start Q Adjustment Lever .................................. 184
INJECTION NOZZLE............................................. 186Removal and Installation ................................... 186
Disassembly ....................................................... 186
Inspection ........................................................... 187
Cleaning ............................................................. 187
Assembly............................................................ 189
Test and Adjustment .......................................... 189
FUEL SYSTEM CHECK........................................ 191
Bleeding Fuel System ........................................ 191
Bleeding Fuel Filter ............................................ 192
Checking Priming Pump .................................... 192
Checking Fuel Filter Switch ............................... 192
POSITIVE CRANKCASE VENTILATION.............. 193
Description ......................................................... 193
Inspection ........................................................... 193
QUICK-GLOW SYSTEM........................................ 194
Component Parts Location ................................ 194
Circuit Diagram .................................................. 195
Description ......................................................... 196
Wiring Diagram .................................................. 197
Glow Control Unit Circuit Inspection (For Cold
Areas)................................................................. 203
Glow Control Unit Circuit Inspection (Except
for Cold Areas)................................................... 206
Component Inspection ....................................... 208
EGR SYSTEM........................................................ 210
Component Parts Location ................................ 210
Description ......................................................... 211
Operation ........................................................... 212
Wiring Diagram .................................................. 213
System Inspection.............................................. 217
Component Inspection ....................................... 218
SOLENOID TIMER................................................ 220
Description ......................................................... 220
Operation ........................................................... 220
Wiring Diagram .................................................. 222
Inspection ........................................................... 224
FUEL CUT SYSTEM.............................................. 225
Wiring Diagram .................................................. 225
FUEL HEATER SYSTEM...................................... 226
Description ......................................................... 226
Wiring Diagram .................................................. 227
System Inspection.............................................. 228
Component Inspection ....................................... 228
FAST IDLE CONTROL CIRCUIT.......................... 230
Wiring Diagram .................................................. 230
Electrical Components Inspection ..................... 231
KA
SERVICE DATA AND SPECIFICATIONS (SDS). 232
General Specifications ....................................... 232
Inspection and Adjustment ................................ 232
System Chart
Camshaft position sensorc
ECM
(ECCS
control
module)
Mass air flow sensorc
Engine coolant temperature sensorc
Heated oxygen sensor*c
Ignition switchc
Throttle position sensorc
Neutral position switchc
Vehicle speed sensorc
Air conditioner switchc
Battery voltagec
Power steering oil pressure switchc
Intake air temperature sensorc
*: LHD models
Fuel injection &
mixture ratio controlcInjectors
Distributor ignition systemcPower transistor
Idle air control systemcIACV-AAC valve
IACV-FICD solenoid valve
Swirl control valve controlcSwirl control valve control
solenoid valve
EVAP canister controlcEVAP canister purge control
solenoid valve
Fuel pump controlcFuel pump relay
Heated oxygen sensor moni-
tor & on board diagnostic
systemcMalfunction indicator lamp
(On the instrument panel)
Acceleration cut controlcAir conditioner relay
Heated oxygen sensor
heater control*cHeated oxygen sensor
heater
ENGINE AND EMISSION CONTROL OVERALL SYSTEMKA
EC-13
ECCS COMPONENT PARTS/CONTROL SYSTEMS APPLICATION
ItemDIAGNOSTIC TEST MODE
WORK
SUPPORTSELF-DIAG-
NOSTIC
RESULTSDATA
MONITORACTIVE
TESTFUNCTION
TEST
ECCS COMPONENT PARTS
INPUT
Camshaft position sensor X X
Mass air flow sensor X X
Engine coolant temperature
sensorXXX
Heated oxygen sensor X
Vehicle speed sensor X X
Throttle position sensor X X X X
Intake air temperature sensor X 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
switchXX
Battery voltage X
OUTPUT
Injectors X X X
Power transistor (Ignition timing) XX (Ignition
signal)XXX
IACV-AAC valve X X X X
Air conditioner relay X
Fuel pump relay X X X X
Swirl control valve control
solenoid valveXXX
EVAP canister purge control
solenoid valve*XXX
X: Applicable
* : This item is indicated as ``EGRC SOL/V'' on the CONSULT screen.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONKA
CONSULT (Cont'd)
EC-47
SELF-DIAGNOSTIC MODE
Regarding items detected in ``SELF-DIAG RESULTS'' mode, refer to ``DIAGNOSTIC TROUBLE CODE
INDEX'', EC-1.
DATA MONITOR MODE
Monitored item
[Unit]ECM
input
signalsMain
signalsDescription Remarks
CMPSRPM
(POS) [rpm]
jj
lIndicates the engine speed computed
from the POS signal (1É signal) of the
camshaft position sensor.
MAS AIR/FL SE [V]
jjlThe signal voltage of the mass air flow
sensor is displayed.lWhen the engine is stopped, a certain
value is indicated.
COOLAN TEMP/S
[ÉC] or [ÉF]
jj
lThe engine coolant temperature (deter-
mined by the signal voltage of the engine
coolant temperature sensor) is displayed.lWhen the engine coolant temperature
sensor is open or short-circuited, ECM
enters fail-safe mode. The engine coolant
temperature determined by the ECM is
displayed.
O2 SEN [V]
jjlThe signal voltage of the heated oxygen
sensor is displayed.lLHD models only
M/R F/C MNT
[RICH/LEAN]
jj
lDisplay of heated oxygen sensor signal
during air-fuel ratio feedback control:
RICH ... means the mixture became
``rich'', and control is being affected
toward a leaner mixture.
LEAN ... means the mixture became
``lean'', and control is being affected
toward a rich mixture.lAfter turning ON the ignition switch,
``RICH'' is displayed until air-fuel mixture
ratio feedback control begins.
lWhen the air-fuel ratio feedback is
clamped, the value just before the clamp-
ing is displayed continuously.
lLHD models only
VHCL SPEED SE
[km/h] or [mph]
jjlThe vehicle speed computed from the
vehicle speed sensor signal is displayed.
BATTERY VOLT [V]
jjlThe power supply voltage of ECM is dis-
played.
THRTL POS SEN [V]
jjlThe throttle position sensor signal volt-
age is displayed.
INT/A TEMP SE
[ÉC] or [ÉF]
j
lThe intake air temperature (determined
by the signal voltage of the intake air
temperature sensor) is indicated.
START SIGNAL
[ON/OFF]
jjlIndicates [ON/OFF] condition from the
starter signal.lAfter starting the engine, [OFF] is
displayed regardless of the starter signal.
CLSD THL/POSI
[ON/OFF]
jj
lIndicates [ON/OFF] condition from the
throttle position sensor signal.
AIR COND SIG
[ON/OFF]
jj
lIndicates [ON/OFF] condition of the air
conditioner switch as determined by the
air conditioner signal.
P/N POSI SW
[ON/OFF]
jj
lIndicates [ON/OFF] condition from the
park/neutral position switch signal.
PW/ST SIGNAL
[ON/OFF]
jj
l[ON/OFF] condition of the power steering
oil pressure switch determined by the
power steering oil pressure signal is indi-
cated.
NOTE:
Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONKA
CONSULT (Cont'd)
EC-48
ACTIVE TEST MODE
TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY)
FUEL INJECTION
lEngine: Return to the original trouble
condition
lChange the amount of fuel injection
using CONSULT.If trouble symptom disappears, see
CHECK ITEM.
lHarness and connectorlFuel injectorslHeated oxygen sensor
IACV-AAC/V
OPENING
lEngine: After warming up, idle the
engine.
lChange the IACV-AAC valve opening
percent using CONSULT.Engine speed changes according to the
opening percent.lHarness and connectorlIACV-AAC valve
ENG COOLANT
TEMP
lEngine: Return to the original trouble
condition
lChange the engine coolant
temperature using CONSULT.If trouble symptom disappears, see
CHECK ITEM.
lHarness and connectorlEngine coolant temperature sensorlFuel injectors
IGNITION TIMING
lEngine: Return to the original trouble
condition
lTiming light: SetlRetard the ignition timing using
CONSULT.If trouble symptom disappears, see
CHECK ITEM.
lAdjust ignition timing (by moving
camshaft position sensor)
POWER BALANCE
lEngine: After warming up, idle the
engine.
lA/C switch ``OFF''lShift lever ``N''lCut off each injector signal one at a
time using CONSULT.Engine runs rough or dies.
lHarness and connectorlCompressionlInjectorslIgnition coil with power transistorlSpark plugs
FUEL PUMP RELAY
lIgnition switch: ON (Engine stopped)lTurn the fuel pump relay ``ON'' and
``OFF'' using CONSULT and listen to
operating sound.Fuel pump relay makes the operating
sound.lHarness and connectorlFuel pump relay
EGRC SOLENOID
VALVE
(EVAP canister
purge control
solenoid valve)
lIgnition switch: ONlTurn solenoid valve ``ON'' and ``OFF''
with CONSULT and listen to
operating sound.Solenoid valve makes an operating
sound.lHarness and connectorlEVAP canister purge control solenoid
valve
SWIRL CONT SOL
VALVE
lIgnition switch: ON (Engine stopped)lTurn solenoid valve ``ON'' and ``OFF''
with CONSULT and listen to
operating sound.Solenoid valve makes an operating
sound.lHarness and connectorlSwirl control valve control solenoid
valve
SELF-LEARNING
CONT
lIn this test, the coefficient of self-learning control mixture ratio returns to the original coefficient by touching ``CLEAR'' on the
screen.
ON BOARD DIAGNOSTIC SYSTEM DESCRIPTIONKA
CONSULT (Cont'd)
EC-50
Symptom Matrix Chart
SYMPTOM
Reference page
HARD/NO START/RESTART (EXCP. HA)
ENGINE STALL
HESITATION/SURGING/FLAT SPOT
SPARK KNOCK/DETONATION
LACK OF POWER/POOR ACCELERATION
HIGH IDLE/LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEATS/WATER TEMPERATURE HIGH
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION
BATTERY DEAD (UNDER CHARGE)
OVERCOOLS
OVERCHARGING
Warranty Symptom Code AA AB AC AD AE AF AG AH AJ AK AL AM HA 1P 1X
Basic engine control system
Fuel Fuel pump circuitllljlljjjEC-151
Fuel pressure regulator system
llljljlljlEC-22
Injector circuit
llljlll lEC-144
Evaporative emission systemjjjj
ljjjj jEC-19
Air Positive crankcase ventilation systemjjjj
ljjjj jjEC-21
Incorrect idle speed adjustmentjj jjjj jEC-25
Swirl control valve circuitjj
lEC-161
IACV-AAC valve circuit
llljllllljjEC-131
IACV-FICD solenoid valve circuitjjjjjjjjj jEC-168
Ignition Incorrect ignition timing adjustmentjj
lll ll lEC-25
Ignition circuit
lllll ll lEC-99
EVAP EVAP canister purge control solenoid
valve circuit
ljjjj j jEC-140
Main power supply and ground circuit
llljj jj jj jEC-75
Air conditioner circuitjjjjjjjjj j jHA section
ECCS system
ECCS Camshaft position sensor circuitllllljj jEC-82
Mass air flow sensor circuit
lllll ljjEC-89
Heated oxygen sensor circuit
lljlljlEC-123, 127
Engine coolant temperature sensor circuit
llljllljjlEC-95
Throttle position sensor circuit
ll lllll lEC-113
Incorrect throttle position sensor adjust-
ment
ljjljjljEC-58
Vehicle speed sensor circuitjj j jEC-118
ECMjjjjjjjjjjjEC-61
Start signal circuitjEC-149
Neutral position switch circuitjjjj jEC-136
Power steering oil pressure switch circuitjjjEC-157
l; High Possibility Item
j; Low Possibility Item(continued on next page)
TROUBLE DIAGNOSIS Ð General DescriptionKA
EC-62
SYSTEM
Ð Engine mechanical & otherSYMPTOM
Reference page
HARD/NO START/RESTART (EXCP. HA)
ENGINE STALL
HESITATION/SURGING/FLAT SPOT
SPARK KNOCK/DETONATION
LACK OF POWER/POOR ACCELERATION
HIGH IDLE/LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEATS/WATER TEMPERATURE HIGH
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION
BATTERY DEAD (UNDER CHARGE)
OVERCOOLS
OVERCHARGING
Warranty Symptom Code AA AB AC AD AE AF AG AH AJ AK AL AM HA 1P 1X
Fuel Fuel tank
ll
Ð Fuel piping
lljjljj j
Vapor lockj
Valve depositjjjjj jj j
Poor fuel (Heavy weight gasoline, Low
octane)jjjjj jj j
Air Air ductjjjjj j
Air cleanerj
llljj
Air leakage from air duct
(Mass air flow sensor Ð throttle body)jjjjjjjjj j
Throttle body, Throttle wirej
lljlljj jFE section
Air leakage from intake manifold/
Collector/Gasketj
ljjjjljjlÐ
Cranking Batteryjjjjjj jjj
EL section Alternator circuitjjjjjj jjj
Starter circuit
l
FlywheellÐ
Engine Cylinder head
ljljjljj
Ð Cylinder head gasketjjjjj
ljljj
Cylinder blockjjjj
ljj jj
Pistonjjjjj j
ljl
Piston ringjjjjlljjl
Connecting rodljjjj jj j
Bearing
lljljjlj
Crankshaftjjjjj jj j
Valve
mechanismTiming chain
ljljljj j
Camshaft
ljjjj jj j
Intake valvej
lljjljjj
Exhaust valve
ljljlljjl
Exhaust Exhaust manifold/Tube/Muffler/Gasketjllll ljl
Three way catalystjljjljj j
Lubrication Oil pan/Oil strainer/Oil pump/Oil filter/Oil
gallery
ljjlljj jl
Oil level (Low)/Filthy oiljjjjj jj jj
Cooling Radiator/Hose/Radiator filler capjjjjj jj
lj
Thermostatjjjjjj
ljjljj
Water pump
ljjjj jjlj
Water galleryjjjjj jj jj
Cooling fanjjjj
ljljjljj
Coolant level (low)/Contaminated coolantjjjjj jj jj
l; High Possibility Item
j; Low Possibility Item
TROUBLE DIAGNOSIS Ð General DescriptionKA
Symptom Matrix Chart (Cont'd)
EC-63
Overheat
ON BOARD DIAGNOSIS LOGIC
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
indicated.
Diagnostic trouble
code No.Malfunction is detected when ...Check Items
(Possible Cause)
28
lEngine coolant temperature reaches an abnormally
high temperature.lCooling fan
lRadiator hose
lRadiator
lRadiator cap
lWater pump
lThermostat
For more information, refer to ``MAIN 12
CAUSES OF OVERHEATING'', EC-108.
CAUTION:
When a malfunction is indicated, be sure to replace the coolant following the procedure in MA sec-
tion (``Changing Engine Coolant'', ``ENGINE MAINTENANCE''). Also, replace the engine oil.
lFill 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 FLUIDS AND LUBRICANTS'').
lAfter refilling coolant, run engine to ensure that no water-flow noise is emitted.
OVERALL FUNCTION CHECK
WARNING:
Never remove the radiator cap when the engine is hot. Seri-
ous burns could be caused by high pressure fluid escaping
from the radiator.
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.
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 step and go to
``DIAGNOSTIC PROCEDURE'' on next page.
2. Confirm whether customer filled the coolant or not. If cus-
tomer filled the coolant, go to ``DIAGNOSTIC PROCEDURE''
on next page.
AEC640
TROUBLE DIAGNOSIS FOR ``OVER HEAT'' (DTC 28)KA
EC-106