Page 385 of 2267

PROCEDURE A
INSPECTION START
CHECK POWER SUPPLY.
1. Turn ignition switch to ªLOCKº posi-
tion.
2. Disconnect cooling fan relay-1 and
fan motor-1 connector.
3. Turn ignition switch to ªONº position.
4. Check voltage between cooling fan
motor-1 connector terminal
p1, fan
relay-1 connector terminal
p1and
ground.
Voltage: Battery voltage
OK
ENG
Check the following:
l10A fuse
l40A, 100A, fusible
links
lHarness for open or
short-circuit between
cooling fan motor-1
and battery.
lHarness for open or
short-circuit between
cooling fan relay-1 and
fuse.
If NG, replace fuse or
fusible links or repair har-
ness or connectors.
CHECK GROUND CIRCUIT.
1. Turn ignition switch to ªLOCKº posi-
tion.
2. Disconnect cooling fan relay-2 and
fan motor-2 harness connector.
3. Check harness continuity
between cooling fan relay-1 con-
nector terminal
p5and cooling
fan relay-2 connector terminal
p4; cooling fan motor-1 con-
nector terminal
p2and cooling
fan relay-2 connector terminal
p3.Continuity should exist.
If OK, check harness for short-
circuit.
4. Check harness continuity
between cooling fan motor-2
connector terminal
p1and
cooling fan relay-1 connector
terminal
p3; cooling fan
motor-2 connector terminal
p2
and ground.Continuity should
exist.
If OK, check harness for short-
circuit.
OK
ENG
Repair harness or con-
nectors.
pC
YEC385 Cooling fan relay-1
connectorCooling fan motor-1
connector
NEF416
.Under the vehicle
A/C compressor
.Cooling fan motor-1
harness connector
NEF417
.Radiator
lower hose
.Cooling fan
motor-2
harness
connector
.Under the vehicle
YEC386
Cooling fan relay-2
connector Cooling fan motor-1
connector
Cooling fan
relay-1 con-
nector
YEC387 Cooling fan
relay-1 connectorCooling fan motor-2
connector
H
H
H
TROUBLE DIAGNOSIS 8CD20T
Cooling Fan (Overheat) (Cont'd)
EC-91
Page 386 of 2267

pC
CHECK OUTPUT SIGNAL CIRCUIT.
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM
terminal
219and cooling fan relay-1 con-
nector terminal
p2.
Continuity should exist.
If OK, check harness for short-circuit.
OK
ENG
Check the following:
lHarness connectorsE43,F2
lHarness for open or short-
circuit between cooling fan
relay-1 and ECM
If NG, repair harness or con-
nectors.
CHECK COMPONENT
(Cooling fan relay-1, 2).
Refer to ªCOMPONENT INSPECTIONº,
EC-CD-96.
OK
ENG
Replace cooling fan relay.
CHECK COMPONENT
(Cooling fan motors).
Refer to ªCOMPONENT INSPECTIONº,
EC-CD-96.
OK
ENG
Replace cooling fan motors.
Disconnect and reconnect harness connec-
tors in the circuit. Then retest.
Trouble is not fixed.
Check ECM pin terminals for damage and
check the connection of ECM harness con-
nector. Reconnect ECM harness connector
and retest.
INSPECTION END
PROCEDURE B
INSPECTION START
CHECK POWER SUPPLY.
1. Turn ignition switch to ªLOCKº position.
2. Disconnect cooling fan relay-2, 3 and
cooling fan motor-1.
3. Turn ignition switch to ªONº position.
4. Check voltage between cooling fan
motor-1 connector terminal
p1; cooling
fan relay-2 connector terminal
p1; cool-
ing fan relay-3 connector terminals
p1&
p3and ground.
Voltage: Battery voltage
OK
ENG
Check the following:
l10A-fusel40A, 50A, 100A fusible
links
lHarness for open or
short-circuit between fan
motor-1, fan relay-3 and
fusible link or fan relay-2,
3 and fuse.
If NG, replace fuse or fus-
ible link or repair harness or
connectors.
pD
NEF207A
Cooling fan relay-1
connector
NEF203A
Cooling fan
relay-2
connector Cooling fan
motor-1
connector Cooling fan
relay-3
connector
H
H
H
H
H
H
H
H
TROUBLE DIAGNOSIS 8CD20T
Cooling Fan (Overheat) (Cont'd)
EC-92
Page 387 of 2267

pD
CHECK GROUND CIRCUIT.
1. Turn ignition switch to ªLOCKº position.
2. Disconnect cooling fan motor-2 harness
connector.
3. Check harness continuity between
cooling fan motor-1 connector termi-
nal
p2and cooling fan relay-2 con-
nector terminal
p3; cooling fan
motor-2 connector terminal
p1and
cooling fan relay-3 connector termi-
nal
p5; cooling fan relay-2 connec-
tor terminal
p5and ground.
Continuity should exist.
If OK, check harness for short-circuit.
4. Check harness continuity between
cooling fan motor-2 terminal
p2and
ground.
OK
ENG
Repair harness or connec-
tors.
CHECK OUTPUT SIGNAL CIRCUIT.
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM
terminal
220and cooling fan relay-3
connector terminal
p2& cooling fan
relay-2 connector terminal
p2.
Continuity should exist.
If OK, check harness for short-circuit.
OK
ENG
Check the following:
lHarness connectorsE43,F2
lHarness for open or
short-circuit between
cooling fan relay-2, 3 and
ECM.
If NG, repair harness or
connectors.
CHECK COMPONENT
(Cooling fan relay-2, 3).
Refer to ªCOMPONENT INSPECTIONº, EC-
CD-96.
OK
ENG
Replace cooling fan relays.
CHECK COMPONENTS
(Cooling fan motors).
Refer to ªCOMPONENT INSPECTIONº, EC-
CD-96.
OK
ENG
Replace cooling fan motors.
Disconnect and reconnect harness connec-
tors in the circuit. Then retest.
Trouble is not fixed
Check ECM pin terminals for damage and
check the connection of ECM harness con-
nector. Reconnect ECM harness connector
and retest.
INSPECTION END
NEF876
Cooling fan motor-1
connectorCooling fan relay-2
connector
Cooling fan
motor-2
connectorCooling fan relay-3
connector
YEC389 Cooling fan motor-2
connector
E18
NEF204A
Cooling fan
relay-3
connector
Cooling fan
relay-2
connector
H
H
H
H
H
H
H
TROUBLE DIAGNOSIS 8CD20T
Cooling Fan (Overheat) (Cont'd)
EC-93
Page 388 of 2267

pB
CHECK COOLING SYSTEM FOR LEAK.
Apply pressure to the cooling system with a
tester, and check if the pressure drops.
Testing pressure:
157kPa (1.57 bar, 1.6 kg/cm
2, 23 psi)
Pressure should not drop.
CAUTION:
Higher than the specified pressure may
cause radiator damage.
OK
ENG
Check the following
for leaks:
lHoselRadiatorlWater pump
Refer to LC section
(ªWater Pumpº).
CHECK RADIATOR CAP.
Apply pressure to cap with a tester.
Radiator cap relief pressure:
Standard
78 - 98 kPa (0.78 - 0.98 bar,
0.8 - 1.0 kg/cm
2, 11 - 14 psi)
Limit
59 - 88 kPa (0.59 - 0.88 bar,
0.6 - 0.9 kg/cm
2,9-13psi)
OK
ENG
Replace radiator
cap.
CHECK THERMOSTAT.
1. Check valve seating condition at normal
room temperatures.
It should seat tightly.
2. Check valve opening temperature and
maximum valve lift.
Valve opening temperature:
76.5ÉC (170ÉF) [standard]
Maximum valve lift:
More than 8 mm/90ÉC
(0.31 in/194ÉF)
3. Check if valve is closed at 5ÉC (9ÉF)
below valve opening temperature.
For details, refer to LC section
(ªThermostatº).
OK
ENG
Replace thermostat.
Check engine coolant temperature sensor.
Refer to ªCOMPONENT INSPECTIONº,
EC-69.
OK
ENG
Replace engine cool-
ant temperature sen-
sor.
If the cause can not be isolated, go to ª12
MAIN CAUSES OF OVERHEATINGº on
next page.
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 instru-
ment 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 ªOVERALL FUNCTION CHECKº.
Hose adapter
.SLC754AA
SLC755AA
SLC343
H
H
H
H
H
H
TROUBLE DIAGNOSIS 8CD20T
Cooling Fan (Overheat) (Cont'd)
EC-94
Page 389 of 2267

12 MAIN CAUSES OF OVERHEATING
Engine Step Inspection item Equipment Standard Reference page
OFF 1
lBlocked radiatorlBlocked condenserlBlocked radiator grillelBlocked bumper
lVisual No blocking þ
2
lCoolant mixturelCoolant tester 50 - 50% coolant mix-
tureSee ªRECOMMENDED
FLUIDS AND LUBRI-
CANTSº in MA section.
3
lCoolant levellVisual Coolant up to MAX level
in reservoir tank and
radiator filler neckSee ªChanging Engine
Coolantº, ªENGINE
MAINTENANCEº in MA
section.
4
lRadiator caplPressure tester 78 - 98 kPa
(0.78 - 0.98 bar, 0.8 -
1.0 kg/cm
2, 11 - 14 psi)
59-98kPa
(0.59 - 0.98 bar, 0.6 -
1.0 kg/cm
2,9-14psi)
(Limit)See ªSystem Checkº
ªENGINE COOLING
SYSTEMº in LC section.
ON*2 5
lCoolant leakslVisual No leaks See ªSystem Checkº
ªENGINE COOLING
SYSTEMº in LC section.
ON*2 6
lThermostatlTouch the upper and
lower radiator hosesBoth hoses should be
hotSee ªThermostatº and
ªRadiatorº, ªENGINE
COOLING SYSTEMº in
LC section.
ON*1 7
lCooling fanlCONSULT Operating See ªTROUBLE DIAG-
NOSIS 8º.
OFF 8
lCombustion gas leaklColor checker
chemical tester
4 Gas analyzerNegative þ
ON*3 9
lCoolant temperature
gaugelVisual Gauge less than 3/4
when drivingþ
lCoolant overflow to
reservoir tanklVisual No overflow during driv-
ing and idlingSee ªChanging Engine
Coolantº, ªENGINE
MAINTENANCEº in MA
section.
OFF*4 10
lCoolant return from
reservoir tank to
radiatorlVisual Should be initial level in
reservoir tankSee ªENGINE MAINTE-
NANCEº in MA section.
OFF 11
lCylinder headlStraight gauge feeler
gauge0.1 mm (0.004 in) Maxi-
mum distortion (warping)See ªInspectionº, ªCYL-
INDER HEADº in EM
section.
12
lCylinder block and
pistonslVisual No scuffing on cylinder
walls or pistonSee ªInspectionº, ªCYL-
INDER BLOCKº in EM
section.
*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.
For more information, refer to ªOVERHEATING CAUSE ANALYSISº in LC section.
TROUBLE DIAGNOSIS 8CD20T
Cooling Fan (Overheat) (Cont'd)
EC-95
Page 390 of 2267
COMPONENT INSPECTION
Cooling fan relays-1, -2, -3
Check continuity between terminalsp3andp5.
Conditions Continuity
12V direct current supply between relay
terminals
p1andp2Ye s
No current supplyNo
If NG, replace cooling fan relay.
Cooling fan relay-2
Check continuity between terminalsp3andp4.
Conditions Continuity
No current supplyYe s
12V direct current supply between relay
terminals
p1andp2No
Cooling fan motors-1 and -2
1. Disconnect cooling fan motor harness connectors.
2. Supply cooling fan motor terminals with battery voltage and
check operation.
Terminals
(!)(@)
Cooling fan motor-1 and -2
p1p2
Cooling fan motor should operate.
If NG, replace cooling fan motor.
3 5
12
3 5
1 4 2
3 5
1 4 2
YEC391
Cooling fan relay 1
Cooling fan relay 3
Cooling fan relay 2
AEC781
FUSE
Cooling fan
motor-1 & -2
TROUBLE DIAGNOSIS 8CD20T
Cooling Fan (Overheat) (Cont'd)
EC-96
Page 391 of 2267
Needle Lift Sensor (NLS)
The needle lift sensor is built into the No. 1 nozzle. Its inductive
pick-up element senses the lifting of the injection nozzle needle
and thus the start of injection. The signal is evaluated by the
ECM and compared with the target timing. Deviations in timing,
for example caused by changes in fuel temperature, are sensed
by the ECM and corrected.
Malfunction is detected when ....Check Items
(Possible Cause)
lAn improper signal from the sensor is sent to ECM.lHarness or connectors
(The sensor circuit is open or shorted.)
lNeedle lift sensor
lAir in fuel line
lClogging No. 1 injection nozzle
DIAGNOSTIC TROUBLE CONFIRMATION
PROCEDURE
NOTE:
Before diagnostic trouble confirmation, be sure to check
battery voltage is above 9V.
1) Turn ignition switch to ªONº position and select
ªDATA MONITORº mode with CONSULT-II.
2) Start engine and run it for 2 seconds above 1,200
rpm.
NEF689 Nozzle holder
NozzleInductive
pick-up coli
TROUBLE DIAGNOSIS 9CD20T
EC-97
Page 392 of 2267
YEC806
NEEDLE
LIFT SEN-
SOR
: Detectable line for DTC
: Non-detectable line for DTC
ECM
TROUBLE DIAGNOSIS 9CD20T
Needle Lift Sensor (NLS) (Cont'd)
EC-98