GDI -Troubleshooting 13A-128 FAIL-SAFE FUNCTION REFERENCE TABLE When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled by means of the pre-set control logic to maintain safe conditions for driving. Malfunctioning itemControl contents during malfunction Air flow sensor1. Suspends lean burn operation. 2. Uses the throttle position sensor signal and engine speed signal (crank angle sensor signal) to take reading of the basic injector drive time and basic ignition timing from the pre - set mapping. Intake air temperature sensorControls as if the intake air temperature is 25_ C. Throttle position sensor (2nd channel)1. Suspends lean burn operation. 2. Controls the throttle opening angle feedback (half as much as the opening rate in the normal condition) by using signals from the throttle position sensor (1st channel). However, this controlling system is not applied if the throttle position sensor (1st channel) and throttle position sensor (2nd channel) combination output voltage is outside 4 - 6 V. 3. Refrains from controlling the throttle opening angle feedback if the throttle position sensor (1st channel) is also defective. Engine coolant temperature sensorControls as if the engine coolant temperature is 80_ C. (Moreover, the control system is working until the ignition switch is turned OFF if the sensor signal returns to normal.) Camshaft position sensorCuts the fuel supply once a malfunction is detected. (Only when there has been no occasion of detecting No.1 cylinder top dead centre after the ignition switch is turned ON.) Vehicle speed sensor1. Suspends lean burn operation. However, the control is cancelled as a certain time passes by with the engine speed of 1,500 r/min or more. 2. Suspends lean burn operation during the engine idling. Barometric pressure sensorControls as if the barometric pressure is 101 kPa. Detonation sensorFixes the ignition timing as that for regular gasoline. Injector1. Suspends lean burn operation. 2. Suspends the exhaust gas recirculation. Ignition coil (incorporating pow- er transistor)1. Suspends lean burn operation. 2. Cuts off the fuel supply to cylinders with an abnormal ignition signal. Fuel pressure sensor1. Controls as if the fuel pressure is 5MPa. 2. Suspends fuel injection. (when the low pressure is detected and the engine speed is more than 3,000r/min) Alternator FR terminalRefrains from controlling to suppress the alternator output to electrical load. (Operated as a normal alternator) Accelerator pedal position sen- sor (2nd channel)1. Suspends lean burn operation. 2. Controls the throttle valve position by using signals from the accelerator pedal position sensor (1st channel). (However, the control system is not applicable if the difference from the accelerator pedal position sensor (1st channel) output voltage is 1.0V or higher.) 3 . Suspends the electronic controlled throttle valve system if accelerator pedal position sensor (1st channel) is also defective. www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk
GDI -Troubleshooting 13A-130 INSPECTION CHART FOR DIAGNOSIS CODES Code No.Diagnosis itemReference page 11Oxygen sensor system13A-131 12Air flow sensor system13A-133 13Intake air temperature sensor system13A-135 14Throttle position sensor (2nd channel) system13A-137 21Engine coolant temperature sensor system13A-138 22Crank angle sensor system13A-140 23Camshaft position sensor system13A-142 24Vehicle speed sensor system13A-144 25Barometric pressure sensor system13A-145 31Detonation sensor system13A-146 41Injector system13A-147 44Ignition coil (incorporating power transistor) system (for No. 1 and No. 4 cylinders)13A-148 52Ignition coil (incorporating power transistor) system (for No. 2 and No. 5 cylinders)13A-148 53Ignition coil (incorporating power transistor) system (for No. 3 and No. 6 cylinders)13A-148 54Immobilizer system13A-150 56Abnormal fuel pressure system13A-151 64Alternator FR terminal system13A-153 77Accelerator pedal position sensor (2nd channel) system13A-154 78Accelerator pedal position sensor (1st channel) system13A-156 79Throttle position sensor (1st channel) system13A-158 89Abnormality in fuel pressure system13A-160 91Electronic-controlled throttle valve system13A-161 92Throttle valve position feedback system13A-162 93Throttle valve control servo system13A-163 94Communication line system with throttle valve controller13A-164 96Throttle valve controller system13A-165 NOTE Code No. 56 may be also output when air is sucked in high-pressure fuel line due to no fuel supply. www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk
GDI -Troubleshooting 13A-148 OK Use an analyzer to measure the signal waveform at engine-A/T-ECU connectors D-119 and D-120. DEngine: Idling DSelector lever position: P DVoltage between terminal 1 and earth OK: A normal waveform should be displayed as described on P.13A-214 (INSPEC- TION PROCEDURE US- ING AN ANALYZER).NGCheck the following connector: B-61 OK Check the following connectors: B-117 , B-114 injector>, B-118 , B-115 , B-103 injector>, B-104 NG RepairNG OK OK Check the harness wire between the injector and the intermediate connector.NG Replace the engine-A/T-ECU. Repair Repair From the previouspage OK Check the harness wire between injector and the intermediate connector.NG Repair OK Replace the injector. Check the trouble symptoms.NGReplace the injector driver. Code No.44, 52, 53 Ignition coil (incorporating power transistor) systemProbable cause Range of Check DEngine speed is approx. 50 - 4,000 r/min. DEngine is not cranking. Set Conditions DThe ignition failure sensor does not send a signal about a certain cylinder for four seconds. However, except that the ignition failure sensor does not send a signal about all of cylinders.DMalfunction of the ignition coil DMalfunction of the ignition failure sensor DMalfunction of sparkplug DOpen or short circuit in the primary ignition circuit or loose connector contact DMalfunction of engine-A/T-ECU www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk
GDI -Troubleshooting 13A-149 OK Check trouble symptom. OK Check trouble symptom. OK Check the following connectors: B-101, B-108, B-112, B-113, B-116, B-119 NG Repair OK Replace the engine-A/T-ECU. NGNG Replace the ignition failure sensor. OK Check the harness wire between the engine-A/T-ECU and the igni- tion failure sensor. OK Check the ignition failure sensor. (Refer to GROUP 16 - Ignition System.)NG Check the following connectors: B-04, D-120 Check the ignition coil. (Refer to GROUP 16 - Ignition System.)NG Replace Measure at the ignition coil connectors B-101, B-108, B-112, B-113, B-116, B-119. DDisconnect the connector, and measure at the harness side. (1) Voltage between 1 and earth (Ignition switch: ON) OK: System voltage (2) Voltage between 3 and earth (Engine: cranking) OK: 0.5 - 4.0 V (3) Continuity between 2 and earth OK: ContinuityReplace OK NG Repair OK Check the following connectors: B-07, B-107, E-13, D-223 (1) NG NGRepair NG Check and repair the harness wire between the ignition coil and ignition failure sensor. Check and repair the harness wire between the ignition failure sensor and ignition switch. Check the following connectors: B-107, D-119 Repair NG (2) NG OK Check trouble symptom. Check the harness wire between the engine-A/T-ECU and the igni- tion coil. Repair NGOK Replace the engine-A/T-ECU. Check and repair the harness wire between the ignition coil and earth. (3) NG Measure at the ignition failure sensor connector B-04. DDisconnect the connector, and measure at the harness side. (1) Voltage between 2 and earth (Ignition switch: ON) OK: 4 V or more (2) Continuity between 1 and earth OK: Continuity NG There is short circuit oropencircuit in the ignition signal output harness of the ignition failure sensor. Check and repair the harness. (1) NG Check and repair the harness wire between the ignition failure sensor and earth. (2) NG Measure at the engine-A/T-ECU connector D-120. DConnect the connector. DVoltage between 45 and earth (Engine: 3,000 r/min) OK: 0.3 - 3.0 VOK Repair NG www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk
GDI -Troubleshooting 13A-172 OK Check the following items in that order. DCheck the sparkplug DCheck the compression pressure DCheck if foreign materials (water, alcohol, etc.) got into fuel. OK Clamp the leads of the ignition coil No.1 terminal with atiming light pick-up in order. Does thetiming lightflash when the engine iscranked?NOCheck the ignition coil (built-in power transistor) system (Refer to P.13A-148, code No.44.) From the previouspage OK Check the trouble symptoms. OK Check ignition coil spark for each cylinder. 1. Remove the ignition coil. 2. Install a new sparkplug to the removed ignitioncoil. 3. Disconnect the injector intermediate connector. Caution Never touch the connector terminal as approx. 100 V is applied to the injector, or you are seriously injured. 4. Earth the sparkplug electrodesecurely. 5. Check that the sparkplug igniteswhen theengine is cranked.NGReplace the ignition coil. YES Check the ignitiontimingwhen cranking. OK: approx. 5_BTDCNGCheck that the crankanglesensor andtiming beltcover are properly installed. Replace the injector.NG Inspection procedure 6 Initial combustion but no complete combustion (starting impossible), long time to start (hard starting) Probable cause In such cases as the above, the cause is probably that the spark plugs are generating sparks by the spark are weak, or the initial mixture is not appropriate.DMalfunction of fuel supply system DMalfunction of of fuel pressure control solenoid valve DMalfunction of the ignition system DMalfunction of the electronic-controlled throttle valve system DMalfunction of the engine-A/T-ECU OK MUT- IIData list 21 Engine coolant temperature sensor (Refer to P.13A-198.)NGCheck theengine coolant temperaturesensor system (Refer to P.13A-138, code No.21.) OK MUT- IISelf-Diag Code Is a diagnosis code set?YESRefer to P.13A-130, INSPECTION CHART FOR DIAGNOSIS CODES. Check the battery voltage when cranking. OK: 8 V or higherNGCheck the battery. NO MUT- IIActuator Test 07 Fuel pump(low pressure) (Refer to P.13A-203.)NGCheck fuelpumpsystem (low-pressure) (Refer to P.13A-193, Inspection procedure 29.) OK To the nextpage www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk
GDI -Troubleshooting 13A-173 NGReplace the injector.Check the trouble symptoms. OK Check the following items in that order. DCheck the sparkplug DCheck the compression pressure DCheck the fuel lines for clogging. DCheck if foreign materials (water, alcohol, etc.) got into fuel. OK Check ignition coil spark for each cylinder. 1. Remove the ignition coil. 2. Install a new sparkplug to the removed ignitioncoil. Caution Never touch the connector terminal as approx. 100 V is applied to the injector, or you are seriously injured. 3. Disconnect the injector intermediate connector. 4. Earth the sparkplug electrodesecurely. 5. Check that the sparkplug igniteswhen theengine is cranked.NGReplace the ignition coil. Check the ignitiontimingwhen cranking. OK: Approx. 5_BTDCNGCheck that the crankanglesensor andtiming beltcover are installed properly. NO Adjust the throttle position sensor (Refer to P.13A-220.) OK Is starting good if the engine iscranked with the accelerator pedalslightly depressed?YESDClean the throttle valve area. (Refer to P.13A-220) DAdjust the throttle position sensor (Refer to P.13A-220.) OK MUT- IIData list 79 Throttle position sensor (1st channel) (Refer to P.13A-198.)NGCheck the throttle valve position feedback system. (Refer to P.13A-162, code No.92.) OK Check fuel leakage. (Refer to P.13A-225.)NGRepair OK MUT- IIActuator Test 74 Fuel pressure sensor (Refer to P.13A-203.)NGCheck abnormal fuel pressure. (Refer to P.13A-151, code No.56.) OK MUT- IIData list 18 Cranking signal (Refer to P.13A-198.)NGCheck the ignition switch-ST system and inhibitor switch (Refer to 13A-191, Inspection procedure 27.) From the previouspage www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk
GDI -Troubleshooting 13A-175 OK NG Air is sucked in the air intake system, or EGR gas leaks. DBroken intake manifold gasket DDamaged air intake hose DDamaged vacuum hose DFaulty EGR valve seat Check the trouble symptoms. OK Check the following items in that order. DCheck the sparkplug DCheck the exhaust gas emission control system DCheck the EGR control system DCheck the compression pressure DCheck if foreign materials (water, kerosine,etc.) got into fuel. OK Check ignition coil spark for each cylinder. 1. Remove the ignition coil. 2. Install a new sparkplug to the removed ignitioncoil. 3. Disconnect the injector intermediate connector. Caution Never touch the connector terminal as approx. 100 V is applied to the injector, or you are seriously injured. 4. Earth the sparkplug electrodesecurely. 5. Check that the sparkplug igniteswhen theengine is cranked.NGReplace the ignition coil. Clean around the throttle valve. (Refer to P.13A-220.) OK Check the ignition timing. (Refer to GROUP 11A - Engine Adjustment.)NGCheck that the crankanglesensor andtiming beltcover are properly installed. OK MUT- IIData list 68 EGR valve (Refer to P.13A-198.)NGCheck the EGR valve system (Refer to P.13A-196, Inspection procedure 35.) OK MUT- IIData list 14 Throttle position sensor (2nd channel) After warming-up, let theengine run at idlingwith no load. OK: When idling, 3,900 - 4,800 mVNGDClean around the throttle valve. (Refer to P.13A-220) DAdjust the throttle position sensor (Refer to P.13A-220.) OK MUT- IIData list 67 Stoplampswitch (Refer to P.13A-198.)NGCheck the stoplampswitch system (Refer to P.13A-195, Inspection procedure 32.) OK MUT- IIData list 28 A/C switch (Refer to P.13A-198.)NGCheck the A/C switch and A/C relay system (Refer to P.13A-194, Inspection procedure 31.) OK MUT- IIData list 27 Power steering oil pressure switch (Refer to P.13A-198.)NGCheck the power steering oil pressure switch system (Refer to P.13A-194, Inspection procedure 30.) From the previouspage OK MUT- IIData list 31 Small lampswitch (Refer to P.13A-198.)NGCheck the smalllampswitch system (Refer to P.13A-195, Inspection procedure 33.) www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk
GDI -Troubleshooting 13A-177 Inspection procedure 9 When the engine is cold, it stalls at idling. (Die out) Probable cause In such cases as the above, the cause is probably that the air/fuel mixture is inappropriate when theengine iscold, or that the intake air volume is insufficient.DMalfunction of the electronic-controlled throttle valve system DMalfunction of the throttle body OK NG Replace the injector. Check the trouble symptoms. Check the following items in that order. DCheck the sparkplug DCheck the compression pressure DCheck theengine oilviscosity. OK Check ignition coil spark for each cylinder. 1. Remove the ignition coil. 2. Install a new sparkplug to the removed ignitioncoil. 3. Disconnect the injector intermediate connector. Caution Never touch the connector terminal as approx. 100 V is applied to the injector, or you are seriously injured. 4. Earth the sparkplug electrodesecurely. 5. Check that the sparkplug igniteswhen theengine is cranked.NGReplace the ignition coil. OK Check the ignition timing. (Refer to GROUP 11A - Engine Adjustment.)NGCheck that the crankanglesensor andtiming beltcover are properly installed. NO Measure fuel high-pressure between the fuel pump (high pressure) and injector. (Refer to P.13A-222.) OK Does theenginestall right after the acceleratorpedal is released?YESDClean around the throttle valve. (Refer to P.13A-220.) DAdjust the throttle position sensor. (Refer to P.13A-220.) OK MUT- IIData list 68 EGR valve (Refer to P.13A-198.)NGCheck the EGR valve system. (Refer to P.13A-196, Inspection procedure 35.) OK MUT- IIData list 21 Engine coolant temperature sensor (Refer to P.13A-198.)NGCheck theengine coolant temperaturesensor system. (Refer to P.13A-138, code No.21.) OK MUT- IIData list 26 Acceleratorpedal positionswitch (Refer to P.13A-198.)NGCheck the acceleratorpedal positionswitch system. (Refer to P.13A-192, Inspection procedure 28.) NO MUT- IIData list 14 Throttle position sensor (2nd channel) (Refer to P.13A-198.)NGCheck the throttle valve position feedback system. (Refer to P.13A-162, code No.92.) NO Is engine-idling stable after the warming-up?YESCheck the unstableidling (rough, hunting). (Refer to P.13A-174, Inspection procedure 7.) NO MUT- IISelf-Diag Code Is a diagnosis code set?YESRefer to P.13A-130, INSPECTION CHART FOR DIAGNOSIS CODES. Has the batterybeen disconnectedrecently?YESAfter warming-up, let theengine run at idling for 10 minutes. www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk
