
SEF500V
Fast Idle Cam (FIC)
COMPONENT DESCRIPTIONNEEC0502The FIC is installed on the throttle body to maintain adequate
engine speed while the engine is cold. It is operated by a volumet-
ric change in wax located inside the thermo-element. The thermo-
element is operated by engine coolant temperature.
For inspection refer to ªTROUBLE DIAGNOSIS-BASIC
INSPECTIONº, ªBasic Inspectionº, EC-3086.
Idle Speed/Ignition Timing/Idle Mixture Ratio
Adjustment
NEEC0028PREPARATIONNEEC0028S05+Make sure that the following parts are in good order.
a)Battery
b)Ignition system
c)Engine oil and coolant levels
d)Fuses
e)ECM harness connector
f)Vacuum hoses
g)Air intake system
(Oil filler cap, oil level gauge, etc.)
h)Fuel pressure
i)Engine compression
j)Throttle valve
k)EVAP system
+On models equipped with air conditioner, checks should be carried out while the air conditioner is
ªOFFº.
+When measuring ªCOº percentage, insert probe more than 40 cm (15.7 in) into tail pipe.
+Turn off headlamps, heater blower.
+Keep front wheels pointed straight ahead.
BASIC SERVICE PROCEDUREKA24DE (EURO OBD)
Fast Idle Cam (FIC)
EC-3035

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)
Warranty symptom code AA AB AC AD AE AF AG AH AJ AK AL AM HA
Engine Cylinder head
55555 55 5
EM section Cylinder head gasket 4 3
Cylinder block
66666 66 64 Piston
Piston ring
Connecting rod
Bearing
Crankshaft
Valve
mecha-
nismTiming chain
5 5 5 5 5 5 5 5 EM section Camshaft
Intake valve
3
Exhaust valve
Exhaust Exhaust manifold/Tube/
Muffler/Gasket
5 5 5 5 5 5 5 5 FE section
Three way catalyst
Lubrica-
tionOil pan/Oil strainer/Oil pump/
Oil filter/Oil gallery
55555 55 5MA section,
LC section
Oil level (Low)/Filthy oil
Cooling Radiator/Hose/Radiator filler
cap
55555 55 45LC section Thermostat 5
Water pump
Water gallery
Coolant level (low)/
Contaminated coolantMA section
1 - 6: The numbers refer to the order of inspection.
TROUBLE DIAGNOSIS Ð GENERAL
DESCRIPTION
KA24DE (EURO OBD)
Symptom Matrix Chart
EC-3105

DescriptionNEEC1594SYSTEM DESCRIPTIONNEEC1594S01
Sensor Input Signal to ECMECM func-
tionActuator
Camshaft position sensor Engine speed
Idle air
controlIACV-AAC valve Mass air flow sensor Amount of intake air
Engine coolant temperature sensor Engine coolant temperature
Ignition switch Start signal
Throttle position sensor Throttle position
PNP switch Neutral position
Air conditioner switch Air conditioner operation
Power steering oil pressure switch Power steering load signal
Battery Battery voltage
Vehicle speed sensor Vehicle speed
Intake air temperature sensor Intake air temperature
This system automatically controls engine idle speed to a specified
level. Idle speed is controlled through fine adjustment of the
amount of air which bypasses the throttle valve via IACV-AAC
valve. The IACV-AAC valve repeats ON/OFF operation according
to the signal sent from the ECM. The camshaft position sensor
detects the actual engine speed and sends a signal to the ECM.
The ECM then controls the ON/OFF time of the IACV-AAC valve
so that engine speed coincides with the target value memorized in
ECM. The target engine speed is the lowest speed at which the
engine can operate steadily. The optimum value stored in the ECM
is determined by taking into consideration various engine
conditions, such as during warm up, deceleration, and engine load
(air conditioner, power steering and cooling fan operation).
SEF040E
COMPONENT DESCRIPTIONNEEC1594S02The IAC valve-AAC valve is moved by ON/OFF pulses from the
ECM. The longer the ON pulse, the greater the amount of air that
will flow through the valve. The more air that flows through the
valve, the higher the idle speed.
CONSULT-II Reference Value in Data Monitor
Mode
NEEC1595
MONITOR ITEM CONDITION SPECIFICATION
IACV-AAC/V+Engine: After warming up
+Air conditioner switch: OFF
+Shift lever: ªNº
+No-loadIdle Approx. 30%
2,000 rpm Ð
DTC P0505 ISC SYSTEMKA24DE (EURO OBD)
Description
EC-3295

On Board Diagnosis LogicNEEC1534If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will
rise.
When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is
indicated.
DTC No. Malfunction is detected when ...Check Items
(Possible Cause)
P1217
1217+Engine coolant temperature reaches an abnormally high
temperature.+Cooling fan (crankshaft driven)
Radiator hose
+Radiator
+Radiator cap
+Water pump
+Thermostat
+Engine coolant temperature sensor
For more information, refer to ªMAIN 11 CAUSES
OF OVERHEATINGº, EC-3348.
CAUTION:
When a malfunction is indicated, be sure to replace the coolant. Refer to MA section, ªChanging Engine
Coolantº. Also, replace the engine oil.
1) Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure
to use coolant with the proper mixture ratio. Refer to MA section, ªAnti-freeze Coolant Mixture
Ratioº.
2) After refilling coolant, run engine to ensure that no water-flow noise is emitted.
SEF621W
Overall Function CheckNEEC1535WARNING:
Never remove the radiator cap when the engine is hot. Serious
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 steps and go to ªDiagnos-
tic Procedureº, EC-3345.
2) Confirm whether customer filled the coolant or not. If customer
filled the coolant, skip the following steps and go to ªDiagnos-
tic Procedureº, EC-3345.
DTC P1217 ENGINE OVER
TEMPERATURE
KA24DE (EURO OBD)
On Board Diagnosis Logic
EC-3344

ECM Terminals and Reference Value
Specification data are reference values and are measured between each terminal and ground.
CAUTION:
Do not use ECM ground terminals when measuring input/output voltage. Doing so may damage the
ECM's transistor. Use a ground other than ECM terminals, such as the ground.
TER-
MINAL
NO.WIRE
COLORITEM CONDITION DATA (DC Voltage)
14 G/B Cooling fan relayEngine is running.
Cooling fan is not operatingBATTERY VOLTAGE
(11 - 14V)
Engine is running.
Cooling fan is operatingApproximately 0.1V
On Board Diagnosis Logic
This diagnosis continuously monitors the engine coolant temperature.
If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will
rise.
When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is
indicated.
Malfunction is detected when ... Check Items (Possible Cause)
+Cooling fan does not operate properly (Overheat).
+Cooling fan system does not operate properly (Overheat).
+Engine coolant was not added to the system using the proper
filling method.+Harness or connectors
(The cooling fan circuit is open or shorted.)
+Cooling fan
+Radiator hose
+Radiator
+Radiator cap
+Water pump
+Thermostat
+Fan belt
+Engine coolant temperature sensor
For more information, refer to ªMAIN 12 CAUSES OF
OVERHEATINGº, EC-3501.
CAUTION:
When a malfunction is indicated, be sure to replace the coolant following the procedure in the MA
section (ªChanging Engine Coolantº, ªENGINE MAINTENANCEº). Also, replace the engine oil.
1) Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure
to use coolant with the proper mixture ratio. Refer to MA section (ªAnti-freeze Coolant Mixture
Ratioº, ªRECOMMENDED LUBRICANTS AND FLUIDSº).
2) After refilling coolant, run engine to ensure that no water-flow noise is emitted.
DTC 0208 OVER HEATYD25DDTi
EC-3490

Bulb Replacement
The headlamp is a semi-sealed beam type which uses a replace-
able halogen bulb. The bulb can be replaced from the engine
compartment side without removing the headlamp body.
+Grasp only the plastic base when handling the bulb.
Never touch the glass envelope.
1. Disconnect the battery cable.
2. Disconnect the harness connector from the back side of the
bulb.
3. Pull off the rubber cap.
4. Push and raise retaining pin to loosen it.
5. Remove the headlamp bulb carefully. Do not shake or rotate
the bulb when removing it.
6. Install in the reverse order of removal.
CAUTION:
Do not leave headlamp reflector without bulb for a long
period of time. Dust, moisture, smoke, etc. entering head-
lamp body may affect the performance of the headlamp.
Remove headlamp bulb from the headlamp reflector just
before a replacement bulb is installed.
Aiming Adjustment
When performing headlamp aiming adjustment, use an aiming
machine, aiming wall screen or headlamp tester. Aimers should
be in good repair, calibrated and operated in accordance with
respective operation manuals.
If any aimer is not available, aiming adjustment can be done as
follows:
For details, refer to the regulations in your own country.
a. Keep all tires inflated to correct pressures.
b. Place vehicle and tester on one and same flat surface.
c. See that there is no-load in vehicle (coolant, engine oil
filled up to correct level and full fuel tank) other than the
driver (or equivalent weight placed in driver's position).
CAUTION:
Be sure aiming switch is set to ª0º when performing aiming
adjustment on vehicles equipped with headlamp aiming
control.
GEL452A
SEL596Y
SEL597Y
HEADLAMP Ð Conventional Type Ð
EL-3027

Trouble Diagnosis of Turbocharger
Preliminary check:
+Check that the engine oil level is between MIN and MAX of
the dipstick. (When the engine oil amount is more than MAX,
the oil flows into the inlet duct through the blow-by gas
passage, and the turbocharger is misjudged failure.)
+Ask the customer if he/she always runs the vehicle in idle
engine speed to cool the oil down after driving.
+Replace the turbocharger assembly when any malfunction is
found after unit inspections specified in the table below.
+If no malfunction is found after the unit inspections, judge that
the turbocharger body has no failure. Check the other parts
again.
Inspection item Inspection resultSymptom (when each inspection item meets each
inspection result)
Oil leakage Smoke NoiseInsufficient
power/
acceleration
failure
Turbine wheelOil leaks.n
nn
Carbon is accumulated.n
jj
Friction with housing.nj
j
Blades are bent or broken.
Compressor wheelInside the air inlet is seriously contaminated
by oil.jj
Friction with housing.njj
Blades are bent or broken.
After checking both turbine and compressor,
inspect rotor shaft end play.There is resistance when the rotor shaft is
rotated by your fingertips.nnj
The rotor shaft sometimes does not rotate
by your fingertips.
There is too much play in the bearing.nnjn
Oil return portCarbon or sludge is accumulated in the
waste oil hole.n
nn
: Large possibility
j: Medium possibility
n: Small possibility
EXHAUST MANIFOLD, TURBOCHARGERYD25DDTi
Inspection (Cont'd)
EM-3044

Removal operation
15. Install the engine slingers (standard service part) to front-left
and rear-right.
: 29.5 - 37.3 Nzm (3.0 - 3.8 kg-m, 22 - 27 ft-lb)
WARNING:
For engines without engine slingers, attach proper slingers
and bolts described in the PARTS CATALOG.
16. Hook hoists to slingers to secure the position.
17. Remove installation nuts for left and right engine mount insu-
lators.
18. Remove crankshaft position sensor (TDC sensor) from trans-
mission.
19. Separate engine and transmission, remove the engine.
CAUTION:
+While performing operation, check that all necessary
wires and pipes are disconnected.
+Avoid interference with parts on the vehicle.
Installation
Install the engine in the reverse order of the removal procedure.
+Keep each mount insulator from oil adherence and damage.
+As for a location with positioning pin, insert the pin correctly
to the hole of mating part.
+While keeping each mount insulator free from twisting,
tighten mounting bolts and nuts for the engine mount.
Inspection
+Before starting the engine, check levels of coolant, engine oil,
and other operating fluids, and if necessary, refill them to the
specified level.
+Start the engine, and check that there is no abnormal noise
or vibration.
+Warm up the engine to the sufficient temperature, and check
that there is no leakage of coolant, greases, fuel, or exhaust
gas.
SEM893G
SEM896G
ENGINE REMOVALYD25DDTi
Removal (Cont'd)
EM-3065