TROUBLE DIAGNOSIS
EC-1409
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TROUBLE DIAGNOSISPFP:00004
Trouble Diagnosis IntroductionEBS0036Z
INTRODUCTION
The engine has an ECM to control major systems such as fuel injec-
tion control, fuel injection timing control, glow control system, etc.
The ECM accepts input signals from sensors and instantly actuators.
It is essential that both input and output signals are proper and sta-
ble. At the same time, it is important that there are no malfunctions
such as vacuum leaks, or other malfunctions with the engine.
It is much more difficult to diagnose a malfunction that occurs inter-
mittently rather than continuously. Most intermittent malfunctions are
caused by poor electric connections or improper wiring. In this case,
careful checking of suspected circuits may help prevent the replace-
ment of good parts.
A visual check only may not find the cause of the incidents. A road
test with CONSULT-II or a circuit tester connected should be per-
formed. Follow the EC-1410, "
WORK FLOW" .
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 incidents, especially
intermittent ones. Find out what symptoms are present and under
what conditions they occur. A “Diagnostic Worksheet” like the exam-
ple on next page should be used.
Start your diagnosis by looking for “conventional” incidents first. This
will help troubleshoot driveability incidents on an electronically con-
trolled engine vehicle.
MEF036D
SEF233G
SEF234G
TROUBLE DIAGNOSIS
EC-1411
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Description for Work Flow
DIAGNOSTIC WORK SHEET
There are many operating conditions that lead to the malfunction of
engine components. A good grasp of such conditions can make trou-
bleshooting faster and more accurate.
In general, each customer feels differently about an incident. It is
important to fully understand the symptoms or conditions for a cus-
tomer complaint.
Utilize a diagnostic worksheet like the one shown below in order to
organize all the information for troubleshooting.
STEP DESCRIPTION
STEP IGet detailed information about the conditions and the environment when the incident/symptom occurred using the
EC-1411, "
DIAGNOSTIC WORK SHEET" .
STEP IIBefore confirming the concern, check and write down (print out using CONSULT-II) the DTC, then erase the DTC.
Refer to EC-1406
.
If the incident cannot be verified, perform EC-1441, "
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
Study the relationship between the cause, specified by DTC, and the symptom described by the customer. (The
“Symptom Matrix Chart” will be useful. Refer to EC-1416
.) Also check related service bulletins for information.
STEP IIITry to confirm the symptom and under what conditions the incident occurs.
The “DIAGNOSTIC WORK SHEET” is useful to verify the incident. Connect CONSULT-II to the vehicle in DATA
MONITOR (AUTO TRIG) mode and check real time diagnosis results.
If the incident cannot be verified, perform EC-1441, "
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
If the malfunction code is detected, skip STEP IV and perform STEP V.
STEP IVTry to detect the DTC by driving in (or performing) the “DTC Confirmation Procedure”. Check and read the DTC by
using CONSULT-II.
During the DTC verification, be sure to connect CONSULT-II to the vehicle in DATA MONITOR (AUTO TRIG) mode
and check real time diagnosis results.
If the incident cannot be verified, perform EC-1441, "
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
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 simplified “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 PXXXX.
If the normal code is indicated, proceed to the Basic Inspection, EC-1412
. Then perform inspections according to the
Symptom Matrix Chart. Refer to EC-1416
.
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-II 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 CONSULT-II.
Refer to EC-1425
or EC-1437 .
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-23, "
How to Per-
form Efficient Diagnosis for an Electrical Incident" , “Circuit Inspection”.
Repair or replace the malfunction parts.
If the malfunctioning part cannot be detected, perform EC-1441, "
TROUBLE DIAGNOSIS FOR INTERMITTENT
INCIDENT" .
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 confirm the normal code (DTC P0000) is detected. If the incident is
still detected in the final 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 fixed) DTC in ECM. (Refer to
EC-1406
.)
SEF907L
EC-1426
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TROUBLE DIAGNOSIS
TERMI-
NAL
NO.WIRE
COLORITEM CONDITIONDATA
(DC Voltage and Pulse Signal)
A1
A2
A3
A4L/W
Y/PU
PU
YEDU drive No. 2
EDU drive No. 4
EDU drive No. 3
EDU drive No. 1[Engine is running]
●Warm-up condition
●Idle speed0 - 4V
[Engine is running]
●Warm-up condition
●Engine speed is 2,000 rpm0 - 4V
A5
A6
A7B
B
BECM ground[Engine is running]
●Idle speedApproximately 0V
A8
A9R
RPower supply for ECM[Ignition switch “ON”]BATTERY VOLTAGE
(11 - 14V)
A10 R Mass air flow sensor[Engine is running]
●Warm-up condition
●Idle speed0.5 - 2.5V
[Engine is running]
●Warm-up condition
●Engine speed is 2,000 rpm1.5 - 3.5V
A11 L/OREngine coolant tempera-
ture sensor[Engine is running]
●Warm-up conditionApproximately 0 - 4.8V
Output voltage varies with engine
coolant temperature
A12 PU Fuel temperature sensor[Engine is running]
●Warm-up conditionApproximately 0 - 4.8V
Output voltage varies with fuel
temperature
A21 BAccelerator pedal
released position switch
ground[Ignition switch “ON”]Approximately 0V
A22 LGAccelerator pedal position
sensor 1 ground[Ignition switch “ON”]Approximately 0V
A23 B Sensor's ground[Engine is running]
●Warm-up condition
●Idle speedApproximately 0V
PBIB0387E
PBIB0388E
PBIB0389E
PBIB0390E
TROUBLE DIAGNOSIS
EC-1427
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ECA24 BMass air flow sensor
ground[Engine is running]●Warm-up condition
●Idle speedApproximately 0V
A25 G/W Injector's ground[Engine is running]
●Warm-up condition
●Idle speedApproximately 0V
A26 LG/RAccelerator pedal position
sensor 2 ground[Ignition switch “ON”]Approximately 0V
A27 W Sensor's power supply[Ignition switch “ON”]Approximately 5V
A28 PU/RAccelerator pedal position
sensor 1 power supply [Ignition switch “ON”]Approximately 5V
A29 W/PU EDU injector check signal[Engine is running]
●Warm-up condition
●Idle speed1 - 5V
[Engine is running]
●Warm-up condition
●Engine speed is 2,000 rpm1 - 5V
A31 W/L Power supply for ECM[Ignition switch “ON”]BATTERY VOLTAGE
(11 - 14V)
B3
B4
B5
B6W
OR/B
W/L
GYEGR volume control valve[Engine is running]
●Warm-up condition
●Idle speed0.1 - 14V
(Voltage signals of each ECM ter-
minals differ according to the con-
trol position of EGR volume
control valve.)
B9 G/BFuel injector adjustment
resistor No.2
[Ignition switch “ON”]0.2 - 4.8V
(There are individual differences
between fuel injector adjustment
resistors.) B10 Y/BFuel injector adjustment
resistor No.4
B11 R/BFuel injector adjustment
resistor No.3
B12 W/BFuel injector adjustment
resistor No.1
B13
B14Y/R
Y/RCommon rail fuel pressure
sensor[Engine is running]
●Warm-up condition
●Idle speed1.6 - 1.8V
[Engine is running]
●Warm-up condition
●Engine speed is 2,000 rpm1.8 - 2.0V TERMI-
NAL
NO.WIRE
COLORITEM CONDITIONDATA
(DC Voltage and Pulse Signal)
PBIB0391E
PBIB0392E
EC-1428
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TROUBLE DIAGNOSIS
B15 WAccelerator pedal position
sensor 1[Ignition switch “ON”]
●Engine stopped
●Accelerator pedal fully released0.8 - 1.3V
[Ignition switch “ON”]
●Engine stopped
●Accelerator pedal fully depressedMore than 3.5V
B16 GAccelerator pedal position
sensor 2[Ignition switch “ON”]
●Engine stopped
●Accelerator pedal fully released0.3 - 1.8V
[Ignition switch “ON”]
●Engine stopped
●Accelerator pedal fully depressedMore than 3.0V
B18 R/GCamshaft position sensor
ground[Engine is running]
●Warm-up condition
●Idle speedApproximately 0V
B19 R/Y Camshaft position sensor[Engine is running]
●Warm-up condition
●Idle speed0 - 3V
[Engine is running]
●Warm-up condition
●Engine speed is 2,000 rpm0 - 8V
B20 L/RCrankshaft position sen-
sor (TDC) ground[Engine is running]
●Warm-up condition
●Idle speedApproximately 0V
B21 L/GCrankshaft position sen-
sor (TDC)[Engine is running]
●Warm-up condition
●Idle speed0 - 12.5V
[Engine is running]
●Warm-up condition
●Engine speed is 2,000 rpm0 - 30.0V TERMI-
NAL
NO.WIRE
COLORITEM CONDITIONDATA
(DC Voltage and Pulse Signal)
PBIB0393E
PBIB0394E
PBIB0395E
PBIB0396E
TROUBLE DIAGNOSIS
EC-1429
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ECB23 GY/LAccelerator pedal position
sensor 2 power supply[Ignition switch “ON”]Approximately 5V
D1 L/OR Tachometer[Engine is running]
●Warm-up condition
●Idle speed0 - 12.5V
[Engine is running]
●Warm-up condition
●Engine speed is 2,000 rpm0 - 12.5V
D2 OR Glow lamp[Ignition switch “ON”]
●Glow lamp is “ON”Approximately 1.0V
[Ignition switch “ON”]
●Glow lamp is “OFF”BATTERY VOLTAGE
(11 - 14V)
D9 OR/L Malfunction indicator[Ignition switch “ON”]Approximately 1.0V
[Engine is running]
●Idle speedBATTERY VOLTAGE
(11 - 14V)
D11 L Air conditioner relay[Engine 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 0.1V
D14 G/YAccelerator pedal
released position switch[Ignition switch “ON”]
●Engine stopped
●Accelerator pedal slightly depressedBATTERY VOLTAGE
(11 - 14V)
[Ignition switch “ON”]
●Engine stopped
●Accelerator pedal fully releasedApproximately 0V
D18
D19W/R
W/RIgnition switch [Ignition switch “ON”]BATTERY VOLTAGE
(11 - 14V)
D23 PU/W Air conditioner switch[Engine 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 0.1V
D24
D26G
GECM relay (self-shutoff)[Ignition switch “ON”]
[Ignition switch “OFF”]
●For a few seconds after turning ignition
switch “OFF”Approximately 0V
[Ignition switch “OFF”]
●A few seconds passed after turning ignition
switch “OFF”BATTERY VOLTAGE
(11 - 14V) TERMI-
NAL
NO.WIRE
COLORITEM CONDITIONDATA
(DC Voltage and Pulse Signal)
PBIB0397E
PBIB0398E
TROUBLE DIAGNOSIS
EC-1431
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EC
: Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.)
CONSULT-II FunctionEBS0037H
CONSULT-II INSPECTION PROCEDURE
1. Turn ignition switch OFF.
2. Connect CONSULT-II to data link connector, which is located
under the driver side dash panel.
3. Turn ignition switch ON.
E11 L CAN communication line[Ignition switch “ON”]Approximately 2.6 - 3.2V
Output voltage varies with the
communication status.
E12 P/BPower steering oil pres-
sure switch[Engine is running]
●Steering wheel is being turnedApproximately 0V
[Engine is running]
●Steering wheel is not being turnedBATTERY VOLTAGE
(11 - 14V)
E13 G/ORPark/Neutral position
switch[Ignition switch “ON”]
●Gear position is “Neutral” Approximately 0V
[Ignition switch “ON”]
●Except the above gear positionBATTERY VOLTAGE
(11 - 14V)
E16 G/W Suction control valve 2[Engine is running]
●Warm-up condition
●Idle speed0 - 12.5V
[Engine is running]
●Warm-up condition
●Engine speed is 2,000 rpm0 - 12.5V
E21 L/B Vehicle speed sensor[Engine is running]
●Lift up the vehicle
●In 2nd gear position
●Vehicle speed is 30 km/h (19 MPH)0 - 5V TERMI-
NAL
NO.WIRE
COLORITEM CONDITIONDATA
(DC Voltage and Pulse Signal)
PBIB0401E
PBIB0402E
PBIB0386E
PBIB0376E
TROUBLE DIAGNOSIS
EC-1433
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ENGINE CONTROL COMPONENT PARTS/CONTROL SYSTEMS APPLICATION
X: Applicable
SELF-DIAGNOSTIC MODE
Regarding items detected in “SELF-DIAG RESULTS” mode, refer to — EC-1393, "INDEX FOR DTC" .
DATA MONITOR MODE
ItemDIAGNOSTIC TEST MODE
SELF-DIAG
RESULTSDATA MONI-
TORACTIVE
TEST
ENGINE CONTROL COMPONENT PARTS
INPUTCrankshaft position sensor (TDC)××
Camshaft position sensor×
Engine coolant temperature sensor××
Vehicle speed sensor××
Fuel temperature sensor××
Accelerator pedal position sensor 1××
Accelerator pedal position sensor 2××
Accelerator pedal released position switch××
Common rail fuel pressure sensor××
Park/neutral position (PNP) switch×
Mass air flow sensor××
Battery voltage××
Power steering oil pressure switch×
Stop lamp switch×
Absolute pressure sensor××
Fuel injector adjustment resistor×
OUTPUTSuction control valve×××
Fuel injector×××
Glow relay××
Cooling fan relay×××
EGR volume control valve××
MONITOR ITEMECM
INPUT
SIG-
NALMAIN
SIG-
NALSCAN
DIAG
SUP-
PORT
MNTRCONDITION SPECIFICATION
CKPS·RPM (TDC) [rpm]××
●The engine speed computed
from the crankshaft position
sensor (TDC) signal is dis-
played.
COOLAN TEMP/S
[°C] or [°F]××
●The engine coolant tempera-
ture (determined by the signal
voltage of the engine coolant
temperature sensor) is dis-
played.When the engine coolant temper-
ature circuit is open or short, ECM
enters fail-safe mode. The engine
coolant temperature determined
by the ECM is displayed.
VHCL SPEED SE
[km/h] or [mph]××
●The vehicle speed computed
form the vehicle speed sensor
signal is displayed.
FUEL TEMP SEN [°C] or [°F]××
●The fuel temperature (deter-
mined by the signal voltage of
the fuel temperature sensor) is
displayed.