EC-1376
[QR20(WITHOUT EURO-OBD)]
REFRIGERANT PRESSURE SENSOR
4. CHECK REFRIGERANT PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch “OFF”.
2. Check harness continuity between refrigerant pressure sensor terminal 1 and engine ground. Refer to
Wiring Diagram.
3. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 6.
NG >> GO TO 5.
5. DETECT MALFUNCTIONING PART
Check the following.
●Harness connectors E61, F38
●Harness for open or short between ECM and refrigerant pressure sensor
>> Repair open circuit or short to ground or short to power in harness or connectors.
6. CHECK REFRIGERANT PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM terminal 83 and refrigerant pressure sensor terminal 2. Refer to
Wiring Diagram.
3. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 8.
NG >> GO TO 7.
7. DETECT MALFUNCTIONING PART
Check the following.
●Harness connectors E61, F38
●Harness for open or short between ECM and refrigerant pressure sensor
>> Repair open circuit or short to ground or short to power in harness or connectors.
8. CHECK INTERMITTENT INCIDENT
Refer to EC-1192, "
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
OK or NG
OK >> Replace refrigerant pressure sensor.
NG >> Repair or replace.
Removal and InstallationEBS00NAQ
REFRIGERANT PRESSURE SENSOR
Refer to ATC-129, "REFRIGERANT LINES" . Continuity should exist.
Continuity should exist.
ENGINE CONTROL SYSTEM
EC-1399
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System ChartEBS0037B
*: The input signals are sent to the ECM through CAN communication line.
Fuel Injection Control SystemEBS0036G
SYSTEM DESCRIPTION
Three types of fuel injection control are provided to accommodate engine operating conditions; normal control,
idle control and start control. The ECM determines the appropriate fuel injection control. Under each control,
the amount of fuel injected is adjusted to improve engine performance.
Pulse signals are exchanged between ECM and Electronic Drive Unit (EDU). EDU controls fuel injectors
according to the input signals to adjust the amount of fuel injected to the preset value.
START CONTROL
Input/Output Signal Chart
When the ECM receives a start signal from the ignition switch, the
ECM adapts the fuel injection system for the start control. The
amount of fuel injected at engine starting is a preset program value
in the ECM. The program is determined by the engine speed, engine
coolant temperature and common rail fuel pressure.
For better startability under cool engine conditions, the lower the
coolant temperature becomes, the greater the amount of fuel
injected. The ECM ends the start control when the engine speed
reaches the specific value, and shifts the control to the normal or idle
control.
Input (Sensor) ECM Function Output (Actuator)
●Accelerator pedal position sensor
●Accelerator pedal released position switch
●Common rail fuel pressure sensor
●Fuel temperature sensor
●Engine coolant temperature sensor
●Crankshaft position sensor (TDC)
●Camshaft position sensor
●Vehicle speed sensor
●ESP/TCS/ABS control unit*
●Ignition switch
●Stop L amp s witch
●Air conditioner switch
●Mass air flow sensor
●Park/neutral position switch
●Battery voltage
●Power steering oil pressure switch Fuel injection controlEDU, Fuel injectors and Suction control
valve
Fuel injection timing controlEDU, Fuel injectors and Suction control
valve
Fuel cut controlEDU, Fuel injectors and Suction control
valve
Glow control system Glow relay & glow indictor lamp
On board diagnostic system Malfunction indicator (MI)
EGR volume control EGR volume control valve
Cooling fan control Cooling fan relay
Air conditioning cut control Air conditioner relay
Sensor Input Signal to ECM ECM Function Actuator
Engine coolant temperature sensor Engine coolant temperature
Fuel injection
control (start
control)EDU
Fuel injectors
Suction control valve Crankshaft position sensor (TDC) Engine speed
Camshaft position sensor Piston position
Ignition switch Start signal
Common rail fuel pressure sensor Common rail fuel pressure
SEF648S
TROUBLE DIAGNOSIS
EC-1435
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NOTE:
Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically. INT/A VOLUME [mg/]
●The intake air volume computed
from the mass air flow sensor
signal is displayed.
BARO SEN [kPa]××
●The barometric pressure (deter-
mined by the signal voltage from
the absolute pressure sensor
built into the ECM) is displayed.
CYL COUNT [0/1/2/3]
●The cylinder being injected is
displayed.
0 ... Cylinder No.1 is injected.
1 ... Cylinder No.3 is injected.
2 ... Cylinder No.4 is injected.
3 ... Cylinder No.2 is injected.
Voltage [V]
Voltage, frequency, duty cycle or
pulse width measured by the
probe.Only “#” is displayed if item is
unable to be measured.
Figures with “#”s are temporary
ones.
They are the same figures as an
actual piece of data which was
just previously measured. [Hz] or
[%] Frequency [msec], [Hz] or
[%]
DUTY-HI
DUTY-LOW
PLS WIDTH-HI
PLS WIDTH-LOW
CAN COMM
[OK/NG]×
●Indicates the communication
condition of CAN communica-
tion line.●These items are not displayed
in “SELECTION FROM MENU”
mode. CAN CIRC 1
[OK/UNKWN]×
CAN CIRC 2
[OK/UNKWN]×
CAN CIRC 3
[OK/UNKWN]×
CAN CIRC 4
[OK/UNKWN]×
CAN CIRC 5
[OK/UNKWN]×
CAN CIRC 6
[OK/UNKWN]×
CAN CIRC 7
[OK/UNKWN]× MONITOR ITEMECM
INPUT
SIG-
NALMAIN
SIG-
NALSCAN
DIAG
SUP-
PORT
MNTRCONDITION SPECIFICATION
EC-1436
[YD]
TROUBLE DIAGNOSIS
ACTIVE TEST MODE
REAL TIME DIAGNOSIS IN DATA MONITOR MODE
CONSULT-II has two kinds of triggers and they can be selected by touching “SETTING” in “DATA MONITOR”
mode.
1. “AUTO TRIG” (Automatic trigger):
–The malfunction will be identified on the CONSULT-II screen in
real time.
In other words, DTC will be displayed if the malfunction is
detected by ECM.
At the moment a malfunction is detected by ECM, “MONITOR”
in “DATA MONITOR” screen is changed to “Recording Data ...
xx%” as shown in the figure, and the data after the malfunction
detection is recorded. Then when the percentage reached
100%, “REAL-TIME DIAG” screen is displayed. If “STOP” is
touched on the screen during “ Recording Data ... xx%”, “REAL-
TIME DIAG” screen is also displayed.
The recording time after the malfunction detection and the recording speed can be changed by “TRIG-
GER POINT” and “Recording Speed”. Refer to CONSULT-II OPERATION MANUAL.
2. “MANU TRIG” (Manual trigger):
–DTC will not be displayed automatically on CONSULT-II screen
even though a malfunction is detected by ECM.
DATA MONITOR can be performed continuously even though a
malfunction is detected.
Use these triggers as follows:
1. “AUTO TRIG”
–While trying to detect the DTC by performing the “DTC Confir-
mation Procedure”, be sure to select to “DATA MONITOR
(AUTO TRIG)” mode. You can confirm the malfunction at the
moment it is detected.
TEST ITEM CONDITION JUDGEMENT CHECK ITEM (REMEDY)
POWER BAL-
ANCE
●Engine: After warming up, idle the
engine.
●A/C switch “OFF”
●Shift lever “N”
●Cut off each injector signal one at
a time using CONSULT-IIEngine runs rough or dies.
●Harness and connectors
●Compression
●Fuel injectors
COOLING FAN
●Ignition switch: ON
●Operate the cooling fan at “LOW”,
“HI” speed and turn “OFF” using
CONSULT-II.Cooling fan moves at “LOW”, “HI”
speed and stops.●Harness and connector
●Cooling fan motor
●Cooling fan relay
OFF ACCEL PO
SIG
●This mode is used for ECM to learn accelerator pedal released positions.
GLOW RELAY
●Ignition switch: ON (Engine
stopped)
●Turn the glow relay “ON” and
“OFF” using CONSULT-II and lis-
ten to operating sound.Glow relay makes the operating
sound.●Harness and connector
●Glow relay
EGR VOL CONT/
V
●Ignition switch: ON
●Change EGR volume control
valve opening step using CON-
SULT-II.EGR volume control valve makes
an operating sound.●Harness and connector
●EGR volume control valve
PRES REGULA-
TOR
●Ignition switch: ON
●Change fuel pressure in common
rail using CONSULT-IIFuel leaks.●Fuel line
●Fuel pressure relief valve
PBIB0480E
SEF707X
POWER STEERING OIL PRESSURE SWITCH
EC-1571
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5.CHECK INTERMITTENT INCIDENT
Refer to EC-1441, "
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" .
>>INSPECTION END
Component InspectionEBS003PW
POWER STEERING OIL PRESSURE SWITCH
1. Disconnect power steering oil pressure switch harness connector and then start engine.
2. Check continuity between power steering oil pressure switch ter-
minal 1 and 2 under the following conditions.
Removal and InstallationEBS008ZH
POWER STEERING OIL PRESSURE SWITCH
Refer to PS-34, "HYDRAULIC LINE" .
Conditions Continuity
Steering wheel is being fully turned. Yes
Steering wheel is not being turned. No
PBIB0435E
FUEL SYSTEM
FL-3
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FUEL SYSTEMPFP:17503
Checking Fuel LinesEBS00KOS
Inspect fuel lines, filler cap and tank for improper attachment, leaks,
cracks, damage, loose connections, chafing or deterioration.
If necessary, repair or replace damaged parts.
General PrecautionsEBS00KOT
WARNING:
when replacing fuel line parts, be sure to observe the following.
●Put a “ CAUTION: INFLAMMABLE” sign in workshop.
●Be sure to work in a well-ventilated area and furnish workshop with a CO2 fire extinguisher.
●Do not smoke while servicing fuel system, keep open flames and spark away from work area.
CAUTION:
●Before removing fuel line parts, carry out the following procedures.
–a) Put drained fuel in an explosion-proof container and put the lid on securely, keep the container
in safe area.
–b) Release fuel pressure from fuel line, Refer to EC-775, "FUEL PRESSURE RELEASE" [QR20DE
(WITH EURO-OBD)], EC-1139, "
FUEL PRESSURE RELEASE" [QR20DE (WITHOUT EURO-OBD)],
EC-42, "
FUEL PRESSURE RELEASE" [QR25DE (WITH EURO-OBD)] or EC-452, "FUEL PRESSURE
RELEASE" [QR25DE (WITHOUT EURO-OBD)].
–c) Disconnect battery ground cable.
●Always replace O-ring and clamps with new ones.
●Do not kink or twist tubes when they are being installed.
●Do not tighten hose clamps excessively to avoid damaging hoses.
Tighten high-pressure rubber hose clamp so that clamp
end is 3 mm (0.12 in) from hose end.
Tightening torque specifications are the same for all rubber
hose clamps.
Ensure that screw does not contact adjacent parts.
●After installing tubes, make sure there is no fuel leakage at
connections in the following steps.
–a) Apply fuel pressure to fuel lines with turning ignition
switch “ON” (with engine stopped). Then check for fuel
leaks at connections.
–b) Start the engine and rev it up and check for fuel leaks at
connections.
SMA803A
MMA104A
FL-4
[QR]
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
PFP:17042
Removal and InstallationEBS00KOU
REMOVAL
WARNING:
Be sure to read “General Precautions” when working on fuel system. Refer to FL-3, "
General Precau-
tions" .
1. Release fuel pressure from fuel line. Refer to EC-775, "
FUEL
PRESSURE RELEASE" [QR20DE (WITH EURO-OBD)], EC-
11 3 9 , "FUEL PRESSURE RELEASE" [QR20DE (WITHOUT
EURO-OBD)],EC-42, "
FUEL PRESSURE RELEASE"
[QR25DE (WITH EURO-OBD)] or EC-452, "FUEL PRESSURE
RELEASE" [QR25DE (WITHOUT EURO-OBD)].
2. Open fuel filer lid.
3. Open the filler cap and release the pressure inside the fuel tank.
4. Check fuel level on level place. If gauge indicates more than the
level shown in figure (full or almost full), drain fuel from fuel tank
until gauge indicates level shown in figure or below.
In case of fuel pump does not operate, take following procedure.
a. Insert fuel tube of less than 25 mm (0.98 in) in diameter into fuel
filler tube through fuel filler opening to draw fuel from fuel filler
tube.
b. Disconnect fuel filler hose from fuel filler tube.
c. Insert fuel tube into fuel tank through fuel filler hose to draw fuel
from fuel tank.
●As a guide, fuel level becomes the position shown in figure or
below when approximately 15 liter (13-1/4 lmp qt) of fuel are drained from fuel tank.
NOTE:
Adjusting fuel level is to prevent fuel from spilling, when fuel level sensor unit, fuel filter and fuel pump
assembly is removed.
KBIA0278E
1. Lock ring 2.Main fuel level sensor unit, fuel filter
and fuel pump assembly3.Jet pump, fuel hose and jet pump
inlet assembly
4. Chamber 5. Seal packing 6. Sub fuel level sensor unit
KBIA0280E
FEL0403D
FL-6
[QR]
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
●If necessary, remove the chamber from the bottom of the fuel tank.
●Remove the chamber by sliding toward the rear of the vehicle.
Removal of sub fuel level sensor unit.
●Raise and release the sub fuel level sensor unit to remove.
●If necessary, remove the jet pump inlet from the bottom of the fuel tank.
To remove it, pinch the tabs (2 places).
INSPECTION AFTER REMOVAL
Make sure the fuel pump strainer is free from foreign materials, If any are found, remove them.
INSTALLATION
Install in the reverse order of removal paying attention to the follow-
ing.
●When installing the chamber and jet pump, insert them fully until
a click sound of full stopper engagement is heard (Ditto for jet
pump inlet).
●Connect the quick connector as follows.
1. Check the connection for damage and foreign materials.
2. Align the connector with the tube, then insert the connector straight into the tube until a click is heard.
3. After connecting, make sure that the connection is secure by following the steps below.
●Visually confirm that the two retainer tabs are connected to the connector.
●Pull the tube and the connector to make sure they are securely connected.
●Install fuel level sensor unit with mating mark (triangular pro-
trusion) facing between two carved lines on fuel tank. (Figure
shows left side of fuel tank.)
NOTE:
On right side of fuel tank, there are three carved lines on fuel
tank. Set mating mark between two outer carved lines.
●Install the inspection hole cover with the front mark (arrow)
facing front of the vehicle (Both for RH and LH).
INSPECTION AFTER INSTALLATION
Make sure there is no fuel leakage at connections in the following steps.
1. Apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then check for fuel
leaks at connections.
2. Start the engine and rev it up and check for fuel leaks at connections.
KBIA0302E
KBIA0282E