EC-644
[QR (WITHOUT EURO-OBD)]
ELECTRICAL LOAD SIGNAL
13.CHECK HEADLAMP INPUT SIGNAL CIRCUIT FOR OPEN OR SHORT
1. Stop engine.
2. Disconnect ECM harness connector.
3. Disconnect lighting switch harness connectors.
4. Check harness continuity between ECM terminal 53 and lighting switch terminal 9, 10 under the following
conditions.
5. Also check harness for short to ground and short to power.
OK or NG
OK >> GO TO 15.
NG >> GO TO 14.
14.DETECT MALFUNCTIONING PART
Check the following.
lHarness connectors E60, F36
lDiode E123, E124
lHarness for open and short between ECM and lighting switch
>> Repair open circuit or short to ground or short to power in harness or connectors.
15.CHECK INTERMITTENT INCIDENT
PerformEC-453, "
TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT".
>>INSPECTION END
16.CHECK HEATER FAN CONTROL FUNCTION
1. Start engine.
2. Turn “ON” the fan control switch.
3. Check the blower fan motor. Does the blower fan motor activate?
Ye s o r N o
Yes >>GOTO17.
No >> Refer toAT C - 3 0 , "
TROUBLE DIAGNOSIS".
Condition Continuity
1 Should exist
2 Should not exist
PBIB0662E
ON BOARD DIAGNOSTIC (OBD) SYSTEM
EC-667
[YD]
C
D
E
F
G
H
I
J
K
L
MA
EC
Therefore, be sure to receive all keys from vehicle owner. Regarding the procedure of NATS initial-
ization and NATS ignition key ID registration, refer to CONSULT-II operation manual, NATS.
Malfunction Indicator (MI)EBS0036Q
DESCRIPTION
The MI is located on the instrument panel.
1. The MI will light up when the ignition switch is turned ON without
the engine running. This is a bulb check.
lIf the MI does not light up, refer toDI-39, "WARNING LAMPS"
or seeEC-825.
2. When the engine is started, the MI should go off.
If the MI remains on, the on board diagnostic system has
detected an engine system malfunction.
On Board Diagnostic System Function
The on board diagnostic system has the following two functions.
Diagnostic Test Mode I - Bulb Check
In this mode, the MI on the instrument panel should stay ON. If it remains OFF, check the bulb. Refer toDI-39,
"WA RN ING LA MPS"or seeEC-825.
Diagnostic Test Mode I - Malfunction Warning
SAT652J
Diagnostic Test
ModeKEY and ENG.
Sta tusFunction Explanation of Function
Mode I Ignition switch in
ON position
Engine stoppedBULB CHECK This function checks the MI bulb for damage (blown, open
circuit, etc.).
IftheMIdoesnotcomeon,checkMIcircuit.(SeeEC-825,
"MI&DATA LINK CONNECTORS".)
Engine running MALFUNCTION
WARN IN GThis is a usual driving condition. When ECM detects a mal-
function, the MI will light up to inform the driver that a mal-
function has been detected.
MI Condition
ON When the malfunction is detected or the ECM's CPU is malfunctioning.
OFF No malfunction.
EM-20
[QR20DE]
INTAKE MANIFOLD
Tightening Intake Manifold collector bolts and nuts
lTighten in numerical order as shown in the figure.
NOTE:
No.6 means double tightening of bolts 1.
Installation of Electric Throttle Control Actuator
lTighten fixing bolts of electric throttle control actuator equally and diagonally in several steps.
lAfter installation perform procedure inEM-20, "INSPECTION AFTER INSTALLATION".
Connecting Quick Connector of Fuel Hose
lInstall quick connector as follows. (The steps are the same for quick connectors on engine side and vehi-
cle)
1. Make sure no foreign substances are deposited in and around tube and quick connector and no damage
on them.
2. Thinly apply new engine oil around the fuel tube tip end.
3. Align center to insert quick connector straightly into fuel tube.
lInsert fuel tube into quick connector until the first spool on fuel
tubes is inserted completely and the second one is positioned
slightly below the quick connectors bottom end.
CAUTION:
lHold A position in illustration when inserting fuel tube
into quick connector.
lCarefully align center to avoid inclined insertion to pre-
vent damage to O-ring inside quick connector.
lInsert until you hear a “click” sound and actually feel the
engagement.
lTo avoid misidentification of engagement with a similar sound, be sure to perform the next step.
4. Before clamping fuel hose with hose clamps, pull quick connector hard by hand holding A position. Make
sure it is completely engaged (connected) so that it does not come out from fuel tube.
NOTE:
Recommended pulling force is 50 N (5.1 kg, 11.2 lb).
5. Install quick connector cap on quick connector joint.
lDirect arrow mark on quick connector cap to upper side (The
figure shows quick connector cap for engine side).
6. Install fuel hose to hose clamp.
INSPECTION AFTER INSTALLATION
lCheck connections for fuel leakage.
1. Start the engine, and run it for a few minutes with engine at idle.
2. Stop the engine, and check for fuel leakage both visually and by odor of gasoline.
NOTE:
Use mirrors for checking on invisible points.
KBIA0234E
KBIA0272E
KBIA0298E
EM-168
[YD22DDTi]
PRIMARY TIMING CHAIN
INSPECTION AFTER REMOVAL
Timing Chain
Check for cracks and excessive wear at roller links. Replace
chain if necessary.
INSTALLATION
1. Install rear chain case.
a. Apply a continuous bead of Genuine Liquid Gasket or eqivalent
on locations shown in the figure. Refer toEM-103, "
Precautions
for Liquid Gasket".
A: Apply bead so that it does not protrude into the oil passage.
B, C: Minimize overlapping area of bead, by starting and ending
at areas of bead as shown in the figure. Apply so that the portion
marked * comes at an external location but cannot be viewed
externally after engine assembly.
D: Leave the start and end areas of the bead slightly protruding
from the case surface.
SEM984C
JEM139G
SBIA0212E
SERVICE INFORMATION FOR ELECTRICAL INCIDENT
GI-25
lVehicle vibration
lHeat sensitive
lFreezing
lWater intrusion
lElectrical load
lCold or hot start up
Get a thorough description of the incident from the customer. It is important for simulating the conditions of the
problem.
Vehicle Vibratio n
The problem may occur or become worse while driving on a rough road or when engine is vibrating (idle with
A/C on). In such a case, you will want to check for a vibration related condition. Refer to the following illustra-
tion.
CONNECTORS & HARNESS
Determine which connectors and wiring harness would affect the electrical system you are inspecting. Gently
shake each connector and harness while monitoring the system for the incident you are trying to duplicate.
This test may indicate a loose or poor electrical connection.
HINT
Connectors can be exposed to moisture. It is possible to get a thin film of corrosion on the connector termi-
nals. A visual inspection may not reveal this without disconnecting the connector. If the problem occurs inter-
mittently, perhaps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean the
terminals on related connectors in the system.
SENSORS & RELAYS
Gentlyapply a slight vibration to sensors and relays in the system you are inspecting.
This test may indicate a loose or poorly mounted sensor or relay.
ENGINE COMPARTMENT
There are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of the
things to check for are:
lConnectors not fully seated.
lWiring harness not long enough and is being stressed due to engine vibrations or rocking.
lWires laying across brackets or moving components.
lLoose, dirty or corroded ground wires.
lWires routed too close to hot components.
To inspect components under the hood, start by verifying the integrity of ground connections. (Refer to Ground
Inspection described later.) First check that the system is properly grounded. Then check for loose connection
by gently shaking the wiring or components as previously explained. Using the wiring diagrams inspect the
wiring for continuity.
BEHIND THE INSTRUMENT PANEL
SGI839
GI-48
TERMINOLOGY
Exhaust gas recirculation control-BPT
valveEGRC-BPT valve BPT valve
Exhaust gas recirculation control-solenoid
valveEGRC-solenoid valve EGR control solenoid valve
Exhaust gas recirculation temperature sen-
sor
EGRT sensor Exhaust gas temperature sensor
EGR temperature sensor
Flash electrically erasable programmable
read only memoryFEEPROM ***
Flash erasable programmable read only
memoryFEPROM ***
Flexible fuel sensor FFS ***
Flexible fuel system FF system ***
Fuel pressure regulator *** Pressure regulator
Fuel pressure regulator control solenoid
valve*** PRVR control solenoid valve
Fuel trim FT ***
Heated Oxygen sensor HO2S Exhaust gas sensor
Idle air control system IAC system Idle speed control
Idle air control valve-air regulator IACV-air regulator Air regulator
Idle air control valve-auxiliary air control
valveIACV-AAC valve Auxiliary air control (AAC) valve
Idle air control valve-FICD solenoid valve IACV-FICD solenoid valve FICD solenoid valve
Idle air control valve-idle up control sole-
noid valveIACV-idle up control solenoid valve Idle up control solenoid valve
Idle speed control-FI pot ISC-FI pot FI pot
Idle speed control system ISC system ***
Ignition control IC ***
Ignition control module ICM ***
Indirect fuel injection system IFI system ***
Intake air IA Air
Intake air temperature sensor IAT sensor Air temperature sensor
Knock *** Detonation
Knock sensor KS Detonation sensor
Malfunction indicator lamp MIL Check engine light
Manifold absolute pressure MAP ***
Manifold absolute pressure sensor MAPS ***
Manifold differential pressure MDP ***
Manifold differential pressure sensor MDPS ***
Manifold surface temperature MST ***
Manifold surface temperature sensor MSTS ***
Manifold vacuum zone MVZ ***
Manifold vacuum zone sensor MVZS ***
Mass air flow sensor MAFS Air flow meter
Mixture control solenoid valve MC solenoid valve Air-fuel ratio control solenoid valve
Multiport fuel injection System MFI system Fuel injection controlNEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM
IDX-3
A
C
D
E
F
G
H
I
J
K
L B
IDX
ALPHABETICAL INDEX
Brake fluid level and line check ...........................BR-9
Brake hydraulic line ...........................................BR-11
Brake inspection ................................................MA-39
Brake lines and cables inspection .....................MA-39
Brake master cylinder ........................................BR-13
Brake pedal .........................................................BR-6
Brake switch ........................EC-329,EC-562,EC-810
BRK/SW - Wiring diagram ...EC-330,EC-564,EC-811
Bulb specifications ..............................................LT-67
Bumper, front .........................................................EI-6
Bumper, rear ..........................................................EI-9
C
Camshaft inspection(QR20DE) .........................EM-38
Camshaft inspection(YD22DDTi) ....................EM-150
Camshaft position sensor (CMPS) ..................EC-739
Camshaft position sensor (PHASE) ..EC-223,EC-507
Camshaft(QR20DE) ..........................................EM-33
Camshaft(YD22DDTi) ......................................EM-149
CAN - Wiring diagramEC-115,EC-461,LAN-6,LAN-12
CAN (Controller Area Network) .........AT-129,AT-351,
LAN-3
,LAN-5,LAN-11
CAN Communication ..........................................TF-53
CAN communicationEC-28,EC-114,EC-393,EC-460,
AT-129
,AT-351,BRC-53,BRC-59,BRC-90,BRC-108,
LAN-3
,LAN-5,LAN-11
Canister-See EVAP canister .............EC-374,EC-649
CHARGE - Wiring diagram ................................SC-13
Charging system ................................................SC-12
Chassis and body maintenance ........................MA-35
CHIME - Wiring diagram .....................................DI-54
CIGAR - Wiring diagram ..................................WW-25
Cigarette lighter ...............................................WW-25
Circuit breaker ...................................................PG-12
CKPS - Wiring diagram ...................................EC-736
Clearance lamp ........................................LT-4,LT-40
Clock ...................................................................DI-60
CLOCK - Wiring diagram ....................................DI-60
Closed loop control ..............................EC-25,EC-390
Clutch cover .......................................................CL-15
Clutch disc .........................................................CL-15
Clutch master cylinder .........................................CL-9
Clutch operating cylinder ...................................CL-11
Clutch pedal .........................................................CL-5
Clutch release bearing .......................................CL-13
Clutch release mechanism ................................CL-13
Clutch withdrawal lever ......................................CL-13
CMPS - Wiring diagram ...................................EC-741
Coil spring (rear) ...............................................RSU-8
Collision diagnosis ...........................................SRS-46
Combination meter .....................................DI-4,DI-22
Combination switch ................................LT-24,LT-44
Common rail fuel pressure sensor ...................EC-723
Component Location (auto A/C) .........ATC-31,MTC-4
Compression pressure(QR20DE) ......................EM-52
Compression pressure(YD22DDTi) .................EM-173
Compressor clutch removal and installation ..ATC-129
Compressor special service tool ......................ATC-11
Condenser .....................................................ATC-138
Connecting rod bearing clearance(QR20DE) ...EM-83
Connecting rod bearing clearance(YD22DDTi)EM-206
Connecting rod bushing clearance(QR20DE) ..EM-83
Connecting rod bushing clearance(YD22DDTi)EM-200
Connecting rod(QR20DE) .................................EM-82
Connecting rod(YD22DDTi) ..............EM-198,EM-202
Console box - See Instrument panel ..........IP-3,IP-10
CONSULT for engine ............EC-86,EC-434,EC-691
CONSUT for VDC ...........................................BRC-77
Control unit .....................................ATC-104,MTC-19
Control units (terminal arrangement) .................PG-73
Controller Area Network (CAN) ........AT-129,AT-351,
LAN-3
,LAN-5,LAN-11
Converter housing installation ...........AT-459,AT-556
COOL/F - Wiring diagram ...EC-315,EC-552,EC-763
Coolant mixture ratio .........................................MA-19
Coolant replacement(QR20DE) ........................MA-20
Coolant replacement(YD22DDTi) .....................MA-27
Cooling circuit (engine)(QR20DE) ......................CO-7
Cooling circuit (engine)(YD22DDTi) .................CO-28
Cooling fan control system(QR20DE) ...............CO-13
Cooling fan motor ..............................EC-324,EC-561
Cooling fan relay ................................EC-324,EC-561
Cooling fan(QR20DE) .......................................CO-13
Cooling fan(YD22DDTi) ....................................CO-34
Coupling sleeve (M/T) ...........................MT-19,MT-24
Cowl top ..............................................................EI-12
Cowl top cover ....................................................EI-12
Crankcase ventilation system ..........................EC-663
Crankcase ventilation system - See Positive crankcase
ventilation ...........................................EC-375
,EC-650
Crankshaft position sensor (POS) .....EC-217,EC-501
Crankshaft position sensor (TDC) ...................EC-734
Crankshaft(QR20DE) ........................................EM-65
Crankshaft(YD22DDTi) ...................................EM-200
CRFPS - Wiring diagram .................................EC-724
Cylinder block boring(QR20DE) .......................EM-86
Cylinder block boring(YD22DDTi) ...................EM-204
Cylinder block(QR20DE) ..................................EM-64
Cylinder block(YD22DDTi) ..............................EM-188
Cylinder head bolt tightening(QR20DE) ...........EM-54
Cylinder head bolt tightening(YD22DDTi) .......EM-175
Cylinder head gasket selection(YD22DDTi) ...EM-175
Cylinder head(QR20DE) ...................................EM-52
Cylinder head(YD22DDTi) ..............................EM-173
D
Data link connector ............................EC-371
,EC-646
Data link connector for Consult ...........EC-88,EC-435,
EC-691
Daytime light system .............................................LT-9
Daytime running light - See Daytime light systemLT-9
DEF - Wiring diagram .......................................GW-10
Desiccant Assembly .......................ATC-27,ATC-140
Diagnosis sensor unit .....................................SRS-39
LT-6
HEADLAMP
Trouble Diagnoses
EKS003CF
Aiming AdjustmentEKS003CG
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 man-
uals.
If any aimer is not available, aiming adjustment can be done as follows:
For details, refer to the regulations in your own country.
lKeep all tires inflated to correct pressures.
lPlace vehicle and tester on one and same flat surface.
lSee 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).
Symptom Possible cause Repair order
Headlamp LH do not operate.1. Bulb
2. Grounds E24 and E50
3. 15A fuse
4. Lighting switch1. Check bulb.
2. Check grounds E24 and E50.
3. Check 15A fuse (No. 40, located in fuse
and fusible link box). Verify battery posi-
tive voltage is present at terminal 8 of
lighting switch.
4. Check lighting switch.
Headlamp RH do not operate.1. Bulb
2. Grounds E24 and E50
3. 15A fuse
4. Lighting switch1. Check bulb.
2. Check grounds E24 and E50.
3. Check 15A fuse (No. 41, located in fuse
and fusible link box). Verify battery posi-
tive voltage is present at terminal 5 of
lighting switch.
4. Check lighting switch.
High beam LH do not operate, but low
beam LH operates.1. Bulb
2. Open in high beam LH circuit
3. Lighting switch1. Check bulbs.
2. Check the wire between lighting switch
terminal 9 and headlamp LH terminal 1
for an open circuit.
3. Check lighting switch.
Low beam LH does not operate, but high
beam LH operates.1. Bulb
2. Open in low beam LH circuit
3. Lighting switch1. Check bulb.
2. Check the wire between lighting switch
terminal 10 and headlamp LH terminal 3
for an open circuit.
3. Check lighting switch.
High beam RH do not operate, but low
beam RH operates.1. Bulb
2. Open in high beam RH circuit
3. Lighting switch1. Check bulbs.
2. Check the wire between lighting switch
terminal 6 and headlamp RH terminal 1
for an open circuit.
3. Check lighting switch.
Low beam RH does not operate, but high
beam RH operates.1. Bulb
2. Open in low beam RH circuit
3. Lighting switch1. Check bulb.
2. Check the wire between lighting switch
terminal 7 and headlamp RH terminal 3
for an open circuit.
3. Check lighting switch.
High beam indicator does not work.1. Bulb
2. Grounds M27 and M70
3. Open in high beam circuit1. Check bulb in combination meter.
2. Check grounds M27 and M70.
3. Check the wire between lighting switch
terminal 9 and combination meter termi-
nal 61(LHD models) or 50(RHD models)
for an open circuit.