WATER PUMP
CO-43
[YD22DDTi]
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INSPECTION AFTER REMOVAL
Visually check if there is no significant dirt or rusting on the
water pump body and vane.
Make sure that there is no looseness in the vane shaft, and that
it turns smoothly when rotated by hand.
If there are any unusualness, replace water pump assembly as
necessary.
INSTALLATION
Install in the reverse order of removal.
Install water pump pulley with the front mark (painted white, used to prevent errors during assembly) fac-
ing the front of engine. Refer to CO-42, "
WATER PUMP" .
INSPECTION AFTER INSTALLATION
Check for leaks of engine coolant using the radiator cap tester adapter (special service tool:
EG17650301) and the radiator cap tester (commercial service tool). Refer to CO-31, "
CHECKING RADIA-
TOR SYSTEM FOR LEAKS" .
Start and warm up engine. Visually check if there is no leaks of engine coolant.
SBIA0132E
THERMOSTAT AND WATER PIPING
CO-45
[YD22DDTi]
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INSPECTION AFTER REMOVAL
Thermostat
Place a string so that it is caught in the valves of the thermostat.
Immerse fully in a container filled with water. Heat while stirring.
The valve opening temperature is the temperature at which the
valve opens and falls from the thread.
Continue heating. Check the full-open lift amount.
After checking the full-open lift amount, lower the water temper-
ature and check the valve closing temperature.
Standard values
If out of the standard, replace thermostat.
INSTALLATION
Note the following, and install in the reverse order of removal.
Install the thermostat with the whole circumference of each
flange part fit securely inside the rubber ring.
Install the thermostat with the jiggle valve facing upwards.
INSPECTION AFTER INSTALLATION
Check for leaks of engine coolant using the radiator cap tester adapter (special service tool:
EG17650301) and the radiator cap tester (commercial service tool). Refer to CO-31, "
CHECKING RADIA-
TOR SYSTEM FOR LEAKS" .
Start and warm up engine. Visually check if there is no leaks of engine coolant.
SLC252B
Item Thermostat
Valve opening temperature 80 - 84°C (176 - 183° F)
Full-open lift amount More than 10 mm/ 95°C (0.39 in/ 203 °F)
Valve closing temperature More than 77°C (171°F)
JLC300B
EC-13
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ECA
CONSULT-II Reference Value in Data Monitor Mode
1134
ECM Terminals and Reference Value .................1134
On Board Diagnosis Logic ..................................1135
DTC Confirmation Procedure ..............................1135
Wiring Diagram ...................................................1136
Diagnostic Procedure ..........................................1137
Component Inspection ........................................1138
Removal and Installation .....................................1138
DTC P1274 FUEL PUMP .......................................1139
Description ..........................................................1139
CONSULT-II Reference Value in Data Monitor Mode
1139
ECM Terminals and Reference Value .................1139
On Board Diagnosis Logic ..................................1140
DTC Confirmation Procedure ..............................1140
Wiring Diagram ...................................................1141
Diagnostic Procedure ..........................................1142
Component Inspection ........................................1143
Removal and Installation .....................................1143
DTC P1275 FUEL PUMP .......................................1144
Description ..........................................................1144
CONSULT-II Reference Value in Data Monitor Mode
1144
ECM Terminals and Reference Value .................1144
On Board Diagnosis Logic ..................................1145
DTC Confirmation Procedure ..............................1145
Wiring Diagram ...................................................1146
Diagnostic Procedure ..........................................1147
Component Inspection ........................................1148
Removal and Installation .....................................1148
DTC P2135 APP SENSOR ....................................1149
Description ..........................................................1149
CONSULT-II Reference Value in Data Monitor Mode
1149
ECM Terminals and Reference Value .................1149
On Board Diagnosis Logic ..................................1150
DTC Confirmation Procedure ..............................1150
Wiring Diagram ...................................................1151
Diagnostic Procedure ..........................................1152
Component Inspection ........................................1154
Removal and Installation .....................................1154
DTC P2146, P2149 FUEL INJECTOR POWER SUP-
PLY .........................................................................1155
Component Description .......................................1155
CONSULT-II Reference Value in Data Monitor Mode
1155
ECM Terminals and Reference Value .................1155
On Board Diagnosis Logic ..................................1156
DTC Confirmation Procedure ..............................1157
Wiring Diagram ...................................................1158
Diagnostic Procedure ..........................................1159
DTC P2147, P2148 FUEL INJECTOR CIRCUIT ...1160
Component Description .......................................1160
CONSULT-II Reference Value in Data Monitor Mode
1160
ECM Terminals and Reference Value .................1160
On Board Diagnosis Logic ..................................1161
DTC Confirmation Procedure ..............................1161Wiring Diagram ....................................................11 6 3
Diagnostic Procedure ..........................................11 6 4
Component Inspection .........................................11 6 5
Removal and Installation .....................................11 6 6
DTC P2228, P2229 BARO SENSOR .....................116 7
Description ...........................................................11 6 7
On Board Diagnosis Logic ...................................11 6 7
DTC Confirmation Procedure ..............................11 6 7
Diagnostic Procedure ..........................................11 6 8
GLOW CONTROL SYSTEM ..................................116 9
Description ...........................................................11 6 9
Wiring Diagram ....................................................11 7 0
Diagnostic Procedure ..........................................11 7 2
Component Inspection .........................................11 7 6
Removal and Installation .....................................11 7 6
BRAKE SWITCH ....................................................117 7
Description ...........................................................11 7 7
CONSULT-II Reference Value in Data Monitor Mode
11 7 7
ECM Terminals and Reference Value ..................11 7 7
Wiring Diagram ....................................................11 7 8
Diagnostic Procedure ..........................................11 7 9
Component Inspection .........................................11 8 0
PNP SWITCH .........................................................118 2
Description ...........................................................11 8 2
CONSULT-II Reference Value in Data Monitor Mode
11 8 2
ECM Terminals and Reference Value ..................11 8 2
Wiring Diagram ....................................................11 8 3
Diagnostic Procedure ..........................................11 8 4
PSP SWITCH .........................................................118 6
Component Description .......................................11 8 6
CONSULT-II Reference Value in Data Monitor Mode
11 8 6
ECM Terminals and Reference Value ..................11 8 6
Wiring Diagram ....................................................11 8 7
Diagnostic Procedure ..........................................11 8 8
Component Inspection .........................................11 8 9
Removal and Installation .....................................11 8 9
FUEL TRANSPORT PUMP ...................................119 0
Description ...........................................................11 9 0
ECM Terminals and Reference Value ..................11 9 1
Wiring Diagram ....................................................11 9 2
Diagnostic Procedure ..........................................11 9 4
Component Inspection .........................................11 9 7
Removal and Installation .....................................11 9 8
START SIGNAL .....................................................119 9
Wiring Diagram ....................................................11 9 9
Diagnostic Procedure ..........................................1200
MI & DATA LINK CONNECTORS ..........................1202
Wiring Diagram ....................................................1202
SERVICE DATA AND SPECIFICATIONS (SDS) ...1204
General Specifications .........................................1204
Mass Air Flow Sensor ..........................................1204
Engine Coolant Temperature Sensor ..................1204
Fuel Rail Pressure Sensor ...................................1204
Glow Plug ............................................................1204
EGR Volume Control Valve .................................1204
EC-17
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ECA
ECM Terminals and Reference Value .................1427
On Board Diagnosis Logic ..................................1428
DTC Confirmation Procedure ..............................1428
Wiring Diagram ...................................................1429
Diagnostic Procedure ..........................................1430
Component Inspection ........................................1431
Removal and Installation .....................................1431
DTC P1275 FUEL PUMP .......................................1432
Description ..........................................................1432
CONSULT-II Reference Value in Data Monitor Mode
1432
ECM Terminals and Reference Value .................1432
On Board Diagnosis Logic ..................................1433
DTC Confirmation Procedure ..............................1433
Wiring Diagram ...................................................1434
Diagnostic Procedure ..........................................1435
Component Inspection ........................................1436
Removal and Installation .....................................1436
DTC P2135 APP SENSOR ....................................1437
Description ..........................................................1437
CONSULT-II Reference Value in Data Monitor Mode
1437
ECM Terminals and Reference Value .................1437
On Board Diagnosis Logic ..................................1438
DTC Confirmation Procedure ..............................1438
Wiring Diagram ...................................................1439
Diagnostic Procedure ..........................................1440
Component Inspection ........................................1442
Removal and Installation .....................................1442
DTC P2146, P2149 FUEL INJECTOR POWER SUP-
PLY .........................................................................1443
Component Description .......................................1443
CONSULT-II Reference Value in Data Monitor Mode
1443
ECM Terminals and Reference Value .................1443
On Board Diagnosis Logic ..................................1444
DTC Confirmation Procedure ..............................1445
Wiring Diagram ...................................................1446
Diagnostic Procedure ..........................................1447
DTC P2147, P2148 FUEL INJECTOR CIRCUIT ...1448
Component Description .......................................1448
CONSULT-II Reference Value in Data Monitor Mode
1448
ECM Terminals and Reference Value .................1448
On Board Diagnosis Logic ..................................1449
DTC Confirmation Procedure ..............................1449
Wiring Diagram ...................................................1451
Diagnostic Procedure ..........................................1452
Component Inspection ........................................1454
Removal and Installation .....................................1454
DTC P2228, P2229 BARO SENSOR ....................1455
Description ..........................................................1455
On Board Diagnosis Logic ..................................1455
DTC Confirmation Procedure ..............................1455
Diagnostic Procedure ..........................................1455
GLOW CONTROL SYSTEM .................................1457
Description ..........................................................1457
Wiring Diagram ...................................................1458
Diagnostic Procedure ..........................................1460Component Inspection .........................................1464
Removal and Installation .....................................1464
EGR VOLUME CONTROL SYSTEM .....................1465
Description ...........................................................1465
CONSULT-II Reference Value in Data Monitor Mode
1466
ECM Terminals and Reference Value ..................1466
Wiring Diagram ....................................................1467
Diagnostic Procedure ..........................................1468
Component Inspection .........................................1469
Removal and Installation .....................................1470
TC BOOST CONTROL SOLENOID VALVE ..........1471
Description ...........................................................1471
ECM Terminals and Reference Value ..................1471
Wiring Diagram ....................................................1472
Diagnostic Procedure ..........................................1473
Component Inspection .........................................1474
BRAKE SWITCH ....................................................1475
Description ...........................................................1475
CONSULT-II Reference Value in Data Monitor Mode
1475
ECM Terminals and Reference Value ..................1475
Wiring Diagram ....................................................1476
Diagnostic Procedure ..........................................1477
Component Inspection .........................................1478
PNP SWITCH .........................................................1479
Description ...........................................................1479
CONSULT-II Reference Value in Data Monitor Mode
1479
ECM Terminals and Reference Value ..................1479
Wiring Diagram ....................................................1480
Diagnostic Procedure ..........................................1481
PSP SWITCH .........................................................1483
Component Description .......................................1483
CONSULT-II Reference Value in Data Monitor Mode
1483
ECM Terminals and Reference Value ..................1483
Wiring Diagram ....................................................1484
Diagnostic Procedure ..........................................1485
Component Inspection .........................................1486
Removal and Installation .....................................1486
FUEL TRANSPORT PUMP ...................................1487
Description ...........................................................1487
ECM Terminals and Reference Value ..................1488
Wiring Diagram ....................................................1489
Diagnostic Procedure ..........................................1491
Component Inspection .........................................1494
Removal and Installation .....................................1495
START SIGNAL .....................................................1496
Wiring Diagram ....................................................1496
Diagnostic Procedure ..........................................1497
MI & DATA LINK CONNECTORS ..........................1498
Wiring Diagram ....................................................1498
SERVICE DATA AND SPECIFICATIONS (SDS) ...1500
General Specifications .........................................1500
Mass Air Flow Sensor ..........................................1500
Engine Coolant Temperature Sensor ..................1500
Fuel Rail Pressure Sensor ...................................1500
Glow Plug ............................................................1500
PRECAUTIONS
EC-25
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Do not disassemble ECM.
If battery cable is disconnected, the memory will return to
the initial ECM values.
The ECM will now start to self-control at its initial values.
Engine operation can vary slightly when the cable is dis-
connected. However, this is not an indication of a malfunc-
tion. Do not replace parts because of a slight variation.
When connecting ECM harness connector, fasten it
securely with levers as far as they will go as shown in the
figure.
When connecting or disconnecting pin connectors into or
from ECM, take care not to damage pin terminals (bend or
break).
Make sure that there are not any bends or breaks on ECM
pin terminal, when connecting pin connectors.
Securely connect ECM harness connectors.
A poor connection can cause an extremely high (surge)
voltage to develop in coil and condenser, thus resulting in
damage to ICs.
Keep engine control system harness at least 10 cm (4 in)
away from adjacent harness, to prevent engine control sys-
tem malfunctions due to receiving external noise, degraded
operation of ICs, etc.
Keep engine control system parts and harness dry.
Before replacing ECM, perform ECM Terminals and Refer-
ence Value inspection and make sure ECM functions prop-
erly. Refer to EC-95
.
Handle mass air flow sensor carefully to avoid damage.
Do not disassemble mass air flow sensor.
Do not clean mass air flow sensor with any type of deter-
gent.
Do not disassemble electric throttle control actuator.
Even a slight leak in the air intake system can cause seri-
ous incidents.
Do not shock or jar the camshaft position sensor (PHASE),
crankshaft position sensor (POS).
PBIB1164E
PBIB1512E
PBIB0090E
MEF040D
PRECAUTIONS
EC-27
[QR (WITH EURO-OBD)]
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Do not depress accelerator pedal when starting.
Immediately after starting, do not rev up engine unneces-
sarily.
Do not rev up engine just prior to shutdown.
When installing C.B. ham radio or a mobile phone, be sure
to observe the following as it may adversely affect elec-
tronic control systems depending on installation location.
–Keep the antenna as far as possible from the electronic
control units.
–Keep the antenna feeder line more than 20 cm (8 in) away
from the harness of electronic controls.
Do not let them run parallel for a long distance.
–Adjust the antenna and feeder line so that the standing-
wave radio can be kept smaller.
–Be sure to ground the radio to vehicle body.
Wiring Diagrams and Trouble DiagnosisEBS010L3
When you read wiring diagrams, refer to the following:
GI-14, "How to Read Wiring Diagrams"
PG-2, "POWER SUPPLY ROUTING" for power distribution circuit
When you perform trouble diagnosis, refer to the following:
GI-10, "HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES"
GI-23, "How to Perform Efficient Diagnosis for an Electrical Incident"
SEF709Y
SEF708Y
ENGINE CONTROL SYSTEM
EC-35
[QR (WITH EURO-OBD)]
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EC
*2: This signal is sent to the ECM through CAN communication line.
*3: ECM determines the start signal status by the signals of engine speed and battery voltage.
SYSTEM DESCRIPTION
The amount of fuel injected from the fuel injector is determined by the ECM. The ECM controls the length of
time the valve remains open (injection pulse duration). The amount of fuel injected is a program value in the
ECM memory. The program value is preset by engine operating conditions. These conditions are determined
by input signals (for engine speed and intake air) from both the crankshaft position sensor and the mass air
flow sensor.
VARIOUS FUEL INJECTION INCREASE/DECREASE COMPENSATION
In addition, the amount of fuel injected is compensated to improve engine performance under various operat-
ing conditions as listed below.
During warm-up
When starting the engine
During acceleration
Hot-engine operation
When selector lever is changed from N to D (A/T models)
High-load, high-speed operation
During deceleration
During high engine speed operation
MIXTURE RATIO FEEDBACK CONTROL (CLOSED LOOP CONTROL)
The mixture ratio feedback system provides the best air-fuel mixture ratio for driveability and emission control.
The three way catalyst (manifold) can then better reduce CO, HC and NOx emissions. This system uses
heated oxygen sensor 1 in the exhaust manifold to monitor whether the engine operation is rich or lean. The
ECM adjusts the injection pulse width according to the sensor voltage signal. For more information about
heated oxygen sensor 1, refer to EC-176
. This maintains the mixture ratio within the range of stoichiometric
(ideal air-fuel mixture).
This stage is referred to as the closed loop control condition.
Heated oxygen sensor 2 is located downstream of the three way catalyst (manifold). Even if the switching
characteristics of heated oxygen sensor 1 shift, the air-fuel ratio is controlled to stoichiometric by the signal
from heated oxygen sensor 2.
Open Loop Control
The open loop system condition refers to when the ECM detects any of the following conditions. Feedback
control stops in order to maintain stabilized fuel combustion.
Deceleration and acceleration
High-load, high-speed operation
Malfunction of heated oxygen sensor 1 or its circuit
Insufficient activation of heated oxygen sensor 1 at low engine coolant temperature
High engine coolant temperature
During warm-up
After shifting from N to D (A/T models)
PBIB0121E
EC-36
[QR (WITH EURO-OBD)]
ENGINE CONTROL SYSTEM
When starting the engine
MIXTURE RATIO SELF-LEARNING CONTROL
The mixture ratio feedback control system monitors the mixture ratio signal transmitted from heated oxygen
sensor 1. This feedback signal is then sent to the ECM. The ECM controls the basic mixture ratio as close to
the theoretical mixture ratio as possible. However, the basic mixture ratio is not necessarily controlled as orig-
inally designed. Both manufacturing differences (i.e., mass air flow sensor hot wire) and characteristic
changes during operation (i.e., injector clogging) directly affect mixture ratio.
Accordingly, the difference between the basic and theoretical mixture ratios is monitored in this system. This is
then computed in terms of “injection pulse duration” to automatically compensate for the difference between
the two ratios.
“Fuel trim” refers to the feedback compensation value compared against the basic injection duration. Fuel trim
includes short term fuel trim and long term fuel trim.
“Short term fuel trim” is the short-term fuel compensation used to maintain the mixture ratio at its theoretical
value. The signal from heated oxygen sensor 1 indicates whether the mixture ratio is RICH or LEAN compared
to the theoretical value. The signal then triggers a reduction in fuel volume if the mixture ratio is rich, and an
increase in fuel volume if it is lean.
“Long term fuel trim” is overall fuel compensation carried out long-term to compensate for continual deviation
of the short term fuel trim from the central value. Such deviation will occur due to individual engine differences,
wear over time and changes in the usage environment.
FUEL INJECTION TIMING
Two types of systems are used.
Sequential Multiport Fuel Injection System
Fuel is injected into each cylinder during each engine cycle according to the firing order. This system is used
when the engine is running.
Simultaneous Multiport Fuel Injection System
Fuel is injected simultaneously into all four cylinders twice each engine cycle. In other words, pulse signals of
the same width are simultaneously transmitted from the ECM.
The four injectors will then receive the signals two times for each engine cycle.
This system is used when the engine is being started and/or if the fail-safe system (CPU) is operating.
FUEL SHUT-OFF
Fuel to each cylinder is cut off during deceleration or operation of the engine at excessively high speeds.
SEF337W