OVERHEATING CAUSE ANALYSIS
CO-5
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Except cool-
ing system
parts mal-
function— Overload on engineAbusive drivingHigh engine rpm under no
load
Driving in low gear for
extended time
Driving at extremely high
speed
Powertrain system mal-
function
— Installed improper size
wheels and tires
Dragging brakes
Improper ignition timing
Blocked or restricted air
flowBlocked bumper —
— Blocked radiator grilleInstalled car brassiere
Mud contamination or
paper clogging
Blocked radiator —
Blocked condenser
Blocked air flow
Installed large fog lamp Symptom Check items
CO-8
ENGINE COOLANT
DRAINING ENGINE COOLANT
1. Open radiator drain plug (1) at the bottom of radiator, and
remove radiator cap.
CAUTION:
Be careful not to allow engine coolant to contact drive belts.
When draining all engine coolant in the system, also perform the following steps.
2. Remove air relief plug (1) on heater feed tube.
lLHD models
lRHD models
3. Open cylinder block drain plug. Refer toEM-110, "
CYLINDER BLOCK".
4. Remove reservoir tank, drain engine coolant, then clean reservoir tank.
5. Check drained engine coolant for contaminants such as rust, corrosion or discoloration.
If contaminated, flush engine cooling system. Refer toCO-9, "
FLUSHING COOLING SYSTEM".
REFILLING ENGINE COOLANT
1. Install reservoir tank, and radiator drain plug.
CAUTION:
Be sure to clean radiator drain plug and install with new O-ring.
lIf water drain plugs on cylinder block are removed, close and tighten them. Refer toEM-110,
"CYLINDER BLOCK".
2. Make sure that each hose clamp has been firmly tightened.
2 : Engine under cover (front)
A : Loosen.
: Vehicle front
PBIC3634E
2 : Water hose (from reservoir tank)
3 : Fuel filter
: Vehicle front
PBIC3348E
2 : Water hose (from reservoir tank)
: Vehicle front
PBIC3635E
Radiator drain plug:
: 1.2 N·m (0.12 kg-m, 11 in-lb)
CO-22
WATER PUMP
lEngine coolant will leak from cylinder block, so have a receptacle ready below.
CAUTION:
lHandle the water pump vane so that it does not contact any other parts.
lWater pump cannot be disassembled and should be replaced as a unit.
INSPECTION AFTER REMOVAL
lVisually check if there is no significant dirt or rusting on the
water pump body and vane.
lMake sure that there is no looseness in the vane shaft, and that
it turns smoothly when rotated by hand.
lIf there are any unusualness, replace water pump assembly as
necessary.
INSTALLATION
lInstall in the reverse order of removal.
lInstall cooling fan (crankshaft driven type) with the front mark “AISIN” facing the front of engine. Refer to
CO-19, "
Removal and Installation".
INSPECTION AFTER INSTALLATION
lCheck for leaks of engine coolant using the radiator cap tester adapter [SST: EG17650301] and the radia-
tor cap tester (commercial service tool). Refer toCO-7, "
CHECKING RADIATOR SYSTEM FOR LEAKS".
lStart and warm up engine. Visually check if there is no leaks of engine coolant.
PBIC3354E
CO-24
THERMOSTAT AND WATER PIPING
Removal and Installation
EBS01E6X
WARNING:
Do not remove radiator cap and/or reservoir tank cap when engine is hot. Serious burns could occur
from high pressure engine coolant escaping from radiator and/or reservoir tank.
REMOVAL
1. Remove front engine undercover and middle engine undercover. Refer toEI-15, "FRONT BUMPER".
2. Drain engine coolant from radiator drain plug at the bottom of radiator, and from water drain plug at the
side of cylinder block. Refer toCO-7, "
Changing Engine Coolant"andEM-110, "CYLINDER BLOCK".
CAUTION:
Perform this step when engine is cold.
3. Remove engine cover. Refer toEM-20, "
INTAKE MANIFOLD".
4. Disconnect radiator hoses (upper and lower) from engine side. Refer toCO-11, "
RADIATOR".
5. Remove air inlet pipe and air duct between air cleaner case and turbocharger. Refer toEM-15, "
AIR
CLEANER AND AIR DUCT"andEM-28, "TURBO CHARGER".
6. Remove water outlet, water inlet and thermostat.
7. Remove thermostat housing.
8. Disconnect heater return hose and water hoses at heater return pipe side, and remove heater return pipe.
9. Remove oil level gauge guide mounting bolt, vacuum hoses (to turbocharger boost control solenoid valve)
and spill hose. Refer toEM-36, "
OIL PAN AND OIL STRAINER",EM-20, "INTAKE MANIFOLD"andEM-
44, "INJECTION TUBE AND FUEL INJECTOR".
10. Disconnect water hoses (to EGR cooler) (A/T models), vacuum hoses and heater feed hose at heater
feed pipe side, and remove heater feed pipe. Refer toEM-20, "
INTAKE MANIFOLD".
INSPECTION AFTER REMOVAL
Thermostat
lPlace a string so that it is caught in the valves of the thermostat.
Immerse fully in a container filled with water. Heat while stirring.
lThe valve opening temperature is the temperature at which the
valve opens and falls from the thread.
lContinue heating. Check the full-open lift amount.
lAfter checking the full-open lift amount, lower the water temper-
ature and check the valve closing temperature.
Standard values
lIf out of the standard, replace thermostat.
INSTALLATION
Note the following, and install in the reverse order of removal.
lSecurely insert each hose, and install clamp at a position where it does not interfere with the pipe bulge.
lWhen inserting heater feed pipe end into cylinder head, apply a neutral detergent to O-ring. Then insert it
immediately.
SLC252B
Item Thermostat
Valve opening temperature 80.5 - 83.5°C (177 - 182°F)
Full-open lift amount More than 9 mm/ 95°C (0.35 in/ 203°F)
Valve closing temperature More than 77°C(171°F)
DI-1
DRIVER INFORMATION SYSTEM
K ELECTRICAL
CONTENTS
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SECTIONDI
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B
DI
DRIVER INFORMATION SYSTEM
PRECAUTION ............................................................ 3
Precautions for Supplemental Restraint System
(SRS)“AIRBAG”and“SEATBELTPRE-TEN-
SIONER” .................................................................. 3
Wiring Diagrams and Trouble Diagnosis .................. 3
COMBINATION METERS ........................................... 4
System Description .................................................. 4
UNIFIED METER CONTROL UNIT ...................... 4
POWER SUPPLY AND GROUND CIRCUIT ........ 4
SPEEDOMETER ................................................... 4
TACHOMETER ..................................................... 4
WATER TEMPERATURE GAUGE ........................ 4
FUEL GAUGE ....................................................... 5
ODO/TRIP METER ............................................... 5
TRIP COMPUTER ................................................ 5
ENGINE OIL MAINTENANCE INFORMATION..... 6
METER ILLUMINATION CONTROL ..................... 6
CLOCK .................................................................. 6
AMBIENT AIR TEMPERATURE INDICATION ...... 6
Component Parts and Harness Connector Location..... 7
Arrangement of Combination Meter ......................... 8
Internal Circuit .......................................................... 9
Wiring Diagram — METER — ................................ 10
Terminals and Reference Value for Combination
Meter ...................................................................... 12
Self-Diagnosis Mode of Combination Meter ........... 13
FUNCTION .......................................................... 13
OPERATION PROCEDURE ............................... 13
TEST ITEM ......................................................... 13
CONSULT-II Function (METER) ............................. 15
CONSULT-II BASIC OPERATION ....................... 15
SELF-DIAG RESULTS ........................................ 16
DATA MONITOR ................................................. 17
Trouble Diagnosis .................................................. 18
HOW TO PERFORM TROUBLE DIAGNOSIS ... 18
PRELIMINARY CHECK ...................................... 19
Symptom Chart ...................................................... 19
Power Supply and Ground Circuit Inspection ........ 19
Vehicle Speed Signal Inspection ............................ 20
Engine Speed Signal Inspection ............................ 21Engine Coolant Temperature Signal Inspection ..... 21
Fuel Level Sensor Signal Inspection ...................... 22
Ambient Sensor Signal Inspection .......................... 24
Fuel Gauge Fluctuates, Indicates Wrong Value, or
Varies ...................................................................... 25
Fuel Gauge Does Not Move to Full position ........... 25
DTC [U1000] CAN Communication Circuit ............. 26
DTC [B2205] Vehicle Speed Circuit ........................ 26
Electrical Components Inspection .......................... 27
FUEL LEVEL SENSOR UNIT CHECK ................ 27
AMBIENT SENSOR CHECK ............................... 27
Removal and Installation of Combination Meter ..... 27
WARNING LAMPS .................................................... 28
System Description ................................................. 28
OIL PRESSURE WARNING LAMP ..................... 28
Component Parts and Harness Connector Location... 28
Schematic ............................................................... 29
Wiring Diagram — WARN — .................................. 30
A/T MODELS ....................................................... 30
M/T MODELS ...................................................... 37
Oil Pressure Warning Lamp Stays Off (Ignition
Switch ON) ............................................................. 44
Oil Pressure Warning Lamp Does Not Turn Off (Oil
Pressure Is Normal) ................................................ 45
Oil Pressure Warning Lamp Keeps Blinking (Oil
Level Is Normal) ..................................................... 46
Component Inspection ............................................ 47
OIL PRESSURE SWITCH ................................... 47
OIL LEVEL SENSOR .......................................... 47
A/T INDICATOR ........................................................ 48
System Description ................................................. 48
Wiring Diagram — AT/IND — ................................. 49
A/T Indicator Does Not Illuminate ........................... 50
WARNING CHIME ..................................................... 51
System Description ................................................. 51
POWER SUPPLY AND GROUND CIRCUIT ....... 51
LIGHT WARNING CHIME ................................... 51
KEY REMINDER WARNING CHIME .................. 51
LOW-FUEL WARNING CHIME ........................... 51
SEAT BELT WARNING CHIME ........................... 52
DI-4
COMBINATION METERS
COMBINATION METERS
PFP:24814
System DescriptionEKS00L8E
UNIFIED METER CONTROL UNIT
lSpeedometer, odo/trip meter, tachometer, fuel gauge and water temperature gauge are controlled by the
unified meter control unit, which is built into the combination meter.
lWarning lamp and indicator lamp are controlled by signals drawn from each unit with CAN communication
and components connected directly to the combination meter.
lOdo/trip meter display is included in the combination meter, which displays odometer, trip-meter, vehicle
information (trip computer, engine oil maintenance information)
*and A/T position*.
*: Vehicles with each system only.
lClock display is included in the combination meter, which displays current time, ambient air temperature*
and 4WD indicator*.
*: Vehicles with each system only.
lUnified meter control unit corresponds a CONSULT-II function (self-diagnosis results and data monitor).
lThe following items can be checked during self-diagnosis mode.
–Sweep of gauges pointer
–Present gauge values
–Odo/trip meter display and clock display segments
–Condition of warning lamps/indicator lamps controlled by unified meter control unit
–Battery voltage
–Driver's seat belt buckle switch status
–CPU status of unified meter control unit
POWER SUPPLY AND GROUND CIRCUIT
Power is supplied at all times
lthrough 10A fuse [No.19, located in the fuse block (J/B)]
lto combination meter terminal 3.
With the ignition switch in the ON or START position, power is supplied
lthrough 10A fuse [No.14, located in the fuse block (J/B)]
lto combination meter terminal 16.
Ground is supplied
lto combination meter terminals 13 and 23
lthrough grounds M21, M80 and M83.
SPEEDOMETER
The speedometer indicates the vehicle speed.
lABS actuator and electric unit (control unit) converses a pulse signal from wheel sensor to vehicle speed
signal, and transmits vehicle speed signal to combination meter with CAN communication.
lCombination meter converses the vehicle speed signal to angle signal, and commands to speedometer.
TACHOMETER
The tachometer indicates engine speed in revolutions per minute (rpm).
lECM converses a signal from crank position sensor to engine speed signal, and transmits to combination
meter with CAN communication.
lCombination meter converses the engine speed signal to angle signal, and commands to tachometer.
WATER TEMPERATURE GAUGE
The water temperature gauge indicates the engine coolant temperature.
lECM converses a signal from water temperature sensor to engine coolant temperature signal, and trans-
mits to combination meter with CAN communication.
lCombination meter converses the engine coolant temperature signal to angle signal, and commands to
water temperature gauge.
DI-6
COMBINATION METERS
ENGINE OIL MAINTENANCE INFORMATION
lEngine oil maintenance information displays maintenance intervals of engine oil.
lWith ignition switch ON position, engine oil maintenance information is displayed on odo/trip meter display
for 5 seconds.
NOTE:
Refer to Owner's Manual for setting.
METER ILLUMINATION CONTROL
When the lighting switch is turned ON, the odo/trip meter switch (1)
can be used to adjust the brightness of the combination meter illumi-
nation.
CLOCK
With ignition switch ON position, combination meter displays clock
on clock display. Time can be adjusted by clock switch (1). Clock can
be adjusted to 12-hour or 24-hour cycle clock.
NOTE:
If the battery cable is disconnected, the clock displays the time 12:00
in 12-hour mode.
AMBIENT AIR TEMPERATURE INDICATION
Combination meter displays ambient air temperature on clock display.
With ignition switch ON, “°C” blinks for a while. Ambient air temperature indication can be selected between
Centigrade and Fahrenheit.
Combination meter reads ambient air temperature signal from ambient sensor.
Signal is supplied
lfrom combination meter terminal 49
lthrough ambient sensor terminals 1 and 2
lto combination meter terminal 50.
When a temperature detected by sensor rises, combination meter controls increase of the indicated tempera-
ture depending on engine heat and other effective factors.
lIf the vehicle speed is more than 20 km/h, the indicated temperature rises according to the vehicle speed.
lIf the vehicle speed is less than 20 km/h, the indicated temperature is maintained.
When a temperature detected by sensor falls, the temperature is indicated immediately.
NOTE:
The range indicated on the display is between-30 and 60°C for Centigrade or between-22 and 99°Ffor
Fahrenheit.
lWhen the temperature is from-40°C(-40°F) to-30°C(-22°F), “--°C” is indicated on the display as
over range.
lWhen the temperature is under-40°C(-40°F) or over 60°C(140°F), nothing is indicated.
lWhen indicated temperature becomes less than 3°C(37°F), ambient air temperature indication blinks
warning. After blinking for 20 seconds, only “°C” blinks. At more than 4°C(39°F) the display stops blink-
ing.
SKIB4848E
PKIC1129E
COMBINATION METERS
DI-13
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Self-Diagnosis Mode of Combination MeterEKS00L8K
FUNCTION
The following items can be checked during self-diagnosis mode.
lSweep of gauges pointer
lPresent gauge data values
lOdo/trip meter display and clock display segments
lCondition of warning lamps/indicator lamps controlled by unified meter control unit
lBattery voltage
lDriver's seat belt buckle switch status
lCPU of unified meter control unit status
OPERATION PROCEDURE
To initiate combination meter self-diagnosis mode, refer to the following procedure.
1. Turn ignition switch ON while pressing clock switch (1).
2. Press and hold clock switch until “tESt” is indicated on odo/trip
meter display (within 7 seconds after the ignition switch ON).
3. Release odo/trip meter switch when “tESt” is indicated.
4. Combination meter self-diagnosis mode starts.
5. Pressodo/tripmeterswitchtogotonextitem.RefertoDI-13,
"TEST ITEM".
NOTE:
Combination meter self-diagnosis mode exits upon turning the igni-
tion switch to OFF or ACC position.
TEST ITEM
PKIC1129E
Te s t
orderTest Item Description of test/data Notes
1 GAGE Sweeps all gauges.Sweeps gauges within 10 seconds.
If any of gauges is not sweeped, replace combination
meter.
2 (All segments illuminated)Illuminates all segments on odo/trip
meter display and clock display.If any of the segments is not illuminated, replace com-
bination meter.
3 bulbIlluminates all lamps controlled by unified
meter control unit.If any of lamp controlled by unified meter control unit is
not illuminated, replace combination meter.
4 rXXXX/FAILDisplays ROM status as “r XXXX” or
“FAIL”.If “FAIL” is displayed, replace combination meter.
5 nrXXXX — Not used for service.
6 EE XX/FAILDisplays memory status as “EE XX” or
“FAIL”.If “FAIL” is displayed, replace combination meter.
7 dtXXXX — Not used for service.
8 Sc1XX — Not used for service.
9 Sc2XX — Not used for service.
10 EprXX — Not used for service.
11 1nFXX Displays market info value.$1C = EUR-LHD
$23 = EUR-RHD
12 cYLXX Displays engine configuration value.$08 = 8 cylinder
$06 = 6 cylinder
$04 = 4 cylinder
13 FFXXXX — Not used for service.
14 tF — Not used for service.
15 ot1XX — Not used for service.
16 ot0XX — Not used for service.