TROUBLE DIAGNOSIS
EC-107
[QR (WITH EURO-OBD)]
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EC
DATA MONITOR MODE
Monitored Item
×: Applicable
Monitored item
[Unit]ECM
INPUT
SIGNALSMAIN
SIG-
NALSDescription Remarks
ENG SPEED [rpm]××
Indicates the engine speed computed from the
signals of the crankshaft position sensor
(POS) and camshaft position sensor (PHASE).
Accuracy becomes poor if engine
speed drops below the idle rpm.
If the signal is interrupted while
the engine is running, an abnor-
mal value may be indicated.
MAS A/F SE-B1 [V]××
The signal voltage of the mass air flow sensor
is displayed.When the engine is stopped, a
certain value is indicated.
B/FUEL SCHDL
[msec]×
“Base fuel schedule” indicates the fuel injec-
tion pulse width programmed into ECM, prior
to any learned on board correction.
A/F ALPHA-B1 [%]×
The mean value of the air-fuel ratio feedback
correction factor per cycle is indicated.
When the engine is stopped, a
certain value is indicated.
This data also includes the data
for the air-fuel ratio learning con-
trol.
COOLAN TEMP/S
[°C] or [°F]××
The engine coolant temperature (determined
by the signal voltage of the engine coolant
temperature sensor) is displayed.
When the engine coolant temper-
ature sensor is open or short-cir-
cuited, ECM enters fail-safe
mode. The engine coolant tem-
perature determined by the ECM
is displayed.
HO2S1 (B1) [V]××
The signal voltage of the heated oxygen sen-
sor 1 is displayed.
HO2S2 (B1) [V]×
The signal voltage of the heated oxygen sen-
sor 2 is displayed.
HO2S1 MNTR (B1)
[RICH/LEAN]××
Display of heated oxygen sensor 1 signal dur-
ing air-fuel ratio feedback control:
RICH: means the mixture became “rich”, and
control is being affected toward a leaner mix-
ture.
LEAN: means the mixture became “lean”, and
control is being affected toward a rich mixture.After turning ON the ignition
switch, “RICH” is displayed until
air-fuel mixture ratio feedback
control begins.
When the air-fuel ratio feedback
is clamped, the value just before
the clamping is displayed contin-
uously.
HO2S2 MNTR (B1)
[RICH/LEAN]×
Display of heated oxygen sensor 2 signal:
RICH: means the amount of oxygen after three
way catalyst is relatively small.
LEAN: means the amount of oxygen after
three way catalyst is relatively large.
When the engine is stopped, a
certain value is indicated.
VHCL SPEED SE
[km/h] or [mph]××
The vehicle speed computed from the vehicle
speed signal is displayed.
BATTERY VOLT [V]××
The power supply voltage of ECM is dis-
played.
ACCEL SEN 1 [V]××
The accelerator pedal position sensor signal
voltage is displayed.
ACCEL SEN 2 signal is con-
verted by ECM internally. Thus, it
differs from ECM terminal voltage
signal. ACCEL SEN 2 [V]×
THRTL SEN 1 [V]××
The throttle position sensor signal voltage is
displayed.
THRTL SEN 2 signal is con-
verted by ECM internally. Thus, it
differs from ECM terminal voltage
signal. THRTL SEN 2 [V]×
EVAPORATIVE EMISSION SYSTEM
EC-525
[QR (WITH EURO-OBD)]
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EC
Component InspectionEBS010VY
EVAP CANISTER
Check EVAP canister as follows:
1. Block port B . Orally blow air through port A .
Check that air flows freely through port C .
2. Block port A . Orally blow air through port B .
Check that air flows freely through port C .
FUEL CHECK VALVE
1. Blow air through connector on fuel tank side.
A considerable resistance should be felt and a portion of air flow
should be directed toward the EVAP canister side.
2. Blow air through connector on EVAP canister side.
Air flow should be smoothly directed toward fuel tank side.
3. If fuel check valve is suspected of not properly functioning in
steps 1 and 2 above, replace it.
FUEL TANK VACUUM RELIEF VALVE (BUILT INTO FUEL FILLER CAP)
1. Wipe clean valve housing.
2. Check valve opening pressure and vacuum.
3. If out of specification, replace fuel filler cap as an assembly.
PBIB0663E
SEF552Y
SEF989X
Pressure: 15.3 - 20.0 kPa (0.153 - 0.200 bar,
0.156 - 0.204 kg/cm
2 , 2.22 - 2.90 psi)
Va c u u m :−6.0 to −3.4 kPa (−0.060 to −0.034 bar,
−0.061 to −0.035 kg/cm
2 , −0.87 to −0.49 psi)
SEF943S
EC-608
[QR (WITHOUT EURO-OBD)]
TROUBLE DIAGNOSIS
DATA MONITOR MODE
Monitored Item
×: Applicable
Monitored item [Unit]ECM
INPUT
SIGNALSMAIN
SIG-
NALSDescription Remarks
ENG SPEED [rpm]××
Indicates the engine speed computed from the
signals of the crankshaft position sensor
(POS) and camshaft position sensor (PHASE).
Accuracy becomes poor if engine
speed drops below the idle rpm.
If the signal is interrupted while the
engine is running, an abnormal
value may be indicated.
MAS A/F SE-B1 [V]××
The signal voltage of the mass air flow sensor
is displayed.When the engine is stopped, a
certain value is indicated.
B/FUEL SCHDL
[msec]×
“Base fuel schedule” indicates the fuel injec-
tion pulse width programmed into ECM, prior
to any learned on board correction.
A/F ALPHA-B1 [%]×
The mean value of the air-fuel ratio feedback
correction factor per cycle is indicated.
When the engine is stopped, a
certain value is indicated.
This data also includes the data
for the air-fuel ratio learning con-
trol.
COOLAN TEMP/S
[°C] or [°F]××
The engine coolant temperature (determined
by the signal voltage of the engine coolant
temperature sensor) is displayed.
When the engine coolant tempera-
ture sensor is open or short-cir-
cuited, ECM enters fail-safe mode.
The engine coolant temperature
determined by the ECM is dis-
played.
HO2S1 (B1) [V]××
The signal voltage of the heated oxygen sen-
sor 1 is displayed.
HO2S2 (B1) [V]×
The signal voltage of the heated oxygen sen-
sor 2 is displayed.
HO2S1 MNTR (B1)
[RICH/LEAN]××
Display of heated oxygen sensor 1 signal dur-
ing air-fuel ratio feedback control:
RICH: means the mixture became “rich”, and
control is being affected toward a leaner mix-
ture.
LEAN: means the mixture became “lean”, and
control is being affected toward a rich mixture.After turning ON the ignition
switch, “RICH” is displayed until
air-fuel mixture ratio feedback
control begins.
When the air-fuel ratio feedback is
clamped, the value just before the
clamping is displayed continu-
ously.
HO2S2 MNTR (B1)
[RICH/LEAN]×
Display of heated oxygen sensor 2 signal:
RICH: means the amount of oxygen after three
way catalyst is relatively small.
LEAN: means the amount of oxygen after
three way catalyst is relatively large.
When the engine is stopped, a
certain value is indicated.
VHCL SPEED SE
[km/h] or [mph]××
The vehicle speed computed from the vehicle
speed signal is displayed.
BATTERY VOLT [V]××
The power supply voltage of ECM is displayed.
ACCEL SEN 1 [V]××
The accelerator pedal position sensor signal
voltage is displayed.ACCEL SEN 2 signal is converted
by ECM internally. Thus, it differs
from ECM terminal voltage signal. ACCEL SEN 2 [V]×
THRTL SEN 1 [V]××
The throttle position sensor signal voltage is
displayed.THRTL SEN 2 signal is converted
by ECM internally. Thus, it differs
from ECM terminal voltage signal. THRTL SEN 2 [V]×
INT/A TEMP SE
[°C] or [°F]××
The intake air temperature (determined by the
signal voltage of the intake air temperature
sensor) is indicated.
EVAPORATIVE EMISSION SYSTEM
EC-965
[QR (WITHOUT EURO-OBD)]
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EC
Component InspectionEBS01155
EVAP CANISTER
Check EVAP canister as follows:
1. Block port B . Orally blow air through port A .
Check that air flows freely through port C .
2. Block port A . Orally blow air through port B .
Check that air flows freely through port C .
FUEL CHECK VALVE
1. Blow air through connector on fuel tank side.
A considerable resistance should be felt and a portion of air flow
should be directed toward the EVAP canister side.
2. Blow air through connector on EVAP canister side.
Air flow should be smoothly directed toward fuel tank side.
3. If fuel check valve is suspected of not properly functioning in
steps 1 and 2 above, replace it.
FUEL TANK VACUUM RELIEF VALVE (BUILT INTO FUEL FILLER CAP)
1. Wipe clean valve housing.
2. Check valve opening pressure and vacuum.
3. If out of specification, replace fuel filler cap as an assembly.
PBIB0663E
SEF552Y
SEF989X
Pres-
sure:15.3 - 20.0 kPa (0.153 - 0.200 bar,
0.156 - 0.204 kg/cm
2 , 2.22 - 2.90 psi)
Va c u u m :−6.0 to −3.4 kPa (−0.060 to −0.034 bar,
−0.061 to −0.035 kg/cm
2 , −0.87 to −0.49 psi)
SEF943S
FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY
FL-7
[QR]
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FL
a. Removal of main fuel level sensor unit, fuel filter and fuel pump
assembly:
i. Raise main fuel level sensor unit, fuel filter and fuel pump
assembly, and disconnect jet pump.
ii. Leave jet pump on fuel tank with fuel hose.
CAUTION:
Do not disconnect jet pump and fuel hose.
iii. If necessary, remove chamber from the bottom of fuel tank by
sliding toward the rear of the vehicle.
b. Removal of sub fuel level sensor unit:
i. Raise and release sub fuel level sensor unit to remove.
ii. If necessary, remove jet pump inlet from the bottom of fuel tank by pinching tabs.
CAUTION:
Do not separate jet pump inlet and fuel hose.
INSPECTION AFTER REMOVAL
Make sure that fuel pump strainer is free from foreign materials. If any are found, remove them.
INSTALLATION
Note the following, and install in the reverse order of removal.
Chamber and Jet Pump
When installing chamber and jet pump, insert them fully until a click
sound of full stopper engagement is heard (Ditto for jet pump inlet).
Main and Sub Fuel Level Sensor Unit
1. Install seal packing to fuel tank without any twist.
2. Face fuel level sensor unit, fuel filter and fuel pump assembly as
shown in the figure, and install it to fuel tank. (Figure shows left
side of fuel tank.)
CAUTION:
Do not bend float arm during installing.
NOTE:
On right side of fuel tank, there are three carved lines on fuel
tank. Set mating mark between two outer carved lines.
3. Tighten rock ring with rock ring wrench (commercial service tool).
CAUTION:
Install rock ring horizontally.
Quick Connector
Connect quick connector as follows:
1. Check the connection for damage and foreign materials.
KBIA0281E
KBIA0302E
KBIA0282E
FUEL LEVEL SENSOR UNIT
FL-21
[YD22DDTi]
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CAUTION:
The quick connector can be removed when the tabs are
completely depressed. Do not twist it more than neces-
sary.
Do not use any tools to disconnect quick connector.
Keep the resin tube away from heat. Be especially careful
when welding near the tube.
Prevent acid liquid such as battery electrolyte etc. from
getting on resin tube.
Do not bend or twist the tube during installation and
removal.
Do not remove the remaining retainer on hard tube (or
equivalent) except when resin tube or retainer is
replaced.
When resin tube or fuel level sensor unit is replaced, also
replace retainer with a new one.
To keep clean the connecting portion and to avoid dam-
age and foreign materials, cover them completely with
plastic bags or something similar.
8. Using a fuel tank lock ring wrench (commercial service tool),
remove the lock ring.
9. Remove main fuel level sensor unit (Left hand) and sub fuel level sensor unit (Right hand).
CAUTION:
Do not bend the float arm during removal.
Avoid impacts such as falling when handling components.
Left hand (main fuel level sensor unit):
If necessary, remove the chamber from the bottom of the fuel tank.
Remove the chamber by sliding toward the rear of the vehicle.Retainer color : Green (Fuel feed tube)
: Gray (Fuel return tube)
SBIA0504E
PBIC0163E
PBIC0240E
MAINSHAFT AND GEARS
MT-75
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MT
If any crack, damage, or excessive wear is found on cam face of
baulk ring or working face of insert, replace it.
BAULK RING CLEARANCE
Triple-cone synchronizer (1st and 2nd)
Check the clearance between outer baulk ring, synchronizer
cone and inner baulk ring as follows.
CAUTION:
The clearances “A”, “B” and “C” are controlled with outer
baulk ring, synchronizer cone and inner baulk ring as a set.
Replace them as a set if the clearances are outside the limit
value.
1. Measure the clearance “A” at 2 points or more diagonally oppo-
site using a feeler gauge when pressing baulk ring toward clutch
gear taper cone. And then calculate mean value.
2. Measure the clearance “B” at 2 points or more diagonally oppo-
site using a feeler gauge. And then calculate mean value.
SMT867D
PCIB1358E
Clearance “A”
Standard value : 0.6 - 1.2 mm (0.024 - 0.047 in)
Limit value : 0.3 mm (0.012 in)
PCIB1359E
Clearance “B”
Standard value : 0.6 - 1.1 mm (0.024 - 0.043 in)
Limit value : 0.2 mm (0.008 in)
PCIB1360E
MT-76
MAINSHAFT AND GEARS
3. Measure the clearance “C” at 2 points or more diagonally oppo-
site using a feeler gauge when pressing baulk ring toward clutch
gear taper cone. And then calculate mean value.
Bearing
Check items below. If necessary, replace them with new ones.
Damage and rough rotation of bearing
ASSEMBLY
1. Press in reverse main gear using the drifts and the press stand.
CAUTION:
Be careful with orientation of reverse main gear.
Do not reuse reverse main gear.Clearance “C”
Standard value : 0.7 - 1.1 mm (0.028 - 0.043 in)
Limit value : 0.3 mm (0.012 in)
PCIB1361E
MTF0041D
SCIA0939E
SCIA0992E