Downloaded from www.Manualslib.com manuals search engine Maintenance and Lubrication: 0B-13
Brake
Foot brake
Check the following:
• that brake pedal has proper travel,
• that brake works properly,
• that it is free from noise,
• that vehicle does not pull to one side when brake is applied.
• and that brake do not drag.
Parking brake
Check that lever has proper travel.
WARNING!
With vehicle parked on a fairly steep slope,
make sure nothing is in the way downhill to
avoid any personal injury or property
damage. Be prepared to apply regular brake
quickly even if vehicle should start to move.
Check to ensure that parking brake is fully effective
when the vehicle is stopped on the safe slope and brake
lever is pulled all the way.
Steering
• Check to ensure that steering wheel is free from instability, or abnormally heavy feeling. • Check that the vehicle does not wander or pull to one
side.
Engine
• Check that engine responds readily at all speeds.
• Check that engine is free from abnormal noise and abnormal vibration.
Body, Wheels and Power Transmitting System
Check that body, wheels and power transmitting system
are free from abnormal noise and abnormal vibration or
any other abnormal condition.
Meters and Gauge
Check that speedometer, odometer, fuel meter,
temperature gauge, etc. are operating accurately.
Lights
Check that all lights operate properly.
Windshield Defroster
Periodically check that ai r comes out from defroster
outlet when operating heater or air conditioning.
Set mode control lever to defroster position and fan
switch lever to “HI” position for this check.
Specifications
Tightening Torque SpecificationsS7RS0B0207001
Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”.
Special Tools and Equipment
Recommended Fluids and LubricantsS7RS0B0208001
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Engine oil drain plug 35 3.5 25.5 )
Oil filter 14 1.4 10.5 for reference )
Engine oilSG, SH, SJ, SL or SM grade (Refer to “Engine Oil and Filter Change” for engine
oil viscosity.)
Engine coolant
(Ethylene glycol base coolant) “Antifreeze/Antico
rrosion coolant”
Brake fluid Refer to reservoir cap of brake master cylinder.
Manual transaxle oil Refer to “Manual Transaxle Oil Change in Section 5B”.
Automatic transaxle fluid Refer to “A/T Fluid Change in Section 5A”.
Door hinges Engine oil or water resistance chassis grease
Hood latch assembly Engine oil or water resistance chassis grease
Key lock cylinder Spray lubricant
Downloaded from www.Manualslib.com manuals search engine 1-ii Table of Contents
DTC P0123: Throttle / Pedal Position Sensor / Switch “A” (Main) Circuit High ....................... 1A-85
DTC P0131 / P0132: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-
1) ..................................................................... 1A-88
DTC P0133: O2 Sensor (HO2S) Circuit Slow
Response (Sensor- 1) ...................................... 1A-91
DTC P0134: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor -1) ........................... 1A-92
DTC P0137 / P0138: O2 Sensor (HO2S) Circuit Low Voltage / High Voltage (Sensor-
2) ..................................................................... 1A-94
DTC P0140: O2 Sensor (HO2S) Circuit No Activity Detected (Sensor -2) ........................... 1A-97
DTC P0171 / P0172: Fuel System Too Lean / Rich ................................................................. 1A-98
DTC P0222: Throttle / Pedal Position Sensor / Switch “B” (Sub) Circuit Low ....................... 1A-100
DTC P0223: Throttle / Pedal Position Sensor / Switch “B” (Sub) Circuit High ...................... 1A-102
DTC P0300 / P0301 / P0302 / P0303 / P0304: Random / Multiple Cylin der Misfire Detected
/ Cylinder 1 / Cylinder 2 / Cylinder 3 /
Cylinder 4 Misfire Detected ........................... 1A-105
DTC P0327 / P0328: Knoc k Sensor 1 Circuit
Low / High ..................................................... 1A-107
DTC P0335: Crankshaft Position (CKP) Sensor “A” Circuit .......................................... 1A-109
DTC P0340: Camshaft Position (CMP) Sensor “A” Circuit .......................................... 1A-111
DTC P0350: Ignition Coil Primary / Secondary Circuit ............................................................ 1A-114
DTC P0401 / P0402: Exhaust Gas Recirculation Flow Insufficient Detected /
Excessive Detected ...................................... 1A-116
DTC P0403: Exhaust Gas Recirculation Control Circuit ................... ............................ 1A-118
DTC P0420: Catalyst System Efficiency
below Threshold ................ ............................ 1A-120
DTC P0443: Evaporativ e Emission System
Purge Control Valve Circuit ........................... 1A-122
DTC P0480: Fan 1 (Radiator Cooling Fan) Control Circuit ................... ............................ 1A-124
DTC P0500: Vehicle Speed Sensor “A” Malfunction .................................................... 1A-128
DTC P0532: A/C Refrigerant Pressure Sensor “A” Circuit Low ... ............................... 1A-130
DTC P0533: A/C Refrigerant Pressure Sensor “A” Circuit High ................................. 1A-132
DTC P0601 / P0602 / P0607: Internal Control Module Memory Check Sum Error / Control
Module Programming Error / Control Module
Performance ................................................. 1A-134
DTC P0616: Starter Relay Circuit Low............ 1A-135
DTC P0617: Starter Relay Circuit High ........... 1A-136
DTC P0620: Generator Control Circuit ........... 1A-137
DTC P0625 / P0626: Generator Field Terminal Circuit Low / High . .......................... 1A-139
DTC P1501 / P1502: Electric Load Current Sensor Circuit Low / High . ............................ 1A-141 DTC P1510: ECM Back-Up Power Supply
Malfunction .................................................... 1A-143
DTC P1603: TCM Trouble Code Detected ..... 1A-144
DTC P1674: CAN Communication (Bus Off Error) ............................................................. 1A-145
DTC P1676: CAN Communication (Reception Error for TCM) ............................................... 1A-148
DTC P1678: CAN Communication (Reception Error for BCM) ............................................... 1A-149
DTC P1685: CAN Communication (Reception Error for ABS/ESP ® Control Module) ........... 1A-150
DTC P2101: Throttle Actuator Control Motor Circuit Range / Performance ......................... 1A-152
DTC P2102: Throttle Actuator Control Motor Circuit Low .................................................... 1A-154
DTC P2103: Throttle Actuator Control Motor Circuit High.................................................... 1A-155
DTC P2111 / P2112: Throttle Actuator Control System - Stuck Open / Closed ...................... 1A-156
DTC P2119: Throttle Actu ator Control Throttle
Body Range / Performance ........................... 1A-157
DTC P2122: Throttle / Pedal Position Sensor / Switch “D” (Main) Circuit Low Input............. 1A-159
DTC P2123: Throttle / Pedal Position Sensor / Switch “D” (Main) Circuit High Input ............ 1A-161
DTC P2127: Throttle Pedal Position Sensor / Switch “E” (Sub) Circuit Low Input ................ 1A-164
DTC P2128: Throttle / Pedal Position Sensor
/ Switc
h “E” (Sub) Circuit High Input ............. 1A-166
DTC P2135: Throttle / Pedal Position Sensor / Switch “A”/“B” (Main / Sub) Voltage
Correlation..................................................... 1A-168
DTC P2138: Throttle / Pedal Position Sensor / Switch “D”/“E” (Main / Sub) Voltage
Correlation..................................................... 1A-171
DTC P2227 / P2228 / P2229: Barometric Pressure Circuit Malfunction ......................... 1A-173
Inspection of ECM and Its Circuits .................. 1A-175
ECM Power and Ground Circuit Check........... 1A-194
Fuel Injector Circuit Check .............................. 1A-198
Fuel Pump and Its Circuit Check..................... 1A-200
Fuel Pressure Check....................................... 1A-203
A/C System Circuits Check ............................. 1A-205
Electric Load Signal Circuit Check .................. 1A-209
Radiator Cooling Fan Low Speed Control System Check ............................................... 1A-211
Radiator Cooling Fan High Speed Control System Check ............................................... 1A-213
Repair Instructions ......... .................................1A-216
Idle Speed and IAC Throttle Valve Opening Inspection ...................................................... 1A-216
Special Tools and Equipmen t .........................1A-217
Special Tool .................................................... 1A-217
Aux. Emission Control Devices ............. 1B-1
Diagnostic Information and Procedures ............1B-1
EGR System Inspection ...................................... 1B-1
Repair Instructions ............ ..................................1B-1
EVAP Canister Purge Inspec tion ........................ 1B-1
Downloaded from www.Manualslib.com manuals search engine 1A-2 Engine General Information and Diagnosis:
• Be sure to read “Precautions for Electrical Circuit Service in Section 00” befo re inspection and observe
what is written there.
• ECM replacement: When substituting a known-good ECM, check for the
following conditions. Neglec ting this check may cause
damage to a known-good ECM.
– Resistance value of all relays, actuators is as specified respectively.
– MAP sensor, A/C refrigerant pressure sensor and TP sensor are in good condition and none of power
circuits of these sensors is shorted to ground.
• Communication of ECM, BCM, ABS/ESP ® control
module, combination meter, keyless start control
module, steering angle sensor (ESP ® model) and
TCM (A/T model), is esta blished by CAN (Controller
Area Network). (For more detail of CAN
communication for ECM, refer to “CAN
Communication System Description”). Therefore,
handle CAN communication line with care referring to
“Precaution for CAN Communication System in
Section 00”.
• Immobilizer transponder code registration after
replacing ECM
When ECM is replaced with new one or with another
one, make sure to register immobilizer transponder
code to ECM correctly according to “Procedure after
ECM Replacement in Section 10C”.Precautions of ECM Circuit InspectionS7RS0B1100003
• ECM connectors are waterproofed. Each terminal of the ECM connectors is sealed up with the grommet.
Therefore, when measuring ci rcuit voltage, resistance
and/or pulse signal at ECM connector, do not insert
the tester’s probe into th e sealed terminal at the
harness side. When measuring circuit voltage,
resistance and/or pulse signal at ECM connector,
connect the special tool to the ECM connectors. And,
insert the tester’s probe into the special tool’s
connectors at the harness side, and then measure
voltage, resistance and/or pulse signal. Or, ECM and
its circuits may be damaged by water.
• Wire colors of the special tool’s connectors are different from the ones of the ECM connectors.
However, the circuit arrangement of the special tool’s
connectors is same as the one of the ECM
connectors. Therefore, measure circuit voltage and
resistance by identifying the terminal location subject
to the measurement.
Precautions of Electric Throttle Body System
Calibration
S7RS0B1100004
After performing one of works described below, it is
necessary to re-register the completely closed throttle
valve reference position stored in memory of ECM. (For
detailed information, refer to “Description of Electric
Throttle Body System Calibration”.) For the procedure to
register such data in ECM, refer to “Electric Throttle
Body System Calibration in Section 1C”.
• To shut off backup power of ECM for such purposes of battery replacement or “DOME” fuse removal
• To erase DTCs P0122, P01 23, P0222, P0223, P2101,
P2102, P2103, P2111, P2112, P2113, P2119, P2123,
P2127, P2128, P2135 and/or P2138
• To replace ECM
• To replace throttle body and/or accelerator pedal position (APP) sensor assembly
General Description
Statement on Cleanliness and CareS7RS0B1101001
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in the thousands of an
millimeter (ten thous ands of an inch).
Accordingly, when any internal engine parts are
serviced, care and cleanliness are important.
It should be understood that proper cleaning and
protection of machined surfaces and friction areas is part
of the repair procedure. This is considered standard
shop practice even if not specifically stated.
• A liberal coating of engine oil should be applied to friction areas during assembly to protect and lubricate
the surfaces on initial operation. • Whenever valve train components, pistons, piston
rings, connecting rods, rod bearings, and crankshaft
journal bearings are removed for service, they should
be retained in order.
At the time of installation, they should be installed in
the same locations and with the same mating
surfaces as when removed.
• Battery cables should be disconnected before any major work is performed on the engine.
Failure to disconnect cables may result in damage to
wire harness or other electrical parts.
Downloaded from www.Manualslib.com manuals search engine 1A-4 Engine General Information and Diagnosis:
Driving Cycle
A “Driving Cycle” consists of engine startup and engine
shutoff.
2 Driving Cycle Detection Logic
The malfunction detected in the first driving cycle is
stored in ECM memory (in t he form of pending DTC) but
the malfunction indicator lamp does not light at this time.
It lights up at the second detection of same malfunction
also in the next driving cycle.
Pending DTC
Pending DTC means a DTC detected and stored
temporarily at 1 driving cycle of the DTC which is
detected in the 2 driving cycle detection logic.
Freeze Frame Data
ECM stores the engine and driving conditions (in the
form of data as shown in the figure) at the moment of the
detection of a malfunction in its memory. This data is
called “Freeze frame data”.
Therefore, it is possible to know engine and driving
conditions (e.g., whether the engine was warm or not,
where the vehicle was running or stopped, where air/fuel
mixture was lean or rich) when a malfunction was
detected by checking the freeze frame data. Also, ECM
has a function to store each freeze frame data for three
different malfunctions in the order as each malfunction is detected. Utilizing this function,
it is possible to know the
order of malfunctions that ha ve been detected. Its use is
helpful when rechecking or diagnosing a trouble.
Priority of freeze frame data:
ECM has 4 frames where the freeze frame data can be stor ed. The first frame stores the freeze frame data of the
malfunction which was detected first. Howe ver, the freeze frame data stored in this frame is updated according to the
priority described. (If malfunction as described in the upper square “1” is detected while the freeze frame data in the
lower square “2” has been stored, the freeze frame data “2” will be updated by the freeze frame data “1”.)
In the 2nd through the 4th frames, the freeze frame data of each malfunction is stored in the order as each malfunction
is detected. These data are not updated.
Shown in the table are examples of how freeze frame data are stored when two or more malfunctions are detected.
[A]: 1st or 2nd in parentheses here represents which position in the order
the malfunction is detected.
[A]
I3RB0A110002-01
Priority Freeze frame data in frame 1
1 Freeze frame data at initial detection of malfuncti
on among misfire detected (P0300 – P0304), fuel
system too lean (P0171) and fuel system too rich (P0172)
2 Freeze frame data when a malfunctio n other than those in “1” is detected
Malfunction detected order Frame
Frame 1 Frame 2 Frame 3 Frame 4
Freeze frame data to be updated 1st freeze frame
data 2nd freeze frame
data 3rd freeze frame
data
No malfunction No freeze frame data
1 P0401 (EGR)
detected Data at P0401
detectionData at P0401
detection
——
2 P0171 (Fuel system)
detected Data at P0171
detectionData at P0401
detectionData at P0171
detection
—
3 P0300 (Misfire)
detected Data at P0171
detectionData at P0401
detectionData at P0171
detectionData at P0300
detection
4 P0301 (Misfire)
detected Data at P0171
detectionData at P0401
detectionData at P0171
detectionData at P0300
detection
Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-9
Air Intake System DescriptionS7RS0B1101006
The main components of the air intake system are air cleaner (1), air cleaner outlet hose (2), electric throttle body (3)
(for the details, refer to “Description of Electric Throttle Body System”.), and intake manifold (4).
The air (by the amount corresponding to throttle valve (5) opening and engine speed) is filtered by the air cleaner,
distributed by the intake, and finally drawn into each combusti on chamber. Electric throttle body is not equipped with
IAC valve for idle speed control. Idle speed control is done by the throttle actuator (6) which opens/closes the throttle
valve. (For the details, refer to “Description of Electric Throttle Body System”).
Description of Electric Throttle Body SystemS7RS0B1101007
The Electric Throttle Body System consists of electric throttle body asse mbly, APP sensor assembly, ECM and throttle
actuator control relay.
Among them, assembly components are as follows.
• Electric throttle body assembly: throttle valve, throttle actuator, 2 throttle position sensors
• APP sensor assembly: Accelerator pe dal, 2 accelerator position sensors
Operation Description
ECM (5) detects opening (depressed extent of pedal) of the accelerator pedal based on signal voltage of the APP
sensor (1) and using that data and engi ne operation condition, it calculates the optimum throttle valve opening. On the
other hand, it detects the throttle valve opening based on the signal voltage of the throttle position sensor (3) included
in the throttle body (2) and compares it with above calculated optimum throttle valve opening. When there is a
difference between them, ECM controls the duty ratio (100% – 0%) according to this difference to drive the throttle
actuator (motor) (4) included in the throttle body. When th ere is no difference, ECM controls the duty ratio to about
15% to maintain the throttle valve opening . In this way, the throttle valve (17) is opened and closed to achieve the
optimum throttle valve opening.
In this system, as the thrott le position sensor and APP sensor have 2 sensors (main and sub) each, highly accurate
and highly reliable control and abnormality detection are assured. Also, when ECM detects an abnormality in the
system, it turns off the th rottle actuator control relay (8) to step controlling the throttle actuator.
When the throttle actuator control relay is turned off, the throttle valve is fixed at the specified opening below from its
completely closed position (default openin g) by the force of the return spring and open spring included in the throttle
body.
This throttle body is not equipped with IAC valve for idle speed control. Idle speed control is done by the throttle
actuator which opens/closes the throttle valve.
4 2
1
3
5
6
I5RW0A110006-02
Downloaded from www.Manualslib.com manuals search engine 1A-22 Engine General Information and Diagnosis:
Diagnostic Information and Procedures
Engine and Emission Control System CheckS7RS0B1104001
Refer to the following items for the details of each step.Step Action Yes No 1 ) Customer complaint analysis
1) Perform customer complaint analysis referring to “Customer Complaint Analysis”.
Was customer complaint analysis performed? Go to Step 2. Perform customer
complaint analysis.
2 ) DTC / Freeze frame data check, record and clearance
1) Check for DTC (including pending DTC) referring to “DTC / Freeze Frame Data Check, Record and
Clearance”.
Is there any DTC(s)? Print DTC and freeze
frame data or write them
down and clear them by
referring to “DTC
Clearance”, and go to
St ep 3 .Go to Step 4.
3 ) Visual inspection
1) Perform visual inspection referring to “Visual Inspection”.
Is there any faulty condition? Repair or replace
malfunction part, and go
to Step 11.
Go to Step 5.
4 ) Visual inspection
1) Perform visual inspection referring to “Visual Inspection”.
Is there any faulty condition? Repair or replace
malfunction part, and go
to Step 11.
Go to Step 8.
5 ) Trouble symptom confirmation
1) Confirm trouble symptom referring to “Trouble Symptom Confirmation”.
Is trouble symptom identified? Go to Step 6.
Go to Step 7.
6 ) Rechecking and record of DTC / Freeze frame data
1) Recheck for DTC and freeze frame data referring to “DTC Check”.
Is there any DTC(s)? Go to Step 9.
Go to Step 8.
7 ) Rechecking and record of DTC / Freeze frame data
1) Recheck for DTC and freeze frame data referring to “DTC Check”.
Is there any DTC(s)? Go to Step 9.
Go to Step 10.
8 ) Engine basic inspection and engine symptom
diagnosis
1) Check and repair according to “Engine Basic Inspection”
and “Engine Symptom Diagnosis”.
Are check and repair complete? Go to Step 11. Check and repair
malfunction part(s), and
go to Step 11.
9 ) Troubleshooting for DTC
1) Check and repair according to applicable DTC diag. flow.
Are check and repair complete? Go to Step 11. Check and repair
malfunction part(s), and
go to Step 11.
10 ) Intermittent problems check
1) Check for intermittent problems referring to “Intermittent Problems Check”.
Is there any faulty condition? Repair or replace
malfunction part(s), and
go to Step 11.
Go to Step 11.
Downloaded from www.Manualslib.com manuals search engine Engine General Information and Diagnosis: 1A-25
Step 2: DTC / Freeze Frame Data Check, Record and
Clearance
First, check DTC (including pending DTC), referring to
“DTC Check”. If DTC is indicated, print it and freeze
frame data or write them down and then clear them by
referring to “DTC Clearance”. DTC indicates malfunction
that occurred in the system but does not indicate
whether it exists now or it occurred in the past and the
normal condition has been restored now. To check which
case applies, check the sy mptom in question according
to Step 5 and recheck DTC according to Step 6 and 7.
Attempt to diagnose a trouble based on DTC in this step
only or failure to clear the DTC in this step will lead to
incorrect diagnosis, trouble diagnosis of a normal circuit
or difficulty in troubleshooting.
Step 3 and 4: Visual Inspection
As a preliminary step, be sure to perform visual check of
the items that support proper function of the engine
referring to “Visual Inspection”.
Step 5: Trouble Symptom Confirmation
Based on information obtained in “Step 1: Customer
Complaint Analysis: ” and “Step 2: DTC / Freeze Frame
Data Check, Record and Clearance: ”, confirm trouble
symptoms. Also, reconfirm DTC according to “DTC
Confirmation Procedure” described in each DTC diag.
flow.
Step 6 and 7: Rechecking and Record of DTC /
Freeze Frame Data
Refer to “DTC Check” for checking procedure.
Step 8: Engine Basic Inspection and Engine
Symptom Diagnosis
Perform basic engine check according to “Engine Basic
Inspection” first. When the end of the flow has been
reached, check the parts of the system suspected as a
possible cause referring to “Engine Symptom Diagnosis”
and based on symptoms appearing on the vehicle
(symptoms obtained through steps of customer
complaint analysis, trouble symptom confirmation and/or
basic engine check) and repair or replace faulty parts, if
any.
Step 9: Troubleshooting for DTC (See each DTC
Diag. Flow)
Based on the DTC indicated in Step 6 or 7 and referring
to the applicable DTC diag. flow, locate the cause of the
trouble, namely in a sensor, switch, wire harness,
connector, actuator, ECM or other part and repair or
replace faulty parts. Step 10: Intermittent Problems Check
Check parts where an intermit
tent trouble is easy to
occur (e.g., wire harness, connector, etc.), referring to
“Intermittent and Poor Connec tion Inspection in Section
00” and related circuit of DTC recorded in Step 2.
Step 11: Final Confirmation Test
Confirm that the problem symptom has gone and the
engine is free from any abnormal conditions. If what has
been repaired is re lated to the DTC, clear the DTC once,
perform DTC confirmation procedure and confirm that no
DTC is indicated.
Malfunction Indicator Lamp (MIL) CheckS7RS0B1104002
1) Turn ON ignition switch (with engine at stop) and check that MIL (1) lights.
If MIL does not light up (or MIL dims) but engine can
be starting, go to “MIL Does Not Come ON with
Ignition Switch ON and Engine Stop (but Engine Can
Be Started)” for troubleshooting.
If MIL does not light with ignition switch ON and
engine does not start though it is cranked up, go to
“ECM Power and Ground Circuit Check”.
2) Start engine and check that MIL turns OFF. If MIL remains ON and no DTC is stored in ECM, go
to “Malfunction Indicator Lamp Remains ON after
Engine Starts” for troubleshooting.
1
I4RS0A110012-01