EC-1030
< PRECAUTION >[MR18DE]
PRECAUTIONS
On Board Diagnostic (OBD) System of Engine
INFOID:0000000001679887
The ECM has an on board diagnostic system. It will light up the malfunction indicator lamp (MI) to warn the
driver of a malfunction causing emission deterioration.
CAUTION:
Be sure to turn the ignition switch OFF and disconnect the negative battery cable before any repair
or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc. will
cause the MI to light up.
Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will
cause the MI to light up due to the open circuit. (Be sure the connector is free from water, grease,
dirt, bent terminals, etc.)
Certain systems and components, especially those related to OBD, may use a new style slide-lock-
ing type harness connector. For description and how to disconnect, refer to XX-XX, "*****"
.
Be sure to route and secure the harnesses properly after work. The interference of the harness with
a bracket, etc. may cause the MI to light up due to the short circuit.
Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube
may cause the MI to light up due to the malfunction of the EVAP system or fuel injection system, etc.
Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM before
returning the vehicle to the customer.
General PrecautionsINFOID:0000000001162002
Always use a 12 volt battery as power source.
Do not attempt to disconnect battery cables while engine is
running.
Before connecting or disconnecting the ECM harness con-
nector, turn ignition switch OFF and disconnect negative bat-
tery cable. Failure to do so may damage the ECM because
battery voltage is applied to ECM even if ignition switch is
turned OFF.
Before removing parts, turn ignition switch OFF and then dis-
connect battery ground cable.
Do not disassemble ECM.
If a battery cable is disconnected, the memory will return to
the ECM value.
The ECM will now start to self-control at its initial value.
Engine operation can vary slightly when the terminal is dis-
connected. However, this is not an indication of a malfunc-
tion. Do not replace parts because of a slight variation.
If the battery is disconnected, the following emission-related
diagnostic information will be lost within 24 hours.
-Diagnostic trouble codes
-1st trip diagnostic trouble codes
-Freeze frame data
-1st trip freeze frame data
-System readiness test (SRT) codes
-Test values
When connecting ECM harness connector (1), fasten (B) it
securely with a lever as far as it will go as shown in the figure.
SEF289H
2. ECM
A. Loosen
PBIA9222J
PBIB2947E
PRECAUTIONS
EC-1031
< PRECAUTION >[MR18DE]
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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) volt-
age to develop in coil and condenser, thus resulting in dam-
age to ICs.
Keep engine control system harness at least 10 cm (4 in) away
from adjacent harness, to prevent engine control system mal-
functions 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 Reference
Value inspection and make sure ECM functions properly.
Refer to EC-990, "
Reference Value".
Handle mass air flow sensor carefully to avoid damage.
Do not clean mass air flow sensor with any type of detergent.
Do not disassemble electric throttle control actuator.
Even a slight leak in the air intake system can cause serious
incidents.
Do not shock or jar the camshaft position sensor (PHASE),
crankshaft position sensor (POS).
After performing each TROUBLE DIAGNOSIS, perform DTC
CONFIRMATION PROCEDURE or Component Function
Check. The DTC should not be displayed in the DTC Confirmation
Procedure if the repair is completed. The Component Function
Check should be a good result if the repair is completed.
PBIB0090E
MEF040D
SAT652J
PREPARATION
EC-1033
< PREPARATION >[MR18DE]
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PREPARATION
PREPARATION
Special Service ToolsINFOID:0000000001162003
Commercial Service ToolsINFOID:0000000001162004
Tool number
Tool nameDescription
KV10117100
Heated oxygen sensor
wrenchLoosening or tightening heated oxygen sensor
with 22 mm (0.87 in) hexagon nut
KV10114400
Heated oxygen sensor
wrenchLoosening or tightening heated oxygen sensor 2
a: 22 mm (0.87 in)
KV10118400
Fuel tube adapterMeasuring fuel pressure
S-NT379
S-NT636
PBIB3043E
Tool name Description
Quick connector re-
leaseRemoving fuel tube quick connectors in engine
room
(Available in SEC. 164 of PARTS CATALOG: Par
No. 16441 6N210)
Socket wrench Removing and installing engine coolant tempera-
ture sensor
PBIC0198E
S-NT705
EC-1034
< PREPARATION >[MR18DE]
PREPARATION
Oxygen sensor thread
cleanerReconditioning the exhaust system threads before
installing a new oxygen sensor. Use with anti-
seize lubricant shown below.
a: 18 mm diameter with pitch 1.5 mm for Zirco-
nia Oxygen Sensor
b: 12 mm diameter with pitch 1.25 mm for Tita-
nia Oxygen Sensor
Anti-seize lubricant
i.e.: (Permatex
TM
133AR or equivalent
meeting MIL specifica-
tion MIL-A-907)Lubricating oxygen sensor thread cleaning tool
when reconditioning exhaust system threads. Tool name Description
AEM488
S-NT779
EC-1038
< SERVICE DATA AND SPECIFICATIONS (SDS) [MR18DE]
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
Idle SpeedINFOID:0000000001162007
*: Under the following conditions
A/C switch: OFF
Electric load: OFF (Lights, heater fan & rear window defogger)
Steering wheel: Kept in straight-ahead position
Ignition TimingINFOID:0000000001162008
*: Under the following conditions
A/C switch: OFF
Electric load: OFF (Lights, heater fan & rear window defogger)
Steering wheel: Kept in straight-ahead position
Calculated Load ValueINFOID:0000000001162009
Mass Air Flow SensorINFOID:0000000001162010
*: Engine is warmed up to normal operating temperature and running under no load.Condition Specification
No load* (in Neutral position) 700 ± 50 rpm
Condition Specification
No load* (in Neutral position) 15 ± 5° BTDC
Condition Specification (Using CONSULT-III or GST)
At idle10 – 35 %
At 2,500 rpm10 – 35 %
Supply voltageBattery voltage (11 – 14 V)
Output voltage at idle0.8 – 1.1V*
Mass air flow (Using CONSULT-III or GST)1.0 – 4.0 g·m/sec at idle*
2.0 – 10.0 g·m/sec at 2,500 rpm*
INSPECTION AND ADJUSTMENT
EC-1049
< BASIC INSPECTION >[K9K]
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>> INSPECTION END
6.CHECK ENGINE CONDITION
Check that the oil level is correct and that the engine coolant temperature is normal operation tempera-
ture.60°C (140°F)
Engine running at idle speed.
- Select “HIGH PRES CIRCUIT LEAK TEST” in “ACTIVE TEST” mode with CONSULT-III.
- Engine will perform 4 acceleration cycles.
- Select “DATA MONITOR” mode with CONSULT-III.
- Check that the “RAIL PRES SET” and “RAIL PRESSURE” indication.
- Does “RAIL PRESSURE” follow “RAIL PRES SET” at during the phase of 4 acceleration cycles?
Is the inspection result normal?
YES >> GO TO 22.
NO >> GO TO 7.
7.CHECK ENGINE COOLANT TEMPERATURE AND FUEL TEMPERATURE
1. Select “DATA MONITOR” mode with CONSULT-III.
2. Check that the “FUEL TEMP” indication when operating at idle speed is between 60 - 80°C (140 - 176°F)
3. Check that the “WATER TEMP” indication is between 80 - 90°C (176 - 194°F)
NOTE:
When the fuel temperature is above 136°C (277°F), the maximum rail pressure is reduced to protect the
plastic pipes.
When the coolant temperature is above 100°C (212°F), the maximum rail pressure is reduced to protect the
engine.
Are the
“FUEL TEMP” and “WATER TEMP” within the reference value range?
YES >> GO TO 8.
NO >> Check the fuel pump temperature sensor (Refer to EC-1137, "
Component Inspection") or engine
coolant temperature sensor (Refer to EC-1133, "
Component Inspection").
8.CHECK HIGH PRESSURE SUPPLY PUMP (VOLUMETRIC CONTROL VALVE) POWER SUPPLY
1. Turn ignition switch OFF.
2. Disconnect high pressure supply pump (volumetric control valve) harness connector.
3. Turn ignition switch ON.
4. Check the voltage between high pressure supply pump (volumetric control valve) harness connector and
ground.
Is the inspection result normal?
YES >> GO TO 10.
NO >> GO TO 9.
9.DETECT MALFUNCTIONING PART
Check the following.
IPDM E/R
Harness for open or short between ECM and high pressure supply pump (volumetric control valve)
Harness for open or short between IPDM E/R and high pressure supply pump (volumetric control valve)
>> Repair open circuit or short to ground or short to power in harness or connectors.
10.CHECK HIGH PRESSURE SUPPLY PUMP (VOLUMETRIC CONTROL VALVE) OUTPUT SIGNAL CIR-
CUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
High pressure supply pump
(volumetric control valve)
Ground Voltage
Connector Terminal
F54 1 Ground Battery voltage
INSPECTION AND ADJUSTMENT
EC-1051
< BASIC INSPECTION >[K9K]
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YES >> GO TO 15.
NO >> Repair open circuit or short to ground or short to power in harness or connectors.
15.CHECK HIGH PRESSURE SUPPLY PUMP (PRESSURE CONTROL VALVE)-II
Refer to EC-1123, "
Component Inspection".
Is the inspection result normal?
YES >> GO TO 16.
NO >> Replace high pressure supply pump.
16.CHECK FUEL RAIL PRESSURE SENSOR POWER SUUPLY CIRCUIT
1. Turn ignition switch OFF.
2. Disconnect fuel rail pressure sensor harness connector.
3. Turn ignition switch ON.
4. Check the voltage between fuel rail pressure sensor harness connector and ground.
Is the inspection result normal?
YES >> GO TO 17.
NO >> Repair open circuit or short to ground or short to power in harness or connectors.
17.CHECK FUEL RAIL PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check the continuity between fuel rail pressure sensor harness connector and ECM harness connector.
4. Also check harness for short to ground and short to power.
Is the inspection result normal?
YES >> GO TO 18.
NO >> Repair open circuit or short to ground or short to power in harness or connectors.
18.CHECK FUEL RAIL PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Check the continuity between fuel rail pressure sensor harness connector and ECM harness connector.
2. Also check harness for short to ground and short to power.
Is the inspection result normal?
YES >> GO TO 19.
NO >> Repair open circuit or short to ground or short to power in harness or connectors.
19.CHECK FUEL RAIL PRESSURE SENSOR
Refer to EC-1139, "
Component Inspection".
Is the inspection result normal?
YES >> GO TO 20.
NO >> Replace fuel rail.
20.CHECK FUEL RAIL PRESSURE-I
1. Reconnect all harness connectors disconnected.
Fuel rail pressure sensor
Ground Voltage (V)
Connector Terminal
F51 3 Ground Approx. 5
Fuel rail pressure sensor ECM
Continuity
Connector Terminal Connector Terminal
F51 2 F10 15 Existed
Fuel rail pressure sensor ECM
Continuity
Connector Terminal Connector Terminal
F51 1 F10 19 Existed
INSPECTION AND ADJUSTMENT
EC-1055
< BASIC INSPECTION >[K9K]
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>> GO TO 3.
3.REPLACE ECM
Replace ECM.
>> GO TO 4.
4.WRITE ECM DATA
1. Turn ignition switch OFF, wait at least 30 seconds and then turn ON.
2. Perform “PRGRM REINITIALIZE” in WORK SUPPORT mode with CONSULT-III.
3. Perform “WRT DATA AFTR REPLC CPU” in WORK SUPPORT mode with CONSULT-III.
4. Perform initialization of NATS system and registration of all NATS ignition key IDs.
Refer to SEC-7, "
ECM RE-COMMUNICATING FUNCTION : Description" (with intelligent key system) or
SEC-83, "
ECM RE-COMMUNICATING FUNCTION : Description" (without intelligent key system).
5. Turn ignition switch OFF, wait at least 30 seconds and then turn ON.
6. Select “DATA MONITOR” mode in ECM with CONSULT-III.
7. Check that the “CODE PROGRAM” indication.
Which is displayed on CONSULT-III?
YES >> GO TO 6.
NO >> GO TO 5.
5.WRITE ECM DATA
1. Perform initialization of NATS system and registration of all NATS ignition key IDs.
Refer to SEC-7, "
ECM RE-COMMUNICATING FUNCTION : Description" (with intelligent key system) or
SEC-83, "
ECM RE-COMMUNICATING FUNCTION : Description" (without intelligent key system).
2. Turn ignition switch OFF, wait at least 30 seconds and then turn ON.
3. Select “DATA MONITOR” mode in ECM with CONSULT-III.
4. Check that the “CODE PROGRAM” indication.
Which is displayed on CONSULT-III?
YES >> GO TO 6.
NO >> Repeat above steps.
6.PERFORM VIN REGISTRATION
1. Start engine and warm it up to normal operating temperature.
NOTE:
The start-up phase may last up to 30 seconds.
2. Turn ignition switch OFF, wait at least 30 seconds and then turn ON.
3. Perform “VIN REGISTRATION” in WORK SUPPORT mode with CONSULT-III.
4. Follow the instruction of CONSULT-III display.
NOTE:
After replace ECM, stored DTC may appear on other control unit. Clear the malfunction memory of these
control unit.
>> END
EGR VOLUME CONTROL VALVE CLOSED POSITION LEARNING
EGR VOLUME CONTROL VALVE CLOSED POSITION LEARNING : Description
INFOID:0000000001162524
EGR Volume Control Valve Closed Position Learning is an operation to learn the fully closed position of the
EGR volume control valve by monitoring the EGR volume control valve control position sensor output signal.
EGR VOLUME CONTROL VALVE CLOSED POSITION LEARNING : Special Repair
Requirement
INFOID:0000000001162525
1.START
1. Turn ignition switch ON.
2. Perform “EGR ADAPTIVES” in WORK SUPPORT mode with CONSULT-III.