PRECAUTIONS
CO-33
< PRECAUTION >[MR18DE]
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CAUTION:
Be careful not to damage the mating surfaces.
Tap Tool to insert it (1), and then slide it by tapping on the side (2)
as shown.
In areas where Tool is difficult to use, use plastic hammer to lightly
tap the parts, to remove it.
CAUTION:
If for some unavoidable reason suitable tool such as screw-
driver is used, be careful not to damage the mating surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Remove old liquid gasket adhering to the liquid gasket applica-
tion surface and the mating surface, using scraper.
Remove liquid gasket completely from the groove of the liquid
gasket application surface, bolts, and bolt holes.
2. Thoroughly clean the mating surfaces and remove adhering
moisture, grease and foreign materials.
3. Attach liquid gasket tube to Tool.
Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-27, "
Recommended Chemical Prod-
ucts and Sealants".
4. Apply liquid gasket without breaks to the specified location with the specified dimensions.
If there is a groove for the liquid gasket application, apply liquid gasket to the groove.
As for the bolt holes, normally apply liquid gasket inside the
holes. Occasionally, it should be applied outside the holes.
Make sure to read the text of service manual.
Within five minutes of liquid gasket application, install the mat-
ing component.
If liquid gasket protrudes, wipe it off immediately.
Do not retighten nuts or bolts after the installation.
After 30 minutes or more have passed from the installation, fill
engine oil and engine coolant.
CAUTION:
If there are specific instructions in this manual, observe them. Tool number : KV10111100 (J-37228)
WBIA0566E
Tool number : WS39930000 ( — )
PBIC0003E
WBIA0567E
SEM159F
THERMOSTAT
CO-45
< ON-VEHICLE REPAIR >[MR18DE]
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THERMOSTAT
ComponentINFOID:0000000001337850
Removal and InstallationINFOID:0000000001337851
REMOVAL
1. Drain engine coolant. Refer to CO-35, "Changing Engine Coolant".
2. Remove water inlet.
3. Remove thermostat.
4. Remove water pump. Refer to CO-44, "
Removal and Installation".
5. Remove thermostat housing.
INSPECTION AFTER REMOVAL
Place a thread (A) so that it is caught in the valves of thermostat
(1). Immerse fully in a container (B) 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 valve lift amount.
After checking the maximum valve lift amount, lower the water
temperature and check the valve closing temperature.
1. Thermostat housing 2. Water hose 3. Radiator hose (lower)
4. Water inlet 5. Thermostat 6. Rubber ring
7. Gasket A. To oil cooler B. To radiator
Engine front
PBIC4485E
PBIC3314J
WATER OUTLET AND WATER CONTROL VALVE
CO-47
< ON-VEHICLE REPAIR >[MR18DE]
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WATER OUTLET AND WATER CONTROL VALVE
ComponentINFOID:0000000001337852
Removal and InstallationINFOID:0000000001337853
REMOVAL
1. Drain engine coolant. Refer to CO-35, "Changing Engine Coolant".
CAUTION:
Perform this step when the engine is cold.
2. Remove air duct. Refer to EM-154, "
Component".
3. Remove radiator hose (upper). Refer to CO-40, "
Component".
4. Remove heater hoses and water hoses.
5. Remove water outlet.
6. Remove water control valve.
7. Remove engine coolant temperature sensor, if necessary.
CAUTION:
Handle carefully to avoid any shock to engine coolant temperature sensor.
Replace the gasket with a new one.
INSPECTION AFTER REMOVAL
1. Engine coolant temperature sensor 2. Rubber ring 3. Water control valve
4. Gasket 5. Water hose 6. Gasket
7. Water hose 8. Water outlet 9. Heater hose
10. Heater hose 11. Radiator hose (upper) 12. Water hose
A. To heater B. To electronic throttle control actuator C. To oil cooler
D. To radiator Front
WBIA0856E
CO-52
< FUNCTION DIAGNOSIS >[K9K]
DESCRIPTION
FUNCTION DIAGNOSIS
DESCRIPTION
Engine Cooling SystemINFOID:0000000001381580
1. Engine 2. Radiator 3. Heater core
4. Reservoir tank 5. Water pump 6. Thermostat
7. Air relief plug 8. Oil cooler 9. EGR cooler
MBIB9046E
CO-56
< PRECAUTION >[K9K]
PRECAUTIONS
CAUTION:
Be careful not to damage the mating surfaces.
Tap Tool to insert it (1), and then slide it by tapping on the side (2)
as shown.
In areas where Tool is difficult to use, use plastic hammer to lightly
tap the parts, to remove it.
CAUTION:
If for some unavoidable reason suitable tool such as screw-
driver is used, be careful not to damage the mating surfaces.
LIQUID GASKET APPLICATION PROCEDURE
1. Remove old liquid gasket adhering to the liquid gasket applica-
tion surface and the mating surface, using scraper.
Remove liquid gasket completely from the groove of the liquid
gasket application surface, bolts, and bolt holes.
2. Thoroughly clean the mating surfaces and remove adhering
moisture, grease and foreign materials.
3. Attach liquid gasket tube to Tool.
Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-27, "
Recommended Chemical Prod-
ucts and Sealants".
4. Apply liquid gasket without breaks to the specified location with the specified dimensions.
If there is a groove for the liquid gasket application, apply liquid gasket to the groove.
As for the bolt holes, normally apply liquid gasket inside the
holes. Occasionally, it should be applied outside the holes.
Make sure to read the text of service manual.
Within five minutes of liquid gasket application, install the mat-
ing component.
If liquid gasket protrudes, wipe it off immediately.
Do not retighten nuts or bolts after the installation.
After 30 minutes or more have passed from the installation, fill
engine oil and engine coolant.
CAUTION:
If there are specific instructions in this manual, observe them. Tool number : KV10111100 (J-37228)
WBIA0566E
Tool number : WS39930000 ( — )
PBIC0003E
WBIA0567E
SEM159F
EC-5
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P Component Function Check ..................................
316
Diagnosis Procedure .............................................316
Component Inspection (Fuel Pump) .....................318
IGNITION SIGNAL ...........................................319
Description ............................................................319
Component Function Check ..................................319
Diagnosis Procedure .............................................319
Component Inspection (Ignition Coil with Power
Transistor) .............................................................
322
Component Inspection (Condenser) .....................322
MALFUNCTION INDICATOR ...........................324
Description ............................................................324
Component Function Check ..................................324
Diagnosis Procedure .............................................324
POSITIVE CRANKCASE VENTILATION ........325
Description ............................................................325
Component Inspection ..........................................325
REFRIGERANT PRESSURE SENSOR ...........326
Description ............................................................326
Component Function Check ..................................326
Diagnosis Procedure .............................................326
ECU DIAGNOSIS .......................................328
ECM ..................................................................328
Reference Value ...................................................328
Wiring Diagram - ENGINE CONTROL SYSTEM - ..339
Fail Safe ...............................................................358
DTC Inspection Priority Chart .............................360
DTC Index ............................................................361
How to Set SRT Code ........................................363
Test Value and Test Limit ..................................365
SYMPTOM DIAGNOSIS ............................366
ENGINE CONTROL SYSTEM SYMPTOMS ....366
Symptom Table .....................................................366
NORMAL OPERATING CONDITION ...............370
Description ............................................................370
PRECAUTION ............................................371
PRECAUTIONS ................................................371
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ...............................................................
371
Precaution for Procedure without Cowl Top Cover ..371
Precautions For Xenon Headlamp Service ...........371
On Board Diagnostic (OBD) System of Engine
and A/T ..................................................................
372
General Precautions .............................................372
PREPARATION .........................................375
PREPARATION ................................................375
Special Service Tools ............................................375
Commercial Service Tools ....................................375
ON-VEHICLE MAINTENANCE ..................377
FUEL PRESSURE ...........................................377
Inspection ..............................................................377
EVAPORATIVE EMISSION SYSTEM .............379
Inspection ..............................................................379
SERVICE DATA AND SPECIFICATIONS
(SDS) ..........................................................
380
SERVICE DATA AND SPECIFICATIONS
(SDS) ...............................................................
380
Idle Speed .............................................................380
Ignition Timing .......................................................380
Calculated Load Value ..........................................380
Mass Air Flow Sensor ............................................380
HR16DE (WITHOUT EURO-OBD)
BASIC INSPECTION .................................
381
DIAGNOSIS AND REPAIR WORKFLOW ......381
Work Flow ..............................................................381
Diagnostic Work Sheet ..........................................383
INSPECTION AND ADJUSTMENT ................385
BASIC INSPECTION ...............................................385
BASIC INSPECTION : Special Repair Require-
ment .......................................................................
385
ADDITIONAL SERVICE WHEN REPLACING
CONTROL UNIT ......................................................
388
ADDITIONAL SERVICE WHEN REPLACING
CONTROL UNIT : Description ...............................
388
ADDITIONAL SERVICE WHEN REPLACING
CONTROL UNIT : Special Repair Requirement ....
388
IDLE SPEED ............................................................388
IDLE SPEED : Description ....................................389
IDLE SPEED : Special Repair Requirement .........389
IGNITION TIMING ....................................................389
IGNITION TIMING : Description ............................389
IGNITION TIMING : Special Repair Requirement ..389
ACCELERATOR PEDAL RELEASED POSITION
LEARNING ...............................................................
389
ACCELERATOR PEDAL RELEASED POSITION
LEARNING : Description .......................................
389
ACCELERATOR PEDAL RELEASED POSITION
LEARNING : Special Repair Requirement ............
389
THROTTLE VALVE CLOSED POSITION LEARN-
ING ...........................................................................
390
THROTTLE VALVE CLOSED POSITION
LEARNING : Description .......................................
390
THROTTLE VALVE CLOSED POSITION
LEARNING : Special Repair Requirement ............
390
IDLE AIR VOLUME LEARNING ..............................390
IDLE AIR VOLUME LEARNING : Description .......390
EC-13
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ASCD BRAKE SWITCH ...................................964
Description ............................................................964
Component Function Check ..................................964
Diagnosis Procedure .............................................964
Component Inspection (ASCD Brake Switch) .......966
Component Inspection (ASCD Clutch Switch) ......966
ASCD INDICATOR ...........................................968
Description ............................................................968
Component Function Check ..................................968
Diagnosis Procedure .............................................968
COOLING FAN .................................................969
Description ............................................................969
Component Function Check ..................................969
Diagnosis Procedure .............................................969
Component Inspection ..........................................971
ELECTRICAL LOAD SIGNAL .........................973
Description ............................................................973
Component Function Check ..................................973
Diagnosis Procedure .............................................973
FUEL INJECTOR .............................................975
Description ............................................................975
Component Function Check ..................................975
Diagnosis Procedure .............................................975
Component Inspection ..........................................976
FUEL PUMP .....................................................978
Description ............................................................978
Component Function Check ..................................978
Diagnosis Procedure .............................................978
Component Inspection (Fuel Pump) .....................980
IGNITION SIGNAL ...........................................981
Description ............................................................981
Component Function Check ..................................981
Diagnosis Procedure .............................................981
Component Inspection (Ignition Coil with Power
Transistor) .............................................................
984
Component Inspection (Condenser) .....................984
MALFUNCTION INDICATOR ...........................986
Description ............................................................986
Component Function Check ..................................986
Diagnosis Procedure .............................................986
POSITIVE CRANKCASE VENTILATION ........987
Description ............................................................987
Component Inspection ..........................................987
REFRIGERANT PRESSURE SENSOR ...........988
Description ............................................................988
Component Function Check ..................................988
Diagnosis Procedure .............................................988
ECU DIAGNOSIS .......................................990
ECM ..................................................................990
Reference Value ...................................................990
Wiring Diagram - ENGINE CONTROL SYSTEM - 1000
Fail Safe ..............................................................1017
DTC Inspection Priority Chart ...........................1019
DTC Index ...........................................................1020
How to Set SRT Code ......................................1021
Test Value and Test Limit .................................1023
SYMPTOM DIAGNOSIS ...........................1024
ENGINE CONTROL SYSTEM .......................1024
Symptom Table ...................................................1024
NORMAL OPERATING CONDITION ............1028
Description ...........................................................1028
PRECAUTION ...........................................1029
PRECAUTIONS ..............................................1029
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" .............................................................
1029
Precaution for Procedure without Cowl Top Cover 1029
Precautions For Xenon Headlamp Service .........1029
On Board Diagnostic (OBD) System of Engine ...1030
General Precautions ............................................1030
PREPARATION ........................................1033
PREPARATION ..............................................1033
Special Service Tools ..........................................1033
Commercial Service Tools ...................................1033
ON-VEHICLE REPAIR ..............................1035
FUEL PRESSURE ..........................................1035
Inspection ............................................................1035
EVAPORATIVE EMISSION SYSTEM ............1037
Inspection ............................................................1037
SERVICE DATA AND SPECIFICATIONS
(SDS) .........................................................
1038
SERVICE DATA AND SPECIFICATIONS
(SDS) ..............................................................
1038
Idle Speed ...........................................................1038
Ignition Timing .....................................................1038
Calculated Load Value ........................................1038
Mass Air Flow Sensor ..........................................1038
K9K
BASIC INSPECTION ................................
1039
DIAGNOSIS AND REPAIR WORKFLOW .....1039
Work Flow ............................................................1039
Diagnostic Work Sheet ........................................1041
INSPECTION AND ADJUSTMENT ...............1043
BASIC INSPECTION .............................................1043
BASIC INSPECTION : Description ......................1043
ENGINE CONTROL SYSTEM
EC-31
< FUNCTION DIAGNOSIS >[HR16DE (WITH EURO-OBD)]
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System DescriptionINFOID:0000000001161139
ECM performs various controls such as fuel injection control and ignition timing control.
Component Parts LocationINFOID:0000000001161140
1. Ignition coil (with power transistor)
and spark plug2. Intake valve timing control solenoid
valve3. Refrigerant pressure sensor
4. Knock sensor 5. Fuel injector 6. Cooling fan motor
7. Camshaft position sensor (PHASE) 8. IPDM E/R 9. ECM
10. Mass air flow sensor (with intake air
temperature sensor)11. Engine coolant temperature sensor 12. Electric throttle control actuator
(with built in throttle position sensor
and throttle control motor)
13. EVAP canister purge volume control
solenoid valve
PBIB2939E