EC-1154
< COMPONENT DIAGNOSIS >[K9K]
P0380 GLOW RELAY
P0380 GLOW RELAY
DTC LogicINFOID:0000000001162618
DTC DETECTION LOGIC
NOTE:
Conditions for applying the diagnostic procedure to the stored DTCs:
The DTC is declared present after attempts have been made to start the engine.
Special notes:
If the DTC is present, it will be difficult to start the vehicle, or even impossible when cold, or preheating will
be continuous and the heater plugs will deteriorate.
Diagnosis ProcedureINFOID:0000000001162619
1.CHECK GLOW RELAY POWER SUPPLY CIRCUIT
1. Turn ignition switch OFF.
2. Disconnect glow relay harness connector.
3. Turn ignition switch ON.
4. Check the voltage between glow relay connector and ground.
Is the inspection result normal?
YES >> GO TO 3.
NO >> GO TO 2.
2.DETECT MALFUNCTIONING PART
Check the following.
Harness connectors E8, F8
Harness for open or short between ECM and glow relay
Harness for open or short between IPDM E/R and glow relay
Harness for open and short between glow relay and battery
>> Repair open circuit or short to ground or short to power in harness or connectors.
3.CHECK GLOW RELAY INPUT CIRCUIT FOR OPEN AND SHORT-I
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check the continuity between glow relay 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 4.
NO >> Repair open circuit or short to ground or short to power in harness or connectors.
DTC No. Trouble diagnosis name Possible cause
P0380GLOW PLUG DIAGNOSTIC CONNECTION
CO: Open circuit
CC.0: Short circuit to ground
CC.1: Short circuit to +12V Harness or connectors
(The glow relay circuit is open or shorted.)
Glow relay
Glow relay
Ground Voltage
Connector Terminal
F55 3 Ground Battery voltage
Glow relay ECM
Continuity
Connector Terminal Connector Terminal
F55 9 F11 80 Existed
EC-1156
< COMPONENT DIAGNOSIS >[K9K]
P0381 GLOW CONTROL SYSTEM
P0381 GLOW CONTROL SYSTEM
DTC LogicINFOID:0000000001162620
DTC DETECTION LOGIC
NOTE:
Conditions for applying the diagnostic procedure to the stored DTCs:
The DTC is declared present after several attempts have been made to start the engine.
Special notes:
If the DTC is present, it will be difficult to start the vehicle, or even impossible when cold, or preheating will
be continuous and the heater plugs will deteriorate.
Diagnosis ProcedureINFOID:0000000001162621
1.CHECK GLOW RELAY POWER SUPPLY CIRCUIT
1. Turn ignition switch OFF.
2. Disconnect glow relay harness connector.
3. Turn ignition switch ON.
4. Check the voltage between glow relay connector and ground.
Is the inspection result normal?
YES >> GO TO 3.
NO >> GO TO 2.
2.DETECT MALFUNCTIONING PART
Check the following.
Harness connectors E8, F8
Harness for open or short between ECM and glow relay
Harness for open or short between IPDM E/R glow relay
Harness for open and short between glow relay and battery
>> Repair open circuit or short to ground or short to power in harness or connectors.
3.CHECK GLOW RELAY INPUT CIRCUIT FOR OPEN AND SHORT-I
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check the continuity between glow relay 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 4.
NO >> Repair open circuit or short to ground or short to power in harness or connectors.
DTC No. Trouble diagnosis name Possible cause
P0381GLOW CONTROL UNIT CIRCUIT
CC.0: Short circuit to ground
CO.1: Open circuit or short circuit to +12V Harness or connectors
(The glow relay circuit is open or shorted.)
Glow relay
Glow plug
Glow relay
Ground Voltage
Connector Terminal
F55 3 Ground Battery voltage
Glow relay ECM
Continuity
Connector Terminal Connector Terminal
F55 9 F11 80 Existed
EC-1230
< ECU DIAGNOSIS >[K9K]
ECM
PRE-HEATING/IGNITION SUBFUNCTION
Test Condition: Engine Stopped and Ignition Switch ON
Test Condition: Engine at Idle
SUBFUNCTION
Test Condition: Engine Stopped and Ignition Switch ON
4 Accelerator pedalACCEL/PDL POS0% = ACCEL/PDL POS < 100%
Indicates the percentage of the
accelerator pedal position be-
tween no load and full load posi-
tion.
In the event of a malfunction, per-
form the trouble diagnosis for APP
SENSOR (DTC P0225, and
P2120) and SENSOR POWER
SUPPLY (DTC P0641 and
P0651). PEDAL POS TRACK1 Indicates the percentage of the
accelerator pedal position be-
tween no load and full load posi-
tion.
PL PTNMR T1 V0.4V < PL PTNMR T1V < 4.64V
Indicates the percentage of the
accelerator pedal position be-
tween no load and full load posi-
tion.
PEDAL POS TRACK2 Indicates the percentage of the
accelerator pedal position be-
tween no load and full load posi-
tion.
PL PTNMR T2 V0.27V < PL PTNMR T2V < 3.75V
Indicates the percentage of the
accelerator pedal position be-
tween no load and full load posi-
tion. Order Function Parameter Display and notes Trouble diagnosis
Order Function Parameter Display and notes Trouble diagnosis
1 Preheating PREHEAT RLY CONT INACTIVE NONE
2Engine coolant tem-
peratureWATER TEMPClose to ambient temperature
(cold engine).
Indicates the engine coolant
temperature in °C.In the event of a malfunction, per-
form the trouble diagnosis for DTC
P0115 ETC SENSOR.
3 Battery voltage BATTERY VOLTAGE12 V < BATTERY VOLTAGE <
14.4VIn the event of a malfunction, per-
form the trouble diagnosis for
CHARGING SYSTEM.
4 Intake air temperature INLET AIR TEMIndicates the intake air tempera-
ture in °C. This information is
provided by the IAT sensor.In the event of a malfunction, per-
form the trouble diagnosis for DTC
P0110 IAT SENSOR.
Order Function Parameter Display and notes Trouble diagnosis
1 Preheating PREHEAT RLY CONT INACTIVE NONE
2Engine coolant tem-
peratureWATER TEMPIndicates the engine coolant
temperature in °C.In the event of a malfunction, per-
form the trouble diagnosis for DTC
P0115 ETC SENSOR.
3 Battery voltage BATTERY VOLTAGE13 V < BATTERY VOLTAGE <
16VIn the event of a malfunction, per-
form the trouble diagnosis for
CHARGING SYSTEM.
4Intake air tempera-
tureINLET AIR TEMIndicates the intake air tempera-
ture in °C. This information is
provided by the IAT sensor.In the event of a malfunction, per-
form the trouble diagnosis for DTC
P0110 IAT SENSOR.
ENGINE CONTROL SYSTEM SYMPTOMS
EC-1255
< SYMPTOM DIAGNOSIS >[K9K]
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SYMPTOM DIAGNOSIS
ENGINE CONTROL SYSTEM SYMPTOMS
Symptom TableINFOID:0000000001162698
NOTE:
Only consult this customer complaint after a complete check using the CONSULT-III.
Symptom Trouble diagnosis Reference page
No communication with the ECM CHART 1EC-1256, "
Diag-
nosis Procedure"
Starting malfunctionEngine does not start or starts with difficulty CHART 2EC-1257, "
Diag-
nosis Procedure"
Starting difficult with cold engine CHART 3EC-1259, "Diag-
nosis Procedure"
Impossible to shut off engine CHART 4EC-1261, "Diag-
nosis Procedure"
Idle speed malfunctionEngine Idle speed too high CHART 5EC-1262, "
Diag-
nosis Procedure"
Engine Idle speed too low or unstable CHART 6EC-1263, "Diag-
nosis Procedure"
Behavior while drivingEngine stalling CHART 7EC-1265, "
Diag-
nosis Procedure"
No or very little acceleration, increase in engine speed CHART 8EC-1267, "Diag-
nosis Procedure"
Engine bucking CHART 9EC-1270, "Diag-
nosis Procedure"
Erratic acceleration CHART 10EC-1272, "Diag-
nosis Procedure"
No engine braking CHART 11EC-1274, "Diag-
nosis Procedure"
Loss of power CHART 12EC-1275, "Diag-
nosis Procedure"
Too much power CHART 13EC-1278, "Diag-
nosis Procedure"
Overspeed at idle speed or on releasing brake CHART 14EC-1280, "Diag-
nosis Procedure"
Excessive consumption CHART 15EC-1281, "Diag-
nosis Procedure"
Engine knock CHART 16EC-1283, "Diag-
nosis Procedure"
Engine overheating CHART 17EC-1285, "Diag-
nosis Procedure"
Noise, odors or smokeEngine smokes when started CHART 18EC-1286, "
Diag-
nosis Procedure"
Engine emits blue smoke CHART 19EC-1287, "Diag-
nosis Procedure"
Engine smokes when revved CHART 20EC-1289, "Diag-
nosis Procedure"
Engine emits white smoke (especially when starting) CHART 21EC-1290, "Diag-
nosis Procedure"
Emission control not satisfactory CHART 22EC-1291, "Diag-
nosis Procedure"
ENGINE OVERHEATING
EC-1285
< SYMPTOM DIAGNOSIS >[K9K]
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ENGINE OVERHEATING
DescriptionINFOID:0000000001162731
CHART 17: ENGINE OVERHEATING
Diagnosis ProcedureINFOID:0000000001162732
1.CHECK COOLING SYSTEM
Check the cooling system. Refer to CO-53, "
Troubleshooting Chart".
Is the inspection result normal?
YES >> GO TO 2.
NO >> Repair or replace.
2.CHECK ECM POWER SUPPLY AND GROUND CIRCUIT
Check ECM power supply and ground circuit. Refer to EC-1106, "
Diagnosis Procedure".
Is the inspection result normal?
YES >> GO TO 3.
NO >> Repair or replace harness or connector.
3.CHECK WIRING HARNESS
Visually check the condition of the engine wiring harness.
Is the inspection result normal?
YES >> GO TO 4.
NO >> Repair or replace harness or connector.
4.CHECK ENGINE COOLANT TEMPERATURE SENSOR
Check engine coolant temperature sensor. Refer to EC-1133, "
Component Inspection".
Is the inspection result normal?
Yes >> GO TO 5.
No >> Repair or replace.
5.CHECK COOLING FAN OPERATION
Check cooling fan operation. Refer to EC-1211, "
Component Function Check".
Is the inspection result normal?
YES >>INSPECTION END
NO >> Repair or replace.
PRECAUTIONS
EM-253
< PRECAUTION >[K9K]
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Precaution for Liquid GasketINFOID:0000000001381456
REMOVAL OF LIQUID GASKET
After removing the mounting bolts and nuts, separate the mating
surface using a seal cutter and remove the liquid gasket.
CAUTION:
Be careful not to damage the mating surfaces.
In areas where the cutter is difficult to use, use a plastic hammer to
lightly tap the liquid gasket applied area.
CAUTION:
If for some unavoidable reason a tool such as a flat-bladed
screwdriver is used, be careful not to damage the mating sur-
faces.
LIQUID GASKET APPLICATION PROCEDURE
1. Using a scraper, remove the old liquid gasket adhering to the
gasket application surface and the mating surface.
Remove the liquid gasket completely from the groove of the
gasket application surface, mounting bolts and bolt holes.
2. Wipe the gasket application surface and the mating surface with
white gasoline (lighting and heating use) to remove adhering
moisture, grease and foreign materials.
3. Attach the liquid gasket to the tube presser.
Use Genuine Liquid Gasket or equivalent.
4. Apply the liquid gasket without breaks to the specified location
with the specified dimensions.
If there is a groove for the liquid gasket application, apply the
gasket to the groove.
As for the bolt holes, normally apply the gasket inside the
holes. If specified, it should be applied outside the holes. Make
sure to read the instruction in this manual.
Within five minutes of gasket application, install the mating
component.
If the liquid gasket protrudes, wipe it off immediately.
Do not retighten after the installation.
After 30 minutes or more have passed from the installation, fill
the engine oil and coolant.
CAUTION:
If there are instructions in this manual, observe them.
Precaution for Diesel EquipmentINFOID:0000000001381457
CLEANLINESS
CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE HIGH PRES-
SURE DIRECT INJECTION SYSTEM
Risks relating to contamination
PBIC0275E
PBIC0003E
EMA0622D
SEM159F
SERVICE INFORMATION FOR ELECTRICAL INCIDENT
GI-57
< BASIC INSPECTION >
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An unclamped or loose harness can cause wiring to be pinched by seat components (such as slide guides)
during vehicle vibration. If the wiring runs under seating areas, inspect wire routing for possible damage or
pinching.
HEAT SENSITIVE
The customer's concern may occur during hot weather or after car
has sat for a short time. In such cases you will want to check for a
heat sensitive condition.
To determine if an electrical component is heat sensitive, heat the
component with a heat gun or equivalent.
CAUTION:
Do not heat components above 60°C (140°).
If incident occurs while heating the unit, either replace or properly
insulate the component.
FREEZING
The customer may indicate the incident goes away after the car
warms up (winter time). The cause could be related to water freez-
ing somewhere in the wiring/electrical system.
There are two methods to check for this. The first is to arrange for
the owner to leave his car overnight. Make sure it will get cold
enough to demonstrate his complaint. Leave the car parked out-
side overnight. In the morning, do a quick and thorough diagnosis
of those electrical components which could be affected.
The second method is to put the suspect component into a freezer
long enough for any water to freeze. Reinstall the part into the car
and check for the reoccurrence of the incident. If it occurs, repair or
replace the component.
WATER INTRUSION
The incident may occur only during high humidity or in rainy/snowy
weather. In such cases the incident could be caused by water intru-
sion on an electrical part. This can be simulated by soaking the car
or running it through a car wash.
CAUTION:
Do not spray water directly on any electrical components.
ELECTRICAL LOAD
The incident may be electrical load sensitive. Perform diagnosis with
all accessories (including A/C, rear window defogger, radio, fog
lamps) turned on.
COLD OR HOT START UP
On some occasions an electrical incident may occur only when the car is started cold, or it may occur when
the car is restarted hot shortly after being turned off. In these cases you may have to keep the car overnight to
make a proper diagnosis.
SGI842
SGI843
SGI844
SGI845
HAC-2
PTC HEATER CONTROL SYSTEM ..................63
PTC HEATER (300 WATT) .......................................63
PTC HEATER (300 WATT) : Wiring Diagram -
PTC Heater (300 Watt) - .........................................
63
PTC HEATER (1500 WATT) .....................................67
PTC HEATER (1500 WATT) : Wiring Diagram -
PTC Heater (1500 Watt) - .......................................
68
SYMPTOM DIAGNOSIS .............................72
AIR CONDITIONER CONTROL ........................72
Symptom Matrix Chart ..........................................72
INSUFFICIENT COOLING .................................73
Component Function Check ...................................73
Performance Test Diagnoses .................................74
Performance Chart .................................................75
Test Reading ..........................................................76
Trouble Diagnoses for Unusual Pressure ...............77
INSUFFICIENT HEATING .................................81
Component Function Check ...................................81
NOISE ................................................................83
Component Function Check ...................................83
PRECAUTION .............................................84
PRECAUTIONS .................................................84
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" .................................................................
84
Precaution for Procedures Without Cowl Top Cov-
er ............................................................................
84
Working with HFC-134a (R-134a) ..........................84
Precaution for Service Equipment ..........................85
AUTO AIR CONDITIONER (W/O NAVI)
BASIC INSPECTION ...................................
86
DIAGNOSIS AND REPAIR WORKFLOW .........86
How to Perform Trouble Diagnosis For Quick And
Accurate Repair ......................................................
86
INSPECTION AND ADJUSTMENT ...................87
Operational Check ..................................................87
FUNCTION DIAGNOSIS .............................89
FUNCTION INFORMATION ..............................89
Component Part Location .......................................89
REFRIGERATION SYSTEM ..............................91
Refrigerant Cycle ....................................................91
Refrigerant System Protection ................................91
AUTOMATIC AIR CONDITIONER SYSTEM .....92
Control System Diagram ........................................92
Control System Description ....................................92
Discharge Air Flow .................................................94
Switches And Their Control Function ......................95
CAN COMMUNICATION SYSTEM ...................96
System Description .................................................96
DIAGNOSIS SYSTEM (BCM) ............................97
CONSULT-III Function (BCM) ................................97
SELF-DIAGNOSIS FUNCTION .........................98
Front Air Control Self-Diagnosis .............................98
A/C System Self-Diagnosis Code Chart ...............104
COMPONENT DIAGNOSIS ......................106
MODE DOOR MOTOR .....................................106
System Description ...............................................106
Mode Door Motor Component Function Check ....107
Mode Door Motor Diagnosis Procedure ................109
AIR MIX DOOR MOTOR ..................................110
System Description ...............................................110
Air Mix Door Motor Component Function Check ..111
Air Mix Door Motor Diagnosis Procedure ..............112
INTAKE DOOR MOTOR ...................................114
System Description ...............................................114
Intake Door Motor Component Function Check ....115
Intake Door Motor Diagnosis Procedure ...............116
BLOWER MOTOR CONTROL SYSTEM .........118
System Description ...............................................118
Front Blower Motor Component Function Check ..119
Front Blower Motor Diagnosis Procedure .............120
Front Blower Motor Component Inspection ..........123
MAGNET CLUTCH ...........................................124
System Description ...............................................124
Magnet Clutch Component Function Check .........124
Magnet Clutch Diagnosis Procedure ....................125
AMBIENT SENSOR ..........................................130
Component Description ........................................130
Ambient Sensor Diagnosis Procedure ..................130
Ambient Sensor Component Inspection ...............131
IN-VEHICLE SENSOR ......................................133
Component Description ........................................133
In-Vehicle Sensor Diagnosis Procedure ...............133
In-Vehicle Sensor Component Inspection .............135
SUNLOAD SENSOR ........................................136
System Description ...............................................136
Sunload Sensor Diagnosis Procedure ..................136
Sunload Component Inspection ............................137
INTAKE SENSOR .............................................139
Component Inspection ..........................................139
Intake Sensor Diagnosis Procedure .....................139
Intake Sensor Component Inspection ...................140
PTC HEATER CONTROL SYSTEM .................142