EC-1028
< SYMPTOM DIAGNOSIS >[MR18DE]
NORMAL OPERATING CONDITION
NORMAL OPERATING CONDITION
DescriptionINFOID:0000000001161998
FUEL CUT CONTROL (AT NO LOAD AND HIGH ENGINE SPEED)
If the engine speed is above 1,800 rpm under no load (for example, the selector lever position is neutral and
engine speed is over 1,800 rpm) fuel will be cut off after some time. The exact time when the fuel is cut off var-
ies based on engine speed.
Fuel cut will be operated until the engine speed reaches 1,500 rpm, then fuel cut will be cancelled.
NOTE:
This function is different from deceleration control listed under Multiport Fuel Injection (MFI) System, EC-705,
"SystemDiagram".
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]
C
D
E
F
G
H
I
J
K
L
MA
EC
N
P O
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
EC-1032
< PRECAUTION >[MR18DE]
PRECAUTIONS
When measuring ECM signals with a circuit tester, never allow
the two tester probes to contact.
Accidental contact of probes will cause a short circuit and
damage the ECM power transistor.
Do not use ECM ground terminals when measuring input/out-
put voltage. Doing so may result in damage to the ECM’s tran-
sistor. Use a ground other than ECM terminals, such as the
ground.
Do not operate fuel pump when there is no fuel in lines.
Tighten fuel hose clamps to the specified torque.
Do not depress accelerator pedal when starting.
Immediately after starting, do not rev up engine unnecessar-
ily.
Do not rev up engine just prior to shutdown.
When installing C.B. ham radio or a mobile phone, be sure to
observe the following as it may adversely affect electronic
control systems depending on installation location.
-Keep the antenna as far as possible from the electronic con-
trol units.
-Keep the antenna feeder line more than 20 cm (8 in) away
from the harness of electronic controls.
Do not let them run parallel for a long distance.
-Adjust the antenna and feeder line so that the standing-wave
ratio can be kept smaller.
-Be sure to ground the radio to vehicle body.
SEF348N
SEF709Y
SEF708Y
INSPECTION AND ADJUSTMENT
EC-1043
< BASIC INSPECTION >[K9K]
C
D
E
F
G
H
I
J
K
L
MA
EC
N
P O
INSPECTION AND ADJUSTMENT
BASIC INSPECTION
BASIC INSPECTION : DescriptionINFOID:0000000001162514
NOTE:
Only consult the tests after following the diagnostic procedure chart.
Some specific checks are grouped under the “tests” heading and are used as required in different diagnostic
charts.
BASIC INSPECTION : Special Repair Requirement (TEST 1: Low Pressure Fuel Sup-
ply System Check)
INFOID:0000000001162515
NOTE:
CAUSE
- No fuel can be seen in the transparent supply pipe leading to the pump or large air bubbles can be seen
(small air bubbles are permitted).
- engine does not start.
1.CHECK CONFORMITY
Check the conformity and presence of the fuel (gasoline instead of diesel, contaminated fuel).
Is the inspection result normal?
Yes >> GO TO 2.
No >> Bleed the fuel supply system with the manual priming pump.
Basic test Trouble diagnosis Reference page
Low pressure fuel supply system check TEST 1EC-1043, "
BASIC INSPEC-
TION : Special Repair Re-
quirement (TEST 1: Low
Pressure Fuel Supply System
Check)"
Internal fuel transfer pump check TEST 2EC-1044, "
BASIC INSPEC-
TION : Special Repair Re-
quirement (TEST 2: Internal
Fuel Transfer Pump Check)"
High pressure supply pump (Pressure control valve) check TEST 3EC-1044, "
BASIC INSPEC-
TION : Special Repair Re-
quirement [TEST 3: High
Pressure Supply Pump (Pres-
sure Control Valve) Check]"
High pressure supply pump (Volumetric control valve) check TEST 4EC-1045, "
BASIC INSPEC-
TION : Special Repair Re-
quirement [TEST 4: High
Pressure Supply Pump (Volu-
metric Control Valve) Check]"
Rail high pressure regulation check TEST 5EC-1048, "
BASIC INSPEC-
TION : Special Repair Re-
quirement (TEST 5: Rail High
Pressure Regulation Check)"
Major leak in fuel injectors/fuel injectors open TEST 6EC-1052, "
BASIC INSPEC-
TION : Special Repair Re-
quirement (TEST 6: Major
Leak in Fuel Injectors/Fuel In-
jectors Open)"
Incorrect fuel injection quantity TEST 7EC-1053, "
BASIC INSPEC-
TION : Special Repair Re-
quirement (TEST 7: Incorrect
Fuel Injection Quantity)"
EC-1044
< BASIC INSPECTION >[K9K]
INSPECTION AND ADJUSTMENT
2.CHECK FUEL CIRCUIT
Does the fuel circulate correctly when pumped manually?
Ye s o r N o
Ye s > > G O T O 5 .
No >> GO TO 3.
3.CHECK FOR LEAK
Look for leaks on the unions.
Are there leaks in the hoses and unions?
Yes >> Carry out the required repairs.
No >> GO TO 4.
4.CHECK FUEL FILTER
Check the correctness of the fuel filter.
Is the fuel filter correct?
Ye s > > G O T O 5 .
No >> Replace the fuel filter with a genuine part.
5.INSPECTION END
Low pressure circuit OK.
>>INSPECTION END
BASIC INSPECTION : Special Repair Requirement (TEST 2: Internal Fuel Transfer
Pump Check)
INFOID:0000000001162516
NOTE:
CONDITIONS PRIOR TO TEST
- Test 1 Low pressure fuel supply system check has been carried out previously and results are satisfactory.
CAUSE
- Fuel can be seen in the transparent supply pipe leading to the pump.
- However, fuel does not move during starting.
1.CHECK INTERNAL FUEL TRANSFER PUMP
1. Disconnect high pressure supply pump (volumetric control valve) harness connector
2. Remove fuel return pipe from the pump and block it so that it is sealed. Connect a pipe to the pump to
measure the flow of diesel.
3. To authorise a 15 second cranking engine and carry out this test it is essential to carry out the following
procedure: measure the flow of diesel.
- Turn ignition switch ON.
- Perform “SAVE DATA FOR CPU REPLC” in WORK SUPPORT mode with CONSULT-III.
- Perform “PRGRM REINITIALIZE” in WORK SUPPORT mode with CONSULT-III.
- Cranking engine for at least 15 seconds (starting speed 250 rpm)
- Check the flow rate of the fuel being collected in a graduated measuring cylinder (500 ml minimum).The
minimum flow rate must be 25 ml every 15 sec.
- Perform “WRT DATA AFTR REPLC CPU” in WORK SUPPORT mode with CONSULT-III.
Does the flow measure less than 25ml?
Yes >> Replace high pressure supply pump.
No >> GO TO 2.
2.INSPECTION END
Low pressure system OK.
>>INSPECTION END
BASIC INSPECTION : Special Repair Requirement [TEST 3: High Pressure Supply
EC-1046
< BASIC INSPECTION >[K9K]
INSPECTION AND ADJUSTMENT
Pump (Volumetric Control Valve) Check]
INFOID:0000000001162518
NOTE:
CONDITIONS PRIOR TO TEST
- The entire low pressure system must be in good condition.
- Check the sealing of the high pressure pipes and unions.
CAUSE
- Not enough or no rail pressure during starting.
- Rail reference pressure during starting, minimum 15 000 kPa (150 bar, 153 kg/cm
2, 2175 psi).
1.CHECK HIGH PRESSURE SUPPLY PUMP (VOLUMETRIC CONTROL VALVE)-I
Refer to EC-1110, "
Component Inspection".
Is the inspection result normal?
YES >> GO TO 2
NO >> Replace high pressure supply pump.
2.CHECK HIGH PRESSURE SUPPLY PUMP (VOLUMETRIC CONTROL VALVE)-II
Reconnect all harness connectors disconnected.
Turn ignition switch ON.
Select “DATA MONITOR” mode with CONSULT-III.
Check that the “FUEL FLOW S/V CU” indication when the cranking engine.
Is the excitation current between 0.6 - 1.0A?
YES >> GO TO 6.
NO >> GO TO 3.
3.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 5.
NO >> GO TO 4.
4.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.
5.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.
3. Check the continuity between high pressure supply pump (volumetric control valve) harness connector
and ECM harness connector.
High pressure supply pump
(volumetric control valve)
Ground Voltage
Connector Terminal
F54 1 Ground Battery voltage
INSPECTION AND ADJUSTMENT
EC-1047
< BASIC INSPECTION >[K9K]
C
D
E
F
G
H
I
J
K
L
MA
EC
N
P O
4. Also check harness for short to ground and short to power.
Is the inspection result normal?
YES >> INSPECTION END
NO >> Repair open circuit or short to ground or short to power in harness or connectors.
6.CHECK ENGINE CONDITION
Start engine.
Is the engine start?
YES >> GO TO 7.
NO >> GO TO 9.
7.CHECK ENGINE CONDITION
Check that the oil level is correct and that the engine coolant temperature is normal operation temperature
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 PRESSURER” follow “RAIL PRES SET” at ± 5000 kPa(50 bar, 51 kg/cm
2, 725 psi) during the
phase of the 4 acceleration cycles?
NOTE:
If the rail pressure does not reach the setpoint there is an fuel injector leak that is too great or the pressure sig-
nal is incorrect.
Is the inspection result normal?
YES >> GO TO 11.
NO >> GO TO 8.
8.CHECK RAIL HIGH PRESSURE CONTROL CIRCUIT
Carry out TEST 5.
>> GO TO 11.
9.CHECK ENGINE CONDITION
Check that the oil level is correct.
Select “DATA MONITOR” mode with CONSULT-III.
Check that the “RAIL PRES SET” and “RAIL PRESSURE” indication.
Does “RAIL PRESSURER” follow “RAIL PRES SET” when the cranking engine.
NOTE:
If the rail pressure does not reach the setpoint there is an fuel injector leak that is too great or the pressure sig-
nal is incorrect.
Is the inspection result normal?
YES >> GO TO 11.
NO >> GO TO 10.
10.CHECK MAJOR LEAK IN FUEL INJECTOR/FUEL INJECTORS OPEN
Carry out TEST 6.
>> GO TO 11.
11 .INSPECTION END
High pressure supply pump (volumetric control valve) OK.
High pressure supply pump
(volumetric control valve)ECM
Continuity
Connector Terminal Connector Terminal
F54 2 F11 50 Existed