CHG-34
< BASIC INSPECTION >[K9K]
DIAGNOSIS AND REPAIR WORKFLOW
NOTE:
To ensure a complete and thorough diagnosis, the battery, starter and generator test segments must be done
as a set from start to finish.
1.PRELIMINARY INSPECTION
Perform the preliminary inspection. Refer to CHG-37, "
Inspection Procedure".
>> GO TO 2
2.DISABLE THE POWER GENERATION VOLTAGE VARIABLE CONTROL SYSTEM
Disable the power generation voltage variable control with either of the following procedures.
After selecting “ENGINE” on the “SELECT SYSTEM” screen of CONSULT-III, set the “ALTERNATOR DUTY”
value to 0 % by selecting “ALTERNATOR DUTY” with “Active Test”. Continue “Active Test” until the end of
inspection. (When the DUTY value is 0 or 100 %, the normal power generation is performed according to the
characteristic of the IC regulator of the generator.)
Turn the ignition switch OFF, disconnect the battery current sensor connector and leave it disconnected dur-
ing the course of the test.
NOTE:
Running the engine with the battery current sensor disconnected will cause DTC's (P1550-P1554) to set.
After finishing the inspection, connect the battery current sensor connector and erase the self-diagnostic
results history of the engine using CONSULT-III.
>> GO TO 3
3.DIAGNOSIS WITH STARTING/CHARGING SYSTEM TESTER
Perform the charging system test using Starting/Charging System Tester (J-44373). For details and operating
instructions, refer to Technical Service Bulletin.
Te s t r e s u l t
CHARGING SYSTEM NOMAL>>Charging system is normal and will also show “DIODE RIPPLE” test result.
NO CHARGING VOLTAGE>>GO TO 4
LOW CHARGING VOLTAGE>>GO TO 12
HIGH CHARGING VOLTAGE>>GO TO 14
DIODE RIPPLE NORMAL>>Diode ripple is OK and will also show “CHARGING VOLTAGE” test result.
EXCESS RIPPLE DETECTED>>Replace the generator. Perform “DIODE RIPPLE” test again using Starting/
Charging System Tester (J-44373) to confirm repair.
DIODE RIPPLE NOT DETECTED>>GO TO 4
4.INSPECTION WITH CHARGE WARNING LAMP (IGNITION SWITCH IS ON)
Turn the ignition switch ON.
Does the charge warning lamp illuminate?
YES >> GO TO 6
NO >> GO TO 5
5.TERMINAL“2” (OPEN) CIRCUIT INSPECTION
Check terminal “2” circuit for open circuits. Refer to CHG-39, "
Diagnosis Procedure".
Is the terminal
“2” circuit normal?
YES >> Replace generator.
NO >> Repair as needed.
6.INSPECTION WITH CHARGE WARNING LAMP (IDLING)
Start the engine and run it at idle.
Does the charge warning lamp turn OFF?
YES >> GO TO 9
NO >> GO TO 7
7.TERMINAL “2”(SHORT) CIRCUIT INSPECTION
Check terminal “2” circuit for short to ground. Refer to CHG-39, "
Diagnosis Procedure".
Is the terminal
“2” circuit normal?
DIAGNOSIS SYSTEM (BCM)
DEF-9
< FUNCTION DIAGNOSIS >
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DIAGNOSIS SYSTEM (BCM)
COMMON ITEM
COMMON ITEM : CONSULT-III Function (BCM - COMMON ITEM)INFOID:0000000001697545
APPLICATION ITEM
CONSULT-III performs the following functions via CAN communication with BCM.
SYSTEM APPLICATION
BCM can perform the following functions for each system.
NOTE:
It can perform the diagnosis modes except the following for all subsystem selection items.
REAR WINDOW DEFOGGER
REAR WINDOW DEFOGGER : CONSULT-III Function (BCM - REAR DEFOGGER)
INFOID:0000000001697546
Data monitor
ACTIVE TEST
Diagnosis mode Function Description
WORK SUPPORT Changes the setting for each system function.
SELF-DIAG RESULTS Displays the diagnosis results judged by BCM. Refer to XX-XX, "*****"
.
CAN DIAG SUPPORT MNTR Monitors the reception status of CAN communication viewed from BCM.
DATA MONITOR The BCM input/output signals are displayed.
ACTIVE TEST The signals used to activate each device are forcibly supplied from BCM.
ECU IDENTIFICATION The BCM part number is displayed.
CONFIGURATION This function is not used even though it is displayed.
System Sub system selection itemDiagnosis mode
WORK SUPPORT DATA MONITOR ACTIVE TEST
Rear window defogger REAR DEFOGGER××
BCM BCM×
Monitor Item Description
REAR DEF SW Indicates [ON/OFF] condition of rear defogger switch switch.
PUSH SW Indicates [ON/OFF] condition of push switch.
Test Item Description
REAR DEFOGGERThis test is able to check rear window defogger operation. Rear window defogger operates when
“ON” on CONSULT-III screen is touched.
DLK-230
< REMOVAL AND INSTALLATION >[WITH I-KEY, WITHOUT SUPER LOCK]
FRONT DOOR LOCK
FRONT DOOR LOCK
Component Parts LocationINFOID:0000000001315860
Removal and InstallationINFOID:0000000001315861
REMOVAL
1. Remove front door finisher. Refer to INT-13, "Removal and Installation" .
2. Fully close front door window.
3. Remove the front door sealing screen.
NOTE:
If sealing screen is reused, cut butyl tape in a way that leaves it on the sealing screen.
4. Remove front door rear glass run channel. Refer to GW-14, "
Removal and Installation" .
5. Remove the cables from the holder.
6. Remove inside handle bolt, and slide the handle toward the rear
of the vehicle. disengage the handle from the door panel, and
remove the inside handle.
7. Disengage the handle from the door panel, and remove the inside handle.
1. Front door 2. Inside handle 3. Inside handle cable
4. Door lock assembly 5. Outside handle cable 6. TORX bolt (T30)
7. Key cylinder connecting rod 8. Grommet 9. TORX bolt (T30)
10. Rear gasket 11. Door key cylinder assembly
(Driver's side)
Outside handle escutcheon
(passenger's side)12. Outside handle
13. Front gasket 14. Lock knob cable 15. Holder
16. Outside handle bracket
PIIB6523E
PIIB6524E
FRONT DOOR LOCK
DLK-459
< REMOVAL AND INSTALLATION >[WITH I-KEY & SUPER LOCK]
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FRONT DOOR LOCK
Component Parts LocationINFOID:0000000001732026
Removal and InstallationINFOID:0000000001732027
REMOVAL
1. Remove front door finisher. Refer to XX-XX, "*****" .
2. Fully close front door window.
3. Remove the front door sealing screen.
NOTE:
If sealing screen is reused, cut butyl tape in a way that leaves it on the sealing screen.
4. Remove front door rear glass run channel. Refer to XX-XX, "*****"
.
5. Remove the cables from the holder.
6. Remove inside handle bolt, and slide the handle toward the rear
of the vehicle. disengage the handle from the door panel, and
remove the inside handle.
7. Disengage the handle from the door panel, and remove the inside handle.
1. Front door 2. Inside handle 3. Inside handle cable
4. Door lock assembly 5. Outside handle cable 6. TORX bolt (T30)
7. Key cylinder connecting rod 8. Grommet 9. TORX bolt (T30)
10. Rear gasket 11. Door key cylinder assembly
(Driver's side)
Outside handle escutcheon
(passenger's side)12. Outside handle
13. Front gasket 14. Lock knob cable 15. Holder
16. Outside handle bracket
PIIB6523E
PIIB6524E
DLK-600
< REMOVAL AND INSTALLATION >[WITHOUT I-KEY & SUPER LOCK]
FRONT DOOR LOCK
FRONT DOOR LOCK
Component Parts LocationINFOID:0000000001732044
Removal and InstallationINFOID:0000000001732045
REMOVAL
1. Remove front door finisher. Refer to XX-XX, "*****" .
2. Fully close front door window.
3. Remove the front door sealing screen.
NOTE:
If sealing screen is reused, cut butyl tape in a way that leaves it on the sealing screen.
4. Remove front door rear glass run channel. Refer to XX-XX, "*****"
.
5. Remove the cables from the holder.
6. Remove inside handle bolt, and slide the handle toward the rear
of the vehicle. disengage the handle from the door panel, and
remove the inside handle.
7. Disengage the handle from the door panel, and remove the inside handle.
1. Front door 2. Inside handle 3. Inside handle cable
4. Door lock assembly 5. Outside handle cable 6. TORX bolt (T30)
7. Key cylinder connecting rod 8. Grommet 9. TORX bolt (T30)
10. Rear gasket 11. Door key cylinder assembly
(Driver's side)
Outside handle escutcheon
(passenger's side)12. Outside handle
13. Front gasket 14. Lock knob cable 15. Holder
16. Outside handle bracket
PIIB6523E
PIIB6524E
FRONT DOOR LOCK
DLK-751
< REMOVAL AND INSTALLATION >[WITHOUT I-KEY, WITH SUPER LOCK]
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FRONT DOOR LOCK
Component Parts LocationINFOID:0000000001732062
Removal and InstallationINFOID:0000000001732063
REMOVAL
1. Remove front door finisher. Refer to XX-XX, "*****" .
2. Fully close front door window.
3. Remove the front door sealing screen.
NOTE:
If sealing screen is reused, cut butyl tape in a way that leaves it on the sealing screen.
4. Remove front door rear glass run channel. Refer to XX-XX, "*****"
.
5. Remove the cables from the holder.
6. Remove inside handle bolt, and slide the handle toward the rear
of the vehicle. disengage the handle from the door panel, and
remove the inside handle.
7. Disengage the handle from the door panel, and remove the inside handle.
1. Front door 2. Inside handle 3. Inside handle cable
4. Door lock assembly 5. Outside handle cable 6. TORX bolt (T30)
7. Key cylinder connecting rod 8. Grommet 9. TORX bolt (T30)
10. Rear gasket 11. Door key cylinder assembly
(Driver's side)
Outside handle escutcheon
(passenger's side)12. Outside handle
13. Front gasket 14. Lock knob cable 15. Holder
16. Outside handle bracket
PIIB6523E
PIIB6524E
EC-28
< BASIC INSPECTION >[HR16DE (WITH EURO-OBD)]
INSPECTION AND ADJUSTMENT
NO >> GO TO 3.
2.IDLE AIR VOLUME LEARNING
With CONSULT-III
1. Perform Accelerator Pedal Released Position Learning. Refer to EC-26, "
ACCELERATOR PEDAL
RELEASED POSITION LEARNING : Special Repair Requirement".
2. Perform Throttle Valve Closed Position Learning. Refer to EC-27, "
THROTTLE VALVE CLOSED POSI-
TION LEARNING : Special Repair Requirement".
3. Start engine and warm it up to normal operating temperature.
4. Select “IDLE AIR VOL LEARN” in “WORK SUPPORT” mode.
5. Touch “START” and wait 20 seconds.
Is
“CMPLT” displayed on CONSULT-III screen?
YES >> GO TO 4.
NO >> GO TO 5.
3.IDLE AIR VOLUME LEARNING
Without CONSULT-III
NOTE:
It is better to count the time accurately with a clock.
It is impossible to switch the diagnostic mode when an accelerator pedal position sensor circuit has
a malfunction.
1. Perform Accelerator Pedal Released Position Learning. Refer to EC-26, "
ACCELERATOR PEDAL
RELEASED POSITION LEARNING : Special Repair Requirement".
2. Perform Throttle Valve Closed Position Learning. Refer to EC-27, "
THROTTLE VALVE CLOSED POSI-
TION LEARNING : Special Repair Requirement".
3. Start engine and warm it up to normal operating temperature.
4. Turn ignition switch OFF and wait at least 10 seconds.
5. Confirm that accelerator pedal is fully released, turn ignition switch ON and wait 3 seconds.
6. Repeat the following procedure quickly five times within 5 seconds.
- Fully depress the accelerator pedal.
- Fully release the accelerator pedal.
7. Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 20 seconds until the MI stops
blinking and turned ON.
8. Fully release the accelerator pedal within 3 seconds after the MI turned ON.
9. Start engine and let it idle.
10. Wait 20 seconds.
>> GO TO 4.
4.CHECK IDLE SPEED AND IGNITION TIMING
Rev up the engine two or three times and make sure that idle speed and ignition timing are within the specifi-
cations.
For specification, refer to EC-380, "
Idle Speed" and EC-380, "Ignition Timing".
Is the inspection result normal?
YES >> INSPECTION END
NO >> GO TO 5.
5.DETECT MALFUNCTIONING PART
Check the following
SEC897C
ON BOARD DIAGNOSTIC (OBD) SYSTEM
EC-95
< FUNCTION DIAGNOSIS >[HR16DE (WITH EURO-OBD)]
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The 1st trip DTC (whose number is the same as the DTC number) is displayed for the latest self-diagnostic
result obtained. If the ECM memory was cleared previously, and the 1st trip DTC did not reoccur, the 1st trip
DTC will not be displayed.
If a malfunction is detected during the 1st trip, the 1st trip DTC is stored in the ECM memory. The MI will not
light up (two trip detection logic). If the same malfunction is not detected in the 2nd trip (meeting the required
driving pattern), the 1st trip DTC is cleared from the ECM memory. If the same malfunction is detected in the
2nd trip, both the 1st trip DTC and DTC are stored in the ECM memory and the MI lights up. In other words,
the DTC is stored in the ECM memory and the MI lights up when the same malfunction occurs in two consec-
utive trips. If a 1st trip DTC is stored and a non-diagnostic operation is performed between the 1st and 2nd
trips, only the 1st trip DTC will continue to be stored. For malfunctions that blink or light up the MI during the
1st trip, the DTC and 1st trip DTC are stored in the ECM memory.
Procedures for clearing the DTC and the 1st trip DTC from the ECM memory are described in “HOW TO
ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION”.
For malfunctions in which 1st trip DTCs are displayed, refer to “EMISSION-RELATED DIAGNOSTIC INFOR-
MATION ITEMS”. These items are required by legal regulations to continuously monitor the system/compo-
nent. In addition, the items monitored non-continuously are also displayed on CONSULT-III.
1st trip DTC is specified in Service $07 of ISO 15031-5. 1st trip DTC detection occurs without lighting up the
MI and therefore does not warn the driver of a malfunction. However, 1st trip DTC detection will not prevent
the vehicle from being tested, for example during Inspection/Maintenance (I/M) tests.
When a 1st trip DTC is detected, check, print out or write down and erase (1st trip) DTC and Freeze Frame
data as specified in Work Flow procedure Step 2, refer to EC-18, "
Work Flow". Then perform DTC CONFIR-
MATION PROCEDURE or Component Function Check to try to duplicate the malfunction. If the malfunction is
duplicated, the item requires repair.
Freeze Frame Data and 1st Trip Freeze Frame Data
The ECM records the driving conditions such as fuel system status, calculated load value, engine coolant tem-
perature, short term fuel trim, long term fuel trim, engine speed, vehicle speed, absolute throttle position, base
fuel schedule and intake air temperature at the moment a malfunction is detected.
Data which are stored in the ECM memory, along with the 1st trip DTC, are called 1st trip freeze frame data.
The data, stored together with the DTC data, are called freeze frame data and displayed on CONSULT-III or
GST. The 1st trip freeze frame data can only be displayed on the CONSULT-III screen, not on the GST.
Only one set of freeze frame data (either 1st trip freeze frame data or freeze frame data) can be stored in the
ECM. 1st trip freeze frame data is stored in the ECM memory along with the 1st trip DTC. There is no priority
for 1st trip freeze frame data and it is updated each time a different 1st trip DTC is detected. However, once
freeze frame data (2nd trip detection/MI on) is stored in the ECM memory, 1st trip freeze frame data is no
longer stored. Remember, only one set of freeze frame data can be stored in the ECM. The ECM has the fol-
lowing priorities to update the data.
For example, the EGR malfunction (Priority: 2) was detected and the freeze frame data was stored in the 2nd
trip. After that when the misfire (Priority: 1) is detected in another trip, the freeze frame data will be updated
from the EGR malfunction to the misfire. The 1st trip freeze frame data is updated each time a different mal-
function is detected. There is no priority for 1st trip freeze frame data. However, once freeze frame data is
stored in the ECM memory, 1st trip freeze data is no longer stored (because only one freeze frame data or 1st
trip freeze frame data can be stored in the ECM). If freeze frame data is stored in the ECM memory and freeze
frame data with the same priority occurs later, the first (original) freeze frame data remains unchanged in the
ECM memory.
Both 1st trip freeze frame data and freeze frame data (along with the DTCs) are cleared when the ECM mem-
ory is erased. Procedures for clearing the ECM memory are described in “HOW TO ERASE EMISSION-
RELATED DIAGNOSTIC INFORMATION”.
How to Read DTC and 1st Trip DTC
With CONSULT-III
With GST
CONSULT-III or GST (Generic Scan Tool) Examples: P0340, P1148, 1706, etc.
These DTCs are prescribed by ISO 15031-5.
Priority Items
1Freeze frame data Misfire — DTC: P0300 - P0304
Fuel Injection System Function — DTC: P0171, P0172
2 Except the above items (Includes A/T related items)
3 1st trip freeze frame data