TERMINOLOGY
GI-29
< HOW TO USE THIS MANUAL >
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Exhaust gas recirculation control-BPT
valveEGRC-BPT valve BPT valve
Exhaust gas recirculation control-solenoid
valveEGRC-solenoid valve EGR control solenoid valve
Exhaust gas recirculation temperature sen-
sor
EGRT sensor Exhaust gas temperature sensor
EGR temperature sensor
Flash electrically erasable programmable
read only memoryFEEPROM ***
Flash erasable programmable read only
memoryFEPROM ***
Flexible fuel sensor FFS ***
Flexible fuel system FF system ***
Fuel pressure regulator *** Pressure regulator
Fuel pressure regulator control solenoid
valve*** PRVR control solenoid valve
Fuel trim FT ***
Heated Oxygen sensor HO2S Exhaust gas sensor
Idle air control system IAC system Idle speed control
Idle air control valve-air regulator IACV-air regulator Air regulator
Idle air control valve-auxiliary air control
valveIACV-AAC valve Auxiliary air control (AAC) valve
Idle air control valve-FICD solenoid valve IACV-FICD solenoid valve FICD solenoid valve
Idle air control valve-idle up control sole-
noid valveIACV-idle up control solenoid valve Idle up control solenoid valve
Idle speed control-FI pot ISC-FI pot FI pot
Idle speed control system ISC system ***
Ignition control IC ***
Ignition control module ICM ***
Indirect fuel injection system IFI system ***
Intake air IA Air
Intake air temperature sensor IAT sensor Air temperature sensor
Knock *** Detonation
Knock sensor KS Detonation sensor
Malfunction indicator lamp MIL Check engine light
Manifold absolute pressure MAP ***
Manifold absolute pressure sensor MAPS ***
Manifold differential pressure MDP ***
Manifold differential pressure sensor MDPS ***
Manifold surface temperature MST ***
Manifold surface temperature sensor MSTS ***
Manifold vacuum zone MVZ ***
Manifold vacuum zone sensor MVZS ***
Mass air flow sensor MAFS Air flow meter
Mixture control solenoid valve MC solenoid valve Air-fuel ratio control solenoid valve
Multiport fuel injection System MFI system Fuel injection controlNEW TERMNEW ACRONYM /
ABBREVIATIONOLD TERM
GI-44
< PRECAUTION >
PRECAUTIONS
General Precaution
INFOID:0000000001606118
Do not operate the engine for an extended period of time without
proper exhaust ventilation.
Keep the work area well ventilated and free of any flammable
materials. Special care should be taken when handling any flam-
mable or poisonous materials, such as gasoline, refrigerant gas,
etc. When working in a pit or other enclosed area, be sure to prop-
erly ventilate the area before working with hazardous materials.
Do not smoke while working on the vehicle.
Before jacking up the vehicle, apply wheel chocks or other tire
blocks to the wheels to prevent the vehicle from moving. After jack-
ing up the vehicle, support the vehicle weight with safety stands at
the points designated for proper lifting before working on the vehi-
cle.
These operations should be done on a level surface.
When removing a heavy component such as the engine or tran-
saxle/transmission, be careful not to lose your balance and drop
them. Also, do not allow them to strike adjacent parts, especially
the brake tubes and master cylinder.
Before starting repairs which do not require battery power:
Turn off ignition switch.
Disconnect the negative battery terminal.
If the battery terminals are disconnected, recorded memory of
radio and each control unit is erased.
Battery posts, terminals and related accessories contain lead and
lead compounds. Wash hands after handling.
To prevent serious burns:
Avoid contact with hot metal parts.
Do not remove the radiator cap when the engine is hot.
Dispose of or recycle drained oil or the solvent used for cleaning
parts in an appropriate manner.
Do not attempt to top off the fuel tank after the fuel pump nozzle
shuts off automatically.
Continued refueling may cause fuel overflow, resulting in fuel spray
and possibly a fire.
Clean all disassembled parts in the designated liquid or solvent
prior to inspection or assembly.
Replace oil seals, gaskets, packings, O-rings, locking washers,
cotter pins, self-locking nuts, etc. with new ones.
Replace inner and outer races of tapered roller bearings and needle bearings as a set.
Arrange the disassembled parts in accordance with their assembled locations and sequence.
Do not touch the terminals of electrical components which use microcomputers (such as ECM).
Static electricity may damage internal electronic components.
After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection.
Use only the fluids and lubricants specified in this manual.
Use approved bonding agent, sealants or their equivalents when required.
SGI285
SGI231
SEF289H
SGI233
PRECAUTIONS
GI-45
< PRECAUTION >
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Use hand tools, power tools (disassembly only) and recommended
special tools where specified for safe and efficient service repairs.
When repairing the fuel, oil, water, vacuum or exhaust systems,
check all affected lines for leaks.
Before servicing the vehicle:
Protect fenders, upholstery and carpeting with appropriate covers.
Take caution that keys, buckles or buttons do not scratch paint.
WARNING:
To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness
connectors which are related to the engine control system and TCM (transmission control module)
system. The connectors should be disconnected only when working according to the WORK FLOW of
TROUBLE DIAGNOSES in EC and AT sections.
Precaution for Three Way CatalystINFOID:0000000001606119
If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To
prevent this, follow the instructions.
Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst.
When checking for ignition spark or measuring engine compression, make tests quickly and only when nec-
essary.
Do not run engine when the fuel tank level is low, otherwise the engine may misfire, causing damage to the
catalyst.
Do not place the vehicle on flammable material. Keep flammable material off the exhaust pipe and the three
way catalyst.
Precaution for Fuel (Unleaded Regular Gasoline Recommended)INFOID:0000000001606120
Use unleaded regular gasoline with an octane rating of at least 87 AKI (Anti-Knock Index) number (Research
octane number 91).
CAUTION:
Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Do not use E-85
fuel (85% fuel ethanol, 15% unleaded gasoline) unless the vehicle is specifically designed for E-85 fuel
(i.e. Flexible Fuel Vehicle - FFV models). Using a fuel other than that specified could adversely affect
the emission control devices and systems, and could also affect the warranty coverage validity.
PBIC0190E
SGI234
GI-46
< PRECAUTION >
PRECAUTIONS
Precaution for Multiport Fuel Injection System or Engine Control System
INFOID:0000000001606121
Before connecting or disconnecting any harness connector for the
multiport fuel injection system or ECM:
Turn ignition switch to “OFF” position.
Disconnect negative battery terminal.
Otherwise, there may be damage to ECM.
Before disconnecting pressurized fuel line from fuel pump to injec-
tors, be sure to release fuel pressure.
Be careful not to jar components such as ECM and mass air flow
sensor.
Precaution for HosesINFOID:0000000001606122
HOSE REMOVAL AND INSTALLATION
To prevent damage to rubber hose, do not pry off rubber hose with
tapered tool or screwdriver.
To reinstall the rubber hose securely, make sure that hose insertion
length and orientation is correct. (If tube is equipped with hose
stopper, insert rubber hose into tube until it butts up against hose
stopper.)
HOSE CLAMPING
If old rubber hose is re-used, install hose clamp in its original posi-
tion (at the indentation where the old clamp was). If there is a trace
of tube bulging left on the old rubber hose, align rubber hose at
that position.
Discard old clamps; replace with new ones.
SGI787
SMA019D
SMA020D
SMA021D
SERVICE INFORMATION FOR ELECTRICAL INCIDENT
GI-51
< BASIC INSPECTION >
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PBASIC INSPECTION
SERVICE INFORMATION FOR ELECTRICAL INCIDENT
Work FlowINFOID:0000000001691467
WORK FLOW
Control Units and Electrical PartsINFOID:0000000001691468
PRECAUTIONS
Never reverse polarity of battery terminals.
Install only parts specified for a vehicle.
Before replacing the control unit, check the input and output and functions of the component parts.
Do not apply excessive force when disconnecting a connector.
SGI838
STEP DESCRIPTION
STEP 1Get detailed information about the conditions and the environment when the incident occurred.
The following are key pieces of information required to make a good analysis:
WHATVehicle Model, Engine, Transmission/Transaxle and the System (i.e. Radio).
WHENDate, Time of Day, Weather Conditions, Frequency.
WHERERoad Conditions, Altitude and Traffic Situation.
HOWSystem Symptoms, Operating Conditions (Other Components Interaction).
Service History and if any After Market Accessories have been installed.
STEP 2Operate the system, road test if necessary.
Verify the parameter of the incident.
If the problem cannot be duplicated, refer to “Incident Simulation Tests”.
STEP 3Get the proper diagnosis materials together including:
Power Supply Routing
System Operation Descriptions
Applicable Service Manual Sections
Check for any Service Bulletins
Identify where to begin diagnosis based upon your knowledge of the system operation and the customer comments.
STEP 4Inspect the system for mechanical binding, loose connectors or wiring damage.
Determine which circuits and components are involved and diagnose using the Power Supply Routing and Harness Lay-
outs.
STEP 5 Repair or replace the incident circuit or component.
STEP 6Operate the system in all modes. Verify the system works properly under all conditions. Make sure you have not inad-
vertently created a new incident during your diagnosis or repair steps.
CONSULT-III CHECKING SYSTEM
GI-63
< BASIC INSPECTION >
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PCONSULT-III CHECKING SYSTEM
DescriptionINFOID:0000000001691472
When CONSULT-III is connected with a data link connector
equipped on the vehicle side, it will communicate with the control
unit equipped in the vehicle and then enable various kinds of diag-
nostic tests.
Refer to “CONSULT-III Operation Manual” for more information.
Function and System ApplicationINFOID:0000000001728915
x: Applicable.1 : Hood release handle
2 : Data link connector
ALBIA0047ZZ
Diagnostic test mode Function
ENGINE
ABS
AIR BAG
EPS
IPDM E/R
BCM
METER/M&A
INTELLIGENT KEY*
1
TRANSMISSION*
2
NATS
NVIS (NATS BCM OR S/ENT
NATS I-KEY
*1
Work supportThis mode enables a technician to adjust some devices faster
and more accurately by following indications on CONSULT-II.x----x-xx--x
Self-diagnostic results Self-diagnostic results can be read and erased quickly. xxxxxxxxxx - x
Trouble diagnostic recordCurrent self-diagnostic results and all trouble diagnostic
records previously stored can be read.--x---------
Data monitor Input/Output data in the ECU can be read. x x - x x - x x x - - -
CAN diagnostic support
monitorThe communication condition of CAN communication line can
be read.xx - xxxxxx - - -
Active testDiagnostic Test Mode in which CONSULT-II drives actuators
apart from ECU shifting some parameters in a specified range.xx--x--x----
Function testThis mode can show results of self-diagnosis of ECU with either
"OK" or "NG". For engines, more practical tests regarding sen-
sors/switches and/or actuators are available.xxx-----x---
DTC & SRT confirmationThe results of SRT (System Readiness Test) and the self-diag-
nosis status/result can be confirmed.x-----------
DTC work supportThe operating condition to confirm Diagnosis Trouble Codes
can be selected.x-------x---
ECM/ECU part number ECM/ECU part number can be read. x x - x - x - x x - - -
ECU discriminated No.Classification number of a replacement ECU can be read to
prevent an incorrect ECU from being installed.--x---------
Passenger airbag Displays the STATUS (readiness) of front passenger air bag. --x---------
Configuration Sets control module parameters to match vehicle options. -----x------
Steering lock release
*1Condition of steering lock release solenoid. ----------x-
Control unit initialization
*3All registered ignition key IDs in NATS components can be ini-
tialized and new IDs can be registered.---------x--
PIN Read This mode enables technician to get BCM-specific 5-digit code.----------x-
HA-26
< ON-VEHICLE MAINTENANCE >
ELECTRICAL LEAK DETECTOR
2. Connect a suitable A/C manifold gauge set to the A/C service ports.
3. Check if the A/C refrigerant pressure is at least 345 kPa (3.45 bar, 3.52 kg/cm
2, 50 psi) above 16°C. If less
than specification, recover/evacuate and recharge the system with the specified amount of refrigerant.
NOTE:
At temperatures below 16°C, leaks may not be detected since the system may not reach 345 kPa (3.45
bar, 3.52 kg/cm
2, 50 psi).
4. Perform the leak test from the high-pressure side (compressor discharge a to evaporator inlet f) to the
low-pressure side (evaporator drain hose g to shaft seal k). Refer to HA-27, "
Component". Perform a leak
check for the following areas carefully. Clean the component to be checked and move the leak detected
probe completely around the connection/component.
Compressor
Check the fitting of high- and low-pressure flexible hoses, relief valve and shaft seal.
Condenser
Check the fitting of high-pressure flexible hose and pipe, refrigerant pressure sensor.
Liquid tank
Check the refrigerant connection.
Service valves
Check all around the service valves. Ensure service valve caps are secured on the service valves (to
prevent leaks).
NOTE:
After removing A/C manifold gauge set from service valves, wipe any residue from valves to prevent any
false readings by leak detector.
Cooling unit (Evaporator)
With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in
the cooling unit. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer’s recom-
mended procedure for actual wait time) before inserting the leak detector probe into the drain hose.
Keep the probe inserted for at least 10 seconds. Use caution not to contaminate the probe tip with water
or dirt that may be in the drain hose.
5. If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected
leak, then repeat check as outlined above.
6. Do not stop when one leak is found. Continue to check for additional leaks at all system components.
If no leaks are found, perform steps 7-10.
7. Start engine.
8. Set the heater A/C control as follows;
a. A/C switch: ON
b. Mode control dial position: VENT (Ventilation)
c. Intake door lever position: Recirculation
d. Max. cold temperature
e. Fan speed: High
9. Run engine at 1,500 rpm for at least 2 minutes.
10. Turn engine off and perform leak check again following steps 4
through 6 above.
Refrigerant leaks should be checked immediately after stopping
the engine. Begin with the leak detector at the compressor. The
pressure on the high-pressure side will gradually drop after
refrigerant circulation stops and pressure on the low-pressure
side will gradually rise, as shown in the graph. Some leaks are
more easily detected when pressure is high.
11. Before connecting recovery/recycling equipment to vehicle,
check recovery/recycling equipment gauges. No refrigerant
pressure should be displayed. If pressure is displayed, recover
refrigerant from equipment lines.
12. Discharge A/C system using approved refrigerant recovery/recycling equipment. Repair the leaking fitting
or component if necessary.
13. Evacuate and recharge A/C system and perform the leak test to confirm no refrigerant leaks.
14. Perform A/C performance test to ensure system works properly.
SHA839E
HAC-6
< BASIC INSPECTION >[MANUAL AIR CONDITIONER]
INSPECTION AND ADJUSTMENT
INSPECTION AND ADJUSTMENT
Operational CheckINFOID:0000000001203052
The purpose of the operational check is to confirm that the system operates properly.
CHECKING BLOWER
1. Turn blower control dial clockwise to "1" position. Blower should operate on low speed.
2. Turn blower control dial clockwise to "2" position, and continue checking blower speed until all speeds are
checked.
3. Leave blower on Maximum speed.
If NG, go to trouble diagnosis procedure for xxx BLOWER MOTOR CIR HAC-19, "
Front Blower Motor Diagno-
sis Procedure".
If OK, continue the check.
CHECKING DISCHARGE AIR
1. Turn mode door control dial to each position.
2. Confirm that discharge air comes out according to the air distribution table. Refer to XXXX DISCHARGE
AIR FLOW.
If NG, go to trouble diagnosis procedure for HAC-16, "
Mode Door Diagnostic Procedure".
If OK, continue the check.
CHECKING RECIRCULATION
1. Set intake door lever to REC position.
2. Operate intake door lever to FRE position.
3. Listen for intake door position change (you should hear blower sound change slightly).
If NG, go to trouble diagnosis procedure for XXXX INTAKE DOOR.
If OK, continue the check.
CHECKING TEMPERATURE DECREASE
1. Turn temperature control dial counterclockwise to full cold position.
2. Check for cold air at discharge air outlets.
If NG, go to trouble diagnosis procedure for XXXX INSUFFICIENT COOLING.
If OK, continue the check.
CHECKING TEMPERATURE INCREASE
1. Turn temperature control dial clockwise to full hot position.
2. Check for hot air at discharge air outlets.
If NG, go to trouble diagnosis procedure for XXXX INSUFFICIENT HEATING.
If OK, continue the check.
CHECKING A/C SWITCH (IF EQUIPPED)
1. Turn fan control dial to the desired (1 to 4 speed) position.
2. Press A/C switch.
3. A/C switch indicator will turn ON.
• Confirm that the compressor clutch engages (sound or visual inspection).
If NG, go to trouble diagnosis procedure for XXXX MAG CLUTCH CIR.
If OK, continue the check.
CHECKING DEFROST A/C SWITCH (IF EQUIPPED)
1. Turn fan control dial to the desired (1 to 4 speed) position.
2. Turn mode dial to ( ) DEF.
3. Confirm that the compressor clutch engages (sound or visual inspection). Conditions : Engine running at normal operating temperature