EC-672
< SYMPTOM DIAGNOSIS >[HR16DE (WITHOUT EURO-OBD)]
ENGINE CONTROL SYSTEM SYMPTOMS
SYMPTOM
Reference
page
HARD/NO START/RESTART (EXCP. HA)
ENGINE STALL
HESITATION/SURGING/FLAT SPOT
SPARK KNOCK/DETONATION
LACK OF POWER/POOR ACCELERATION
HIGH IDLE/LOW IDLE
ROUGH IDLE/HUNTING
IDLING VIBRATION
SLOW/NO RETURN TO IDLE
OVERHEATS/WATER TEMPERATURE HIGH
EXCESSIVE FUEL CONSUMPTION
EXCESSIVE OIL CONSUMPTION
BATTERY DEAD (UNDER CHARGE)
Warranty symptom code AA AB AC AD AE AF AG AH AJ AK AL AM HA
Fuel Fuel tank
5
5FL-10
Fuel piping 5 5 5 5 5 5FL-4
Va p o r l o c k—
Valve deposit
5 555 55 5—
Poor fuel (Heavy weight gasoline,
Low octane)—
Air Air duct
55555 5EM-27
Air cleanerEM-27
Air leakage from air duct
(Mass air flow sensor — electric
throttle control actuator)
5555EM-27
Electric throttle control actuatorEM-29
Air leakage from intake manifold/
Collector/GasketEM-29
Cranking Battery
111111
11PG-6
Generator circuitCHG-15
Starter circuit 3STR-13
Signal plate 6EM-89
PNP switch 4TM-621
(M/T)
TM-44
(A/T)
Engine Cylinder head
55555 55 5EM-80
Cylinder head gasket 4 3
Cylinder block
66666 66 64
EM-89
Piston
Piston ring
Connecting rod
Bearing
Crankshaft
EC-676
< PRECAUTION >[HR16DE (WITHOUT EURO-OBD)]
PRECAUTIONS
On Board Diagnostic (OBD) System of Engine and A/T
INFOID:0000000001706098
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 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:0000000001706099
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-677
< PRECAUTION >[HR16DE (WITHOUT EURO-OBD)]
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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-328, "
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
PREPARATION
EC-679
< PREPARATION >[HR16DE (WITHOUT EURO-OBD)]
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PREPARATION
PREPARATION
Special Service ToolsINFOID:0000000001705203
Commercial Service ToolsINFOID:0000000001705204
Tool number
Tool nameDescription
KV10117100
Heated oxygen sensor
wrenchLoosening or tighening heated oxygen sensor with
22 mm (0.87 in) hexagon unit
KV10114400
Heated oxygen sensor
wrenchLoosening or tighening heated oxygen sensor 2
a: 22 mm (0.87 in)
KV10118400
Fuel tube adapterMeasuring fuel pressure
S-NT379
S-NT636
PBIB3043E
Tool name Description
Quick connector re-
leaseRemoving fuel tube quick connectors in engine
room
(Available in SEC. 164 of PARTS CATALOG: Par
No. 16441 6N210)
Socket wrench Removing and installing engine coolant tempera-
ture sensor
PBIC0198E
S-NT705
EC-680
< PREPARATION >[HR16DE (WITHOUT EURO-OBD)]
PREPARATION
Oxygen sensor thread
cleanerReconditioning the exhaust system threads before
installing a new oxygen sensor. Use with anti-
seize lubricant shown below.
a: 18 mm diameter with pitch 1.5 mm for Zirco-
nia Oxygen Sensor
b: 12 mm diameter with pitch 1.25 mm for Tita-
nia Oxygen Sensor
Anti-seize lubricant
i.e.: (Permatex
TM
133AR or equivalent
meeting MIL specifica-
tion MIL-A-907)Lubricating oxygen sensor thread cleaning tool
when reconditioning exhaust system threads. Tool name Description
AEM488
S-NT779
DIAGNOSIS AND REPAIR WORKFLOW
EC-687
< BASIC INSPECTION >[MR18DE]
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YES >> GO TO 7.
NO >> GO TO 9.
7.PERFORM SPEC IN DATA MONITOR MODE
With CONSULT-III
Make sure that “MAS A/F SE-B1”, “B/FUEL SCHDL” and “A/F ALPHA-B1” are within the SP value using CON-
SULT-III in “SPEC” of “DATA MONITOR” mode. Refer to EC-781, "
Component Function Check".
Is the measurement value within the SP value?
YES >> GO TO 9.
NO >> GO TO 8.
8.DETECT MALFUNCTIONING PART BY TROUBLE DIAGNOSIS - SPECIFICATION VALUE
Detect malfunctioning part according to EC-782, "
Diagnosis Procedure".
Is malfunctioning part detected?
YES >> GO TO 11.
NO >> GO TO 9.
9.DETECT MALFUNCTIONING SYSTEM BY SYMPTOM TABLE
Detect malfunctioning system according to EC-1024, "
Symptom Table" based on the confirmed symptom in
step 4, and determine the trouble diagnosis order based on possible causes and symptom.
>> GO TO 10.
10.DETECT MALFUNCTIONING PART BY DIAGNOSIS PROCEDURE
Inspect according to Diagnosis Procedure of the system.
NOTE:
The Diagnosis Procedure in EC section described based on open circuit inspection. A short circuit inspection
is also required for the circuit check in the Diagnosis Procedure. For details, refer to Circuit Inspection in GI-
58, "Circuit Inspection".
Is malfunctioning part detected?
YES >> GO TO 11.
NO >> Monitor input data from related sensors or check the voltage of related ECM terminals using CON-
SULT-III. Refer to EC-990, "
Reference Value".
11 .REPAIR OR REPLACE THE MALFUNCTIONING PART
1. Repair or replace the malfunctioning part.
2. Reconnect parts or connectors disconnected during Diagnosis Procedure again after repair and replace-
ment.
3. Check DTC. If DTC is displayed, erase it. Refer to EC-760, "
Diagnosis Description".
>> GO TO 12.
12.FINAL CHECK
When DTC was detected in step 2, perform DTC CONFIRMATION PROCEDURE or Component Function
Check again, and then make sure that the malfunction have been repaired securely.
When symptom was described from the customer, refer to confirmed symptom in step 3 or 4, and make sure
that the symptom is not detected.
Is DTC detected and does symptom remain?
YES-1 >> DTC is detected: GO TO 10.
YES-2 >> Symptom remains: GO TO 6.
NO >> Before returning the vehicle to the customer, make sure to erase unnecessary DTC in ECM and
TCM (Transmission Control Module). (Refer to EC-760, "
Diagnosis Description".) If the comple-
tion of SRT is needed, drive vehicle under the specific DRIVING PATTERN in EC-1021,
"HowtoSetSRTCode".
Diagnostic Work SheetINFOID:0000000001161701
DESCRIPTION
EC-690
< BASIC INSPECTION >[MR18DE]
INSPECTION AND ADJUSTMENT
2. Rev engine (2,000 to 3,000 rpm) two or three times under no
load, then run engine at idle speed for about 1 minute.
3. Check idle speed.
For procedure, refer to EC-692, "
IDLE SPEED : Special Repair
Requirement".
For specification, refer to EC-1038, "
Idle Speed".
Is the inspection result normal?
YES >> GO TO 10.
NO >> GO TO 4.
4.PERFORM ACCELERATOR PEDAL RELEASED POSITION LEARNING
1. Stop engine.
2. Perform EC-693, "
ACCELERATOR PEDAL RELEASED POSITION LEARNING : Special Repair Require-
ment".
>> GO TO 5.
5.PERFORM THROTTLE VALVE CLOSED POSITION LEARNING
Perform EC-694, "
THROTTLE VALVE CLOSED POSITION LEARNING : Special Repair Requirement".
>> GO TO 6.
6.PERFORM IDLE AIR VOLUME LEARNING
Perform EC-694, "
IDLE AIR VOLUME LEARNING : Special Repair Requirement".
Is Idle Air Volume Learning carried out successfully?
YES >> GO TO 7.
NO >> Follow the instruction of Idle Air Volume Learning. Then GO TO 4.
7.CHECK TARGET IDLE SPEED AGAIN
1. Start engine and warm it up to normal operating temperature.
2. Check idle speed.
For procedure, refer to EC-692, "
IDLE SPEED : Special Repair Requirement".
For specification, refer to EC-1038, "
Idle Speed".
Is the inspection result normal?
YES >> GO TO 10.
NO >> GO TO 8.
8.DETECT MALFUNCTIONING PART
Check the Following.
Check camshaft position sensor (PHASE) and circuit. Refer to EC-866, "
DTC Logic".
Check crankshaft position sensor (POS) and circuit. Refer to EC-862, "
DTC Logic".
Is the inspection result normal?
YES >> GO TO 9.
NO >> Repair or replace. Then GO TO 4
9.CHECK ECM FUNCTION
1. Substitute another known-good ECM to check ECM function. (ECM may be the cause of an incident, but
this is a rare case.)
2. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to SEC-7, "
ECM
RE-COMMUNICATING FUNCTION : Description".
>> GO TO 4.
10.CHECK IGNITION TIMING
1. Run engine at idle.
PBIA8513J
EC-692
< BASIC INSPECTION >[MR18DE]
INSPECTION AND ADJUSTMENT
17.DETECT MALFUNCTIONING PART
Check the following.
Check camshaft position sensor (PHASE) and circuit. Refer to EC-866, "
DTC Logic".
Check crankshaft position sensor (POS) and circuit. Refer to EC-862, "
DTC Logic".
Is the inspection result normal?
YES >> GO TO 18.
NO >> Repair or replace. Then GO TO 4
18.CHECK ECM FUNCTION
1. Substitute another known-good ECM to check ECM function. (ECM may be the cause of an incident, but
this is a rare case.)
2. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to SEC-7, "
ECM
RE-COMMUNICATING FUNCTION : Description".
>> GO TO 4.
ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT
ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Description
INFOID:0000000001161703
When replacing ECM, this procedure must be performed.
ADDITIONAL SERVICE WHEN REPLACING CONTROL UNIT : Special Repair Re-
quirement
INFOID:0000000001161704
1.PERFORM INITIALIZATION OF NATS SYSTEM AND REGISTRATION OF ALL NATS IGNITION KEY IDS
Refer to SEC-7, "
ECM RE-COMMUNICATING FUNCTION : Description".
>> GO TO 2.
2.PERFORM ACCELERATOR PEDAL RELEASED POSITION LEARNING
Refer to EC-693, "
ACCELERATOR PEDAL RELEASED POSITION LEARNING : Special Repair Require-
ment".
>> GO TO 3.
3.PERFORM THROTTLE VALVE CLOSED POSITION LEARNING
Refer to EC-694, "
THROTTLE VALVE CLOSED POSITION LEARNING : Special Repair Requirement".
>> GO TO 4.
4.PERFORM IDLE AIR VOLUME LEARNING
Refer to EC-694, "
IDLE AIR VOLUME LEARNING : Special Repair Requirement".
>> END
IDLE SPEED
IDLE SPEED : DescriptionINFOID:0000000001161705
This describes how to check the idle speed. For the actual procedure, follow the instructions in “BASIC
INSPECTION”.
IDLE SPEED : Special Repair RequirementINFOID:0000000001161706
1.CHECK IDLE SPEED
With CONSULT-III