EC-624
< SERVICE INFORMATION >[VK45DE]
ON BOARD REFUELING VAPOR RECOVERY (ORVR)
ON BOARD REFUELING VA
POR RECOVERY (ORVR)
System DescriptionINFOID:0000000001326504
From the beginning of refueling, the air and vapor insi de the fuel tank go through refueling EVAP vapor cut
valve and EVAP/ORVR line to the EVAP canister. The vapor is absorbed by the EVAP canister and the air is
released to the atmosphere.
When the refueling has reached the full level of the fuel tank, the refueling EVAP vapor cut valve is closed and
refueling is stopped because of auto shut-off. The vapor which was absorbed by the EVAP canister is purged
during driving.
WARNING:
When conducting inspections below, be sure to observe the following:
Put a “CAUTION: FLAMMABLE” sign in workshop.
Do not smoke while servicing fuel system. Keep open flames and sparks away from work area.
Be sure to furnish the workshop with a CO
2 fire extinguisher.
CAUTION:
Before removing fuel line parts, carry out the following procedures:
- Put drained fuel in an explosion-pr oof container and put lid on securely.
- Release fuel pressure from fuel line. Refer to EC-665, "
Fuel Pressure Check".
- Disconnect battery ground cable.
Always replace O-ring when the fuel gauge retainer is removed.
Do not kink or twist hose and tube when they are installed.
Do not tighten hose and clamps excessively to avoid damaging hoses.
After installation, run engine an d check for fuel leaks at connection.
Do not attempt to top off the fuel tank afte r the fuel pump nozzle shuts off automatically.
Continued refueling may cause fu el overflow, resulting in fuel spray and possibly a fire.
Diagnosis ProcedureINFOID:0000000001326505
SYMPTOM: FUEL ODOR FROM EVAP CANISTER IS STRONG.
1.CHECK EVAP CANISTER
1. Remove EVAP canister with EVAP canister vent control valve and EVAP control system pressure sensor
attached.
2. Weigh the EVAP canister with EVAP canister vent control valve and EVAP control system pressure sensor
attached.
The weight should be l ess than 2.1 kg (4.6 lb).
OK or NG
OK >> GO TO 2.
NG >> GO TO 3.
2.CHECK IF EVAP CANISTER SATURATED WITH WATER
PBIB1068E
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BASIC SERVICE PROCEDUREEC-661
< SERVICE INFORMATION > [VK45DE]
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OK or NG
OK >> GO TO 15.
NG >> GO TO 17.
15.CHECK IGNITION TIMING AGAIN
1. Run engine at idle.
2. Check ignition timing with a timing light. Refer to EC-661
.
OK or NG
OK >> GO TO 19.
NG >> GO TO 16.
16.CHECK TIMING CHAIN INSTALLATION
Check timing chain installation. Refer to EM-199
.
OK or NG
OK >> GO TO 17.
NG >> 1. Repair the timing chain installation. 2. GO TO 4.
17.DETECT MALFUNCTIONING PART
Check the following.
Check camshaft position sensor (PHASE) and circuit. Refer to EC-911
.
Check crankshaft position sensor (POS) and circuit. Refer to EC-906
.
OK or NG
OK >> GO TO 18.
NG >> 1. Repair or replace. 2. GO TO 4.
18.CHECK ECM FUNCTION
1. Substitute another known-good ECM to check ECM f unction. (ECM may be the cause of an incident, but
this is a rare case.)
2. Perform initialization of IVIS (NAT S) system and registration of all IVIS (NATS) ignition key IDs. Refer to
BL-187, "
ECM Re-Communicating Function".
>> GO TO 4.
19.INSPECTION END
Did you replace ECM, referring this Basic Inspection procedure?
Ye s o r N o
Ye s > > 1 . P e r f o r m EC-662, "VIN Registration".
2. INSPECTION END
No >> INSPECTION END
Idle Speed and Ignition Timing CheckINFOID:0000000001326516
IDLE SPEED
With CONSULT-III
Check idle speed in “DATA MONITOR” mode with CONSULT-III.
With GST
Check idle speed with GST.12
± 5 ° BTDC (in P or N position)
PBIB1487E
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EC-664
< SERVICE INFORMATION >[VK45DE]
BASIC SERVICE PROCEDURE
Without CONSULT-III
NOTE:
It is better to count the ti me accurately with a clock.
It is impossible to switch the di agnostic mode when an accelerator pedal position sensor circuit has
a malfunction.
1. Perform EC-662, "
Accelerator Pedal Released Position Learning".
2. Perform EC-663, "
Throttle Valve Closed Position Learning".
3. Start engine and warm it up to normal operating temperature.
4. Check that all items listed under the topic PREP ARATION (previously mentioned) are in good order.
5. Turn ignition switch OFF and wait at least 10 seconds.
6. Confirm that accelerator pedal is fully releas ed, turn ignition switch ON and wait 3 seconds.
7. Repeat the following procedure quickly five times within 5 seconds.
a. Fully depress the accelerator pedal.
b. Fully release the accelerator pedal.
8. Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 20 seconds until the MIL stops
blinking and turned ON.
9. Fully release the accelerator pedal within 3 seconds after the MIL turned ON.
10. Start engine and let it idle.
11. Wait 20 seconds.
12. Rev up the engine two or three times and make sure that idle speed and ignition timing are within the specifications.
13. If idle speed and ignition timing are not within the specification, Idle Air Volume Learning will not be carried out successfully. In this case, find the cause of t he incident by referring to the Diagnostic Procedure below.
DIAGNOSTIC PROCEDURE
If idle air volume learning cannot be performed successfully, proceed as follows:
1. Check that throttle val ve is fully closed.
2. Check PCV valve operation.
3. Check that downstream of throttl e valve is free from air leakage.
4. When the above three items check out OK, engine component parts and their installation condi-
tion are questionable. Check and elim inate the cause of the incident.
It is useful to perform EC-709
.
5. If any of the following conditions occur after th e engine has started, eliminate the cause of the
incident and perform Idle Air Vo lume Learning all over again:
- Engine stalls.
- Erroneous idle.
ITEM SPECIFICATION
Idle speed 650 ± 50 rpm (in P or N position)
Ignition timing 12 ± 5 ° BTDC (in P or N position)
ITEM SPECIFICATION
Idle speed 650 ± 50 rpm (in P or N position)
Ignition timing 12 ± 5 ° BTDC (in P or N position)
SEC897C
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BASIC SERVICE PROCEDUREEC-665
< SERVICE INFORMATION > [VK45DE]
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Fuel Pressure CheckINFOID:0000000001326522
FUEL PRESSURE RELEASE
With CONSULT-III
1. Turn ignition switch ON.
2. Perform “FUEL PRESSURE RELEASE” in
“WORK SUPPORT” mode with CONSULT-III.
3. Start engine.
4. After engine stalls, crank it two or three times to release all fuel pressure.
5. Turn ignition switch OFF.
Without CONSULT-III
1. Remove fuel pump fuse located in IPDM E/R.
2. Start engine.
3. After engine stalls, crank it 2 or 3 times to release all fuel pres- sure.
4. Turn ignition switch OFF.
5. Reinstall fuel pump fuse after servicing fuel system.
FUEL PRESSURE CHECK
Before disconnecting fuel line, release fuel pressure from fuel line to eliminate danger.
NOTE:
Prepare pans or saucers under the disconnected fuel line because the fuel may spill out. The fuel
pressure cannot be completely released because S50 models do not have fuel return system.
Use Fuel Pressure Gauge Kit (J-44321) to check fuel pressure.
1. Release fuel pressure to zero. Refer to "FUEL PRESSURE RELEASE".
2. Install the inline fuel quick disconnected fitting A between fuel damper (1) and fuel tube.
3. Connect the fuel pressure gauge B (quick connector adapter hose) to the inline fuel quick disconnected fitting.
4. Turn ignition switch ON and check for fuel leakage.
5. Start engine and check for fuel leakage.
6. Read the indication of fuel pressure gauge.
7. If result is unsatisfactory, go to next step.
8. Check the following. Fuel hoses and fuel tubes for clogging
Fuel filter for clogging
Fuel pump
Fuel pressure regulator for clogging
If OK, replace fuel level sensor unit, fuel filter and fuel pump assembly.
If NG, repair or replace.
PBIB1482E
At idling: Approximately 350 kPa (3.57 kg/cm2, 51 psi)PBIB3244E
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EC-672
< SERVICE INFORMATION >[VK45DE]
TROUBLE DIAGNOSIS
When there is an open circuit on MIL circuit, the ECM c
annot warn the driver by lighting up MIL when there
is malfunction on engine control system.
Therefore, when electrical controlled throttle and pa rt of ECM related diagnoses are continuously detected
as NG for 5 trips, ECM warns the driver that engi ne control system malfunctions and MIL circuit is open by
means of operating fail-safe function.
The fail-safe function also operates when above diagnos es except MIL circuit are detected and demands the
driver to repair the malfunction.
DTC No. Detected items Engine operating condition in fail-safe mode
P0102
P0103 Mass air flow sensor circuit Engine speed will not rise more than 2,400 rpm due to the fuel cut.
P0117
P0118 Engine coolant tempera-
ture sensor circuit Engine coolant temperature will be determined by ECM based on the following conditions.
CONSULT-III displays the engine coolant temperature decided by ECM.
Condition Engine coolant temperature decided
(CONSULT-III display)
Just as ignition switch is turned ON
or START 40
°C (104 °F)
Approx. 4 minutes or more after
engine starting. 80
°C (176 °F)
Except as shown above 40 - 80
°C (104 - 176 °F)
(Depends on the time)
When the fail-safe system for engine coolant temperature sensor is activated, the cooling
fan operates while engine is running.
P0122
P0123
P0222
P0223
P2135 Throttle position sensor The ECM controls the electric throttle control actuator in regulating the throttle opening in
order for the idle position to be within +10 degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal
condition.
So, the acceleration will be poor.
P0643 Sensor power supply ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring.
P2100
P2103 Throttle control motor relay ECM stops the electric throttle control actuator control, throttle valve is maintained at a
fixed opening (approx. 5 degrees) by the return spring.
P2101 Electric throttle control function ECM stops the electric throttle control actuator control, throttle valve is maintained at a
fixed opening (approx. 5 degrees) by the return spring.
P2118 Throttle control motor ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring.
P2119 Electric thro ttle control ac-
tuator (When electric throttle control actuator does not function properly due to the return spring
malfunction:)
ECM controls the electric throttle actuator by regulating the throttle opening around the
idle position. The engine speed will not rise more than 2,000 rpm.
(When throttle valve opening angle in fail-safe mode is not in specified range:)
ECM controls the electric throttle control actuator by regulating the throttle opening to 20
degrees or less.
(When ECM detects the throttle valve is stuck open:)
While the vehicle is driving, it slows down gradually by fuel cut. After the vehicle stops, the
engine stalls.
The engine can restart in N or P position, and engine speed will not exceed 1,000 rpm or
more.
P2122
P2123
P2127
P2128
P2138 Accelerator pedal position
sensor
The ECM controls the electric throttle control actuator in regulating the throttle opening in
order for the idle position to be within +10 degrees.
The ECM regulates the opening speed of the throttle valve to be slower than the normal
condition.
So, the acceleration will be poor.
Engine operating condition in fail-safe mode Engine speed will not rise more than 2,500 rpm due to the fuel cut
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TROUBLE DIAGNOSISEC-673
< SERVICE INFORMATION > [VK45DE]
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Symptom Matrix ChartINFOID:0000000001326526
SYSTEM — BASIC ENGINE CONTROL SYSTEM
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 pump circuit 11232 22 3 2 EC-1155
Fuel pressure regulator system 334444444 4EC-665
Fuel injector circuit 11232 22 2EM-190
Evaporative emission system 334444444 4EC-618
Air Positive crankcase ventilation sys-
tem 334444444 41
EC-629
Incorrect idle speed adjustment 1 1 1 1 1 EC-658
Electric throttle control actuator 112332222 2 2EC-1092,
EC-1102
IgnitionIncorrect ignition timing adjustment33111 11 1 EC-658
Ignition circuit 11222 22 2EC-1166
Main power supply and ground circuit 22333 33 23 EC-718
Mass air flow sensor circuit
1
12 2
222 2 EC-761,
EC-768
,
Engine coolant temperature sensor circuit
333
EC-779
,
EC-790
A/F sensor 1 circuit EC-798
,
EC-806
,
EC-814
,
EC-822
,
EC-1129
Throttle position sensor circuit
22EC-784
,
EC-889
,
EC-1041
,
EC-1043
,
E C - 111 6
Accelerator pedal position sensor circuit 3 2 1 EC-1009
,
EC-1104
,
E C - 111 0
,
EC-1122
Knock sensor circuit 2 3 EC-902
Crankshaft position sensor (POS) circuit 2 2EC-906
Camshaft position sensor (PHASE) circuit 3 2EC-911
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EC-674
< SERVICE INFORMATION >[VK45DE]
TROUBLE DIAGNOSIS
1 - 6: The numbers refer to the order of inspection.
(continued on next page)
SYSTEM — ENGINE MECHANICAL & OTHER
Vehicle speed signal circuit 2 3 3 3
EC-992
Power steering pressure sensor circuit 2 3 3EC-998
ECM 22333333333EC-1003,
EC-1007
Intake valve timing control solenoid valve cir-
cuit 32 13223 3
EC-754
PNP switch circuit 3 3 3 3 3 EC-1014
Refrigerant pressure sensor circuit 2 3 3 4EC-1177
Electrical load signal circuit 3EC-1147
Air conditioner circuit 223333333 3 2AT C - 3 2
VIAS control solenoid valve circuit 1EC-1080
ABS actuator and electric unit (control unit) 4EC-1028
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
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TROUBLE DIAGNOSISEC-675
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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
5 FL-10
Fuel piping 5 5 5 5 5 5
EM-190
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 5 EM-173
Air cleaner
EM-173
Air leakage from air duct
(Mass air flow sensor — electric
throttle control actuator)
5555 EM-173
Electric throttle control actuator
EM-175
Air leakage from intake manifold/
Collector/GasketEM-175
Cranking Battery
111111
11
SC-4
Generator circuit
SC-19
Starter circuit 3SC-8
Signal plate 6EM-241
PNP switch 4AT- 1 0 2
Engine Cylinder head
55555 55 5 EM-226
Cylinder head gasket 4 3
Cylinder block
66666 66 6 4
EM-241
Piston
Piston ring
Connecting rod
Bearing
Crankshaft
Va l v e
mecha-
nism Timing chain
55555 55 5 EM-199
Camshaft
EM-211
Intake valve timing controlEM-199
Intake valve
3EM-199
Exhaust valve
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