EC-1524< SERVICE INFOMATION >
[MR TYPE 2]
IGNITION SIGNAL
• Harness for open or short between IPDM E/R and condenser-2 >> Repair open circuit or short to ground or short to power in harness or connectors. 8.
CHECK CONDENSER-2 GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Check harness continuity between condenser-2 terminal 2 and ground.
Refer to Wiring Diagram.
3. Also check harness for short to power.
OK or NG OK >> GO TO 9.
NG >> Repair open circuit or short to power in harness or connectors. 9.
CHECK CONDENSER-2
Refer to EC-1525, " Component Inspection "
OK or NG
OK >> GO TO 10.
NG >> Replace condenser-2. 10.
CHECK IGNITION COIL POWER SUPPLY CIRCUIT-IV
1. Turn ignition switch OFF.
2. Reconnect all harness connectors disconnected.
3. Disconnect ignition coil (1) harness connector.
4. Turn ignition switch ON.
5. Check voltage between ignition coil terminal 3 and ground with CONSULT-III or tester.
OK or NG OK >> GO TO 12.
NG >> GO TO 11. 11.
DETECT MALFUNCTIONING PART
Check the following.
• Harness connector F8
• Harness for open or short between ignition coil and harness connector F8
>> Repair or replace harness or connectors. 12.
CHECK IGNITION COIL GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF. Continuity should exist.
PBIB3328E
Voltage: Battery voltage
PBIB0138E
IGNITION SIGNAL
EC-1525
< SERVICE INFOMATION >
[MR TYPE 2] C
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M A EC
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2. Check harness continuity between ignition coil terminal 2 and ground.
Refer to Wiring Diagram.
3. Also check harness for short to power.
OK or NG OK >> GO TO 13.
NG >> Repair open circuit or short to power in harness or connectors. 13.
CHECK IGNITION COIL OUTPUT SI GNAL CIRCUIT FOR OPEN AND SHORT
1. Disconnect ECM harness connector.
2. Check harness continuity between ECM termi nals 17, 18, 21, 22 and ignition coil terminal 1.
Refer to Wiring Diagram.
3. Also check harness for short to ground and short to power.
OK or NG OK >> GO TO 14.
NG >> Repair open circuit or short to ground or short to power in harness or connectors. 14.
CHECK IGNITION COIL WITH POWER TRANSISTOR
Refer to EC-1525, " Component Inspection " .
OK or NG OK >> GO TO 15.
NG >> Replace ignition coil with power transistor. 15.
CHECK INTERMITTENT INCIDENT
Refer to EC-1138 .
>> INSPECTION END
Component Inspection INFOID:0000000004500424
IGNITION COIL WITH POWER TRANSISTOR CAUTION:
Do the following procedure in the place where ventilation is good without the combustible.
1. Turn ignition switch OFF.
2. Disconnect ignition coil harness connector.
3. Check resistance between ignition coil terminals as follows.
4. If NG, replace ignition coil with power transistor. If OK, go to next step.
5. Turn ignition switch OFF.
6. Reconnect all harness connectors disconnected. Continuity should exist.
Continuity should exist.
Terminal No. (Polarity) Resistance Ω [at 25 °C (77 °F)]
1 and 2 Except 0 or ∞
1 and 3 Except 0
2 and 3 PBIB0847E
EC-1526< SERVICE INFOMATION >
[MR TYPE 2]
IGNITION SIGNAL
7. Remove fuel pump fuse (1) in IPDM E/R (2) to release fuel pres- sure.
NOTE:
Do not use CONSULT-III to releas e fuel pressure, or fuel pres-
sure applies again during the following procedure.
- : Vehicle front
8. Start engine.
9. After engine stalls, crank it two or three times to release all fuel
pressure.
10. Turn ignition switch OFF.
11. Remove all ignition coil harness connectors to avoid the electri-
cal discharge from the ignition coils.
12. Remove ignition coil and spark plug of the cylinder to be checked.
13. Crank engine for 5 seconds or more to remove combustion gas in the cylinder.
14. Connect spark plug and harness connector to ignition coil.
15. Fix ignition coil using a rope etc. with gap of 13 - 17 mm (0.52 - 0.66 in) between the edge of the spark plug and grounded metal
portion as shown in the figure.
16. Crank engine for about 3 seconds, and check whether spark is generated between the spark plug and the grounded metal por-
tion.
CAUTION:
• Do not approach to the spar k plug and the ignition coil
within 50cm. Be careful not to get an electrical shock
while checking, because the el ectrical discharge voltage
becomes 20kV or more.
• It might cause to damage the igni tion coil if the gap of more than 17 mm (0.66 in) is taken.
NOTE:
When the gap is less than 13 mm (0.52 in), the sp ark might be generated even if the coil is mal-
functioning.
17. If NG, replace ignition coil with power transistor.
CONDENSER-2
1. Turn ignition switch OFF.
2. Disconnect condenser-2 harness connector.
3. Check resistance between condenser-2 terminals 1 and 2.
4. If NG, replace condenser-2.
Removal and Installation INFOID:0000000004500425
IGNITION COIL WITH POWER TRANSISTOR
Refer to EM-153 .
Spark should be generated. PBIB2958E
PBIB2325E
Resistance: Above 1 M
Ω [at 25 °C (77 °F)] PBIB0794E
EC-1530< SERVICE INFOMATION >
[MR TYPE 2]
REFRIGERANT PRESSURE SENSOR
1. Disconnect refrigerant pressure sensor (1) harness connector.
- : Vehicle front
2. Turn ignition switch ON.
3. Check voltage between refrigerant pressure sensor terminal 3 and ground with CONSULT-III or tester.
OK or NG OK >> GO TO 5.
NG >> GO TO 4. 4.
DETECT MALFUNCTIONING PART
Check the following.
• Harness connectors E8, F8
• Harness for open or short between refrigerant pressure sensor and ECM
>> Repair open circuit or short to ground or short to power in harness or connectors. 5.
CHECK REFRIGERANT PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT
1. Turn ignition switch OFF.
2. Disconnect ECM harness connector.
3. Check harness continuity between refrigerant pressure sensor terminal 1 and ECM terminal 48.
Refer to Wiring Diagram.
4. Also check harness for short to ground and short to power.
OK or NG OK >> GO TO 7.
NG >> GO TO 6. 6.
DETECT MALFUNCTIONING PART
Check the following.
• Harness connectors E8, F8
• Harness for open or short between refrigerant pressure sensor and ECM
>> Repair open circuit or short to ground or short to power in harness or connectors. 7.
CHECK REFRIGERANT PRESSURE SENSOR INPU T SIGNAL CIRCUIT FOR OPEN AND SHORT
1. Check harness continuity between refrigerant pressure sensor terminal 2 and ECM terminal 41. Refer to Wiring Diagram.
2. Also check harness for short to ground and short to power.
OK or NG BBIA0713E
Voltage: Approximately 5V
SEF479Y
Continuity should exist.
Continuity should exist.
EM
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DISASSEMBLY AND ASSEMBLY
ENGINE STAND SETTING
Setting INFOID:0000000004784310
NOTE:
Explained here is how to disassemble with engine stand supporting transmission surface. When using differ-
ent type of engine stand, note with difference in steps and etc.
1. Remove the engine and the transaxle assembly from the vehicle, and separate the transaxle from the
engine. Refer to EM-88, " Exploded View " .
2. Remove clutch cover and clutch disc (if equipped). Refer to CL-15, " Removal and Installation " .
3. Remove flywheel or driveplate. • Secure flywheel or driveplate with Tool, and remove bolts.
CAUTION:
• Never disassemble flywheel.
• Never place flywheel or driveplate with signal plate facing down.
• When handling signal plate, take car e not to damage or scratch it.
• Handle signal plate in a manner that prevents it from becoming magnetized.
4. Lift the engine with a hoist to install it onto widely use engine stand. CAUTION:
• Use the engine stand that has a load capacity [approximately 135 kg (298 lb) or more] large
enough for supporting the engine weight.
• If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the poten-
tial risk of overturning stand.
- Intake manifold: Refer to EM-28, " Exploded View " .
- Exhaust manifold: Refer to EM-31, " Exploded View " .
- Rocker cover: Refer to EM-46, " Exploded View " .
NOTE:
The figure shows an example of widely use engine stand that
can support mating surface of transaxle with flywheel or drive-
plate removed.
CAUTION:
Before removing the hanging chains, make sure the engine
stand is stable and there is no risk of overturning.
5. Drain engine oil. Refer to LU-8, " Draining " .
6. Drain engine coolant by removing water drain plug (1) from RH side of the engine. Tool number : KV11105210 (J-44716)
EM
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CAUTION:
Dimension L1 of journal No. 3 is the distance fr om the housing base end surface (bulk) (not the
distance from the thrust bearing mounting end surface).
4. Install signal plate to crankshaft if removed.
a. Set the signal plate (1) with the flange facing toward the counter- weight side (engine front side) to the crankshaft rear surface.
b. After positioning crankshaft and signal plate with positioning dowel pin, tighten bolt.
NOTE:
Dowel pin of crankshaft and signal plate is provided as a set for
each.
c. Remove dowel pin. CAUTION:
Be sure to remove dowel pin.
5. Install crankshaft to cylinder block. • Make sure that crankshaft turns smoothly by hand.
CAUTION:
Never install rear oil seal yet.
6. Install main bearing caps in their original positions. • Install the main bearing cap while referring to the front mark(B) and the journal number stamp (A).
NOTE:
Main bearing cap cannot be replaced as a single part,
because it is machined together with cylinder block.
7. Tighten main bearing cap bolts in numerical order shown with the following steps.
a. Apply new engine oil to threads and seat surfaces of the bolts.
b. Tighten main bearing cap bolts in the numerical order shown. A : Dowel pin hole
: Engine front PBIC3749E
.
2. Install engine to engine stand as follows;
a. Remove flywheel (M/T models) or drive plate (1) (A/T or CVT models).
• Secure flywheel (M/T models) or drive plate (A/T or CVT mod-
els) using Tool (A), and remove bolts.
CAUTION:
Be careful not to damage or scratch drive plate (A/T or CVT
models) and contact surface for clutch disc of flywheel (M/T
models).
NOTE:
Figure shows drive plate (1) (A/T or CVT models)
b. Lift the engine with a hoist to install it onto widely use engine stand. CAUTION:
• Use the engine stand that has a load capacity [approximately 135 kg (298 lb) or more] large
enough for supporting the engine weight.
• If the load capacity of stand is not adequate, remo ve the following parts beforehand to reduce the poten-
tial risk of overturning stand.
- Exhaust manifold; Refer to EM-144 .
- Rocker cover; Refer to EM-153 .
NOTE:
The figure shows an example of widely used engine stand (A)
that can support mating surface of transaxle with flywheel (M/T
models) or drive plate (A/T or CVT models) removed.
CAUTION:
Before removing the hanging chains, make sure the engine
stand is stable and there is no risk of overturning.
3. Remove oil pan (upper and lower). Refer to EM-147 .
4. Remove cylinder head. Refer to EM-185 .
5. Remove thermostat housing. Refer to CO-45 .
6. Remove knock sensor. CAUTION:
Carefully handle knock sensor avoiding shocks.
7. Remove crankshaft position sensor (POS) cover and crankshaft position sensor (POS).
7. Oil pressure switch 8. Top ring 9. Second ring
10. Oil ring 11. Snap ring 12. Piston
13. Piston pin 14. Connecting rod 15. Thrust bearing
16. Connecting rod bearing upper 17. Main bearing upper 18. Crankshaft key
19. Main bearing lower 20. Connecting rod bearing lower 21. Connecting rod bearing cap
22. Connecting rod bolt 23. Main bearing cap 24. Main bearing cap bolt
25. Crankshaft 26. Pilot converter (A/T or CVT models) 27. Signal plate
28. Rear oil seal 29. Drive plate (A/T or CVT models) 30. Reinforcement plate (A/T or CVT models)
31. Flywheel (M/T models) 32. Block heater (Canada only) A. Refer to EM-200 PBIC3227J
Terminal and Reference Value for BCM " .
Work Flow INFOID:0000000004306861
1. Check the symptom and customer's requests.
2. Understand the outline of system. Refer to GW-19, " System Description " .
3. According to the trouble diagnosis chart, repa ir or replace the cause of the malfunction.
Refer to GW-31, " Trouble Diagnosis Symptom Chart " .
4. Does power window system operate normally? If Yes, GO TO 5, If No, GO TO 3.
5. Inspection End.
CONSULT-III Function (BCM) INFOID:0000000004306862
CONSULT-III can display each diagnostic item us ing the diagnostic test modes shown following.
ACTIVE TEST 13 W Encoder pulse A signal
When power window motor oper-
ates
15 G Encoder power supply When ignition switch ON or power
window timer operates 10
16 W Front power window motor LH UP
signal When power window motor is op-
erated UP Battery voltage
17 B Ground — 0
19 P Battery power supply — Battery voltage
Terminal Wire Color Item Condition
Voltage (V)
(Approx.) Test Item Description
RETAINED PWR This test is able to supply RAP signal (powe
r) from BCM (body control module) to power window
system and power sunroof system (if equipped). Those systems can be operated when turning on
“RETAINED PWR” on CONSULT-III screen even if the ignition switch is turned OFF.
NOTE:
During this test, CONSULT-III can be operated with ignition switch in OFF position. “RETAINED
PWR” should be turned “ON” or “OFF” on CONSULT-III screen when ignition switch is ON. Then
turn ignition switch OFF to check retained power operation. CONSULT-III might be stuck if “RE-
TAINED PWR” is turned “ON” or “OFF” on CO NSULT-III screen when ignition switch is OFF.