PRECAUTIONSGI-29
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To prevent ECM from storing the diagnostic trou ble codes, do not carelessly disconnect the harness
connectors which are related to the engine cont rol 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 TM sections.
Three Way CatalystINFOID:0000000009462996
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.
Fuel (Regular Unleaded Ga soline Recommended) QR25DEINFOID:0000000009462997
Use unleaded regular gasoline with an octane rating of at least 87 AKI (Anti-Knock Index) number (Research
octane number 91). E-85 fuel (85% fuel ethanol, 15% unl eaded gasoline) may only be used in vehicles specif-
ically designed for E-85 fuel (i.e. Flexible Fuel Vehicle - FFV models).
CAUTION:
Do not use leaded gasoli ne. Using leaded gasoline will damage the three way catalyst. Do not use E-85
fuel (85% fuel ethanol, 15% unlead ed gasoline) unless the vehicle is specifically designed for E-85 fuel
(i.e. Flexible Fuel Vehicle - FFV models). Using a fu el other than that specified could adversely affect
the emission control devices and systems, and could also affect the warranty coverage validity.
Fuel (Regular Unleaded Gasoline Recommended) VQ35DEINFOID:0000000009462998
Use unleaded regular gasoline with an octane rating of at least 87 AKI (Anti-Knock Index) number (Research
octane number 91). E-85 fuel (85% fuel ethanol, 15% unl eaded gasoline) may only be used in vehicles specif-
ically designed for E-85 fuel (i.e. Flexible Fuel Vehicle - FFV models).
CAUTION:
Do not use leaded gasoli ne. Using leaded gasoline will damage the three way catalyst. Do not use E-85
fuel (85% fuel ethanol, 15% unlead ed gasoline) unless the vehicle is specifically designed for E-85 fuel
(i.e. Flexible Fuel Vehicle - FFV models). Using a fu el other than that specified could adversely affect
the emission control devices and systems, and could also affect the warranty coverage validity.
Multiport Fuel Injection System or Engine Control SystemINFOID:0000000009462999
• Before connecting or disconnecti ng 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.
HosesINFOID:0000000009463000
HOSE REMOVAL AND INSTALLATION
SGI787
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GI-30
< PRECAUTION >
PRECAUTIONS
• To prevent damage to rubber hose, do not pry off rubber hose withtapered 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.
• After installing plate clamps, apply force to them in the direction of the arrow, tightening rubber hose equally all around.
Engine OilsINFOID:0000000009463001
Prolonged and repeated contact with used engine oil may cause skin cancer. Try to avoid direct skin contact
with used oil.
If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible.
HEALTH PROTECTION PRECAUTIONS
• Avoid prolonged and repeated contact with oils, particularly used engine oils.
• Wear protective clothing, including impervious gloves where practicable.
• Do not put oily rags in pockets.
• Avoid contaminating clothes, pa rticularly underpants, with oil.
SMA019D
SMA020D
SMA021D
SMA022D
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SERVICE INFORMATION FOR ELECTRICAL INCIDENTGI-39
< BASIC INSPECTION >
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SERVICE INFORMATION FO R ELECTRICAL INCIDENT
Work FlowINFOID:0000000009463011
WORK FLOW
Control Units and Electrical PartsINFOID:0000000009463012
PRECAUTIONS
• Never reverse polarity of battery terminals.
• Install only parts specified for a vehicle.
• Before replacing the control unit, check the i nput and output and functions of the component parts.
• Do not apply excessive force when disconnecting a connector.
SGI838
STEP DESCRIPTION
STEP 1 Get 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:
WHAT Vehicle Model, Engine, Transmission/Transaxle and the System (i.e. Radio).
WHEN Date, Time of Day, Weather Conditions, Frequency.
WHERE Road Conditions, Altitude and Traffic Situation.
HOW System Symptoms, Operating Conditions (Other Components Interaction).
Service History and if any After Market Accessories have been installed.
STEP 2 Operate the system, road test if necessary.
Verify the parameter of the incident.
If the problem cannot be duplicated, refer to “Incident Simulation Tests”.
STEP 3 Get 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 4 Inspect 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 6 Operate 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.
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GI-44
< BASIC INSPECTION >
SERVICE INFORMATION FOR ELECTRICAL INCIDENT
lowing section illustrates ways to simulate the conditions/environment under which the owner experiences an
electrical incident.
The section is broken into the six following topics:• Vehicle vibration
• Heat sensitive
• Freezing
• Water intrusion
• Electrical load
• Cold or hot start up
Get a thorough description of the incident from the customer . It is important for simulating the conditions of the
problem.
VEHICLE VIBRATION
The problem may occur or become worse while driving on a rough road or when engine is vibrating (idle with
A/C on). In such a case, you will want to check for a vi bration related condition. Refer to the following illustra-
tion.
Connector & Harness
Determine which connectors and wiring harness would affect the electrical system you are inspecting. Gently
shake each connector and harness while monitoring the sy stem for the incident you are trying to duplicate.
This test may indicate a loose or poor electrical connection.
Hint
Connectors can be exposed to moisture. It is possible to get a thin film of corrosion on the connector termi-
nals. A visual inspection may not reveal this without disconnecting the connector. If the problem occurs inter-
mittently, perhaps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean the
terminals on related connectors in the system.
Sensor & Relay
Gently apply a slight vibration to sensors and relays in the system you are inspecting.
This test may indicate a loose or poorly mounted sensor or relay.
Engine Compartment
There are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of the
things to check for are:
• Connectors not fully seated.
• Wiring harness not long enough and is being stressed due to engine vibrations or rocking.
• Wires laying across brackets or moving components.
• Loose, dirty or corroded ground wires.
• Wires routed too close to hot components.
To inspect components under the hood, start by verifyi ng the integrity of ground connections. (Refer to Ground
Inspection described later.) First check that the system is properly grounded. Then check for loose connection
by gently shaking the wiring or components as previous ly explained. Using the wiring diagrams inspect the
wiring for continuity.
Behind the Instrument Panel
An improperly routed or improperly clamped harness can become pinched during accessory installation. Vehi-
cle vibration can aggravate a harness which is routed along a bracket or near a screw.
Under Seating Areas
SGI839
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SERVICE INFORMATION FOR ELECTRICAL INCIDENTGI-45
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An unclamped or loose harness can cause wiring to be pinched by seat components (such as slide guides)
during vehicle vibration. If the wiring runs under s eating areas, inspect wire routing for possible damage or
pinching.
HEAT SENSITIVE
• The customer's concern may occur during hot weather or after car has sat for a short time. In such cases you will want to check for a
heat sensitive condition.
• To determine if an electrical component is heat sensitive, heat the component with a heat gun or equivalent.
CAUTION:
Do not heat components above 60 °C (140 °).
• If incident occurs while heating t he unit, either replace or properly
insulate the component.
FREEZING
• The customer may indicate the incident goes away after the car warms up (winter time). The cause could be related to water freez-
ing somewhere in the wiring/electrical system.
• There are two methods to check for this. The first is to arrange for the owner to leave his car overnight. Make sure it will get cold
enough to demonstrate his complaint. Leave the car parked out-
side overnight. In the morning, do a quick and thorough diagnosis
of those electrical components which could be affected.
• The second method is to put the suspect component into a freezer long enough for any water to freeze. Reinstall the part into the car
and check for the reoccurrence of the incident. If it occurs, repair or
replace the component.
WATER INTRUSION
The incident may occur only during high humidity or in rainy/snowy
weather. In such cases the incident could be caused by water intru-
sion on an electrical part. This c an be simulated by soaking the car
or running it through a car wash.
CAUTION:
Do not spray water directly on any electrical components.
ELECTRICAL LOAD
The incident may be electrical load sensitive. Perform diagnosis with
all accessories (including A/C, rear window defogger, radio, fog
lamps) turned on.
COLD OR HOT START UP
On some occasions an electrical incident may occur only when the car is started cold, or it may occur when
the car is restarted hot shortly after being turned off. In these cases you may have to keep the car overnight to
make a proper diagnosis.
SGI842
SGI843
SGI844
SGI845
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GI-46
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SERVICE INFORMATION FOR ELECTRICAL INCIDENT
Circuit Inspection
INFOID:0000000009463015
DESCRIPTION
• In general, testing electrical circuits is an easy ta sk if it is approached in a logical and organized method.
Before beginning it is important to have all available in formation on the system to be tested. Also, get a thor-
ough understanding of system operation. Then you will be able to use the appropriate equipment and follow
the correct test procedure.
• You may have to simulate vehicle vibrations while te sting electrical components. Gently shake the wiring
harness or electrical component to do this.
NOTE:
Refer to GI-40, "How to Check Terminal"
to probe or check terminal.
TESTING FOR “OPENS” IN THE CIRCUIT
Before you begin to diagnose and test the system, you should rough sketch a schematic of the system. This
will help you to logically walk through the diagnosis process. Drawing the sketch will also reinforce your work-
ing knowledge of the system.
Continuity Check Method
The continuity check is used to find an open in the circ uit. The digital multimeter (DMM) set on the resistance
function will indicate an open circuit as over limit (no beep tone or no ohms symbol). Make sure to always start
with the DMM at the highest resistance level.
To help in understanding the diagnosis of open circui ts, please refer to the previous schematic.
• Disconnect the battery negative cable.
• Start at one end of the circuit and work your way to the other end. (At the fuse block in this example)
• Connect one probe of the DMM to the fuse block terminal on the load side.
• Connect the other probe to the fuse block (power) side of SW1. Little or no resistance will indicate that por-
tion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over
limit or infinite resistance condition. (point A)
• Connect the probes between SW1 and the relay. Little or no resistance will indicate that portion of the circuit
has good continuity. If there were an open in the circuit, t he DMM would indicate an over limit or infinite resis-
tance condition. (point B)
• Connect the probes between the relay and the solenoid. Little or no resistance will indicate that portion of the
circuit has good continuity. If there were an open in the ci rcuit, the DMM would indicate an over limit or infi-
nite resistance condition. (point C)
Any circuit can be diagnosed using the approach in the previous example.
Voltage Check Method
To help in understanding the diagnosis of open circui ts please refer to the previous schematic.
In any powered circuit, an open can be found by methodica lly checking the system for the presence of voltage.
This is done by switching the DMM to the voltage function.
• Connect one probe of the DMM to a known good ground.
• Begin probing at one end of the circuit and work your way to the other end.
• With SW1 open, probe at SW1 to check for voltage. voltage; open is further down the circuit than SW1.
OPEN A circuit is open when there is no continuity through a section of the circuit.
SHORT There are two types of shorts.
• SHORT CIRCUIT When a circuit contacts another circuit and causes the normal resistance to
change.
• SHORT TO GROUND When a circuit contacts a ground source and grounds the circuit.
SGI846-A
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GI-48
< BASIC INSPECTION >
SERVICE INFORMATION FOR ELECTRICAL INCIDENT
• When inspecting a ground connection follow these rules:
- Remove the ground bolt or screw.
- Inspect all mating surfaces for tarnish, dirt, rust, etc.
- Clean as required to assure good contact.
- Reinstall bolt or screw securely.
- Inspect for “add-on” accessories which may be interfering with the ground circuit.
- If several wires are crimped into one ground eyelet termi nal, check for proper crimps. Make sure all of the
wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one eye-
let make sure no ground wires have excess wire insulation.
• For detailed ground distribution information, re fer to “Ground Distribution” in PG section.
VOLTAGE DROP TESTS
• Voltage drop tests are often used to find components or circuits which have excessive resistance. A voltage
drop in a circuit is caused by a resistance when the circuit is in operation.
• Check the wire in the illustration. When measuring re sistance with DMM, contact by a single strand of wire
will give reading of 0 ohms. This would indicate a good circuit. When the circuit operates, this single strand
of wire is not able to carry the current. The single st rand will have a high resistance to the current. This will
be picked up as a slight voltage drop.
• Unwanted resistance can be caused by many situations as follows:
- Undersized wiring (single strand example)
- Corrosion on switch contacts
- Loose wire connections or splices.
• If repairs are needed always use wire that is of the same or larger gauge.
Measuring Voltage Drop — Accumulated Method
• Connect the DMM across the connector or part of the ci rcuit you want to check. The positive lead of the
DMM should be closer to power and the negative lead closer to ground.
• Operate the circuit.
• The DMM will indicate how many volts are being used to “push” current through that part of the circuit.
SGI853
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CONSULT CHECKING SYSTEMGI-51
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DescriptionINFOID:0000000009463016
CAUTION:
After disconnecting the CONSULT vehicle interface (VI) from the data link connector, the ignition must
be cycled OFF → ON (for at least 5 seconds) → OFF. If this step is not performed, the BCM may not go
to “sleep mode”, potentiall y causing a discharged battery and a no-start condition.
NOTE:
This vehicle is diagnosed using the CONSULT-III plus.
• When CONSULT 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 diagnos-
tic tests.
• Refer to “CONSULT-III plus Operation Manual” for more informa- tion.
Function and System ApplicationINFOID:0000000009463017
x : Applicable
1: With NAVI
2: With DAS
3: With auto A/C
CONSULT Data Link Connector (DLC) CircuitINFOID:0000000009463018
INSPECTION PROCEDURE
1 : Data link connector
ALAIA0061ZZ
Direct Diagnostic Mode DescriptionABS
IPDM E/R
MULTI AV
1
BCM
TRANSMISSION
AIR BAG
METER/M&A
ENGINE
AV M
2
EPS/DAST 3 HVAC
3
Occupant Detection
ECU identification The ECU part number is displayed. x x x x x x - x x x x -
Self Diagnostic Result The ECU self diagnostic results are displayed. x x x x x x x x x x x -
Data Monitor The ECU input/output data is displayed in real time. x x x x x x x x x x x -
Active Test The ECU activates outputs to test components. x x - x x - - x x - x -
Work support The settings for ECU functions can be changed. x - - x x - x x x - x x
DTC Work Support The status of system monitoring tests and the self diagnosis
status/results can be confirmed. -------x----
Configuration • The vehicle specification can be read and saved.
• The vehicle specification can be written when replacing ECU. ---x--------
TROUBLE DIAG
RECORD Other results or histories, etc. that are recorded in ECU are
displayed. -----x------
Warning History Displays the history of the combination meter warning lamp in-
dicators. ------x-----
CALIB DATA The calibration values of the ECU are displayed. - - - - x - - - - - - -
CAN Diag Support Mntr The result of transmit/receive diagnosis of CAN communication
is displayed. xxxxxxxxxxx-
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