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> TOYOTA REPAIR MANUAL Aug., 2000 FOREWORD This repair manual has been prepared to provide information covering general service repairs for the 1KD~ FTV engine equipped on the LAND CRUISER/LAND CRUISER PRADO. Applicable models: KDJS0, 95 series Al information in this manual is based on the latest product information at the time of publication. However, specifications and procedures are subject to change without nolice. TOYOTA MOTOR CORPORATION (©2000 TOYOTA MOTOR CORPORATION Ail rights reserved. This book may not be repro- ‘duced oF copied, in whole or in part, without the ‘weitten permission of Toyota Motor Corporation. First Printing: Jul. 10, 2000 01-0007 10-00 CAUTION This manual does not include all the necessary items about repair and service. This manual is made for the purpose of the use for the persons who have special techniques and certifications. in the cases that non-specialized or uncertified technicians perform repair or service only using this manu- al or without proper equipment or tool, that may cause severe injury to you or other people around and also cause damage to your customer's vehicle. In order to prevent dangerous operation and damages to your customer's vehicle, be sure to follow the instruction shown below. + Mustread this manual thoroughly. itis especially important to have good understanding all the contents written in the PRECAUTION of "IN" section + The service method written in this manualis very eftective to pertorm repair and service. When performing the operations following the procedures using this manual, be sure to use tools spe- cified and recommended. If using non-specified or recommended tools and service method, be sure to confirm safety of the technicians and any possibility of causing personal injury or damage to the customer's vehicle before starting the operation. + Ifpartreplacementis necessary, must replace the part with the same part number or equivalent part. Do not replace it with inferior quality. + Itis important to note that this manual contains various "Cautions" and "Notices" that must be carefully abserved in order to reduce the risk of personal injury during service or repair, or the possibility that improper service or repair may damage the vehicle or render it unsafe. Itis also important to understand that these "Cautions" and "Notices” are not exhaustive, because it is important to warn of all the possible hazardous consequences that might result from failure to follow these instructions. INTRODUCTION PREPARATION SERVICE SPECIFICATIONS DIAGNOSTICS ENGINE MECHANICAL TURBOCHARGING EMISSION CONTROL ELECTRONIC CONTROL DIESEL ENGINE FUEL COOLING LUBRICATION STARTING CHARGING ALPHABETICAL INDEX | Ll | INTRODUCTION HOW TO USE THIS MANUAL . 7 GENERAL INFORMATION IN IDENTIFICATION INFORMATION |... IN-3 ENGINE SERIAL NUMBER INS REPAIR INSTRUCTIONS - IN GENERAL INFORMATION Ina FOR ALL OF VEHICLES ... cece IN-8 PRECAUTION Ing HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS... IN-9 GENERAL INFORMATION . IN-o HOW TO PROCEED WITH TROUBLESHOOTING .. cee INO HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDURE ...... IN-20 TERMS |... cee INAS ABBREVIATIONS USED IN THIS MANUAL IN-25: Nt INTRODUCTION — HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL GENERAL INFORMATION 1. INDEX ‘An INDEX is provided on the first page of each section to guide you to the item to be repaired, To assist you in finding your way through the manual, the section title and major heading are given at the top of every page. 2. PRECAUTION At the beginning of each section, a PRECAUTION is given that pertains to all repair operations contained in that section. Read these precautions before starting any repair task. 3. TROUBLESHOOTING TROUBLESHOOTING tables are included for each system to help you diagnase the problem and find the cause. The fundamentals of how to proceed with troubleshooting are described on page IN~9. Be sure to read this before pertorming troubleshooting. 4, PREPARATION Preparation lists the SST (Special Service Tools), recommended taols, equipment, lubricant and SSM (Spe- cial Service Materials) which should be prepared before beginning the operatian and explains the purpose of each one. 5. REPAIR PROCEDURES Most repair operations begin with an overview iliustcation. It identifies the components and shows how the parts fit together. Example: Driven Rotor Crankshatt Front Oil Seal SY aie Vane a ¢ Gasket 5, Plug 49 (500, 36) Kim (kafom, #ibi)_] : Specified torque ovine @Non-reusablepart exe m2 INTRODUCTION HOW TO USE TAS MANUAL ‘The procedures are presented in a step-by-step format + The illustration shows what to do and where to do it. + The task heading tells what to do. + The detailed text tells how to perform the task and gives other information such as specifications and warnings. Example in | Taskeading what do 21, CHECK PISTON STROKE OF OVERDRIVE BRAKE (a) Place SST and a dial indicator onto the overdtive brake pis- ton as shown in the illustration, ‘SST 09350-30020 (09350-06120) Ilustration: what go Eee inene? Set part No. Component part No. Detailed text; how todo task {b) Measure the stroke applying and releasing the compressed air (392 —785 kPa, 4— Bkgt/cm?or57— 114psi) as shown in the illustration. Piston stroke: 1.40 — 1.70 mm (0.0551 — 0.0669 in.) ea This format provides the experienced technician with a FAST TRACK to the information needed. The upper case task heading can be read at a glance when necessary, and the text below it provides detailed informa- tion. Important specifications and warnings always stand out in bold type. 6. REFERENCES References have been kept to a minimum. However, when they are required you are given the page to refer to, 7. SPECIFICATIONS ‘Specifications are presented in bold type throughout the text where needed. You never have to leave the procedure to look up your specifications. They are also found in Service Specifications section for quick ref- erence. 8. CAUTIONS, NOTICES, HINTS: + CAUTIONS are presented in bold type, and indicate there is a possibility of injury to you or other people. + NOTICES are also presented in bold type, and indicate the possibility of damage to the components being repaired, + HINTS are separated from the text but do not appear in bold. They provide aditional information to help you perform the repair efficiently. 9, SIUNIT The UNITS given in this manual are primarily expressed according to the SI UNIT (International System of Unit), and alternately expressed in the metric system and in the English System. Example: Torque: 30 N-m (310 kgf-cm, 22 ft-lbt} INTRODUCTION —_ IDENTIFICATION INFORMATION us IDENTIFICATION INFORMATION ENGINE SERIAL NUMBER The engine serial number is stamped on the engine block, as shown in the illustration. Ns INTRODUCTION — REPAIR INSTRUCTIONS. (a) (b) raarv7] (©) (3) (e) (9) REPAIR INSTRUCTIONS GENERAL INFORMATION BASIC REPAIR HINT Use fender, seat and floor covers to keep the vehicle clean and prevent damage. During disassembly, keep parts in the appropriate order to facilitate reassembly. Observe the following operations (1) Before performing electrical work, disconnect the negative (-) terminal cable from the battery. (2) Ifit is necessary to disconnect the battery for in- spection or repair, always disconnect the negative (-) terminal cable which is grounded to the vehicle body. (3) To prevent damage to the battery terminal, loosen the cable nut and raise the cable straight up without twisting or prying it (4) Clean the battery terminals and cable ends with a clean shop rag. Do not scrape them with a file or oth- er abrasive objects. (5) _ install the cable ends to the battery terminals with the nut loose, and tighten the nut after installation. Do not use a hammer to tap the cable ends onto the terminals. (6) Be sure the cover for the positive (+) terminal is properly in place. Check hose and wiring connectors to make sure that they are secure and correct. Non-reusable parts (1) Always replace cotter pins, gaskets, O-rings and oil seals etc. with new ones. (2) Non-reusable parts are indicated in the component illustrations by the "@" symbol. Precoated paris Precoated parts are bolts and nuts, etc. that are coated with a seal lock adhesive at the factory. (1) If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the specified adhesive. (2) When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply the specified seal lock adhesive to the bolt, nut or threads, (3) Precoated parts are indicated in the component i lustrations by the "*” symbol When necessary, use a sealer on gaskets to prevent leaks. INS INTRODUCTION — REPAIR INSTRUCTIONS (h) Carefully observe all specifications for bolt tightening torques. Always use a torque wrench. (i) Use of special service tools (SST) and special service ma- terials (SSM) may be required, depending on the nature of the repair. Be sure to use SST and SSM where speci- fied and follow the proper work procedure. A list of SST and SSM can be found in section PP (Preparation) in this ce manual i) When replacing fuses, be sure the new fuse has the cor- rect amperage rating. DO NOT exceed the rating or use one with a lower rating Medium Current Fuse and High Current Fuse Equal Amperage Rating lustration Symbol Part Name ‘Abbreviation ae SSP a FUSE FUSE rd A ese sass a MEDIUM CURRENT FUSE M-FUSE ss swoaee Po HIGH CURRENT FUSE H-FUSE ~-9o FUSIBLE LINK FL -PS4- | oncurrsrecaxen ca (k) Care must be taken when jacking up and supporting the vehicle. Be sure to lit and support the vehicle at the prop- er locations. + Cancel the parking brake on the level place and shift the transmission in Neutral (or N position). + When jacking up the front wheels of the vehicle at first piace stoppers behind the rear wheels. + When jacking up the rear wheels of the vehicle at first place stoppers behind the rear wheels. IN-6 INTRODUCTION —_ REPAIR INSTRUCTIONS. + When either the front or rear wheels only should be set rigid racks and place stoppers in front the other wheels on the ground. + After the vehicle is jacked up, be sure to support it on rigid racks. It is extremely dangerous to do any work on a vehicle raised on a jack alone, even for a smail job that can be finished quickly. (i) Observe the following precautions to avoid damage to the following parts: (1) Do not open the cover or case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electric- ity) (2) To disconnect vacuum hoses, pull off the end, not the middle of the hose. (3) To pull apart electrical connectors, pull on the con- nector itself, not the wires. (4) Be careful not to drop electrical components, such as sensors or relays. If they are dropped on a hard floor, they should be replaced and not reused. (5) When steam cleaning an engine, protect the eleo- | tronic components, air filter and emission-related ‘components from water. eats (6) Never use an impact wrench to remove or install temperature switches or temperature sensors. (7) When checking continuity at the wire connector, in- sert the tester probe carefully to prevent terminals from bending. (8) When using a vacuum gauge, never force the hose onto a connector that is too large. Use a step-down adapter for adjustment. Once the hose has been stretched, it may leak. INT INTRODUCTION —_REPAIR INSTRUCTIONS. (m) Tag hoses before disconnecting them: (1) When disconnecting vacuum hoses, use tags to identity how they should be reconnected. (2) After completing a job, double check that the vacu- um hoses are properly connected. A label under the hood shows the proper layout. (n) Unless otherwise stated, all resistance is measured at an ambient temperature af 20°C (68°F). Because the resis- tance may be outside specifications if measured at high temperatures immediately after the vehicle has been run- ning, measurement should be made when the enging has cooled down. IN-8 WWMROQUGTION FOR ALL OF VEHIGLE FOR ALL OF VEHICLES PRECAUTION 1, FOR VEHICLES EQUIPPED WITH A CATALYTIC CONVERTER CAUTION: if large amount of unburned gasoline flows into the converter, it may overheat and create a fire haz- ard. To prevent this, observe the following precautions and explain them to your customer. (a) _ Use only unleaded gasoline. (b) Avoid prolonged idling. Avoid running the engine at idle speed for more than 20 minutes. (c)_ Avoid spark jump test. (1) Perform spark jump test only when absolutely necessary. Perform this test as rapidly as possible. (2) While testing, never race the engine. (a) Avoid prolonged engine compression measurement. Engine compression tests must be done as rapidly as possible. (@) Do not run engine when fuel tank is nearly empty. This may cause the engine to misfire and create an extra load on the converter. (f) Avoid coasting with ignition turned off and prolonged braking (9) Do not dispose of used catalyst along with parts contaminated with gasoline or oil. 2. IF VEHICLE IS EQUIPPED WITH MOBILE COMMUNICATION SYSTEM For vehicles with mobile communication systems such as two-way radios and cellular telephones, observe the following precautions. (1) Install the antenna as far as possible away fram the ECU and sensors of the vehicle's electronic system. (2) _ Install the antenna feeder at least 20 cm (7.87 in.) away from the ECU and sensors of the ve- hicle’s electronic systems. For details about ECU and sensors locations, refer to the section on the applicable component. (3) Avoid winding the antenna feeder together with the other wiring as much as possible, and also avoid running the antenna feeder parallel with other wire harnesses. (4) Check that the antenna and feeder are correctly adjusted. (5) Do not install powerful mobile communications system. 3. FOR USING HAND-HELD TESTER CAUTION: Observe the following items for safety reasons: + Before using the hand-held tester, the hand-held tester’s operator manual should be read throughly. + Be sure to route all cables securely when driving with the hand-held tester connected to the vehicte. (i.e. Keep cables away from feet, pedals, steering wheel and shift lever.) + Two persons are required when test driving with the hand-held tester, one person to drive the vehicle and one person to operate the hand-held tester. INTRODUCTION — HOW 1. TROUBLESHOOT ECU CONTROLLED Ine SYSTEMS HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS GENERAL INFORMATION A large numbers of ECU cantrolled systems are used in the LAND CRUISER/LAND CRUISER PRADO. In general, the ECU controlled system is considered to be a very intricate system Cequiring a high level of techni- cal knowiedge and expert skill to troubleshoot. However, the fact is that if you proceed to inspect the circuits one by one, troubleshooting of these systems is not complex. If you have adequate understanding of the system and a basic knowledge of electricity, accurate diagnosis and necessary repair can be performed to Jocate and fix the problem. This manual is designed through emphasis of the above standpoint to help ser- vice technicians perform accurate and etfective troubleshaating, and is compiled for the following major ECU controlled systems: System Page Engine Dia The troubleshooting procedure and how to make use of it are described on the above pages. FOR USING HAND-HELD TESTER + Before using the hand-held tester, the hand held-tester’s operator manual should be read throughly. + Ifthe hand-held tester cannot communicate with ECU controlled systems when you have connected the cable of the hand-held tester to DLCS, turned the ignition switch ON and operated the scan tool, there is a problem on the vehicle side or too! side. (1) If communication is normal when the taal is connected to another vehicle, inspect the diagnosis data link line (Bus@line) or ECU power circuit of the vehicle, (2) communication is still not possible when the tool is connected to another vehicle, the problem is probably in the fool itself, so pertorm the Seif Test procedures outlined in the Tester Operator's Manual. IND INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS, HOW TO PROCEED WITH TROUBLESHOOTING Carry out troubleshooting in accordance with the procedure on the following page. Here, only the basic pro- cedure is shown. Details are provided in each section, showing the most effective methods far eactt circuit Confirm the troubleshooting procedures first for the relevant circuit before beginning troubleshooting of that circuit (Vehicle Brought to Workshop) D : Vv " [Rape seat tna I 2 orn Confirmation Le 3 _ Sete Crook Trouble — Symptom Simulation 7 f 2,3 Confirm the symptoms and the problem conditions, and check the diagnostic trouble codes. i | (When the prablem symptoms do not appear during confirmation, use the symptom simulation method described later on.) 4 _/ Diagnostic Trouble a 7] / Code Chant | f] Vv | > reste Seton Ta | fl 45,6 Check the results obtained in Step 2, then confirm the inspection procedure for the system or the part Vv which should be checked using tte diagnostic 6 £ Girt inspection or Pais trouble code chart or the problem symptoms table: ree _ / 7 ‘Check and repair the affected system or part in accordance with the instructions in Step 6. 8 After completing repairs, confirm that the problem has been eliminated (if the problem is not reproduced, pertarm the confirmation test under the same conditions and in the same environment as when it occurred for the first time.) WTRODUCTION - HOWTO TROUBLESHOOT ECU CONTROLLED ment 1. CUSTOMER PROBLEM ANALYSIS In troubleshooting, the problem symptoms must be confirmed accurately and all preconceptions must be cleared away in order to give an accurate judgement. To ascertain just what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time it occurred. Important Point in the Problem Analysis: The following 5 items are important points in the problem analysis. Past problems which are thought to be unrelated and the repair history, etc. may also help in some cases, so as much information as possible should be gathered and its relationship with the problem symptoms should be correctly ascertained for reference in troubleshooting. A customer problem analysis table is provided in the troubleshooting section for each system for your use. Important Points in the Customer Problem Analysis ———- © What Vehicle model, system name © When Date, time, occurrence frequency © Where Road conditions ‘¢ Under what concitione? How did it happen? Running conditions, driving conditions, weather conditions Problem symptoms (Sample) Engine control system check sheet. CUSTOMER PROBLEM ANALYSIS GHECK ENGINE CONTROL SYSTEM Check Sheet _|zspectors ‘Customer's Name Model and Mode! Driver's Name Frame No. Data Venice Brovstt is Engine Model im License No. ‘Odometer Reading les DEngine does ine does not eran Initial combustion (0 complete combustios Engine does | [Engine does not crank No initial combusti No complete combustion piticuitto | Gengine cranks slowly Start other, incorrect frst idle Clidling rpmis abnormal C1 High( rpm) ClLow( GPooriaiieg | CRoughicling _Cother GHesitation Back fre ‘CiMuttler explosion (atter-tre) surging knocking other. Door Bre ability Problem Symptoms Soon after starting I depressed engine Stall | C1 After accelerator pedal released During A/C operation Cshining trom NtoD Other sasiant CiSometimes( times per _—_dayimont IN-12 INTRODUCTION - OW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS, 2. SYMPTOM CONFIRMATION AND DIAGNOSTIC TROUBLE CODE CHECK The diagnostic system in the LAND CRUISE/LAND CRUISER PRADO fulfills various functions. The first function is the Diagnostic Trouble Code Check in which a malfunction in the signal circuits to the ECU is stored in code in the ECU memory at the time of occurrence, to be output by the technician during trouble- shooting. Another function is the Input Signal Check which checks if the signals from various switches are sent to the ECU correctly. By using these check functions, the problem areas can be narrowed down quickly and troubleshooting can be performed effectively. Diagnostic functions are incorporated in the following systems in the LAND CRUIS- ER/LAND CRUISER PRADO. Diagnostic Troube | Input Signal Check ] Cher Diagnosis System Code Check | (Sensor Check) Funetion Engine | o ° (with Test Mode) In diagnostic trouble code check, itis very important to determine whether the problem indicated by the diag- nastic trouble code is still occurring or occurred in the past but returned to normal at present. In addition, it must be checked in the problem symptom check whether the malfunction indicated by the diagnostic trouble code is directly related to the problem symptom or not. For this reason, the diagnostic trouble codes should be checked before and after the symptom confirmation to determine the current conditions, as shown in the table below. If this is not done, it may, depending on the case, result in unnecessary troubleshooting fot normally operating systems, thus making it more difficult to locate the problem, or in repairs not pertinent to the problem. Therefore, always follow the procedure in correct order and perform the diagnostic trouble code check. DIAGNOSTIC TROUBLE CODE CHECK PROCEDURE Diagnostic Trouble Code Check (Make a Note of and then clear) Confirmation | Diagnostic Trouble| Pr of Symptoms | Code Check roblem Condition Diagnostic Trouble [Problem symptoms] Same diagnostic | problemis stil occurring in the diagnostic (Cade Display exist trouble code is |tycuit displayed Normralcodeis | The problem is stl occurring in a place > displayed ‘other than in the diagnostic circuit (The diagnostic trouble code displayed first is either for a past problem or itis a secondary problem) (No problem The problem occurred in the diagnostic TEymptoms exist circuit in the past Normal Gode Display,_-LProblem symptoms|Normal codeis | The problems stil occurring in a place Brit displayed other than in the diagnostic circuit No probiem Normal codeis [The problem occurred in a place other Symptoms exist | displayed than in the diagnostic circuit in the past INTRODUCTION ~ HOW TOTROUBLESHOOT ECU CONTROLLED IN-13 SYSTEMS Taking into account the above points, a flow chart showing how to proceed with troubleshooting using the diagnostic trouble code check is shown below. This flow chart shows how to utlize the diagnostic trouble code check effectively, then by carefully checking the results, indicates how to proceed either to diagnos trouble code troubleshooting or to troubleshooting of problem symptoms. ' Diagnostic trouble code check’ _ | Making a nate of and clearing ofthe diagnostic trouble codes displayed Symptom confirmation | [7] Problem symptoms “ No problem symptoms TSmSIOn eS Ueing IRE I) Simulation test using the symptom | simulation methods __g Vv ‘© Diagnostic trouble code displayed '® Normal code displayed ‘* Normal code displayed » Problem symptoms exist © Problem symptoms exist © No problem symptoms exist VY __ YY Troubleshooting of problem indicated Troubleshooting of each ‘System Normal by diagnostic trouble code problem symptom end _ if a diagnostic trouble code was displayed in the initial diagnostic trouble code check, it indicates that the trouble may have occurred in a wire harness or connector in that circuit in the past. Therefore, check the wire hamess and con: nectors (See page IN-20}. IN-14 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS, 3. SYMPTOM SIMULATION The most difficult case in troubleshooting is when there are no problem symptoms occurring. In such cases, a thorough customer problem analysis must be carried out, then simulate the same or similar conditions and environment in which the problem occurred in the customer's vehicle. No matter haw much experience a technician has, or how skilled he may be, if he proceeds to troubleshoot without confirming the problem symptoms he will tend to overlook something important in the repair operation and make a wrong quess somewhere, which will only lead to a standstil. For example, for a problem which only occurs when the en- gine is cold, or for a problem which occurs due to vibration caused by the road during driving, etc., the prob- lem can never be determined so long as the symptoms are confirmed with the engine hot condition or the vehicle at a standstill. Since vibration, heat or water penetration (moisture) is likely cause for problem which is difficult to reproduce, the symptom simulation tests introduced here are effective measures in that the ex- ternal causes are applied to the vehicle in a stopped condition important Points in the Symptom Simulation Test Inthe symptom simulation test, the problem symptoms should of course be confirmed, but the problem area or parts must also be found out. To de this, narrow down the possible problem circuits according to the symp- toms before starting this test and connect a tester beforehand. After that, carry out the symptom simulation test, judging whether the circuit being tested is defective or normal and also confirming the problem symp- (oms at the same time. Refer to the problem symptoms table for each system to narrow down the possible causes of the symptom. 1 | VIBRATION METHOD: When vibration seems to be the major cause. CONNECTORS Slightly shake the connector vertically and horizontally WIRE HARNESS Slightly shake the wire harness vertically and horizontally The connector joint, fulcrum of the vibration, and body through portion are the major areas to be checked thorough: y ‘Swing Slightly PARTS AND SENSOR Vibrate Siightly Apply slight vibration with a finger to the part of the sensor SN considered to be the problem cause and check that the Ry ‘malfunction occurs, TM HINT: Applying strong vibration to relays may resultin open SNF relays, SS Sc Sd. SN | INTRODUCTION - HOW. SYST TQTROUBLESHOOT ECU CONTROLLED INAS 2 | HEAT METHOD: When the problem seems to occur when the suspect area is heated. Heat the component that is the likely cause of the malfunction ‘with a hair dryer or similar object. Check to see ifthe malfunction occurs. NOTICE: (1) Do not heat to more than 60°C (140°F). (Temperature is limited not to damage the components.) (2) Do not apply heat directly to parts in the ECU. ‘When the malfunction seems to occur on a rainy day or ina 3._| WATER SPRINKLING METHOD: (hae ee ondtion, Sprinkle water onto the vehicle and check to see if the malfunc- tion ocours, NOTICE: (1) Never sprinkle water directly into the engine compartment, but indirectly change the temperature and humidity by applying water spray onto the radiator front surface. (2) Never apply water directly onto the electronic ‘components. HINT: Ifa vehicle is subject to water leakage, the leaked water may contasninate the ECU, When testing a vehicle with a water leak- ‘age problem, special caution must be taken. 4 | OTHER: When a malfunction seems to occur when electrical load is excessive. Turn on all electrical loads including the heater blower, head! lights, rear window defogger, etc. and check to see if the mal- function occurs. IN-16 INTRODUCTION - HOW TO TROUBLESHOOT ECU CONTROLLED sysreg 4, DIAGNOSTIC TROUBLE CODE CHART The inspection procedure is shown in the table below. This table permits efficient and accurate troubleshoot- ing using the diagnostic trouble codes displayed in the diagnostic trouble code check. Proceed with trouble shooting in accordance with the inspection procedure given in the diagnostic chart corresponding to the diagnostic trouble codes displayed. The engine diagnostic trouble code chart is shown below as an example. ¢ DTC No. Indicates the diagnostic trouble code. Page or Instructions Indicates the page where the inspection procedure © Trouble Area | foreach circuit is to be found, or gives instructions Indicates the suspect area of the for checking and repairs. problem ‘* Detection item Indicates the system of the problem or | contents of the problem. piadwosmic TROUBLE CODE CHART HINT; Parahetr stein th chart may rofbe exact the same as yourreadng tothe type instrument or ther factoys. | ita "huntn code is displayed djiring the DTC check in check (test) mdde, check the circuit for that code listed in the table below. For details of each code, tum to the page retertpd to under the “See page” for the respgptve ‘DTC No.” in the DTC ghar. ro OTC No amar? Detection tem “Trova Area sot ete) ont Nomen] Memory sankshatt Postion Sensor ‘© Open or short in crankshaft position sensor circuit 2 CrankshattPositionSensorCircuit —§ Crankshatt postion sensor onna| © (01-12) Maltneson Engine ECU cps pen or shor in engine speed sansor Grout 7 (01-28) | saltuncon cere eoe onina| O | ‘© Open or short in E-VAV for main actuator circuit | | ‘© E-VAV for main actuator ‘5 Diesel Trobe Contr Grcuit _|_—© Dosa trot postion sensor rut (01-32) | Mattuncion ‘ Diese! throttle position sensor onnal © | [ees LT erie 1c Mattnetion Engine eo INTRODUCTION — HOW TO TROUBLESHOOT ECU CONTROLLED: IN-17 SYSTEMS, 5. PROBLEM SYMPTOMS TABLE The suspect circuits or parts for each problem symptom are shown in the table below, Use this table to trou- bleshoot the problem when a "Normal" code is displayed in the diagnostic trouble code check but the prob- lem is still occurring. Numbers in the table indicate the inspection order in which the circuits or parts should be checked. HINT: When the problem is not detected by the diagnostic system even though the problem symptom is present, itis considered that the problem is occurring outside the detection range of the diagnostic system, or that the problem is occurring in a system other than the diagnostic system. | © Page Indicates the page where the flow chart for each circuit is located. ‘Circuit Inspection, inspection Order Indicates the circuit which needs to be checked for each problem symptom. Check in the order indicated by the numbers. © Circuit or Part Name Indicates the circuit or part which needs to be checked. © Problem Symptom \— —— —— \ | \ PROBLEM SYUPTOMS TABLE \ | ! \ Symptom \ Suspect Area Seo page Ys. starter Engine does not fank (Does nt start “ ° i Z |2. Starter relay VEU power source Srcuit I-93 t 2. Pro-heating systom ste (intial combustion (Does not tar ‘ 3. Compression EM-2 4 Engine ECU noo _| 1. Pre-heating system st2 2, Sater signal iui bis 3. Watertempeature sensor eD-41 4: ljector Cold engine (Dilfeut to stan) c ‘sine 5. Fuel filter Fut 6. Diese! throttle body Dk 26 7. Engine ECU IN-20 | 1. Slater sgnal creat DENG | 2. injector 3. Ful fiter 4 Diese tivotie body 5. Engine FOU 1. Fuel iter 2. Diesolthoitle body 2 wu N18 INTRODUCTION - HOWTO TROUBLESHOOT ECU CONTROLLED SYSTEMS 6. CIRCUIT INSPECTION How to read and use each page is shown below. « Diagnostic Trouble Code No. and Detection item ‘Circuit Description The major role and operation, eto. of the circuit and its component parts are explained, DTe) 42 | Grankshail Position Sepor Circuit Malfunc- | L tion pf CIRCUIT DESCRIPTION rrousesinmesgiy2urp, ANE soa snzrgenasies 2g erine2 rns Tenia ECU sets —. res * indicates the diagnostic trouble code, diagnostic |" trouble code set parameter and suspect area of the problem. WIRING DIAGRAM “T © Wiring Diagram This shows a wiring diagram of the circuit. Use this diagram together with ELECTRICAL, WIRING DIAGRAM to thoroughly understand the a circuit S T Wire colors are indicated by an alphabetical code. Ole 8 = Black, L = Blue, R = Red, BR LG = Light Green, V = Violet, G = Green, en tes O = Orange, W = White, GR'= Gray, P = Pink, pe —e Y= Yellow Gi. iw le alle The firs letter indicates the basicwire colorand the J — re second letter indicates the color of the stripe. ie Sone Sense INTRODUCTION ~ HOW TO TROUBLESHOOT ECU GONTROLLED IN-19 SYSTEMS, [° Indicates the position of the ignition switch during the check.| | inspection Procedure vock oN Use the inspection procedure to determine (© lanitien Switch LOCK (OFF) (7), !anition Switeh ON | | if the circuit is normal or abnormal, and if Soar ee it is abnormal, use it to determine whether the problem is located in the sensors, Q torion sw lain Switen ACC JD ‘anion Switen START _ actuators, wire hamess or ECU. \ \ INSPECTION PROCEDURE | \ Chock continuity between terminal THW of ECU connector and body ground. Teak "PREPARATION ey aa (@) Remove the glove companment S, {b) Disconnect the E5 connector of ECU inal CHECK: rc gar Measure resistance between termina THW of ECU connector and body ground. Vscwmew | OX: Resistance: 1 Ma or higher I 0K ) | Goto steps. ‘Check water temp. sensor (See page ED-10). X ok | Replace water temp. sensor. —— Indicates the place to check the voltage or resistance. ® Indicates the connector position to be checked, irom the front or back side. J Wire Harness Check trom the connector back side. Check from the connector front side. (without harness) (with harness) In this case, care must be taken not to bend the terminals. # Indicates the condition gf he comecto of ECL during the check ae E6 Connector Connector being checked is connected. Connector being checked is disconnected. IN-20 INTRODUCTION ~ HOW TO TROUBLESHOOT EGU CONTROLLED SYSTEMS. HOW TO USE THE DIAGNOSTIC CHART AND INSPECTION PROCEDU RE CONNECTOR CONNECTION AND TERMINAL IN- SPECTION + For troubleshooting, diagnostic trouble code charts or problem symptom charts are provided for each circuit with detailed inspection procedures on the following pages. + When all the component parts, wire harnesses and con- nectors of each circuit except the ECU are found to be normal in troubleshooting, then it is determined that the problem is in the ECU. Accordingly, if diagnosis is per- formed without the problem symptoms occurring, refer to step 8 to replace the ECU, even if the problem is notin the ECU. So always confirm that the problem symptoms are occurring, or proceed with inspection while using the symptom simulation method + The instructions "Check wire harness and connector’ and "Check and replace ECU" which appear in the inspection procedure, are common and applicable to all diagnostic trouble codes. Follow the procedure outlined below whenever these instructions appear. OPEN CIRCUIT: This could be due to a disconnected wire harness, faulty con- tact in the connector, and a connector terminal pulled out, etc. HINT: + tis rarely the case that a wire is broken in the middle of it, Most cases occur at the connector. In particular, care- fully check the connectors of sensors and actuators. + Faulty contact could be due to rusting of the connector terminals, to foreign materials entering terminals or a de- formation of connector terminals. Simply disconnecting and reconnecting the connectors once changes the condition of the connection and may result in a return to normal operation. Therefore, in troubleshooting, if no ab- normality is found in the wire harness and connector check, but the problem disappears after the check, then the cause is considered to be in the wire harness or con- rectors. SHORT CIRCUIT: This could be due to a contact between wire harness and the body ground or to a short circuit occurred inside the switch, etc. HINT: When there isa short circuit between the wire harness and body ground, check thoroughly whether the wire hares is caught in the body or is clamped properly. INTRODUCTION ~ HOV To TROUBLESHOOT ECU CONTROLLED IN-2t Sensor Side A ECU Side Sensor Side ECU Side 3 <=> Pull Lightly Looseness of Crimping SYSTEMS, 2. CONTINUITY CHECK (OPEN CIRCUIT CHECK) (a) Disconnect the connectors at both ECU and sensor sides. (b) Measure the resistance between the applicable terminals of the connectors. Resistance: 10 or less . Measure the resistance while lightly shaking the wire hax- ness vertically and horizontally. + When tester probes are inserted into a connector, insert the probes from the back. For waterproof connectors in which the probes cannot be inserted from the back, be careful not to bend the terminals when inserting the tester probes. 3. RESISTANCE CHECK (SHORT CIRCUIT CHECK) (a) Disconnect the connectors on both ends. (b) Measure the resistance between the applicable terminals of the connectors and body ground. Be sure to carry out this check on the connectors on both ends. Resistance: 1 MQ or higher HINT: ‘Measure the resistance while lightly shaking the wire harness vertically and horizontally. 4, VISUAL CHECK AND CONTACT PRESSURE CHECK (a) Disconnect the connectors at both ends. (b) Check for rust or foreign material, etc. in the terminals of the connectors. (c) Check crimped portions for looseness or damage and check that the terminals are secured in lock portion. HINT: The terminals should not come out when pulled lightly. (d) Prepare a test male terminal and insert it in the female ter- minal, then pull it out. NOTICE: When testing a gold-plated female terminal, always use a gold-plated male terminal. HINT: When the test terminal is pulled out more easily than others, there may be poor contact in that section. IN-22 INTRODUCTION ~ HOW TOTROUBLESHOOT ECU CONTROLLED SYSTEMS, A Fig. 1 ECU Loren] @ ® Sensory y t Ai} 2. 2 ECU 5. CONNECTOR HANDLING When inserting tester probes into a connector, insert them from the rear of the connector. When necessary, use mini test leads. For water resistant connectors which cannot be accessed from behind, take good care not to deform the connector terminals. 6. CHECK OPEN CIRCUIT For the open circuit in the wire hamess in Fig. 1, perform "(a) Continuity Check” or "(b) Voltage Check’ to locate the section (a) Check the continuity (1) (2) Disconnect connectors A” and °C" and measure the resistance between them. in the case of Fig. 2, Between terminal 1 of connector “A” and terminal 1 of connector "C" -> No continuity (open) Between terminal 2 of connector “A” and terminal 2 of connector "C" > Continuity Therefore, it is found out that there is an open circuit, between terminal 1 of connector "A” and terminal 4 of connector °C” Disconnect connector "B" and measure the resis- tance between the connectors. In the case of Fig. 3, Between terminal 1 of connector "A" and terminal 1 of connector "B1" -» Continuity Between terminal 1 of connector "B2” and terminal 1 of connector "C" > No continuity (open) Therefore, itis found out that there is an open circuit between terminal 1 of connector "B2" and terminal 1 of connector "C’ INTRODUCTION - HOWTO TROUBLESHOOT ECU CONTROLLED IN-23 SYSTEMS, ou ® Sensor é i al Fig. 6 ecu Sensor (b) Check the voltage. Ina circuit in which voltage is applied (to the ECU connec- tor terminal), an open circuit can be checked for by con- ducting a voltage check. As shown in Fig. 4, witht each connector still connected, measure the voltage between body ground and terminal 1 of connector “A” at the ECU SV output terminal, terminal 1 of connector "B", and terminal 1 of connector "C”, in that order. (Cthe results are: 5V: Between Terminal 1 of connector “A’ and Body Ground 5V: Between Terminal 1 of connector "B" and Body Ground OV: Between Terminal 1 of connector "C* and Body Ground Then it is found out that there is an open circuit in the wire hat- ness between terminal 1 of "B” and terminal 1 of "C” 7. CHECK SHORT CIRCUIT Ifthe wire hamessis ground shorted as in Fig. 5, locate the sec- tion by conducting a “continuity check with ground”. Check the continuity with ground, (1) Disconnect connectors “A” and °C” and measure the resistance between terminal 1 and 2 of connec- tor "A" and body ground. In the case of Fig. 6 Between terminal 1 of connector ground > Continuity (short) Between terminal 2 of connector "A" and body ground -» No continuity Therefore, it is found out that there is a short circuit between terminal 1 of connector “A” and terminal 1 of connector "C and body INTRODUCTION (2) HOW To TROUBLESHOOT ECU CONTROLLED SYSTEMS Disconnect connector "B" and measure the resis- tance between terminal 1 of connector "A" and body ground, and terminal 1 of connector "B2" and body ground. Between terminal 1 of connector "A" and body ground > No continuity Between terminal 1 of connector "B2" and body ground > Continuity (short) ‘Therefore, itis found out that there is a short circuit between terminal 1 of connector "B2" and terminal 1 of connector °C" 8. CHECK AND REPLACE ECU First check the ECU ground circuit. Ifit is faulty, repair it If itis normal, the ECU could be faulty, so replace the ECU with a nor- mal functioning one and check that the symptoms appear. Example a) Ground = Pa fA a ECU Side (2) l Ground ! = i Measure the resistance between the ECU ground terminal and the body ground. Resistance: 1 0 or less Disconnect the ECU connector, check the ground terminals on the ECU side and the wire haress side for bend and check the contact pressure. TERMS IN-25 iTRODUCTION —_TEAMS ABBREVIATIONS USED IN THIS MANUAL ‘Abbreviations Meaning AG. ‘A Conattioning Ae ‘Aerating Current ‘Ace Accessory ACIS ‘Acoustic Control Induction System ‘ACSD ‘Automatic Cala Stan Devon ALT Alternator AMP, Ampiier [aPpRox Approxmatoly AT, ‘Automatic Transmigeion Transaxle BACS Boost Alituda Compensation System BAT eatery BIDE. Before Top Dead Center Bvsv Binetalic Vacuum Switcring Vaive ca Gircuit Breaker 00) Calvi Converar for Oxiation bc Direct Curent DLC Data Link Connector ore, Diagnostic Trouble Code E00) Blectronie Gontrol Diesel ECT Electron Gana Transmission ECU Electronic Control Unit EDU Electronic Driving Unit EFL Fjectonic Fuel injection EG Engine EGA Exhaust Gas Recirculation EVAP Evaporative Emission Contra EWAV Electronic Vacuurn Regulating Vawve x Exhaust FPG Formed in Place Gasket FL Fusible Link Fr Front GND. Ground HAG High Alttuge Compensator 1G Ignition In ‘inegrtea ignition Assembly N Intake isc lela Speed Corto) 8 “Junction Block ue Junction Connector uco igus Crystal Display LED. Light Emiting Dioge jus Let Hana IN-26 INTRODUCTION — TERMS HO LeftHand Drive to low MAP) Maniois Absolute Pressure MAX. Maximum wil Maltoncion Indicator Lamp MIN. Minimum Me Muttiurpose Mt ‘Manual Transmission N Noutal 028 Oxygen Sensor On, Overctve os Oversize Ka Parking Brake PS, Power Steering RAM Fandom Access Memory AS Relay Block BH Fight Hang PHO. Fight-Hana Drive ROM ead Only Memory Re Rear 10S ‘Starting Injesion Control System SPEC Speciication| SSM Speci Service Materials SST ‘Special Service Tools S70) ‘Standara Sw Switch TAGH Tachometer 00) “Top Dead Center TEMP, Temperature Te “Transmission TMC TOYOTA Motor Corporation| TWO. Three-Way Catalyst uo Underdtve. voy, ‘Vacuum Contol Vave vin Vehicle identification Number vsv, Vacuum Switching Valve wi wit wi Wire Harness wi wanout wu=Twe Warm Up Tivoe-Way Catalytic Converter aw. “Two Wheel Dive Vehicle (4x2) aw. For Whee! Brivo Venice (4x4) PREPARATION ENGINE MECHANICAL TURBOCHARGING EMISSION CONTROL ELECTRONIC GONTROL DIESEL ENGINE FUEL COOLING LUBRICATION ... STARTING CHARGING PP PP-8, PP PP-i3 PP15 Pte PP-22 PP-27 PP-30 PREPARATION —_ ENGINE MECHANICAL ENGINE MECHANICAL SST (Special Service Tools) ID-TONR valve Spring Compressor - (09222-06010) Femover & Replacer (CYLINDER BLOCK OO 8 (09222-06020) Guide — GYLINDER BLOCK Es (09222-05030) Base ~ PBYLINDER BLOCK = (09223-00010 Gover & Seal Replacer TRING GEAR (09223-15030 Oi Seal & Beating Repacar OVLINDER BLOCK | 19223-50010 Crarkshalt row a Sea (CYLINDER HEAD placer Pp-2 PREPARATION ENGINE WECHANICAL g oRI-TBIO Cranks Oy Seal Replacer TIMING GEAR = ‘05248-55050 Vane Clearance Adust Toul Set, VALVE CLEARANCE - (09248-05510) Valve Liter Pross VALVE CLEARANCE — (05248-05520) Valve Liter Stopper VALVE CLEARANCE 7 (09252-10010) No.1 Roplacer Hardie ~~" evunper stock 05308-10010 0% Seal Puler TIMING GEAR (09330-00021 Companion Fnge Hoigng Too! TING GEAR (09955-20017 Unvereal Pur TIMING GEAR (09950-40011 Puller 8 Set TaNG GEAR TIMING BELT (09951-94010) Hanger 150, TIMING GEAR, TIMING BELT (09952-04010) Side Arm “TIMING GEAR TIMING BELT "(09953-D4620) Center Bolt 150 - TIMING GEAR TiMnG att (09954-04010) Arm 25 ‘Timi Gear ce TIMING BELT PREPARATION — ENGINE MECHANICAL (09955-04041) Claw No.4 AED = (opss 0106) Gawnoe Friis et D9a50- S001? Pater et Tuna GzAR (WHRsI-05010) Wangeriso "iG GEAR - (09952-05010) Slide Arm — TIMING GEAR o — (69953-05010) CeonerBoi 00 Ting GEAR css (09954-05020) caw No TING GEAR asian Pepe a CvaNDER ERD ob (08951-00280) Repacer 28 CyUNDER HEAD © S (09951-00500) Feplacer 50 ~ | evLINDes HEAD ; 2 (09952-06010) Adapter — ‘CYLINDER HEAD * 09950-70010 Handle Set CYLINDER HEAD L- (09951-07100) Handle 00 [evince HEAD Ppa PREPARATION -_ ENGINE MECHANICAL 2 09960-10010 Variable Pin Wrench Set Trimine Gear 7 EE ye Pa Wh Ticea fF (09963-00600) Pin 6 - “| Tiwine GEAR _ (oomR-DI21}) Gauge ay [coupnession PREPARATION. —_ ENGINE MECHANICAL PP-5 RECOMMENDED TOOLS ‘ DOONO-DODIT Hesagan Waren Br _| ps0 tn010 Bana a 09905-00013 Snap Ring Pliers: a PP-6 EQUIPMENT PREPARATION ENGINE MECHANICAL Carbide cuter Caliper gauge Connecting rod aligner Gyinder gauge Dialingicator| Dye penatrant| Engine une-up tester Gasket scraper Micrometer Magnetic tingor Piston rag compressor ton rng expander Prastgage Precision sraght edge Sot brosh Spring ester Vave spring Stool square ‘vawve spring “achomoter Thermometer Torque wrench Valve seat cutor Voblock Verniar calipers PP-7 PREPARATION ENGINE MECHANICAL SSM (Special Service Materials) ‘08876-0008 Sea) Packing Black or equivalent (Firs) ‘08826-00100 Seal Packing 12528, ‘Wate’ temperature wonder gauge THREE BOND 12628 of egunalent (Pe) (08833-00070 Adhesive 1324 Fiywheo) THREE BOND 1924 or equiva Drive pate PP-8 PREPARATION —_TURBOCHARGING TURBOCHARGING SST (Special Service Tools) F TST aanadTatachane Pasar Gane ee Qo TURBOCHARGER PREPARATION —_TURBOCHARGING RECOMMENDED TOOLS, BS ‘09082-00040 TOYOTA Ewcvical Tester PP-10 PREPARATION —_TURBOCHARGING. EQUIPMENT - Dia indicator Protractor ‘Steet square “Torque wrench PPL PREPARATION ~ EMISSION CONTROL EMISSION CONTROL RECOMMENDED TOOLS ‘09082-00040 TOYOTA Electieal Testo: Ppa2 PREPARATION —__EWISSION CONTROL EQUIPMENT IMITYVAG (Hand-held vacuum tester Torque wrench Vacuum gauge PP-13 PREPARATION — ELECTRONIC CONTROL DIESEL ELECTRONIC CONTROL DIESEL RECOMMENDED TOOLS (9082-00) TOYOTA Estes Tesier PP-14 EQUIPMENT PREPARATION — ECTRONIG CONTROL DIESEL. 19 mm deep socket wrench 22mm doop socket wrench (08D # ean 100! Torque wrench ‘Vacuum gauge PREPARATION —_ ENGINE FUEL ENGINE FUEL SST (Special Service Tools) PPS es ‘09528-64010 Foe! Fiter Wiende (9023-12700 Unien War Wench 7mm (09023-12900 Union Nur Wrench 18mm Ste "99092-00242 Turbocharger Prosure Gauge PP16 PREPARATION — ENGINE FUEL RECOMMENDED TOOLS ‘09082-00040 TOYOTA Eleaiica Tester PP-17 PREPARATION — ENGINE FUEL EQUIPMENT “Torave wrench (QD I scan too! PP-18 COOLING SST (Special Service Tools) PREPARATION COOLING. MIE 22 (05230-01010 Aadater Service Tool Sar oo GPO TRADIATOR (09231-14010 Puneh & | RADIATOR PP-19 PREPARATION ~ COOLING RECOMMENDED TOOLS | ‘05082-00040 TOYOTA Electrical Tester PP-20 EQUIPMENT Heater PREPARATION - COOLING Radiator cap tester ‘Thermometer “Torque wrench Vernier calipers PREPARATION ~ COOLING. PP-21 tern Capaciy (Ciassiication| Engine coolant “Toyota Long Lite Coolant or equivalent \Ww/ Rear heater MW | 10.5 ers (11.1 US als, 92 imp. ats) AT | 1.0 ers (11-8 US als, 9.7 imp. ats) wie Power heater BS 95 Iters (10.0 US als, 84 Imp. qs) 10.0 ters (10.6 US q's, 88 Imp. as) Pp22 PREPARATION — LUBRICATION LUBRICATION SST (Special Service Tools) 7 {09032-00100 01 Pan Seal Cuter OL PUMP (09228-10002 OW Fier Wrench ‘Ol AND FILTER PP-23 PREPARATION ~_ LUSRICATION RECOMMENDED TOOLS E (HOA0-OOOIT Henagen Wench Set es — Se HY Se T VS PP-24 PREPARATION _LUSRIGATION EQUIPMENT ‘Gilpressu'e gauge Torque wrench PP25 PREPARATION — LUBRICATION LUBRICANT tom Capacity Ciasstication Engine of API grade OF-4 ry fi 75ers (7.9 US dfs, 66 Imp. ats) (You may also use API CF or E or CO) Drain and refi -wOilfiter change 7.0 ors (7.4 US als, 62 mp. ats) wo Oititer change 6.4 ers (6.8 US ote, 5.6 Imp. ats) PP-26 PREPARATION — LUBRICATION SSM (Special Service Materials) ‘8876-00080 Seal Packing Black er equivalent (FiPo) Oi pump Oilpan (08833-00080 —_Achesve 1944 THREE BOND 1244 LOGTITE 282 oF equivatont (il pressure ewich PP-27 PREPARATION — STARTING STARTING SST (Special Service Tools) Ls (09950-60010 Replacer Ser T Soteeeene sO | © (09951-00380) Replacerse ‘rush heer PP-28 PREPARATION — STARTING. RECOMMENDED TOOLS ‘5082-004 TOYOTA Elccical Tester PP-29 PREPARATION ~_ STARTING EQUIPMENT Dial indicator Commutator 98008 Sandeaper Commute varie calipers Commutator Brush Terque wrench V-block Viso PP-30 PREPARATION — CHARGING CHARGING SST (Special Service Tools) T Rotor rear bearing cover 7 Puter oe one Rep (ee 2 q 3 (09820-00021 ‘Aerator Rea Bearing Puller ; (09820-00030 “venalor Rear Beating Replacee PP-31 PREPARATION — CHARGING RECOMMENDED TOOLS ‘09082-0004 TOYOTA Electical Tester PP-32 EQUIPMENT ‘AmmeterA) PREPARATION — CHARGING Battery specific gravy gauge. Torque wrench Except maintenance-free bavery Verner calipers Rotor (Sip ring) SERVICE SPECIFICATIONS STANDARD BOLT... cee Sst ENGINE MECHANICAL ....... ss S84 TURBOCHARGING sites SSO EMISSION CONTROL cesses SSH ELECTRONIC CONTROL DIESEL ......... SS-13 ENGINE FUEL . cece SSE COOLING... cee SS-17 LUBRICATION ......... ss-19 STARTING cesses cere sS-21 CHARGING cect, $823 SERVICE SPECIFICATIONS —_STANDARO BOLT STANDARD BOLT HOW TO DETERMINE BOLT STRENGTH Bolt Type Hexagon Head Bolt —____——__ Stud Bolt Weld Bolt Normal Recess Bolt Deep Recess Bolt oN OO Ofte one oO wiWasher Ss-2 SERVICE SPECIFICATIONS STANDARD BOLT | ‘Specified torque, clas | ane rch Tnapneaa Tape igs bat Regen | tem 3 7 3 ener | 6 oat 3 1s ee Bw te mf mt ar 12 1.25 47 480 35 53 540 39 " 3 mw fm aw ' 3 nro 8s : : ¢ 7 ow | 8 3 us es | sme ts o is em » |e mw B oT 12 1.25 59 600 43, 85 670 48 Pa is oo | mom ts ts wo wo | : " 3 7 2 ene | 8 Tem : us ee ee ee fw i som » | # ww 2 ® 12 1.25 n 730 5a 80, 810 59 “ ‘3 mo utes 6 ts mio | ° : 3 7 so rr 3 1s mf mt ~{ . B mom « | & 9 © 2 i & | ats sam ‘ 1 ne ts is eo tava | " i ¢ vas a a | is rr ts mo soo | mtao 3 7 # aes oa x | 1B nm st er t ie tena] tate 3 128 a wr | 12 mm) te as foo ms | ste | 8 a 80H rr mm} is oe wo & | 3» om» @ 2 iB tao ne |e top ss-3 HOW TO DETERMINE NUT STRENGTH Nate Present Standard Old Standard Hexagon Nut Class Hexagon Nut Cold Forging Nut Cutting Processed Nut an G '5N (4T) No Mar Washer oar Wan Nota QQ XM os 6N ~ © [4 , mien J 8N uN RN *: Nut with 1 or more marks on one side surface of the nut. HINT: Use the nut with the same number of the nut strength classification or the greater than the bolt strength clas- sification number when tightening parts with a bolt and nut, Example: Bolt = 4T Nut = 4N or more ssa SERVICE SPECIFICATIONS — ENGINE MECHANICAL SERVICE DATA ENGINE MECHANICAL Compression pressure Diference of pressure between each cylinder at 250 «pm Minimum 2,700 KPa (27 5kgllem®, 891 pai) or more 2,200 kPa (22.5kgllom?, 320 psi) of more S500 kPa (5.0 kaon?, 71 ps) or less Valve clearance Adjusting shim thickness, at col Intake Exhaust Mare 2525 2550 2575 2600 2625 2650 2675 2700 2725 2750 2775 2800 225 2850 2075 2000 2005 2950 2975 3000 3025 3050 3075 3100 3125 3150 3178. 3200 325 250 3275 3900 (0.20 0:30 mm (0.008 -0.012 in) 0.35 0.45 mm (0014 ~0.018 in) 2.525 mm (0.0984 in) 2.550 mm (0.1004in) 2.575 mm (0.1014in) 2.800 > (0.1024 in) 2.625 mm (0-1088in}) 2.650 mm (0.1043 in) 2675 mm (0.1058in) 2.700 mm (0.1068in} 2.725 mm (0.1078in) 2.760 mm (0.1088 in) 2.775 mm (0.1083in) 2.800 mm (0.1102 in) 2.825 mm (01112in) 2.850 mm (0.1122in) 2.875 mm (0.1182in) 2.900 mm (0.1142in}, 2.925 mm (0.162in) 2.950 mm (0.164 in.) 2.878 mm (0.1171 in) 3.000 mm (0.118 in) 1.025 mm (0.1194 in) 3,050 mm (0.1201 in) 3,075 mm (0.1211 in) 3.100 mm (0.1220 in) 3.128 mm (0.1290in) 3.160 mm (0.1240 in) 3.178 mm (0.125010) 3.200 mm (0:1260in) 3.225mm(0.1270in) 8.250 mm (0.1280 in) 8.275 mm (0.1288 in) 23.300 mm (0.1269n) Idle speed = (850 — 750 rom Maximum speed _|— 4500 ~ 4,700 pe Timing bet tansionar Protrusion from housing end 8.1-8.8mm (0319-0.350in.) Timing gear Idier gear trust clearance Idler goar inside diameter Ioler gear shat diameter Inler gear oil ewarance Gear backdash SID Maxim sro Maximum sto Maximum 0.08 ~ 0.11 mm (0.0024 0.0043 in} 0.30mm (00118in.) {44,000 ~ 44,025 mm (1.7323 ~ 1.7333 in) 43.955 ~ 43.990 mm (1.7905 ~ 1.7319 in 0.010 0.070 mm (0.0004 ~0.0028 in 0.20 mm (0.0079 in) 0.02 0.15 mm (0.0008 -0.0060 in) 10.20 mm (0.0079 in) SERVICE SPECIFICATIONS — ENGINE MECHANICAL, Ss-5 Cyindernead | warpage (0.18 mm (0.0059in) Valve seat Felacing angle Ywiaka |25°, 45°, 70" Exhaust | 25°, 48°,75° Contacting angle 4s Contacting width Intake | 1.21.6 mm (0.047 ~0.0631n3, Exhaust | 1.6—2.0 mm (0.083 -0.078 in) Valve guide bushing bore ameter TO | 10.985 ~ 11.008 mm (0.4325 ~0.43331n 018 00 } 11.038 ~ 11.056 mn (0.4344 - 0.4953 in) Cylinder head bot outer diameter st0 | 11.8~120 mm (0.485~0.472in) Minimum | 11.6 mm (0.457 in.) Now eyindor head gasket thickness ‘A 0:60-0:90 mm (0.0815 ~0.0354 in 8 | 0.85 ~0.95 mm (0.0835 ~0.0374 in) 6 | 0.90 ~ 1.00 myn (0.0354 ~0.0394 in.) | 0:95 —1.05 mm (0.0874 —0.0813 in) E | 1.00~1.10 mm (0.0394 ~0.0843 in) Valve guide Inside diame {6.010 ~ 6.090 mm (0.2368 -0.2374 in) Bushing (Outside diameter for repr part STD | 11.039 - 11.044 mm (0.4344~ 0.4110 in) 018 0005 | 11.083 ~ 11.094 mm (0.4969 - 0.4968 in) vave Valve overal length ‘STD take | 105.18 ~ 105.75 mm (4.1998 — 4.1694in) Exhaust | 105.02 ~ 105.62 mm (4.1346 4.1583 in Minimum intake | 104.65 ram (4.120 in.) Exhaust | 104.52 mm (4.1150in.) ‘Stem diameter Intake | 5.970 ~5.985 mm (0.23504 - 0.23568 in.) Exhaust | 5.980 ~5.975 mm (0.23465 ~ 0.23524 in) ‘stem oll clearance STD Intake | 0.025 ~0.080 mm (0.0010 0.0024 in) Exhaust | 0.035 ~0.070 mm (00014 ~ 0.0028 in) Maximum intake | 0.08 mm (0.003 in.) Exhaust | 0.10 mm (0.0039 in.) Margin thickness ‘STD Intake | 1.1 mm 0.083.) Exhaust | 1.2mm (0.047 in} Minimum intake | 0.6 mm (0.023 in) Exhaust | 0.7 mm (0.027 in) ‘Valve sexing | Deviation Maximum | 20 mm (0.079 in) Freslengin Paint color uo | 46.8 mm (1.843) None | 46.5 mm (1.831 in) Installed tension at 98.1 mm (1.903in.) Paint color ive | 149.9 166.1 N(15.9- 16.9 Kgl, 93.7 -97.4 In) None | 150.2~ 16581 (159-189 kal, 93.8-37.3 bh) Valve iter (ylinder head iter bore diameter ‘31.000 31.021 mm (1.22047 ~ 1.22190in) Liter damoter 30 986 ~ 30.976 mm (1.21913 ~ 1.219531.) Oil clearance TD | 0.024 ~0.055 mm (0.00098 - 0.00217 in Maximum | 0.08 mm 0.003" in) Camshat Thwust dearance 0.038 — 0.185 mm (0.00138 0.00728 in) Journal oil clearance STD | 0.025 ~0.082 mm (0.0010 - 0.0024 in) Maximum | 0.08 mm (0.0031 in) Journal hametor 27.969 ~ 27,985 mm (1.1011 ~ 1.1018 in) Circle cunut| Maxirnum | 0.08 mm (0.0012 In.) (Cam lobe height STD Intake | 47.180 ~ 47.280 mm (1.85748 — 1.86141 in) Exhaust | 48.070 — 48.170 mm (1.89252 ~ 1.89645 in) Minimum intake | 46.78 mm (1.8409 in) Exhaust | 47.65 mm (1.8760 in) Camshaft gear backlash STD | 0.035 -0.185 mm (0.00138-~ 0.00728 in) Maximum ] 0.389 mm (0.00784 in.) Manifold warpage ‘Maximum [0.4 mm (0,018 ind sso tao) osmcatioam oamascsosrey via) aromeneros No.1 Bearing inside iameter No.2 Bearing inside diameter No.8 Bearing inside ciameter No.1 journal dameter No.2 journal dameter No. journal dameter 42.000 ~ 42,020 mm (1,8535~ 1.6543 in.) 141.000 ~ 41.020 mm (1.6142~ 1.6159 in.) 32.000 ~31.020 mm (1.2598 1.2608 in.) 41.941 ~ 41,960 mm (1.6512 1.6520in.) 449.931 ~ 40,950 mm (1.6115 ~ 1.6122 in) 31,941 ~31,960 mm (1.2575 1.2583 in.) SERVICE SPECIFICATIONS. ENGINE MECHANICAL ss7 Connecting rad "Trust clearance sto Maximum Connecting rod oll clearance sto Maximum Connecting rd bearing canter wal ‘STD Mark 2 thickness (Reterence) Mark 3 Mark 4 Mack S Mark 6 Rodbend Maximum per 100 rim (3.94 in.) Rod ist Maximum par 100 mm (3.96 in) Bushing inside diamator Piston pin diametor (0.10 — 0.90 mn (0.0039 — 0.01185) 0.40 mm (0.0187 in) 0.06 ~ 0.084 mm (0.0014 -0,002 in.) (0.10 mm (0.00389 in) 1.486 ~ 1.489 mm (0.0585 ~ 0.0586 in.) 1.489 ~ 1,492 mm (0.0886 —0.0587 In.) 1.492 ~ 1.485 mm (0.0587 ~0.0589 In} 4495 ~ 1.498 mm (0.0589 ~ 0.0590 in 1.498 ~ 1.40% rom (0.0590 ~ 0.0591 in) 0.03 mm (0.0012 in) 0.15 mm (0.0089 in.) 34,012 ~34.024 mm (1.83905 ~ 1.93952 in.) £33,996 ~ 34.008 mm (1.99642 — 1.99889 in) Piston pin oll earance TD | 0,012 ~0.020 mm (0.00047 ~0,00079 in.) Maximum {0,03 men (0.0012 in) Connecting od bat tension potion giameter 70 | 8500-8600 (0.3346 - 0.2988 in) Minimum | 8.30 mm (0:3268 in) ‘Crankshaft Thus sarance ‘STD [0.040 ~ 0.240 mm (0.0016 0.0084 in Maximum | 0.20 mm (0.0118 in.) ‘Thiust washer thickness STD (STO) | 2.430 ~2.480 mm (0.0957 - 0.0976 in) (US 0.285 | 2.585 ~ 2.605 mm (0,106 -0.1026 in.) (US 1.125) | 2.498 ~2.543 mm (0.0981 ~0.1001 In} Main journal ollclearance STO (STD) | 0,036-0.054 mm (0.0014 ~ 0.0021 in) (UIS 0.28 ara US 0.50) | 0.037 —0.077 mm (0.0015 - 0.0088 n.) Maximum | 0,10 mm (0.0039 in.) Main journal diameter STD Mark 1 | 69.994 ~ 70.000 mm (27587-27559 in.) Mark 2 | 89.988 ~ 68,994 mm (2.7554 ~ 2.7567 in} Mark 3 | 68.982 ~ 69.988 mm (2.7852 ~ 2.7554 in) Main beating center wall hicknass (Reference) STD Mark2 | 2.482 2.485 mm {0.08772 ~0.08783 in) Mark } 2.485 ~ 2.488 mm (0.09783 ~ 0.08795 in) Mark | 2.488 ~ 2.491 mm (0.09786 ~ 0.08807 in.) ‘Mark 5 | 2.491 ~ 2.494 mm (0.09807 -0.08813in ) Mark 6 | 2.494 - 2.487 mm (0.09819 ~ 0.08831 in.) Crank pin diameter 'S¥O Mark 5 | 58.984 59.000 mm (2.3228 ~ 2.3228 in) Mark2 ) 8.988 ~ 58.994 mm (2.3224 ~ 2.3226 in) Mark 3 } 58.982 ~ 58,988 mm (2.3221 ~ 2.5224 in) Cirle runout Maxims | 0.06 mm (0.0024 in.) Main journal taper and out-ot-round Maximum | 0.002 mm (0.0008 in.) ‘Crank pin taper ans aut-ot-round Maximum | 0.002 mm (0.0008 in.) Main bearing cap bot outer careter TD Maxienum 13.500 ~ 14,000 mm (0.6315 ~ 0.5512 in) 12.60 mm (0.4961 in) SS-8 SERVICE SPECIFICATIONS ENGINE MECHANICAL TORQUE SPECIFICATION ere ii icra = = m SERVICE SPECIFICATIONS — TURBOCHARGING SERVICE DATA TUREOCHARGING, sso [Turbocrarger Turbocharging pressure “Turbine shatt anal play “Turbine shatt racial play 205 kPa (2.1 kglom®, 15.6 ps) 0.18 mm (0.0083 in) 0.13 mm (0.0081 in) ‘Step motor Rod stoke 11 = 0.03 mm (0.43 = 0.0012in) Compensate reeistor Resistance Mark 21a—2280 285-303. 972-2980 472-502 600-638. 763-81. 989- 1,051 0 1.290 1,370.0 1727-160 SS-10 SERVICE SPECIFICATIONS —_ TURSOCHARGING TORQUE SPECIFICATION Part ightened Nm atom ‘et “Turbo wate pipe x turbocharger Bot 80 2 71 into Nut 2 122 8 ‘Compressor inlet elbow x Turbocharger 19 198 i Exhaust mantold x Turbocharger 82 530 38 Exhaust maniold x Oyinder head 82 550 38 “Turbo i pe Turbocharger 8 133 10 Turbo ol pipe x Gyinder block ott 2 122 ° Union bot 8 285 19 “Turbocharger stay x Turbocharger, Cynder Block 19 194 16 Turbine out elbow x Turbocharger 29 338) 28 Ot ovel gauge guid x Water inet 80 @ Tit Exhaust mantold heat insulator x Turbocharger 12 122 ® “Turbo insulator x Turbocharger 2 122 @ PCV pine x Cynder head 20 204 5 No.1 water by-pass pipe x Oyinder head 18 14 13 Introooter x Cylinder head Bott A 12 122 ° (See page TO-12) Bol 18 194 13 Intake air temperature sensor x intercooler 20a 300) 2 Intake ai connector x intercooler 10 102 z ss SERVICE SPECIFICATIONS ~ EMISSION CONTROL, EMISSION CONTROL SERVICE DATA E-VAV for EGR Pesistance at 20°C (68°F) 190 EGR cut vSV Resistance, 20°C Ga'F) 9338.0 ss12 ‘SERVICE SPECIFICATIONS _— EMISSION CONTROL TORQUE SPECIFICATION Parttightened New afem itibt ‘VSV assembiy x Tote body 80 82 Zine E-VAV for EGA x intake manos 20 208 15 EGR cooler x EGA valve, Gyinder head 18 133) 10 Front exhaust pipe x Exiaust marifola 2 630 nn Front exhaust pipe x Exhaust tailpipe 3 8 8 Protector x Front exhaust pipe 105 107, 8 SERVICE SPECIFICATIONS - ELECTRONIC CONTAOL DIESEL ELECTRONIC CONTROL DIESEL SERVICE DATA ss-13 pasion sensor ‘Artlow mater | Resistance (THA —E2) at-20°C(-4°F) ] 136-184 KO 20°C (68°F) | 221 ~ 269k at 60°C (140°F) | 0.493 0.687 ka VSV fortute | pesistance 120°C (68"F) [97-480 pressure sensor Fuoltemperature | Resistance 120°C (68°F) 221-2790 sensor at 80°C (176°F) | 0.267 —0.069.0 nae ac temperature | Resistance 20°C (68"F) 2187-2673. Fue pressure tower Votage 475-825 voage: 45-55V Votage drop ‘Apbliod vacuum 18.9 Pa (100 mmig, 3.94 Ha) [0.1 0.3 26.7 kPa (200 mmHg, 7.87 in.) | 0.9-0.5V Ka (900 mg, 11.81 in.H) [05-07 suo prossue 40.0 kPa (300 mmbig, 1.81 inHg) }0.5-0.7 V sensor Votage up Applied pressure 19.6kP@ (0.20 kgllom®, 2.4psi) 0.1 -0.4 V ‘2B.2KPa (040 kglion?, 569psi) |0.4-0.7 V 58.8 KPa (0.80 kgtlom?, BSG) $0.7 -10V 78.5 kPa (0.80 kglon?, 11.4psi) |1.0-1. 98.0 kPa {1.00 kalom?, 1.42 ps) | 1.3~ 1.6 Camshatt postion | Resistance at Cold | 1,690- 2,740.0 sensor attiot | 2,065 ~ 3,205.0 Crankshat| Rosistance ‘Gold | 1,690-2,740.0 postion sensor atHot | 2,055 -3,225 0 Acenert01 POA | esitarce atz0'e |1.5-6.0K0 ss-14 |ERVICE SPECIFICATIONS — ELECTRONIC CONTROL DIESEL TORQUE SPECIFICATION Par sghtened io gram rer Diese rt body x Inka mantels 20 204, 16 Wialor tomporature sensor x cylinder look 20 208 15 Inake ai emperatre sor x tercosie ua 350) 2 ‘Gamshalt poston sensor x Ting gwar ca5@ 85 o 751 Crankshatt postion sensor x Ting gor ease 35 7 7Sinsbh ENGINE FUEL SERVICE SPECIFICATIONS _— ENGINE FUEL SS-15 SERVICE DATA Fusiheator Resistance at 20°0 (68°F) [05-200 [efector Resistance a120°6 (68°F) [25-31 ‘Supply pump 68" ‘Savana ove) | Resitance at20°C (68°F) |15-1.70 ss-16 SERVICE SPECIFICATIONS —_ ENGINE FUEL Part tightened Nm kgtem ‘tee Fue ler bracket x Fuel titer 196. 2a int ‘Nozzle holder clamp x Gylinder head 216 220, 6 Nozzle leakage pipe x injector Holow secow 16 163 12 Union bott 125 128 8 Check valve pig» Overiow screw 98 100 87 te (Check valve x Oylinder head 2 204 15 Injection pipe clamp x Intake manifl & I 44 int Tnisction pipe, Fuel inlet pipe x Common call Tocuse wit SST 316 302 2 35 357 6 Injection pipe x Ijector for use with SST 319 225 24 35 387 26 ‘Nozzle leakage pipe No.2 x Oylinder head Check valve 2 214 18 "Nozzle leakage pipe No.2 x Common rail Bok 127 +0 8 Union boi 127 130 8 ‘Supply pump x Timing gear case 21 28 5 ‘Supply pur slay x Cylinder block, Supply pum. 2 214 5 Fuel niet pipe x Supply pum Tor use with SST 318 325 24 38 357 26 ‘Common ail Cylinder had 38 387 28 SSAT SERVICE SPECIFICATIONS ~ COOLING COOLING SERVICE DATA “rermostal Valve opaning torperature ‘80 84° (176 ~183°F) Valva ft a1 95°C (20°F) | 10.0 mm (0.594 in or moro Radiatorcap | Ree! valve opening pressure ‘STD | 95~ 129 KPa (0.85 ~ 1.25 kgllom®, 13.5-~ 17.8 ps) Minimum | 79 kPa (0.8 kgtem?, 11.5 psi) ss-18 SERVICE SPECIFICATIONS. — TORQUE SPECIFICATION Part tightened Nm kgtem bt Engine dain plug x Engine coolant dain union a 80 ean. Water pump x Cylinder block 13 130) 8 Water pump pulley x Fun coupling 18 185 13 ‘Water nit x Cylinder block 13 130 2 ss419 SERVICE SPECIFICATIONS — LUBRICATION LUBRICATION SERVICE DATA [oipressue atid speed [29 KPa OS nahin? 42 psi ormore 14,500 pm | 245 KPa (2.5 kom? 36 psi Tp eearanse STO 0.05~0:16mm (0.0024 ~ 0.0068 im, Ot puma Maximum | 0.21 mm (0.00830) Body eoarance STD ] 910-017 mm (0.0038 ~0.0087 in) Maximum | (0.20 mm (0.0078 in) Sie clearance S10 ] 0.03 ~0.09 mm 0.0012~0.0035 in) Maximum {0.15 mm (0.0068 in) SS-20 SERVICE SPECIFICATIONS 1 UBRICATION TORQUE SPECIFICATION Par ightened Nm ahem feibr Oipan x Oran pug 34 350) 25 Rolo! valve x Ol pump 2 25 an (i pump x Gyinder Bock Batt 13 130 ° Union bot 6 160 2 ‘Supply pump x Ol pump 2 210 15 ‘Oi strainer x Cynder block a we Ti inc [etpan x Gyindor ck 16 185 2 ‘Atormator bracket x Oi pump 2 210 5 (i cooler cover Drain pig 8 80 Bint ‘Oi-cooler cover x Ol enoler 16 160, 2 | ‘Oi eooier cover x Cylinder balck 13 130) 9 Oil ngzze x Ovinder belek 28 260) 19 SERVICE SPEGIFICATIONS — STARTING. STARTING SERVICE DATA Nooad characterises Current Brush longth TD Minimum Commutator Dameter Undereut dept Circle remaut Magnetic switch contact plate for wear 22 kw 27 kw 3.3hw 22kw 27 Kw 33 kw 22kw 27 kw 3.3 kw 220 27 kw ak sTD 22kw 27 kw 33kw Minimum 22kw 27 kw 3. kw STD Miriam Maximum Maximum 22k 27.3.9 hw Pre-heating [Light ightng time at 28°0 (62°F) ] 2.1 soconds system Grow plug resistance 120°C (68°F) | Approx. 0.72.0 ‘Rated voltage nd ouput power wi fravazKw MU (Cold area spec.) AIT | 12 2.7 Stator AT (Cold area spec) | 12 33KW 120A orloss at 11.5 V 380A orless at 1.0 220 Acres at 11.0 4,000 rpm or more 3,500 rpm or mare 4,200 rpm or more 16:5 mm (0.650 in) 205 mm (0807 in.) 21.0mm (0827 in.) 8.0.mm (0.354 in) 11:00am (0.433;n,) 120mm (0472in) 351mm (1.98;n,) 36 mm (1.42in,) 431mm (1.88i0.) 34mm (1.34n.) 35 mm (1.98 in.) 42mm {5 in) 0.7 mm (0.027 in} 0.2mm (0.008 in) 0.05 mm (0.0020) (03mm (0.035in) 1.8mm (0.083 in) ss-22 SERVICE SPECIFICATIONS STARTING TORQUE SPECIFICATION Pad tightened Nem kgtem feb iow pug x Oyinder head 18, +90 10 ‘Sater housing x Mageetic switch assemby 22,27 kw 93 8 Binet 33kw a 15 8 Fie frame v Starter housing 22kw 13 9 27 kw 93 82in-et 33kw “ 145, 10 Lead wira x Terminal G 22kw 58 60 seins 27.3.3kW 24 240 17 Texminal nt Terminal 30 of starter, Terminal C of tater 22kw 17 173 12 2y,39kw 30 310 22 End cover x Magnetic switch housing 36 6 2 inset ss-23 SERVICE SPECIFICATIONS - CHARGING. CHARGING SERVICE DATA Batory ‘Specific gravity ‘20°C (68°F) | 1.25~ 1.28 votage a1 20°C (68"F) | 125~ 129 ‘Alernator Raled output 12V 1208 olor eallvesistance at 20°C (68°F) J2.1-2520 Slip ring diameter STD | 142~14.4 mm (0.559 - 0.57 in) Minimum | 12.8 mm (0.504 in.) Brush exposed length stp [9.5~11.5mm (0.374—0.453in) Miimy | 1-8 mm (0.059 in.) IGregulator Regulating volage ains'c@30°F) [192-148 S8-24 _ SERVICE SPECIFICATIONS — CHARGING TORQUE SPECIFICATION Partightened Nm aterm Wer Restor end ame without cord Clip» Diva end ame 45 46 ain. Realilor end ame with cord clip x Dive end frame 54 55 ain Resiiier Nader x Lead wire on rector end frame 294 30 25in-ot 1 regulator x Rectifier end tame 20 2 18in.tor 1 regulator x Rectifier holder 20 2 Tin. tor rush holder x Rector holder 20 20 eins rush Aoldor 1G regulator 20 2 1Binabe Rear end cover x Recillor holder 4a 45 32in.t Pat worminal x Rector holder 28 39 Sint “orminal insulator x Rectiir holder [ aa 2 36 inst DIAGNOSTICS ENGINE . HOW TO PROCEED WITH TROUBLESHOOTING CUSTOMER PROBLEM ANALYSIS CHECK PRE-CHECK . DIAGNOSTIC TROUBLE CODE CHART . PARTS LOCATION TERMINALS OF ECU .- PROBLEM SYMPTOMS TABLE CIRCUIT INSPECTION Dit DLs M4 ois DL15, Dit Drie Di-22 Det DIAGNOSTICS — ENGINE ENGINE HOW TO PROCEED WITH TROUBLESHOOTING ‘When using hand-held tester, troubleshoot in accardance with the procedure on the following pages. Titles inside Z—7/ are titles of pages in Vehicle Brought to Workshop this manual, with the page number indicated se in the bottom portion. See the indicated 1 pages for detailed explanations. a 2 Connect hand-heid tester to DLC3. P_DI-4 7 If display indicates a communication fault in tool, inspect DLC3. PDI 7 ca Esa 3 ‘Check Diagnostic Trouble Code and Freezed Frame Data (Pre—-check) 7 ft Record or Print DTC and Freezed Frame Data P. DI-4 TL [[ Clear DTC and Freezed Frame Data P. DI-4 T ub 6 [[ Setting Check (Test) Mode Diagnosis P. D4 7 a 7 Problem Symptom Confirmation engine does not stat, perform steps 10 and 12 first Malfunction LL Malfunction does not occur. ‘occur. 8 [Symptom Simulation P.N-10__77 9 [DTC check PDI 1 Normal i! IE Malfunction code. 10 [J Basic Inspection P.DI-1 11 ff DTC Chat PDH13 ag 12 — ‘Symptom Table = T 14 13, wen eperon Pore 7 ill 15 [J Check for intermittent Problems P.DI-4 7] at Bons PDH soriaton of Problem ay! Confirmation Test 16 7 D2 DIAGNOSTICS ENGINE When not using hand-held tester, troubleshoot in accordance with the procedure on the following pages. Titles inside 7) are titles of pages in Vehicle Brought to Workshop this manual, with the page number indicated in the bottom portion. See the indicated 7 detail )anations. 1 ff Gustomer Problem Analysis pages for detailed explanations a 2 Check and clear Diagnostic Trouble Code (Prec—heck) = a ot 3 Problem Symptom Confirmation TL Malfunction does not occur. ‘Symptom Simulation PIN-10 5 Diagnostic Trouble Code Check PDs Normal code a Lb _ Malfunction code. 8 Basic Inspection 7 [Diagnostic Trouble Code Chart PDS [ POMS a Problem Symptoms Table P.DI-19 10 aa [ Circuit Inspection P. Di-22 " of [[ Paris inspection] Check for Intermittent Problem PDS Identification of Problem ———] fT Adjustment, Repair Malfunction occurs. 8 Ss o i 13 Confirmation Test CED DIAGNOSTICS — ENGINE CUSTOMER PROBLEM ANALYSIS CHECK DLS CiFreazed frame data ( ) ENGINE CONTROL SYSTEM Check Sheet Inspector's: Customer's Name Model ang Model Driver's Name Frame No. Bae venice Engine Mode! Lene Na Odometer neading oe [25a ine doos | T Engine does not crank {No intial combustion TINo complete combustion Dittcuttto | DlEngine cranks stow'y Si other 2 leew Gincorect frst ile Dialing rpm is abnormal Cl High( rom) ElLow( ‘em 3 | 2Poer sting | Gough idling Bother & | Oboe Deststion ClBacktie —CIMutlerexplosionatter-tre) Surging E [_Deveabity | knocking Dtner 2 ‘Soon atersarting CLAM accelerator pedal depressed © | CEngine Stall | C1 Atter accelerator pedal released During A/C operation Dshiting romNtoO other others Dsies Probem Sécurres constant Sometimes tines per daymonth) __ChOnce only ProtlamFrequency | Const Weather Fine — OCiouty Ray Snowy 0 Variousiother Ouidoor 4g | osc Dot Warm Coat Cold approx.__*F!_*e) a Ghaiway Siewree Ginewely lum Cbow Se DRovgrrosd ——_ OOther 58 | Engine Temp. cold OWarmingup — Datter warming up CAnytemp. Other Tisiering Ghuvstaterstering( min) idling Racing Engine Operation | Driving icon Dcceteration CO Deceleration CAC switch ONOFE — Condition of Maitunetion inaeator Lamp | CRemainson __CSometimeslights up —_—_—C1.Does nt ight up Normal Mode | © Normal D Maitunction codes) code Dy Diagnostic Teouble | (Prechocky i Freezed frame dala ( ) Code inspection anon oo <= rma inet cadet code ———*) Dia DIAGNOSTICS _—_ENGINE PRE-CHECK 1. DIAGNOSIS SYSTEM (a) Description When troubleshooting Multiplex ORD (M-OBD) ve- hicles, the only difference from the usual trouble- shooting procedure is that you connect the vehicle to the hand-held tester, and read olf various data output from the vehicle's engine ECU. The vehicle's on-board computer lights up the check engine waming light on the instrument panel when the computer detects a maifunction in the computer itself or in drive system components. In addition to the check engine warning light lighting up when a malfunction is detected, the applicable diagnostic trouble codes are recorded in the engine ECU memory. (See page DI-13) It the malfunction has been repaired, the check engine warning light goss off automatically but the diagnostic trouble codes re main recorded in the engine ECU memory. To check the diagnostic trouble codes, connect the hand-held tester to Data Link Connector 3 (DLC3) on the vehicle or read the number of blinks of the check engine warning light when TC and CG termi- nals on the DLC3 are connected. The hand-held tester also enables you to erase the diagnostic trouble codes and activate the several actuators and check freeze frame date and various forms of engine data, (For operating instructions, see the hand-held tester instruction book.) The diagnosis system operates in normal mode during normal vehicle use. It also has a check (test) mode for technicians to simulate malfunction symp- toms and troubleshoot. Some diagnostic trouble codes use 2 trip detection logic* to prevent erro- neous detection and ensure thorough malfunction detection. By switching the engine ECU to check (test) mode using hand-held tester when trouble~ shooting, the technician can cause the check en- gine warning light to light up for a malfunction that is only detected once or momentarily. (hand-held tester oniy) (See page DI-13) DIAGNOSTICS_— DLs ENGINE *2 trip detection logic: When a logic malfunction is first detected, the mal- function is temporarily stored in the engine ECU memory. if the same malfunction is detected again during the second drive test, this second detection causes the check engine wam- ing light to light up. The 2 trip repeats the same mode a 2nd time. (However, the ignition switch must be turned OFF be- tween the 1st trip and 2nd trip). Freeze frame data: Freeze trame data records the engine condition when malfunction is detected. Because freeze frame data records the engine conditions (fuel sys- tem, calculator load, engine coolant temperature, fuel trim, engine speed, vehicle speed, etc.) when the malfunction is detected. When troubleshooting, itis useful for determining whether the vehicle was running of stopped, the engine was warmed up or not, the air-fuel ratio was lean or rich, etc. at the time of the malfunction (b) Check the DLC3. The vehicle's engine ECU uses {SQ 14230 for commu- “epnmaar: a nication, The terminal arrangement of the DLC3 complies. i1]2\3\4/5/6| 7/8 with SAE J1962 and matches the ISO 14230 format. ISLIZEZEL) DLC3 rm Batley Posie = Boy Ground — 14 Away HINT: It your display shows UNABLE TO CONNECT TO VEHICLE when you have connected the cable of the hand-held tester to the DLC3, turned the ignition switch ON and operated the hand-held tester, there is a problem on the vehicle side or tool side. If communication is normal when the tool is con- nected to another vehicle, inspect the DLC3 on the original vehicle |f communication is still not possible when the tool is connected to another vehicle, the problem is probably in the too! itself, so consult the Service De- partment listed in the too!’s instruction manual. Dis ca mo Lu: 2134/16] DLs Tc DIAGNOSTICS _— ENGINE 2. _ INSPECT DIAGNOSIS (Normal Mode) (a) Check the check engine warning light, (1) The check engine warning light comes on when the ignition switch is turned ON and the engine is not running. HINT: Ifthe check engine warning light does not light up, troubleshoot the combination meter. (2) when the engine is started, the check engine warn- ing light should go off. If the lamp remains on, the diagnosis system has detected a malfunction or ab- normality in the system. (b) _ Check the DTC using hand-held tester. NOTICE: When the diagnosis system is switched from the normal mode to the check (test) mode, it erases al! OTCs and freezed frame data recorded in the normal mode. So before switching modes, always check the DTCs and freezed frame data, and note them down. (1) Prepare the hand-held tester. {2} Connect the hand-held tester to the DLC3 (3) Turn the ignition switch ON and switch the hand~ held tester main switch ON. (4) Use the hand-held tester to check the DTGs and freezed frame data, note them down. (for operating instructions, see the hand-held tester’s instruction book.) (5) Confirm the details of the DTCs. (c) Check the DTC not using hand-held tester. (1) Tum the ignition switch ON. (2) Using SST, connect between terminals 19 (TC) and 4 (CG) of the DLC3 SST 09843-18040 DL ON ON ON ON (OFF OFF OFF One Cycle Start 12and31 Flashing ON OFF LL 0.43 Seconds DIAGNOSTICS — ENGINE (3) Read the DTC from the check engine warning light, Norma ‘As an example, the blinking patterns for codes; nor- 0.25 mal, 12 and 31 are as shown in the illustration. en see HINT: Ifa DTC is not output, check the diagnostic connector (DLC3) circuit (See page DI-112) (4) Check the details of the malfunction using the DTC chart on page DI-13. After completing the check, disconnect terminals 13 (TC) and 4 (CG) and tur off the display. (5) HINT: In the event of 2 or more malfunction codes, the indication will ‘begin from the smalier numbered code to the larger in order. NOTICE: When simulating symptoms without a hand-held tester to check the DTCs, use the normal mode. For code on the DTCs chart subject to "2 wrip detection logic”, turn the igni- tion switch OFF after the symptom is simulated the first time. Then repeat the simulation process again. When the problem has been simulated twice, the check engine warn- ing light lights up and the DTCs are recorded in the engine ECU. 3. INSPECT DIAGNOSIS (Check (Test) Mode) Hand-held tester only. Compared to the normal mode, the check mode has an in- creased sensitivity to detect malfunctions. Furthermore, the same diagnostic items which are detected in the normal mode can also be detected in the check (test) mode. (a) Check the DTC. (1) Initial conditions. + Battery positive voltage 11 V or more + Throttle valve fully closed + Transmission in neutral position + AC switched OFF. Turn the ignition switch OFF. Prepare the hand-held tester. Connect the hand-held tester to the DLC3. ‘Turn the ignition switch ON and push the hand-held tester main switch ON. Switch the hand-held tester from the normal mode to the check (test) mode. (Check that the check en- gine warning light flashes.) Start the engine. (The check engine warning light ‘goes out after the engine start.) Simulate the conditions of the malfunction de- scribed by the customer. NOTICE: Leave the ignition switch ON until you have checked the DTCs, etc. (8) DLs DIAGNOSTICS _— ENGINE Interface Box 0 Break-Out-Box Vehicle Harness (9) After simulating the malfunction conditions, use the hand-held tester diagnosis selector to check the DTCs and freezed frame data, etc HINT: Take care not to turn the ignition switch OFF. Turning the ignition switch OFF switches the diagnosis system from the check (test) mode to the normal mode, so all diagnostic codes, eto. are erased, (10) After checking the DTCs, inspect the applicable cir- cuit (b) Clear the DTC, The following actions will erase the DTCs and freezed frame data * Operating the hand-held tester to erase the codes. (See the hand-held tester's instruc- tion book for operating instructions.) + Disconnecting the battery terminals or ECD fuse. NOTICE: If the hand-held tester switches the engine ECU from the normal mode to the check (test) mode or vice-versa, or if the ignition switch is turned from ON to ACC or OFF during the check (test) mode, the DTCs and freezed frame data will be erased. (©) Measure the engine ECU terminal values using break— out box and hand-held tester. (1) Hook up the break-out-box and hand-held tester to the vehicle. (2) Read the engine ECU input/output values by follow- ing the prompts on the tester screen. HINT: Hand-held tester has a Snapshot” function. This records the measured values and is effective in the diagno- sis of intermittent problems. Please refer to the hand-held tester/break-out-box operator's manual for further details. DLS DIAGNOSTICS ENGINE 4. FAIL-SAFE CHART If any of the following codes is recorded, the engine ECU enters fail-safe mode. DTC Ne. FaiGate Operation a-Sale Deactivation Condions 12 | Outputiime etum to normal eoneon 15 ___[Outputimie 1B OFF 191) _[Outouime 1B OFF 22___ [Engine coolarttonp. 6 faed a 107°C (224 6°F) Flue to normal canaliion 24 [Intake ar tomo. fad at 170°C (308°F) Fotunto normal conition 32 | Compensation vaio i elated vaive Return to noemal condition a Turbo cherger contol ink uly epen “BOF 25 [Turbo pressures sot ated valve Return o rma concion 23, | Fonte i ined at 40° (104.0°F) Retum to rma conan 42 Velie speedieixed at kmh (0 mh) Venicl speed » O ken (9h) 49 | Output tina 3BOFF 7a) | Fuoieut 18 OFF 7a(2) __[Oupattit 1B OFF a7 vated IG OFF4ON or Starter ON ut put ii 5. CHECK FOR INTERMITTENT PROBLEMS Hand-held tester only By putting the vehicle's engine ECU in the check (test) mode, 1 trip detection logic is possible instead of 2 trip detection logic and sensitivity to detect open circuits is increased. This makes it easier to detect intecmit- tent problems, (a) Ciear the OTC (See step 3) (b) Set the check (test) mode (See step 3) (©) Perform a simulation test (See page IN-10) (d) Check the connector and terminal (See page IN-20). (e) Handle the connector (See page IN-20). 6. BASIC INSPECTION When the malfunction code is not confirmed in the DTG check, troubleshooting should be cartied out in order for all possible circuits to be considered as the cases of the problems. in many cases, by carrying out the basic engine check shown in the following flow chart, the location causing the problem can be found quickly and efficiently. Therefore, use of this check is essential in engine trouble- shootin 1 |Is battery positive voltage 11 V or more when engine is stopped? NO | Charge or replace battery. YES [2 Is engine cranked? I-40 DIAGNOSTICS —_ ENGINE NO \,| Brocaed to problem symptoms table on page YES 3. | Check air filter (See page EM-1). NG [Reeair or replace. [x] 4 | Check fuel quality. CHECK: + Check that use only diesel fuel. + Check that the fuel does not contain any impurity, NG | Replace fuel. Lo] 5 | Check engine oil (See page LU-1). na) Add or replace. Le] 6 | Check coolant (See page CO-1). NG | Replace coolant. Lx] DEN DIAGNOSTICS ENGINE 7 | Check diagnostic connector (DLC3) circuit (See page DI-112). oK NU NG | Repair or replace. 8 | Check vacuum pump (See page EC-3). oK NU > Repair or replace. Proceed to problem symptoms table on page DI-19. 7. REFERENCE VALUE OF ENGINE ECU DATA NOTICE: The values given below for "Normal Condition” are repre- sentative values, $0 a vehicle may still be normal even if its values differ from those listed here. So do not decide whether a part is faulty or not solely according to the ”Nor- mal Condition” here. HINT: Engine ECU data can be monitored by hand-held tester. (a) Connect the hand-held tester to the DLG3. () Monitor engine ECU data by following the prompts on the tester screen. Please refer to the hand-held tester operator's manual for further detail (0)_ Reference Value em Inspection Condition Rofeionco Valve Engine at ding” 3-10 mat INJECTION VOLUME | Engine racing at 2,000 rpm* 5— emmiist, Enging racing at 3,000 rp 714 mmst D412 DIAGNOSTICS _— ENGINE INJECTION TIMING. Engine ating” Ex Enging racing at 2,000 pn" yal" CA 2-504, Engine racing at 3.000 rpm" ENGINE SPO) RPM kept stable (Comparison with tachometer) No great changes Engine atiling® 90-100 KPa: Pint Engine racing at 2,000 rpm 95~15KPa Engine racing at 8,000 rpm" 100 ~ 120 Pa: ACOELE POSITION ‘Accelerator pedal fly closed 0-20% ‘Accelerator podal fully opened 80~ 100% IDL SIG ‘Accelerator pada tut closed (650 — 750 rpm STARTER SIG During cranking ON ‘AIG CUT SIG AG switeh OFF ON EGR SYSTEM ating oN GOEL CLOSE SW. ‘Accdorator pada uly close ON AFM ‘Air Flow Rate Through Air Flow Meter ating 5-10 g/sec GOMN RAIL PRESS Engine at iaing™ 30-40 Mpa = INJPILOT ON Engine ating” 700 — 800 us M~ INJPILOT OFF Engine ating” us PILOT ~INJ Engine ating” 500 — 600 ns PUMP VOM ANGLE Engine ating” 70-90°CA HINT: *: Flat and level place, complete warning-up, shift lever to Nor P position, all accessories and A/C are switched OFF. DIAGNOSTICS _—_ENGINE DIAGNOSTIC TROUBLE CODE CHART HINT: Dia Parameters listed in the chart may not be exactly the same as you reading due ta the type of instrument or other factors. Ia malfunction code is displayed during the DTC check in check (test) mode, check the circuit far the codes listed in the table below. For details of each code, turn to the page referred to under the "See page" for the respective "DTC No.” in the DTG chart Engine ECU gene. taco ten rou fea tring Lat | yy (See page (NormalMoge! Memory Tost Mode “Open ora cari poston sensor cut 12} engi speed Senor rout | Casha postion snr (DI-22) | Malfunction (TDC oF G1 circuit) | +Camshaft timing pulley ONION sengno ECU Open odo ahaa gosta sosor eeu 13 [engine spuua sensor Grait | Crankeal oso ener . (D-24) | Maifunetion (NE circuit) *Crankshatt timing pulley ONON ° *Engne ECU Open ors rte constr oat 15 | Tvale convo eorCreun | Tete cart mata - (0-26) | Malfunction + Throttle valve owen ~ *Eegine ECU Toa) | Aecbeater Pedal Postion Sen [Open o shri erator pda ation sensor Ccuk Gg) [80rCircut Mattuncton (Oper | sAccelerator peda postion sensor ‘ONON ° ‘ Shon) Engine ECU von | Atetraar Pats Poston Sem | -Opn or shot n arora pad poaiion senso ero 128 [erect ain Ok |sActroFta etn cso onon | 0 a ‘Switch/Range) Engine ECU ; evden na | O88" or sor wat Tmp ers rout cy (ie tane Sense Cre Ma | ee ong or onon | 0 (0138) Junction Sete - “Open shor make ar tarp eonsorereut 2410) [ithe Ar Teme Sensor Cre | acy i emp, amor orton | oo aturtion ce 2 se. |* Open shor amaephene ty soso xc 24) | Amos Teme Sensor) posparic air temp. sonso but i a ow eter) OFFION (0146) |eutmauncton ‘Rosier 5 Open or hea tw metro sayy [Aon Cras Matunton — [Aston motor oon | 0 rey Segre ECU Open or shar nectar corcton reaitance eaaut ore, [MaaeroreetonRessiance | eto coractonrexanco orion | 0 ) | Malfunction Engine ECU not turbocharger con- aie cy ee ane Wire names owoN (0-57) | roveexitmatincton weehaes Ttochager 2412) | ruocragersysem mature | EGR vave oven | o (080) [on “tow meter ona DIAGNOSTICS — ENGINE 343) (oi-53) Turbocharger stick detectod (Coese) Turbocharger +EGR valve Airflow meter + Engine ECU onion % (01) Turbo Pressure Sensor Circuit Maltunction Open or short in turbo pressure sensor circuit ‘Turbo prossure sensor + Open ar shart in VSV for turbo pressure sensor circuit + \VSV for urbo pressure sansor + Vacuum hose disconnected or blocked ‘Turbocharger EGR valve + Air tow meter +Engine ECU ‘ONON ° (01-70) Fuel Temp. Sensor Circuit Mal fonction + Open or shor ine temp, sensor cvcut + Fue! proscure sonsor Engine ECU ‘ONON 2 Or75) Vohicle Speed Sensor Signat Cicuit Malluntion “Open or shor in vehicle speed sensor creut * Vehicle speed sensor Combination meter Engine ECU (ONON 49 (or77) Common Ral Pressure Sensor Circuit Maltuncion + Open or shor in fue pressure sensor circu for common rail + Fuel prossure sensor for common rit Engine ECU ‘NON ° 7a) (0179) Fual pump Ccut Malfunction (Fuel Leakane} Open or shor in EDU aivout +e0U + Open or short in injector cireut sector + Ope or short in common rail pressure sonsor circuit + Common rail pressure sensor + Fuel ine between supply pump and common rai + Fuel line between common rail and injector *Prossure limiter Engine ECU ‘OWON 78(2\3) (Oi-84) Fuel pump Grau Malfunction (Open Circuit) Fuel pump Greult Malfunction (Quer Force Feed) + Open or shor in SCV circuit +S0v + Supoly pump Engine ECU ‘ONON 97 (0-88) EDU Circuit Malfunction + Open or short in EDU circuit EDU Open or short in SCV circuit +sov + Injactor +Engino ecu ‘ONON 99 Engine Immobilizr Systom Mal function Open or stor in engine inmabiizer system ecu ‘Transponder key amplifior = Transponder key computor ‘Transponder key col + Engin ECU OFFION “1: "ON" displayed in the diagnosis made column indicates that the check engine warning light is lighted up when 2 malfunction is detected “2:"O" in the memory column indicates that a DTC code is recorded in the engine ECU memory when a mal- function occurs. Accordingly, output of diagnostic results in the normal or test mode is done with the ignition switch ON. pHs DIAGNOSTICS —_ ENGINE PARTS LOCATION Step Motor (for Diese! Throttle) VSV (for Turbo Pressure Sensor) VSV (for EGR Valve Close) Engine ECU | Combination Meter Turbo Pressure Sensor / Air Flow Meter ‘Accelerator Pedal Position Sensor Step Motor for Turbocharger Contr (for Turbocharger Cor EGR Valve Fuel Pressure Sensor Injector —| ~ Dies EDU (for EGR Valve Control) Water Temp. Sensor Crankshatt Position Sensor Crankshaft Position Sensor Intake AirTemp. Sensor Giow Plug ‘Supply Pump * Suction Control Vaive + Fuel Temp. Sensor y asso DIAGNOSTICS _—_ENGINE TERMINALS OF ECU Engine ECU Terminals sala jaiioala| 91847 szresbseated Fans ri eae eee nae enue cdi] 3) heheh ake rok@ ri Symbols (Terminal No.) Wiring Color Conaiion STD Voltage (V) B-y-BA [Aways oa sB(ET-)- EV (ES 22) BR BA__[IGswiton ON on4 VG (E6-21) £2 (E620) BBR [IGswich ON 45-55 VOC (68-8) 620 (66-27) | GY-BRW_|IGswtcn ON 45-55 YB—AR-W_| iG switch ON 45-55 ‘Accelorator padal tuly closed 03-08 YR -BRW. ‘Accelerator pedal fuly oponed 29-48 own Aezserator pedal fly doses 03-08) ‘Accelerator pedal fly opened 29-49) GABA __[iGswitch ON. 10-40 ¥-8—AR [Atmospheric omp 05-38 ay_pn [ABBY aCwIm 40 KPa (500m, 1-8) 92-08 Apply pressure 69 kPa (0.7 halen, 8.96 bn.) 32-38) Le¥= aR [iting ar intake temp. 0°C (82°F) t0 80°C (176°F) 5-34 THW (66-14) —€2 (6-20) GAA ___|Iding, engine coolant temp. 60°C (40°F) to 120°C (248 F) 02-10) THF (E8-24) ~E2 (E620) W-BAR [IG swich ON (at engine cola) 05-28 WG (F6-19) -EVG (E511), B=8 | icing, AC switen OFF 05-30 IGSW (€7-9) -E1 (E5-22) B-0-8A | IGswich ON ota ABR | Cranking 6.0 or more Ne+ (5-17) NE (E5-28) B-w ‘ling oe sew rang Pulse generation (See pago 01-22) VveW-aR | IG ewioh ON, Rotate civing wheel slowly Puise genoration (See page 01-75) GA (E5~2)— E01 (E521) 1G switch ON ona oBwe EGR ON (Maintain engine speed at 1,500 rpm after maming up) Pulse goneration (See page 01-87) RB-Wwe8 | SiaterON) onia Wa Wes: WR Wee, #9 (65-13) E01 (E5-21) ai LY-w-8 * W-G-W8 Pulse generation «ee page 01-88) w-w-s — |tding Pulse generation (See page 0-88) LB-w-8 [IG swich ON ona DHI7 DIAGNOSTICS —__ENGINE [AG switch ON (a ing os NG (E8-6)-E1 (€5-22) By-aR = AG switch OFF 14 “TAGH (E6-10)—E1 5-20) BBR |iding Pulse generation’ SREL(E7-16)—F01(E5-21) | GA-W8 [IG wichOn ania ‘Chack engine warning Fant hghis 0-3 W(E7-12)—E1 (E5-22) YeR-8A ~ en Except check engine warning HOhtighis up a4 Giow indicator ight ight u a GND (€7-a) ~E1 (E522) BR-BA as a Except glow naicato ight hghts Up 9-14 1G Swvteh ON e184 ACT (E8-5) ~€1 (E5-22) L-B-8A [ar A‘C cut controled (Driving below 30 km/h, accelerator pedal . fuly opened for 6 sec) ose LUFATES-20)—E1 (E5-22) waeh LU-A(ES-90) Et (E522), BBR | sch On , swe Pulse generation’? UUs (E5-19)—E1 (E5-22), GBR Senerens LU-B (E5-20) 1 (E522) eR TC (E718) -F4 (E5-22) PAL—BA | IG swich ON a4 1G switch ON 0-30 EGRG (65-1) ~€1 (65-22) ReW-BR ‘Maintain enging speed at 1500 "pm afar warming up ot SL (E719) E1 (F522) V=W—BR | Connect hand-held tester 19 DLO Pulse generation"s IMU(E?~14) Et (5-22) P.G-8R [iding Pulse generation’ IMO (E7-21) —1 (E5-22) BALABA__| A few sec. alter engine staring Pulse generaton'4 Brake podal depressed 75-14 ‘STP (EB-14)-E1 (E5-22) Gowan mee ‘Brake pedal eloased o-15 {_ Brake pedal depressed 0-15, ST1~(€8-29)-E1 (€5-22) RG-BA Brake pada weeased 75-14 IND! (€5-26) Et (€5-22) BBR IN (€5-25) Et (5-22) Caan, a ‘ing 05-45 1Ni3 (E5-24) 1 (5-22) ow 8R Ids (5-29) (E5-22) GBR, VN+A(E5-6) - ENE5-28) VB- BA VN-A(ES-§) -F1(E5-22) YR-BA ‘ing Pulse goneraton's YN+B (E5-4) ~ E1(E5-22) Y-6-BA YN-B (E5-3) - ENES-22), a POVi (E5-8)— ENES-22), ayer | Pulse ganaration ova (E5-8) - EVES-22) BA-8R " See page E84) Heater idle up witch ON 0-30 HW (E8-28)~E1 (€5-22) wR ator ile up switch OFF oa Power healer ON 2-18 VcH (€8-16) -E1 (€5-22) G-8R Power heater OFF 75-14 1G switch ON o14 CT (E6-15)~ Et (€5-22) y-BA Power heater OFF operation on pHs DIAGNOSTICS. GND y asst] a im wa REE. oe Lu+B SIT Tle cnp he wa TE y ysis | GND GND VN-B TL. GND wast HM eR RG GND t+ GND ENGINE REFERENCE: INSPECTION USING OSCILLOSCOPE 4: TACH Et Measure set: 5 V/DIV, 10 ms/DIV *2: LUFA, LU-A, LU+B, LU-B <> Et Measure set: 20 W/DIV, 10 ms/DIV "3: SILO E1 Measure set: 5 V/DIV, 1 ms/DIV “4: IMI, IMO < Et Measure set: 5 V/DIV, 100 ms/DIV *5: VN+A, VN-A, VN+B, VN-B @ Et Measure set: 20 V/DIV, 50 ms/DIV plaGNosrics PROBLEM SYMPTOMS TABLE = ENGINE, Duis When the malfunction code is not confirmed the DTG check and the problem still can not be confirmed in the basic inspection, then proceed to this step and perform troubleshooting according to the numbered order given in the table below. ‘Symptom Suspect Area See page Does not erank (Diticult to start) 2 a Stator Starter relay Water temp. sensor Cold engine (Dificu 10 sat} ‘STA signal creut injector Fu titer Compression Engine ECU. ‘Supply pump Fuel pressure sensor Diesel throte Glow plug systom Hot engine (Oitict 0 stan) STA signal circuit Injector Fuel filter Compressiea Engine ECU Supply pump Fool pressure sensor Diesel trots Soon afer stating (Engine al) Fue ter Injector ECU power source circuit Engine ECU Supply pump Fuel pressure sensor Deselttwotie thors (Engine stall) EQU power source circuit Injector FEngino ECU ‘Supply pump Fuck pressure sensor Diesel throttle Incoroet ist ite (Poor iaing) Foster Inoctor Engine EU Say pump Fuel pressure sensor High engine ite speod (Poor ting) ignal ercui| Injector STA signal cveut Engine ECU ‘Supply pump Ful pressute sensor DI-20 DIAGNOSTICS, = ENGINE Lower engine ale speed (Poor iting} 2 4 ‘ 5 TAC signal cxeut Injactor EGA contol cuit Compression Valve clearance I-05 Fu4 one? EM-2 Es 6, Fuel line (Ar beas) a 7. Engine ECU 8. Supply pump Fug 9, Fuel pressure sensor Epa 19.Diesalthrotle D6 1. Inector Fut 2. Fuel line (Air beed) - 3, EGR contol cuit pio? 4, Compression eM? ough ing (Poor ising) 5. Valve ciearanco ews, 6. Engine ECU ED-28 7. Supply pump Fura 8. Fuel pressure sensor e044 8. Diesel inrotie 50-6 1 ijector Fua 2. EGU power source cvcuit Bi-83 3. Compression ewe 4. Fuel no (Ai boos) - Hunting a hot engine (Poor iting) 5. Valve clearanco EMSS. 6. Engina ECU eD-28 7. Supoly pump Fug. 8. Fue! pressure sonsor coe 8. Diesel throttle £0-6 1 Injector rua 2. EOU pane source cuit ob93 3. Compression ewe 4, Fuel tine (Airbed) - Hunting at cold engine (Poor iting) 5, Valve clearanco ews 6, Engine ECU 0-24 7. Suppiy pump Fuss 8. Ful pressure sensor ea 9. Diese! tnratie £0-6 1. ijector Fua 2 Fuel fter Fut 3. EGR control crit one? , (Poor eves 4 Compression EM-2 Hesitation! Poor acceleration (Poor driveability) 5, Engine ECU ED-24 6. Supply pump AS 7. Fuel pressure senor E044 8. Diesel otto 0-6 1 neater Fut 2 EGR contro creuit bra? Krocking (Poor driveabity) 3. Engine ECU eD-24 4. Supply pump 5, Fuel pressure sensor ED 1 Injector rua 2. EGA contol cet ove? » 3. Engine ECU 0-25 Black smoke (Poor diveabilty) Semoun few 5. Ful pressure sensor EDs 6. Diesel hatte ED-6 Di-2t DIAGNOSTICS ENGINE 1. EGR contol cicult beer 2 jects Fu-4 3, Fuel iter Fut White smoke (Poor driveatity) 4. Engine ECU 0-28 5. Supply pump Fuca 5, Ful pressure sensor ED-14 7. Diesel tattle D6 1 Inector Fu4 2, Engine E 0-28 Surging! Hunting (Poor criveainy) 3. Simpy pump Fung 4. Fuel presse sensor 0-18 Di-22 DIAGNOSTICS — ENGINE CIRCUIT INSPECTION DTc 12 Engine Speed Sensor Circuit Malfunction 1 (TDC or Gi Circuit) CIRCUIT DESCRIPTION Camshaft position sensor (Gt signal) consists of a magnet, iron core and pickup coil The Gt signal plate has one tooth on its outer citcumference and is installed the pump drive shaft pulley. When the camshafts rotate, the protrusion on the signal plate and the air gap on the pickup coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pickup coil. The NE signal plate has 34 teeth and is mounted on the crank angle sensor plate. The NE signal sensor generates 34 signals at every engine revolution. The engine ECU detects the standard crankshaft angle based on the G1 signal and the actual crankshalt angle and the engine speed by the NE signal. ores, _| DTC betecing Goniion Tiouble hea Open or short in camkshatt position sansor ercuit, ‘Camshat poston sensor Camshat timing pulley Engine ECU. No camshatt position sensor signal to EGU during cranking 12 | Nocamishatt postion sensor signal to ECU with engine speed L £850.09 or move WIRING DIAGRAM Engine ECU Camshaft Position Sensor nae INSPECTION PROCEDURE HINT: + Perform troubleshooting of OTC 12 first. If no trouble is found, troubleshoot the following mechanical system. + Read freeze frame data using hand-held tester. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting itis useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air-fuel ratio was lean or rich, etc. at the time of the malfunction. DI-23 DIAGNOSTICS = ENGINE 1 [eck resistance of camshaft position sensor (See page ED-17). Reference: INSPECTION USING OSCILLOSCOPE During cranking or idling, check the waveforms between termi- nals G and G-, and NE and NE~ of the ECU connector. HINT: The correct waveforms are as shown NG )| Replace camshaft position sensor. Sv) Gand NE Signal Waveforms Division (TTT ET TH 2. [Check for open and short in harness and connector between ECU and camshaft position sensot (See page IN-20). [«] 3. | Inspect sensor installation and signal plate tooth of pump drive shaft pulley. NG \\) Tighten sensor. Replace pump drive shaft pulley. NG_ | Repair or replace harness or connector. (J Check and replace ECU (See page IN-20). DL-24 DIAGNOSTICS _—_ ENGINE DTC 13 Engine Speed Sensor Circuit Malfunction 2 (NE Circuit) CIRCUIT DESCRIPTION Crankshaft position sensor (NE signal) consists of a magnet, iron core and pickup coil The NE signal plate has 34 teeth and is installed the crank angle sensor plate. The NE signal sensor gener- ates 34 signals of every engine revolution. The ECU detects the standard crankshaft angle based on the G1 signal, and the actual crankshaft angie and the engine speed by the NE signal. Drone. DTC Detecting Condition “rouble Area "No crankshali poston sensor signal to engine ECUTor0.5 | Open or shat in erankshah pasion sensor circuit ‘88, oF mare at 650 rpm or more + Crankshatt postion sensor No cankshat positon senso signl i engine EQUTor20 | *Grank angle sensor late 806.01 more during cranking Engine ECU WIRING DIAGRAM Refer to DTC12 on page Di-22. INSPECTION PROCEDURE HINT: Read freeze frame data using hand-held tester. Because freeze frame records the engine conditions when the maifunction is is detected. When troubleshooting, it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air-fuel ratio was lean oF rich, etc. at the time of the malfunction. 1 | Check resistance of crankshatt position sensor (See page ED-18). Reference: INSPECTION USING OSCILLOSCOPE Refer to DTC 12 on page Dl-22. Replace crankshaft position sensor (See page a ° ™ OK 2 Check for open and short in harness and connector between engine ECU and crankshatt position sensor (See page IN-20). [«] > Repair or replace harness of connector. Di-25 DIAGNOSTICS —_ENGINE 3 | Inspect sensor installation and signal plate teeth of crank angle sensor plate. NG \\| Tighten sensor. Replace crank angle sensor plate. [J Check and replace engine ECU (See page IN-20), Di-26 oyasnoses DTC | 15 Throttle Control Motor Circuit Malfunction CIRCUIT DESCRIPTION Throttle contro! motor is operated by the engine ECU and it opens and closes the throttle vaive. The fully opening of the throttle valve is detected by the throttle fully open position switch which is mounted on the throttle body. If this DTC is stored, the engine ECU shuts down the power for the throttle control motor. DICNa D6 betecing Condon Trove nea Open o° shen inal control motor cro Open or shot in thrattie control motor circuit ‘Throttle control motor . “Tote va 5 ‘ota drive gear : * ios tet boy (open or st in that fl ston exes eee WIRING DIAGRAM 7 Throttle Control Motor —_———(E5)) wu-a 19 99 —— — U8 Y 29. —_—_—_______(s} we " wa ap Ls} moe e 4 Throttle Open Switch KO INSPECTION PROCEDURE HINT: Read freeze frame data using hand-held tester. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting, it is useful for determining whether the veliicle was run- ning or stopped, the engine was warmed up or rot, the air-fuel ratio was lean or rich, etc. at the time of the malfunction. Die DIAGNOSTICS — ENGINE 1 | Check throttle control motor circuit. r Signal Wavetomn PREPARATION: ~ iow | (a) Connect the oscilloscope between terminals LU+A/LU- sa ALU+B/LU-B and E01 af the engine ECU, (b) Start the engine. pL sy] CHECK: end i Check the waveform between terminals LU+A/LU-A/LU+B/ | LU-B and E0/ of the engine ECU when the engine is racing. i Ok: vy ehrisecrbivision “~_sossnn] ~The correct waveforms are as shown. Ok \\| Check and replace engine ECU (See page IN-20). NG 2 Jere throttle control motor (See page ED-6). em NG \ Replace diese! throttle body assembly (See page ED-4), Lo ] 3 Check for open and short in harness and connector between throttle control mo- tor and engine ECU (See page IN-20). we) OK Check and replace engine ECU (See page ED-23), Ropair or replace. Di-28 Diagnostics — ENGINE DTC 19(1) | Accelerator Pedal Position Sensor Circuit Malfunction (Open/Short) CIRCUIT DESCRIPTION The accelerator pedal position sensor is mounted at the accelerator pedal and detects the accelerator pedal opening angle. When the accelerator pedal is fully closed, a voltage of approximately 0.8 Vis applied to ter- minals VA, VAS of the engine ECU. The voitage applied to terminals VA, VAS of the engine ECU increases in proportion to the opening angle of the accelerator pedal and becomes approximately 3.8 V when the ac- celerator pedal is fully opened, The engine ECU judges the vehicle driving conditions from these signals input from terminals VA, VAS and uses them as one of the conditions to control the injection volume and diesel throttle valve position, This system has 2 way accelerator pedal position sensor and accelerator pedal closed position switch for fail safe, BroNs SiC bsecng Sono Tao hen Caan a) eames 05 6 om fowneoav von pouaseas Omar htm tpt ton anc "Toran ad tne 2058 = me _Aettr na fawn 2 (b) 02 40 HINT: Alter confirming DTC 19 (1), use the hand-held fester to confirm the accelerator pedal opening percentage and accelerator pedal close position switch condition ‘Accolorator pedal opening postion expressed as percentage al Trouble area ‘Accelerator pada) tlly cased ‘coaleralor pedal tly open VCC circuit open 0% 0% VA, VAS circu opon or short ‘Approx. 100 %: ‘Approx. 100% | + £26 eteut open I-29 DIAGNOSTICS —_ENGINE WIRING DIAGRAM ASB. Accel Pedal Sensor Engine ECU vere Le ays INSPECTION PROCEDURE HINT: Read freeze frame data using hand-held tester. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting itis useful for determining whether the vehicle was run- ning of stopped, the engine was warmed up or not, the air-fuel ratio was lean or rich, etc. at the time of the malfunction When using hand-held tester: 1 | Connect the hand-held tester, read accelerator pedal opening percentage. PREPARATION: (@) Connect the hand-held tester to the DLC3. (Turn the ignition switch ON and push the hand-held tester main switch ON. CHEC! Read the accelerator pedal opening percentage. ‘Accelerator pedal opening postion ‘Accolorator pedal p expressed as percentage Fully open ‘Approx. 75% Fly closed ADpIOK. 16 % OK \\ Check for intermittent problems (See page DI-4). [J DL30 DIAGNOSTICS —_ ENGINE 2 [srs voltage between terminal 4, 6 of wire harness side connector and body ground. PREPARATION: (a) innect the accelerator pedal position sensor con- nector. (0) _ Turn the ignition switch ON CHECK: Measure the voltage between terminal 4, 6 of the wire harness side connector and body ground. Ok: Aysaaa) Voltage: 4.5 - 5.5 V . + NG )| Go to step 5. oK 3 | Check voltage between terminals VA and E2C, and VAS and E2C2 of engine ECU connector. PREPARATION: (a) Remove the glove companment. (b) Turn the ignition switch ON, CHECK: ‘Measure the voltage between terminals VA and E2C, and VAS and E2C2 of the engine ECU connector. ol ‘Accelerator pedal Vottage (¥) VA 05~1.41 Fully closed vas:o9-23 Va:30-46 Fally open vasaa_ eo ‘0K \\| Check and replace engine ECU (See page IN-20). [+ ] 4 | Check for open and short in harness and connector in VA and VAS circuits be- tween engine ECU and accelerator pedal position sensor (See page IN-20). = NG) | Repair or replace harness or connector. Dist DIAGNOSTICS _~ ENGINE [«] Replace accelerator pedal assembly. 5 | Check voltage between terminals VCC and E2C of engine ECU connector. Remove the glove compartment. (b) Turn the ignition switch ON. CHECK: Measure the valtage between terminals VCC and E2C of the engine ECU connector. OK: Voltage: 4.5-5.5V NG \\| Check and replace engine ECU (See page IN-20). Check for open in harness and connector in VCC circuit between engine ECU and accelerator pedal position sensor (See page IN-20). When not using hand-held tester: 1 | Check voltage between terminal 4, 6 of wire harness side connector and body ground. PREPARATION: (a) Disconnect the accelerator pedal position sensor con- nector. (b) _ Tum the ignition switch ON. CHECI Measure the voltage between terminal 4, 6 of the wire harness side connector and body ground. oO y ~ mon] Voltage: 4.5-5.5V NG ) Goto step 4. Di-32 DIAGNOSTICS _—_ENGINE [J Check voltage between terminals VA and £2C, and VAS and E2C2 of engine ECU connector. TON: ve the glove compartment. (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals VA and E2C, and VAS and E2C2 of the engine ECU connector. OK: ‘Accelerator pada Vvoitage (v) VAO5=1.4 Fuly closed vas-09-53 VA'3.0-36 Fully open VAS:3.48-50 OK \\| Check and replace engine ECU (See page IN-20). 3 | Check for open and short in harness and connector in VA and VAS circuits be- tween engine ECU and accelerator pedal position sensor (See page IN-20). [*] NG | Repair or replace harness or connector. Replace accelerator pedal assembly. 4 | Check voltage between terminals VCC and E2C of engine ECU connector. PREPARATION: (a) Remove the glove compartment. (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals VCC and E2C of the engine ECU connector. OK: Voltage: 4.5 -5.5V Di-33 DIAGNOSTICS ~_ENGINE Check and replace engine ECU (See page IN-20). oK Check for open in harness and connector in VCC circuit between engine ECU and accelerator pedal position sensor (See page IN-20). Deas DIAGNOSTICS — ENGINE DTC 19(2) | Accelerator Pedal Position Sensor Circuit Malfunction (IDL Switch/Range) CIRCUIT DESCRIPTION Refer to DTC 19 (1) on page DI-2a. DTGN [DTC Detecting Conation Trout area \Witne the ECU sensor completed learning and when the elec tric potential diference of No. | and No. 2 sensors has become more than 1.2V or lass than 0.4 V. ier one othe folowingsconinues more han 20 seconds| +Open or shot in aczlrator peda potion sensor det 19:2) Jie tmentte era pont diterence of No 1 ana No, 2 | Acoseator peal postion sensor sensrsis bide ne spciid vale Engine ECU ja) vona = 48 (6 Accelerator ing erevion age of Ne. # ao. 2n ass L than 0.08 WIRING DIAGRAM Refer to DTC 19 (1) on page D-28. INSPECTION PROCEDURE HINT: Read freeze frame data using hand-held tester. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was run- ning or stopped, the engine was warmed up or not, the air-fuel ratio was lean or rich, etc. at the time of the malfunction. 1 {Check voltage between terminal VCC and VCC2 of wire harness side connector and body ground (See page DI-28). NG | Goto step 4. ok 2 [Check voltage between terminals VA and E2C, and VAS and E2C2 of engine ECU | connector (See page DI-28). Check and replace engine ECU (See page IN-20). LJ DI-35 DIAGNOSTICS _—_ENGINE 3. | Check for open and short in harness and connector in VA and VAS circuits be- tween engine ECU and accelerator pedal position sensor (See page IN-20). ok Replace accelerator pedal 4 | Check voltage between terminals VCC and E2C, VCC2 and E2C2 of engine ECU connector (See page DI-28, step 5). NG | Repair or replace harness or connector. NG \\| Check and replace engine ECU (See page IN-20). [«] Check for open in harness and connecter in VCC circuit between engine ECU and accelerator pedal position sensor (See page IN-20). DI-36 DIAGNosTICs — ENGINE DTC 22 Water Temp. Sensor Circuit Malfunction CIRCUIT DESCRIPTION Fig. 1 30 20 10 5 Acceptable The water temperature sensor senses the coolant temperature. A thermistor built into the sensor changes the resistance value according to the coolant temperature. The lower the coolant temperature, the greater the thermistor resistance value, and the higher the coolant temperature, the lower the thermistor re- sistance value (See Fig. 1). ‘The water temperature sensor is connected to the engine ECU g, (See below). The 5 V power source voltage in the engine ECU B 2 [ is applied to the water temperature sensor from the terminal s ‘THW via a resistor R. Thatis, resistor R and the water tempera- 3! F ture sensor are connected in series. When the resistance value © ost of the water temperature sensor changes in accordance with 037 changes in the coolant temperature, the potential at the termi- 02 nal THW also changes. Based on this signal, the engine ECU orl increases the fuel injection volume to improve driveability dur- na fo ing cold engine operation. 0 0 20 40 60 AD 100 {4} (82) (68) (104) (140) (176) (212) Temperature °C (°F) DTG No. DTC Detesing Gandition “Touble Aa Open o sho in watar tmp. Sensor creut 22 | Openorshortin water temp. sonsor cet for 0.5 £8. or more | + Wate tap. sansar Engine ECU HINT: After confirming DTC 22, use the hand-held tester to confirm the water temperature from the CURRENT DATA. Temperature dapayed Matoneon OC AOA) Gpenarcut 140°O (28s For more Shon creat DL37 DIAGNOSTICS —_ ENGINE WIRING DIAGRAM Engine ECU Water Temp. Sensor y 0 INSPECTION PROCEDURE HINT: + IFDTCs 22, 24 and 39 are output simultaneously, E2 (sensor ground) may be open. + Read freeze frame data using hand-held tester. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting itis useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air-fuel ratio was lean or rich, etc. at the time of the malfunction When using hand-held tester: 1 | Connect hand-held tester, and read value of water temperature. PREPARATIOI (a) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the hand-held tester main switch ON CHECK: Read the temperature value on the hand-held tester. oO Same as actual water temperature. HINT: + Ifthere is open circuit, hand-held tester indicates 40°C (-40°F) + If there is short circuit, hand-held tester indicates 140°C (284° F} or more. oK Check for intermittent problems (See page DI-4). NG \\ -40°¢ (-40°F) ... Go to step 2. 140°C (284°F) or more ... Go to step 4. D388 DIAGNOSTICS _— ENGINE 2 [check for open in harness or engine ECU. ON PREPARATION: ® (a) Disconnect the water temperature sensor connector. Water (b) Connect the sensor wire harness terminals together. ‘Temp. Sensor (c) Turn the ignition switch ON. _S CHECK: C + Cc. Read the temperature value on the hand-held tester. ae —cF OK: a ‘Temperature value: 140°C (284°F) or more OK \\| Contirm good connection at sensor. If OK, re- place water temperature sensor, NG 3 [check for open in harness or engine ECU. PRI EPARATION: (DZ (a) Remove the glove compartment. e) Engine ECU (b) Connect between terminals THW and E2 of the engine water Tem, Sensor a ECU connector. HINT: ete The water temperature sensor connector is disconnected. Be- fore checking, do a visual and contact pressure check for the engiie ECU connector (See page IN-20) — t=) | (c) Turn the ignition switch ON. eat 5 Gag | Ht) | check: a ms Read the temperature value on the hand-held tester. Ok: ess THW. ~~ Temperature value: 140°C (284°F) or more ‘i & warra OK \\| Open in hamess between terminal E2 or THW. repair or replace harness. [=] Confirm good connection at engine ECU. If OK, replace engine ECU. Di-39 DIAGNOSTICS —_ ENGINE Temp. Sensor = (Ey ev chub. a J 4 | Check for short in harness and engine ECU. ON PREPARATION: @ (a) Disconnect the water temperature sensor connector. Water Engine ecu | (b) Turn the ignition switch ON. CHECK: Read the temperature value on the hand-held tester. ol Temperature value: ~40°C (-40°F) eI Check for short in harness 5 or engine ECU. Engine ECU = sv) we, | Check and replace engine ECU (See page IN-20). PREPARATION: (@) Remove the glove compartment. (b) _ Disconnect the E8 connector from the engine ECU. HINT: ‘The water temperature sensor connector is disconnected. (@) Turn the ignition switch ON. CHECK: Read the temperature value on the hand-held tester. Ok: ‘Temperature value: —40°C (40°F) OK | Repair or replace harness or connector. Diao DIAGNOSTICS — ENGINE When not using hand-held tester: 1 | Check voltage between terminals THW and E2 of engine ECU connector. PREPARATION: {a) Remove the glove compartment. (b) _ Turn the ignition switch ON. CHECK: Measure the voltage between terminals THW and E2 of the en- gine ECU connector. Ok: Water Temp Crp votage 20168) ; (Engine is coon ga-ga 20 (076) sy (gino hat) outey Ok \\| Check for intermittent problems (See page 0-4). NG NF 2 | Check water temperature sensor (See page ED-11). NG )| Replace water temperature sensor. oK 3 | Check for open and short in harness and connector between engine ECU and water temperature sensor (See page IN-20). LJ Check and replace engine ECU (See page IN-20). na) Repair or replace harness or connector. Dat DIAGNOSTICS _—_ENGINE DTC 24(1) | Intake Air Temp. Sensor Circuit Malfunction CIRCUIT DESCRIPTION The intake air temperature sensor is built into the intake man- ifold and senses the intake air temperature. A thermistor built in the sensor changes the resistance value according to the in- take air temperature. The lower the intake air temperature, the greater the thermistor resistance value, and the higher the in- take air temperature, the lower the thermistor resistance value of Acceptable (See Fig. 1) g3l ‘The intake air temperature sensor is connected to the engine Be ECU. The 5 V power source voltage in the engine ECU is ap- a, plied to the intake air temperature sensor from terminal THA via 2 aresistor R. Thatis the resistor R and the intake air temperature © oat sensor are connected in series. When the resistance value of the intake air temperature sensor changes. Based on this sig- oe g nal, the engine ECU increases the fuel injection volume to im- oal, prove drivability during cold engine operation. -2 02 40 60 60 100 (4) 82 69 104 140 176 212 Temp. °C.(°F) DTC No DTC Detecting Conation Trouble Area avy |Corpersnensat sion src san or | ‘rng atee esc sengre ECU HINT: After confirming DTC 24, use the hand-held tester to confirm the intake air temperature from the CURRENT DATA. Temporature displayed Matlunetion 40°C 40°F) ‘Open ereuit 140° (284° F) or more Shon eeu Diaz DIAGNOSTICS _— ENGINE WIRING DIAGRAM Engine ECU Intake Air Temp. Sensor INSPECTION PROCEDURE HINT: + IFDTC 22, 24, 35 and 39, £2 (sensor ground) may be open. + Read freeze frame data using hand-held tester. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting itis useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air-fuel ratio was lean or rich, ete. at the time of the malfunction. When using hand-held tester: 1 | Connect hand-held tester, and read value of water temperature. | PREPARATION: (@) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the hand-held tester main switch ON. CHECK: Read the temperature value on the hand-held tester. Ok: Same as actual intake air temperature. HINT: + If there is open circuit, hand-held tester indicates 40°C (~40"F). + Ifthere is short circuit, hand-held tester indicates 140°C (284°F) or more, NG —40°C (-40°F) ... Go to step 2. | 140° (284°F) or more ... Go to step 4. DIAGNosTICS _— ENGINE Check for intermittent problems (See page DI-4). 2. | Check for open in harness or engine ECU. [ 7N0N @ Intake Air fino ECU ‘Temp. Sensor fe sv) S13 m= re a ( 2 Laws ° et Lv J PREPARATION: {a) Disconnect the intake air temperature sensor connector. (0) Connect the sensor wire harness terminals together. (c) Turn the ignition switch ON. CHECK: Read the temperature value on the hand-held tester. OK: Temperature value: 140°C (284°F) or more | > Confirm good connection at sensor. If OK, re- place intake air temperature sensor. 3. | Check for open in harness or engine ECU. Engine ECU Intake AirTemp. Sensor 2 y sows [= J place engine EC! Confirm good connection at engine EC! PREPARATION: (a) Remove the glove compartment. (b) Connect between terminals THA and E2 of the engine ECU connector. HINT: The intake air temperature sensor connector is disconnected. Before checking, do a visual and contact pressure check for the engine ECU connector (See page IN-20). (c)_ Turn the ignition switch ON. CHECK: Read the temperature value on the hand-held tester. Ok: ‘Temperature value: 140°C (284°F) or more ——_—_______—————_, Open in harness between terminal E2 or THA, repair or replace harness. Diag DIAGNOSTICS ENGINE 4 | Check for short in harness and engine ECU. on Intake Air Engino ECU Temp. Sensor Lbs ~ [J PREPARATION: (@) Disconnect the intake air temperature sensor connector. (b) Turn the ignition switch ON. CHECK: Read the temperature value on the hand-held tester, OK ‘Temperature value: ~40°C (~40°F) OK | Replace intake air temperature sensor. 5 | Check for short in harness or engine ECU. BD WZ Engine ECU Intake Air Temp. Sensor ov SY Se conocer ¥ pos) PREPARATION: (a) Remove the glove compartment. (0) _ Disconnect the E8 connector from the engine ECU. HINT: The intake air temperature sensor connector is disconnected. (©) Turn the ignition switch ON. CHECK: Read the temperature value on the hand-held tester. Ok: ‘Temperature value: ~40°C (~40°F) OK >| Repair or replace harness or connector. Check and replace engine ECU (See page IN-20). DIAGNOSTICS ENGINE When not using hand-held tester: Das (b) Turn the ignition switch ON. CHECK: £2 gine ECU connector. 1 | Check voltage between terminals THA and E2 of engine ECU connector. on PREPARATION: @® (a) Remove the glove compartment. Measure the voltage between terminals THA and E2 of the en- Ok: Intake Air Temp. v sorra Sorry vensoe 20 (63) 02-38 (Engine is coo) 180/176) (Enging is hot) oats (See page Di-4). OK \\| Check for intermittent problems (J 2 | Check intake air temperature sensor (See page ED-13). NG_)| Replace intake air temperature sensor. Lo] intake air temperature sensor (See page IN-20). 3 | Check for open and short in harness and connector between engine ECU and > Repair or replace harness or connector. Lx] Check and replace engine ECU (See page IN-20). Diag DIAGNOSTICS _—_ ENGINE DTC 24(2) | Atmospheric Temp. Sensor Circuit Malfunc- CIRCUIT DESCRIPTION Fig. 1 ‘The atmospheric temperature sensor is built into the air flow meter and senses the atmospheric temperature. A thermistor buill in the sensor changes the resistance value according to 30 the atmospheric temperature. The lower the atmospheric tem- 20 perature, the greater the thermistor resistance value, and the 10 higher the atmospheric temperature, the lower the thermistor sf Acceptable resistance value (See Fig. 1). ‘The atmospheric temperature sensor is connected to the en- aI gine ECU. The 5 V power source voltage in the engine ECU is. applied to the atmospheric temperature sensor from terminal THAF via a resistor R. That is resistor R and the atmospheric temperature sensor are connected in series. When the resis- tance value of the atmospheric temperature sensor changes. Based on this signal, the engine ECU increases the fuel injec- tion volume to improve drivability during cold engine operation. Resistance kO. 0 2 40 60 8 100 (4) 32 68 104 140 176 212 Temp. °C (°F) Drone. DTC Detecting Conetion Trouble Area “Open or shor in atmaspherc temp, sensor circut ‘Open or shot in atmospheric temp. sonsor circu for 0.5 se. 24 pen oF short P 52° |. atmospheric temp, sensor (bul into ai flow meter) ormore jno ECU HINT: After confirming DTC 24, use the hand-held tester to confirm the atmospheric temperature from the CUR- RENT DATA. Temperature displayed Maitunction 40°C (40°F) pon crcut 140°C (284°F) or more Shor circuit WIRING DIAGRAM Refer to DTC 31 on page DI-51 INSPECTION PROCEDURE HINT: + IFDTC 22, 24, 35 and 39, E2 (sensor ground) may be open. + Read freeze frame data using hand-held tester. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting itis useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air-fuel ratio was lean or rich, etc. at the time of the malfunction DI-a7 DIAGNOSTICS —_ ENGINE When using hand-held tester: 1 | Connect hand-held tester, and read value af atmospheric temperature. PREPARATION: (a) Connect the hand-held tester to the DLC3. (b) _ Turn the ignition switch ON and push the hand-held tester main switch ON. CHEC Read the temperature value on the hand-held tester. Ok: Same as actual atmospheric temperature. HINT: + Ifthere is open circuit, hand-held tester indicates ~40°C (40°F) + Ifthere is short circuit, hand—held tester indicates 140°C (284°F) or more. (" [=] Check for intermittent problems 40°C (40°F)... Go to step 2. 140°C (284°F) or more ... Go to step 4. (See page DI-4). 2. | Check for open in harness or engine ECU. ON PREPARATION: a (a) Disconnect the air flow miter connector. ~ (b) Connect the sensor wire harness terminals together. ‘Atmospheric (5) ¥ | (c) Tur the ignition switch ON. Temp. Sensor i cae] CHECK: Read the temperature value on the hand-held tester. Ok: "Temperature value: 140°C (284°F) or more OK \\| Confirm good connection at sensot. If OK, re- place air flow meter. Dias DIAGNOSTICS —_ENGINE 3 | Check for open in harness or engine ECU. PREPARATIO! (@) Remove the glove compartment. Engine&Cu | (b) Connect between terminals THAF and E2 af the engine AtmosphericTemp. Sensor BY ECU connector. HINT: ‘The air flow meter connector is disconnected. Befare checking, do a visuai and contact pressure check for the engine ECU con- nector (See page IN-20) (c) Tum the ignition switch ON, CHECK: Read the temperature value on the hand-held tester. OK: (On d) Temperature value: 140°C (284°F) or more * NG Open in harness between terminal 2 or THAF, repair or replace harness. Confirm good connection at engine ECU. it OK, replace engine ECU. 4 | Check for short in harness and engine ECU. ON PREPARATION a” (@) Disconnect the air flow meter connector. ‘Atmospheric Enginegcu | (0) Turn the ignition switch ON. Temp. Sensor CHECK: a Read the temperature value on the hand-held tester. Low} ry Temperature value: -40°C (40°F) OK )| Replace air flow meter. Diag DIAGNOSTICS _—_ ENGINE 5 Check for short in harness or engine ECU. | PREPARATION: @ ennoeou (a) Remove the glove compartment. pane Ect (b) Disconnect the E7 connector from the engine ECU. 3 a 3 3 g 28 sv) | MINT: me The air flow meter connector is disconnected. (0) Turn the ignition switch ON. CHECK: Read the temperature value on the hand-held tester. i -9 Oe "Temperature value: ~40°C (40°F) sexs cc E7 Connector NG Check and replace engine ECU (See page IN-20} When not using hand-held tester: esr! | OK | Repair oF replace harness or connector. 1 | Check voltage between terminals THAF and E2 of engine ECU connector. PREPARATION: (@) Remove the glove compartment. (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminals THAF and E2 of the en- gine ECU connector. OK: Ok \\| Check for intermittent problems | (See page DI-4). I-50 DIAGNOSTICS = ENGINE 2 | Check atmospheric temperature sensor (See page ED-13), [ 1) Replace air flow meter. oK 3. | Check for open and short in harness and connector between engine ECU and atmospheric temperature sensor (See page IN-20). ve) [res or replace harness or connector. oK Check and replace engine ECU (Gee page IN-2 I-51 DIAGNOSTICg_—_ ENGINE DTC | 31 |r Flow Circuit Malfunction CIRCUIT DESCRIPTION The air flow meter uses a platinum hot wire. The hot wire ait flow meter consists of a platinum hot wire, therm istor and a control circuit installed in a plastic housing. The hot wire air flow meter works on the principle that the hot wire and thermistor located in the intake ait bypass of the housing detect any changes in the intake air temperature. The hot wire is maintained at the set temperature by controlling the current flow through the hot wire, This current flow is then measured as the output voltage of the air flow meter. The circuit is constructed so that the platinum hot wire and thermistor provide a bridge circuit with the power transistor controlled so that the potentiai of A and B remains equal to maintain the set temperature, Br ‘Thermistor Power Transistor Platinum Hot Wire Output Voltage Platinum HotWire — Thermistor | DIG No. DTC Detecting Gondtion Trouble Area __| Open or son nar ow mater ckcut a opener short in airflow motor cicut win more than 9 see. ihn mtr Engine ECU HINT: Atier contirming DTC 31, use the hand-held tester to confirm the air Now ratio from the CURRENT DATA. ‘Fon Vie ardsoe) Waturcion “Air low meter power source ctxt open = VG circus open or short ‘Approx. 00 184.0 or more + £VG circuit open Di-S2 DIAGNOSTICS _—_ENGINE WIRING DIAGRAM _ Engine Room JB. a sisime (RHO) Engine ECU | 8 3 | pr 10 1E2 (LHD) o 2 ofa) or] -f 2 LB or}? aC Ke Y ECD RELAY E (a0) (RHO) 2) € CHILD) Engine Room FB | w-B. 2, D Alas (LHD) (RHO) (CHOY ly] | J20 (RAD) B LL Jac a ¢ A FEoatey Pog ub} yo Air Flow Meier is INSPECTION PROCEDURE HINT: Read freeze frame data using hand-held tester. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting, it is useful for determining whether the vehicle was run- ning or stopped, thé engine was warmed up or not, the air-fuel ratio was lean or rich, etc. at the time of the malfunction. When using hand-held tester: 1 | Connect hand-held tester, and read vaiue of air flow rate. PREPARATION: (a) Connect the hand-held tester to the DLCS. (b) Tum the ignition switch ON and push the hand-held tester main switch ON. (©) _ Start the engine. CHECK: Read the air flow rate on the hand-held tester. RESULT: Type! Type it Type })! Goto step 2. “wpel) Go to step 5. Diss DIAGNOSTICS — ENGINE 2 | Check voltage of air flow meter power source. | Sur 3 1 na PREPARATION: (@) Disconnect the air flow meter connector. (b) _ Turn the ignition switch ON. CHECK: Measure the voltage between terminal 3 of the air Slow meter connector and body ground. OK: Voltage: 9-14 V NG Check for open in harness and connector be- tween EF1 main relay (Marking: EFI) and air flow meter (See page IN-20). 3 | Check voltage between terminals VG of engine ECU connector and body ground. [«] PREPARATION: (a) Remove the glove compartment door. (b) Start the engine. CHECK: Measure the voltage between terminal VG of the engine ECU connector and body ground while the engine is idling. aK: ~~ Voltage: 0.5 - 3.0 V (P or N position and A/C switch OFF) | OK \\| Check and replace engine ECU (See page IN-20). [oJ 4 | Check for open and short in harness and connector between air flow meter and engine ECU (See page IN-20). ——— Sa a Disa DIAGNOSTICS ENGINE Replace air flow meter. 5 | Check continuity between terminal EVG of engine ECU connector and body ground. PREPARATION: Remove the glove compartment. CHECK: Check the continuity between terminal EVG of the engine ECU connector and body ground. Ok: ~~ Continuity (1 © or less) ¥ sos Check and replace engine ECU (See page IN-20). ok 6 | Check for open in harness and connector between air flow meter and engine ECU (See page IN-20). OK Replace air flow meter. When not using hand-held tester: NG Repair or replace harness or connector. | 1 | Check voltage between terminals VG of engine ECU connector and body ground. PREPARATION: (a) Remove the glove compartment. (b) Start the engine. CHECK; Measure the voltage between terminal VG of the engine ECU connector and body ground while the engine is idling OK: "Voltage: 0.5 ~3.0 V (P or N position and A/C switch OFF) y = __ sosr0 Diss DIAGNOSTICS _— ENGINE ‘Ok \\| Check and replace engine ECU (See page IN-20). [=] 2 | Check voltage of air flow meter power source. PREPARATION: (a) Disconnect the air flow meter connector. () Tum the ignition switch ON. CHEC! Measure the voltage between terminal 3 of the air flow meter connector and body ground. Ok: Voltage: 9-14. V Cheek for open in harness and connector be- {ween EF! main relay (Marking: EFI) and alr flow meter (See page IN-20). [J 3 | Check for open in harness and connector between air flow meter and engine [ ECU (See page IN-20). ok Replace air flow meter. NG_)/ Repair or replace harness or connector. Di-s6 DIAGNOSTICS —_ ENGINE DTC 32 | Injector Correction Resistance Malfunction CIRCUIT DESCRIPTION The correction system is correcting a few vary between each injectors. OG No. DIC Detecting Condiion Trouble Area *inestor correction resistance circuit 32 | opener ator in cteut + Injector conection resistancs (built into injector) Engine ECU. WIRING DIAGRAM Refer to DTC 97 on page DI-88 INSPECTION PROCEDURE HINT: Read freeze frame data using hand-held tester. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was run- ning oF stopped, the engine was warmed up or not, the air-fuel ratio was lean or rich, etc. at the time of the matfunetion. 1 Cheok resistance of ECU terminal for injector correction resistance and body ground. OK \\| Check and replace engine ECU (See page ED-23). Lv J 2 | Check resistance between terminals correction resistance of injector (See page FU-4). oK Repair harness or connector. > Replace the Injector. D157 DIAGNOSTICS — ENGINE : DTC 34(1) | Step motor for turbocharger control circuit malfunction (Open/short) CIRCUIT DESCRIPTION OTC No DTG Detecting Conation Trouble Area sn temporary ortor" is detected and, wil the step motor | “St#P meter sy _ |Site Setanta’ = [wean *: When nn errors detected trom comparison berwean the current condition of the step motor and the monitor sig WIRING DIAGRAM Engine ECU $34 ‘Step Motor for Turbocharger Control 6 Y-B Leis — Logo — DIAGNOSTICS _—_ENGINE INSPECTION PROCEDURE 1 Inspect step motor for turbocharger control (See page TC-3). Le) NG | Replace turbocharger assembly. Check for open and short in harness and connector between step motor and en- Gine ECU (See page IN-20). | NG. | Repair or replace harness or connector. OK Check and replace engine ECU (See page ED-23). amount a uel njation is detected. D9 DIAGNOSTICS — ENGINE DTC 34 (2) | Turbocharger system malfunction DTC 34 (3) | Turbocharger stick detected (Close) CIRCUIT DESCRIPTION DICNo 7C Datacing Gonion Trouble Wea 40 [Namarauelrasaee ema Soeted | upoenager Wen tho condition thal or 60 sac. ormore tne ubocharger EGA Walvo gaia) | PreSSU@Is 20KPa 0.2 Kalen?, 14 ps) ormore above ho} AK Fo ar % value that is set based on the engie revolution and the Engine ECU HINT: INSPECTION PROCEDURE If DTC 36 is output simultaneously, first troubleshoot DIC 36. 1 | check turbocharger assembly (See page TC-1). [J > Replace turbocharger. 2 | Check EGR valve (See page EC-6) OK NG 5) Replace EGR valve. [J 3 | Check air flow meter (See page ED-3) NG | Replace air flow meter. Di-60 DIAGNOSTICS Check and replace engine ECU (See page IN-20). = ENGINE Di-61 DIAGNOSTICS — ENGINE i a DTC 35 Turbo Pressure Sensor Circuit Malfunction CIRCUIT DESCRIPTION The turbo pressure sensor is connected to the intake manifold, The engine ECU detects the intake manifold pressure as a volt- age by the sensor. The engine ECU uses the intake manifold pressure signal for correction of injection volume control and in- jection timing conteal. The VSV for turbo pressure sensor switches the atmosphere applied to the turbo pressure sensor to the intake manifold Pressure. The turbo pressure Sensor monitors both the atmo- sphetic pressure and intake manifold pressure and transmits ‘the autput voltage to the engine ECU, and the engine ECU uses — kPa 253.3 Hg, this atmospheric pressure value for correcting the injection vol- 100 1,900 ume. (3.9) (74.8) fing) Intake Manifold Pressure DTCNe. DTC Detecting Conation Trouble Area "Open or shor in turbo prossure sensor circuit ‘Tutba pressure sonsor + Open or short in VSV for turbo pressure sensor creut + VV for turbo pressure sensor a5 [Ove orshon mute possi sensor cau 2 800.0 sen ee eee socked more + Tutbocharger + EGA vae +Aitflow meter Engine EU. HINT: After confirming DTC 35, use the hand-held tester to confirm the intake manifold pressure from the CUR- RENT DATA. Intake Manifold Pressure (Pa) T Maturation Approe. 0 + Pi circuit shor “VC circuit open or short 250 or more +Prmcreul open +£2 crew open bi-62 DIAGNOSTICS —_ENGWE WIRING DIAGRAM Engine ECU. iC 10 10 ££ DD 2 Twa} BF cera} fi a5 BR Far} (CHD) (RHO) (RHD)(LHO) KLHO\RHD) vis VSV for Pressure Charge Valve Engine Room oR RB (LHD) (RHO) 13 BR Tirbo Pressure Sonsor . | TT st (to) FL 4320 (RHD) _ uc r oe | a we + + ot INSPECTION PROCEDURE HINT: + WOTC 22, 24, 35 and 39 are output simultaneously, £2 (sensor ground) may be open. Read treeze frame data using hand-held testes. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting itis useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the air-fuel ratio was lean or sich, ete. at the time of the malfunction. When using hand-heid tester: 1 | Connect the hand-held tester, and read value of intake manifold pressure. PREPARATION: (a) Connect the hand-held tester to the DLCS, (b) Turn the ignition switch ON and push the hand-held tester main switch ON. CHECK: Read the value of intake manifold pressure on the hand-held tester. Ok: ‘Same as atmospheric pressure. Di-63 DIAGNOSTICS ~ _ ENGINE [J on) Goto siep 5. 2 | Check turbo pressure sensor (See page ED-15). [x] NG | Replace turbo pressure sensor. 3 | Check voltage between terminals VC and E2 of engine ECU connector. PREPARATION: (a) Remove the glove companment. (b) Turn the ignition switch ON. CHEC! Measure the voltage between terminals VC and E2 of the en- gine ECU connector. 1 Voltage: 4.5-5.5V ve) Check and replace engine ECU (See page IN-20). 4 | Check voltage between termi nals PIM and £2 of engine ECU connector. PREPARATION: (a) Remove the glove compartment. (b) _ Tum the ignition switch ON. CHECK: ‘Measure the voltage between terminals PIM and E2 of the en- gine ECU connector. OK: Voltage: 1.7-2.9V Di-64 [] Check for open and short in harness and connector between engine ECU and tur- bo pressure sensor (See page IN-20). _DIAGNOSTICS_—_ENGINE 5 {Check connection of vacuum hose between turbo pressure sensor and VSV for turbo pressure sensor, and VSV for turbo pressure Sensor and intake manifold. Na | Repair or replace. 6 | Check resistance ot VSV for turbo pressure sensor (See page ED-15). J | 1) Replace VSV for turbo pressure sensor. ] 7 | Check VSV for turbo pressure sensor. OK PREPARATION: (a) Remove the glove compartment (b) Disconnect the E7 connector from the engine ECU. (c) Turn the ignition switch ON. CHECI Check the VSV function. (a) Connect between terminal PA of the engine ECU connec- tor and body ground (VSV is ON). (b) Disconnect between terminal PA of the engine ECU con nector and body ground (VSV is OFF). Ok: VSV is ON: = Air from port E flows out through the air filter. BD, VSV is OFF: 4) Air from port E flows out through port G. DIAGNOSTICS [J ENGINE DLS 8 relay (Marking: EFl) (See page (N-20), Check for open and short in harness and connector between engine ECU and VSV for turbo pressure sensor, and VSV for turbo pressure sensor and EFI main [ey Repair harness or connector. 4 OK Replace VSV for turbo pressure sensor 9 | Check turbocharger assembly (See page TC-1). 4 OK NU [> Replace turbocharger. 140 | Check EGR valve (See page EC-6) [= OK Ne Replace EGR valve. 11} Check air flow meter (See page ED-3) NG Replace air flow meter. Le] bi-66 DIAGNOSTICS _— ENGINE Check and replace engine ECU (See page IN-20) When not using hand-held tester: | 1 | Check turbo pressure sensor (See page ED-15). NG_)| Replace turbo pressure sensor. | 2 | Check voltage between terminals VC and E2 of engine ECU connector. PREPARATION: (a) Remave the glove compartment. {b) Tum the ignition switch ON. CHECK: Measure the voltage between terminals VC and E2 of the en- gine ECU connector. Ok: “Voltage: 4.5-5.5V NG \| check and replace engine ECU (See page IN-20). 3 | Check voltage between terminals PIM and E2 of engine ECU connector. PREPARATION: (a) Remove the glove compartment. ()_ Turn the ignition switch ON. CHECK: Measure the voltage between terminals PIM and E2 of the en gine ECU connector. Ok: — Voltage: 1.7-2.9V OK Check and replace engine ECU (See page iN~20). DL-67 DIAGNOSTIC — ENGINE Check for open and short in harness and connector between engine ECU and turbo pressure sensor (See page IN-20). NG_ | Repair or replace harness or connector. ia Le] 5 } Check connection of vacuum hose between turbo pressure sensor and VSV for turbo pressure sensor, and VSV for turbo pressure sensor and intake manifold. NG_)| Repair or replace. 6 | Check resistance of VSV for turbo pressure sensor (See page ED-15). 4 NG )) Replace VSV for turbo pressure sensor. OK Diss DIAGNOSTICS _—_ENGINE Check VSV for turbo pressure sensor. PREPARATION: {a)__Remove the glove compartment, (b) Disconnect the E7 connector from the engine ECU. (c) Tur the ignition switch ON. r is CHECK: Ul i H Gheck the VSV function Ne Ne (a) Connect between terminal PA of the engine ECU cannec- tor and body ground (VSV is ON) (b) Disconnect between terminal PA of the engine ECU con- nector and body graund (VSV is OFF) 7 connector OK: VsV is ON: Air from port E flows out through the air filter. VSV is OFF: Air from port E flows out through part G. OK | Goto step 11. 8 | Check turbocharger assembly (See page TC-1). NG >| Replace turbocharger. OK ~~ 9 | Check EGR valve (See page EC~6) NG >| Replace EGR vaive. oK 10 {Check air flow meter (See page ED-3) NG >} Replace air flow meter. ole DIAGNOSTICS_—_ENGINE a ‘Check and replace engine ECU (See page IN'20). 11] Check Tor open and short in Hamess and connector between engine ECU and VSV for turbo pressure sensor and ECD main relay (Marking: INJ) (See page IN-20). [ 9) Repair harness or connector. oK Replace VSV for turbo pressure sensor. 1-70 DIAGNOSTICS = _ENGINE DTC | 39 | Fuet Temp. Sensor Circuit Malfunction CIRCUIT DESCRIPTION Fig. 1 0 20 ‘0 5 20 0 20 40 60 0 100 (C4) (82) (68) (104) (140) (178) (212) Temperature °C (°F) Resistance ko The {uel temperature sensor senses the fuel temperature. A thermistor built into the sensor changes the resistance value according to the fuel temperature. The lower the fuel tempera- ture, the greater the thermistor resistance value, and the higher the fue! temperature, the lower the thermistor resistance value (See Fig. 1), ‘The fuel temperature sensor is connected to the engine ECU (See below). The 5 V power source voltage in the engine ECU is applied to the fuel temperature sensor from terminal THF via aresistor R. That is, resistor R and the fuel temperature sensor are connected in series. When the resistance value of the fuel temperature sensor changes in accordance with changes in the fuel temperature, the potential at terminal THF also changes. Based on this signal, the engine ECU. Based on this signal, the engine ECU performs the pressure control compensation of the supply pump and error detection compensation of the highly pressurized fuel system. DTG No. TC Detecting Conaition Trouble Ares [~ + Open or short in ful temp, sensor circuit 39 JOpenor short in fuel temp, sensor circu fr 0.5 see. or more. |+Fusl temp. sensor + Engine ECU HINT: Atter confirming DTC 39, use the hand-held tester to confirm the fuel temperature from the CURRENT DATA, “Temperature displayed Mattunction 40°C (40°F) Open circuit 140°C (264°F) or more Short circuit DIAGNOSTICS ~_ ENGINE WIRING DIAGRAM Fuel Temp. Sensor 2 wo 1 8R si BF argo INSPECTION PROCEDURE HINT: + If DTC 22, 24, 35 and 39 are output simultaneously, E2 (sensor ground) may be open. + Read freeze frame data using hand-held tester. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was running or stopped, the engine was warmed up or not, the ait—fuel ratio was lean or rich, eto. at the time of the maifunction. When using hand-held tester: 1 | Connect hand-held tester, and read value of fuel temperature, PREPARATIOI (a) Connect the hand-held tester to the DLC3. (b) Turn the ignition switch ON and push the hand-held tester main switch ON. CHECK: Read the temperature value on the hand-held tester. Ok: ‘Same as actual fuel temperature. HINT: + Withere is open circuit, hand-held tester indicates ~40°C (40°F) + If there is short circuit, hand-held tester indicates 140°C (284"F) or more, [> [=] Check for D4) eee Di-72 DIAGNOSTICS —_ENGINE 2 | Check for open in harness or engine ECU. PREPARATION: Ta) Disconnect the fuel temperature sensor connector. (b) Connect the sensor wire harness terminals together. Engine ECU | (,) Turn the ignition switch ON. Temp. Sensor 3" CHECK: 4 co a ~| | Read the temperature value on the hand-held tester. Lbs oo Ps OK: ‘a ; as [oO ‘Temperature value: 140°C (284°F) or more place fuel pump. [«] OK \\| Contirm good connection at sensor. If OK, re- 3 | Check tor open in harness or engine ECU. PREPARATION: fa) Remove the glove compartment. Engine ECU Fuel Temp. Se ir ee pe ECU connector. HINT: ECU connector (See page IN-20). (©) Turn the ignition switch ON. CHECK: Read the temperature value on the hand-held tester. Ok: “~~ Temperature value: 140°C (284°F) or more 0K \\| Open in harness between terminal E2 or THF, re- pair or replace harness. y ssa [»s J Confirm good connection at engine ECU. If OK, replace engine ECU. (b) Connect between terminals THF and E2 of the engine The fuel temperature sensor connector is disconnected. Before checking, doa visual and contact pressure check for the engine D-73 DIAGNOSTICS — ENGINE 4 \Check for short in harness or engine ECU. | oO PREPARATION: (a) "Disconnect the fuel temperature sensor connector. (0) Turn the ignition switch ON. Fuel Engine ECU Temp. Sensor (en) (CHECK: Lf Read the temperature value on the hand-held tester. Ok: ~_Temperature value: 40°C (40°F) Replace fuel temperature sensor. 5 | Check for short in harness or engine ECU. @ cums PREPARATION: (a) Remove the glove compartment. (0) _ Disconnect the E8 connector from the engine ECU Fuel Temp, Sensor 2 o\ | Qhr i —? 8 —o tu | | The fuel temperature sensor connector is disconnected, [humm o-——o 4% | | (0) _ Tur the ignition switch ON. ui! £ CHECK: Read the temperature value on the hand-held tester. OK: Temperature value: ~80°C (40°F) Mts © EBConnector Repair or replace harness or connector. NG Check and replace engine ECU (See page IN-20), SS ———————— Divs DIAGNOSTICS _— ENGINE When not using hand-held tester: [ 1 | Check voltage between terminals THF and E2 of engine ECU connector. PREPARATION: (a) Remove the glove compartment. {b) Turn the ignition switch ON. (CHECK: ‘Measure the voltage between terminals THF and E2 of the en- gine ECU connecter. Ok: “oce | ‘votage ‘cng cot o2-sav enpanshot) ot -tsv (See page DI-4). [J 2 | Check fuel temperature sensor (See page ED-12). Na | Replace fuel temperature sensor. («J 3. | Check for open and short in harness and connector between engine ECU and fuel temperature sensor (See page IN-20). Xe) Repair or replace harness or connector. DI-75 DIAGNOSTICS ENGINE DTC 42 Vehicle Speed Sensor Signal Circuit Mal- function CIRCUIT DESCRIPTION The vehicle speed sensor outputs a 4-pulse signal for every revolution of the rotor shaff, which is rotated by the transmission output shaft via the driven gear. After this signal is converted into a more precise rectan- gular waveform by the waveform shaping circuit inside the combination meter, itis then transmitted to the engine ECU. The engine ECU determines the vehicle speed based on the frequency of these pulse signals. +-pulse pulse Vehicle Speed Sensor Combination Engine ECU Meter ze DTONo. DTG Detecing Gonaition Trouble Area ‘All conditions below are detected continuously fr 8 sec. oF move: + Oper or short in vehicle speed sensor circu “ (a) Vehicle speed signal: 0 krvh (0 mph) + Vehicle speod sensor | Engine speed 2.400 ~ 4,000 rpm Combination metae (c) Engine coatant temp. 60°C (176°) or more +Engine ECU (d) Accolerator ped opening ange 28 % of more WIRING DIAGRAM Engine ECU Combination Meter Short Connector Center W/8 (LH0)(RHO) Di-76 DIAGNOSTICS —_ ENGINE INSPECTION PROCEDURE HINT: Read freeze frame cata using hand-held tester. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting it is useful for determining whether the vehicle was run- ning or stopped, the engine was warmed up or not, the air-fuel ratio was lean or rich, etc. at the time of the malfunction. 1 | Check operation of speedometer. CHEC Drive the vehicle and check if the operation of the speedometer in the combination meter is normal. HINT: The vehicle speed sensor is operating normally if the speedometer display is normal OK 2 | Check voltage between terminal SP1 of engine ECU connector and body ground. PREPARATION: A” oN sP1 (@ Remove the glove compartment. (b) Shift the shift lever to the neutral (c) Jack up one of the front wheels. (2) Turn the ignition switch ON. CHECK: Measure the voltage between terminal SP1 of the engine ECU connector and body ground when the wheel is turned slowly. Ok: 45-85V Voltage is generated intermittently. | [™» Check and repair harness and connector be- tween combination meter and engine ECU (See page IN-20). oK $$$, Check and replace engine ECU (See page IN-20). Turn the whee! DIAGNOSTICS_~_ENGINE DTC 49 Fuel Pressure Circuit Malfunction CIRCUIT DESCRIPTION Fuel pressure sensor installed on a Common Rail detects the fuel pressure and controls to feed back the pump dischage in order to keep the target pressure (20 - 135 Mpa) set by the engine control computer. DTCNo, DIC Detecting Condition Trouble Area ‘Open or short in fuel pressure sensor crcult for common al Pag | Opon or short in fuel prassure sensor cccuil for commen sail | + Fuel prassure sensor or common rll +eCu HINT: After confirming DTC 49, use the hand-held tester to confirm the fuel rail pressure from the CURRENT DATA. WIRING DIAGRAM Fuel Pressure Sensor Engine ECU a ws &__9 a ay, 23 S 8 ofoi2 eR ae i ) _ = ___BR e624 INSPECTION PROCEDURE HINT: + DTC 22, 24, 39 and 49 are output simultaneously, E2 (sensor ground) may be open. + Read freeze frame data using hand-held tester. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting itis useful for determining whether the vehicle was running or stopped, the engine was warmed up or nol, the airfuel ratio was lean or rich, etc. at the time of the malfunction pi78 DIAGNOSTICS _— ENGINE 1 | Check voltage between terminals VC and E2 of ECM connector. @* VC E2 mera [«) PREPARATION: (a) Remove the glove compartment. (b) _ Turn the ignition switch ON. CHECK: Measure the voltage between terminals VC and E2 of the ECU connector. OK: Voltage: 4.75 - 5.25 V (See page IN-20). re) Check and replace engine ECU 2 Check voltage between terminals PCR and E2 of ECU connector. Lv J PREPARATION: (a) Remove the glove compartment. (b) _ Start the engine. CHECK: Measure the voltage between terminals PCR and E2 of the en- gine ECU connector. Ok: ~~ Voltage: 1.7 V at 20°C (68°F) OK \\| Check and replace engine ECU (See page IN-20). 3. | Check for open and short in harness and connector between fuel pressure sen- sor for common rail and engine ECU (See page IN-20). [«] NG | Repair or replace harness or connector. Replace common rail assembly (See page FU-20). I-79 DIAGNOSTICS _— ENGINE DTC 78 (1) | Fuel Pump Circuit Malfunction (Fuel Leak- age) CIRCUIT DESCRIPTION Refer to DTC 49 on page DI-77. Refer to DTC 97 on page DI-88. DTC No DiC Detecting cordon Trouble Area = Open or short in EDU cuit +eDU Open orsho injector erat sector ac _ | esste shang of conon ris brea agsnstinecio | + Open or sot inconmon al pressure sensor cut quantity and supply quantity of supey pump sGaomman rai pressure sensor +Fualline between sueply pump and commen ri *Fuoiline between commen ri ndinctor + Pressure limtor Engine ECU WIRING DIAGRAM Refer to DTC 49 on page DI-77. Refer to DTC 97 on page DI-88. INSPECTION PROCEDURE HINT: Read freeze frame data using hand-held tester. Because freeze frame records the engine conditions when the malfunction is is detected. When troubleshooting, it is useful for determining whether the vehicle was running or stopped, the engine was warmed up oF not, the air-fuel ratio was lean or rich, etc. at the time of the malfunction. When using hand-held tester: 1 | Are there any other codes (besides DTC 39, DTC 49, DTC 78 (2), DTC 78 (3) or DTC 97) being output? YES \\| Go to relevant DTC chart (See page DI-13). Le) 2 | Open engine hood and check if there is any fuel leakage (See page FU-8). NG | Check and replace. DE80 DIAGNOSTICS __ENGINE oK 3 | Check voltage between terminals PCR and E2 of engine ECU connector. PREPARATION: (a) Remove the glove compartment. (b) Turn the ignition switch ON. mj | CHECK: Ha Measure the voltage between terminals PCR and E2 of the en- gine ECU connector. OK: Voltage: Approx. 1 V at 20°C (68°F) OK | Goto step 5. 4 | Check for open and short in harness and connector between common rail pres~ sure sensor and engine ECU (See page iN-20). NG_)) Repair or replace harness or connector. OK Replace common rail assembly (See page FU-21). 5 | Connect hand-held tester, and read value of compensation of injection quantify between cylinders. PREPARATION: (a) Connect the hand held tester to the DLC3. (b) Turn the ignition switch ON and push the hand—held tester main switch ON. CHEC! Read the compensation of the injection quantify between the cylinders on the hand-held tester. ol “~~ STD: -3-3mmiist Maximum: —4-4 mm%st > Replace corresponding cylinder injector. Dist DIAGNOSTICS — ENGINE. Lx] Check If any fuel is mixed with engine oil. L«] NG_)| Replace injector (See page FU-6). [7 When you start engine, check that if any white smoke is coming out from ex- haust pipe. NG_)/ Replace injector (See page FU-6). [«] Peplace injector (See page FU-€) and com- mon rail assembly (See page FU-21). When not using hand-held tester: 1 Are there any other codes (besides DTC 39, DTC 49, DTC 78 (2), DTC 78 (3) o [J DTC 97) being output? YES\,| Go to relevant DTC chart (See page DI-13). Open engine hood and check if there is any fuel leakage (See page FU-8). NG | Check and replace leakage parts. OK Di-82 DuGNOsTICS ENGINE Check voltage between terminals PCR and E2 of engine ECU connector. PREPARATION: (a) Remove the glove compartment. (o) Turn the ignition switch ON. CHECK: Measure the voltage between terminals PCR and E2 of the en- gine ECU connector. Ok: "Voltage: Approx. 1 V at 20°C (68°F) f NG )| Goto step 5. 4 Check for open and short in harness and connector between common rail pres- sure sensor and engine ECU (See page IN-20). OK Replace common rail assembly (See pag er] FU-21). |) repair o place harness o connector. Check if any fuel is mixed with engine oil. [oJ > Replace injector. haust pipe. When you start the engine, check that if any white smoke is coming out from ex- NG_)| Replace injector (See page FU-6). Di-83 DIAGNOSTICS —_ ENGINE Lo ] Goto step 1 in DTC 78 (2), DTC 78 (3). Di-84 DIAGNOSTICS —_ENGINE { ptc 78 (2) cu) Pump Circuit Malfunction (Open Cir- cuit _ DTC | 78(3) | Fuel Pump Circuit Malfunction (Over Force | Feed) CIRCUIT DESCRIPTION Supply pump is a tandem type and has two circuits of the fuel suction and force feed processes that achieve both high pressure force feed of fuel and reduction of driving torque. In the suction process, it control SCV (Suction Control Valve) which suctions fuel by a plunger. DTONo. DTC Detecing condion ‘Trouble Area Open or shor in SCV creut 78 (2) | Pressure change of common rail against supply quantity of | «SCV 7819) | supply pump is abnormal Supply pump +Engine ECU. WIRING DIAGRAM y SCV (Pump 2) —h 8 CV (Pump 1 2 Engine ECU _—___B-R INSPECTION PROCEDURE HINT: Read freeze frame data using hand-held tester. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting, it is usefut for determining whether the vehicle was run- ning or stopped, the engine was warmed up or not, the air-fuel ratio was lean or rich, etc. at the time of the maltunction. D856 DIAGNOSTICS ENGINE When using hand-held tester: 1 | Are there any other codes (besides DTC 39, DTC 49 or DTC 97) being output? Go to relevant DTC chart (See page DI-13). 2 | Check SCV (See page FU-13). > Replace supply pump (See page FU-16). OK 1 3 | Check for open and short in harness and connector between SCV and engine ECU (See page IN-20). OK 4 | Check voltage between terminals PCV1 and COM, and PCV2 and COM of engine ECU connector. Reference: INSPECTION USING OSCILLOSCOPE CODE 20, | During cranking or idling, check the waveforms between termi- [Division] nals PCVi and COM, and PCV2 and COM of the engine ECU qo | £ connector. i { rt HINT: + ‘The correct waveforms are as shown. GND i some | t 1 NG \\| Check and replace engine ECU y 10 msec./Division sea (See page ED-24). Lx) DI-86 DIAGNOSTICS. Replace supply pump (See page FU-16). When not using hand-held tester: 1 Check SCV (See page FU-13). LJ NG Replace supply pump (See page FU-16). Check for open and shart in harness al ECU (See page IN-20). nd connector between SCV and engine NG Repair or replace harness or connector. [«] Check voltage between terminals PCV1 and COM, and PCV2 and COM of engine ECU connector. GND y zov) | During crar Division) nals POV1 connector. HINT: Reference: INSPECTION USING OSCILLOSCOPE inking or idling, check the waveforms between termi- and COM, and PCV2 and COM of the engine ECU The correct waveforms are as shown. t NG 410 msec,/Division aysisa Check and replace engine ECU (See page ED-24). L«] Check if engine will start. ve) Replace supply pump (See page FU~16). DIAGNOSTIC§_ = ENGINE Two | 4 Peplace injector (See page FU-6) and cor mon rail assembly (See page FU-21), Di-88 DIAGNoSTIgs — ENGINE DTC 97 EDU Circuit Malfunction tected. CIRCUIT DESCRIPTION The ECU has been adopted to drive the injector at high speeds. The EDU has realized high-speed driving under high fuel pressure conditions through the use of a DC/DC converter that provides a high-voltage, quick-charging system. The engine ECU constantly monitors the EDU and stops the engine in case an abnormal condition is de- DIG No. DTC Detecting condition Trouble Area 97 (Open or short in EDU eeuit EDL +sov “Injector Engine ECU Open or shor in EOU circuit + Open or shon in SGV circuit WIRING DIAGRAM DIAGNOSTICS — ENGINE Di-89 Engine ECU Grane EC 20 £8 ____¢ée) e2 UB inecerna.s 2a bier Un + SRB an Pee Em 2 BR INJ4 [E12) R__81 44 coma} 4 G nzinecarti 3 24 e2 rina} INJ3- 3 BR Ns3 {E13} 5 4a con 11 nietor 2 fn E2 INA! INJ2- 4. BR nse (E12 3} te come} vnowpstorRo 7 26 Passenger gyre ini} ‘=8(E5) INd1 Side R/B 5 R inst (3 n comfog IND 3 4 Relay 4 AJA ALA com {13-8 — af] t 1 4J50 (CHD), J52 (RHD), 5 w-e YC 12 a, 8 #4 (19 5} #4 ut} 2 Ey Z - iO wD “Y____es) as 3 WR & BR 6 #2 [E19) 42 —Gidjeno [2 we #1 (E19) = ES) #1 18. wre w — 2) nur eS RW REL aver piso DIAGNOSTICS INSPECTION PROCEDURE HINT: Read freeze frame data using hand-held tester. Because freeze frame records the engine conditions when the malfunction is detected. When troubleshooting, it is useful for determining whether the vehicle was run- ning or stopped, the engine was warmed up or not, the air-fuel ration was lean or rich, ete. at the time of the maffunction. ] 1 | Check voltage of EDU power source. ON PREPARATION: Oi (@) Disconnect the EDU connector. (>) _ Turn the ignition switch ON. CHE Measure the voltage between terminals 6 and 8 of the wire har- ness side connector. OK: Voltage: 9-14 V NG \)| Check EDU power source circuit (See page DI-93). OK 2 | Check resistance between terminals 1 and 2 - 5 of wire harness side connector. PREPARATION: {a) Disconnect the EDU connector. (b) Turn the ignition switch ON, CHECI Measure the resistance between terminals 1 and 2 ~ 5 of the wire harness side connector. Ok: Resistance: 2.5 - 3.1. at 20°C (68°F) —ir correo oK ) Goto step 4. 3 | Check injector (See page FU-4). Ne) Replace injector. Di-st DIAGNOSTICS ENGINE Repair or replace hamess or connector. 4 | Check SCV (See page FU-13). “| NG_ | Replace supply pump (See page FU-16). 5 | Check for open and short in harness and connector between SCV and ECU. |) Repair or replace harness ot connector. o 6 | Check voltage between terminals #1 — #4 and E01 of engine ECU connector. sw ore [Division] OK PREPARATION: Remove the glove compartment. CHECK: During cranking or idling, check the waveform between termi- nals #f1 ~ #4 and E01 of the engine ECU connector with the os- cilloscope. Ok: ~~ Voltage: The correct waveform are as shown. NG ) Check and replace ECU (See page IN-20). #2 here Aa y aise bi-92 DIAGNosTICS. ENGINE 7 | Check voltage between terminals INJF and E01 of engine ECU connector. Wave form CHEC! IMF Division scope. PREPARATION: Remove the glove compartment. P| SW During cranking or idling, check the wave form between termi- nals INJF and E01 of the engine ECU connector with the oscillo- Voltage: The correct waveform are as shown. v sons NG Check and replace ECU (See page IN-20). [J ECU (See page IN-20). 8 | Check for open and short in harness and connector between EDU and engine NG Repair or replace harness or connector. [ « ] Replace EDU. Di-93 DIAGNOSTICS _—_ ENGINE ECU Power Source Circuit CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery positive voltage is applied to the coil, closing the contacts of the EFI relay (Marking: EFl) and supplying power to the terminal +B of the engine ECU. WIRING DIAGRAM 119 river Side JB Ignition Switch Dever Side oI weg ban 2 IGN 1 B. EE T E BO a fa)-9GO)* © Geoc —foeKer) ITroKarD) (RHD)(LHO) WeR Engine Room F/B ECD Relay a9 WB et 2 wy? fea] ng (CAOYRHD) we 1 10, EE D Dap PY De Soo} S92) oF fez iva canna] fame | (CHDYRHD) (RHD\LHD) (CHDXRHD) BR Engine ECU LB Ts (CDT J20 (RD) Lie w-8 cg ig Di-94 DIAGNOSTI INSPECTION PROCEDURE 1 | Check voltage between terminals +B and Et of engine ECU connector. Q eI +B y 0579 NG PREPARATION: (a) Remove the glove compartment door. (p) _ Turn the ignition switch ON. CHEC! Measure the voltage between torminals +8 and E1 of the en- gine ECU connector. OK: Voltage: 9-14 V OK Proceed to next circuit inspection shown on problem symptoms table (See page DI-19). 2 | Check for open in harness and connector between terminal E1 of engine ECU and body ground (See page IN-20). OK > Repair or replace harness or connector. 3. | Check EFI main relay (Markin: : EFI) (See page ED-8). oK > Replace EFI main relay. I-95 DIAGNOSTICS —_ ENGINE 4 | Check EFI fuse. PREPARATION: Remove the EFI fuse from the engine room JB. CHECK: Check the continuity of the EFI fuse. Ok: Continuity ie | NG \\/ Check for short in all harness and components | connected to EFI fuse. 5 | Check for open in harness and connector between engine ECU and EFI main relay (Marking: EFI), and EFI main relay and battery (See page IN-20). [J 6 | Check voltage between terminais \GSW and E1 of engine ECU connector. a1 PREPARATION: (a) Remove the glove compartment door. (b) Tum the ignition switch ON. CHECI Measure the voltage between terminals IGSW and E1 of the engine ECU connector. Ok: Voltage : 9-14V on) Go to step 9. I-96 DIAGNOSTICS_—_ ENGINE 7 | Check ignition switch (See Pub. No. RM517E BE section). [=] 8 | Check for open in harness and connector between ignition switch and engine ECU (See page IN-20). NG _)| Repair or replace harness or connector. ok 9 | Check voltage between terminal MREL of engine ECU connector and body ground. @™ f — a NG ) Replace ignition switch. PREPARATION: (a) Remove the glove compartment door. (b) Turn the ignition switch ON. CHECI Measure the voltage between terminal MREL of the engine ECU connector and body ground Voltage: 9-14 V Check and replace engine ECU (See page IN-20). Oo Lr] ‘Check for open in harness and connector between engine ECU and EFI main relay (Marking: EFI), and EFI main relay and body ground (See page JN-20). Di-97 DIAGNOSTICS _— ENGINE EGR Control Circuit CIRCUIT DESCRIPTION The EGR system recirculates exhaust gas, which is controlled to the proper quantity to suit the driving condi- tions into the intake air mixture to slow down combustion, reduce the combustion temperature and reduce NOx emissions, The lit amount of EGR valve is controlled by the vacuum which is regulated by the E-VRV operated by the engine ECU, If even one of the following conditions is fulfilled, the VSV is turned ON by a signal from the ECU. This results in atmospheric air acting on the EGR vaive, closing the EGR valve and shutting off the exhaust gas (EGR cut-off), Under the following conditions, EGR is cut to maintain driveability. + Before the engine is warmed up + Engine speed over 4,000 rpm WIRING DIAGRAM via Engine ECU 10 10 E 4 1 VSV for EGR Cut, —fie2 Tig = Gag ome BR yyy PER BRI a 2 BW, | (CADYRHD) (RAD YLHOL- IT HOYRAD) v3 B-R| VSV for EGR Valve, es 28 cre irae o3 CD Relay Room J/B le BY 9 9 a “ 4 Meth ae £8 papi E28 — (CADYRAD) B-R “| A Jt (LHD) ie (RHD) ; ote _| x wes ed £] sate ct 4 bi-98 DIAGNOSTICS INSPECTION PROCEDURE When using hand-held tester: 1 | Check connection of vacuum hose. NG | Repair or replace. OK T 2 | Check vacuum between EGR valve and VSV for EGR at 1,500 rpm. ese __Xi, PREPARATION: (P75 Nacuum Gauge Foe (a) Using a3-way connector, connect a vacuum gauge to the hose between the VSV and EGR valve. (b) Warm up the engine to above 80°C (176°F). CHEck: ‘Check the vacuum at 1,500 rpm. RESULT: “ype Vaewum ' OP (Ommig, On. Hg) be u (OkPa (O mmrg, in Hg) — 28 KPa (210 mmHg, 8.3. Hg) r ‘Abgve 28 KPa (210 mmitg. 83in. Hg) Type | Go to step 7. wel) Go to step 10 Di-s9 DIAGNOSTICS —_ ENGINE 3 | Check VSV circuit for EGR. [J PREPARATION: (@) Disconnect the vacuum hose from the VSV for the EGR. (b) Connect the hand-held tester to the OLC3. (©) Turn the ignition switch ON and push the hand-held tes- ter main switch ON. (4) Select the ACTIVE TEST mode on the hand-held tester. heck the operation of VSV for EGR when itis operated by the hand-held tester. OK: VSV is ON: Air from port E flows out through ait filter. SV is OFF: Air does not flow from port E to air filter. Check connection, damage and blockage of vacuum hose. j 4 | Check VSV tor EGR (See page EC-6). Lo] [1 Replace VSV for EGR. 5 | Check for open and short in harness and connector between VSV for EGR and engine ECU (See page IN-20). NG. Repair or replace harness or connector. Di-100 DIAGNOSTICS — ENGINE ground. 6 | Check voltage between terminal EGR of engine ECU connector and body EGR Signal Waveforms 5V/ DIV 1 AERA te | GND. ch an i i 1 msec/ Division (1,500 rpm) _ aus PREPARATION: (@) Remove the glove compartment door. (©) Turn the ignition switch ON CHECK: Measure the voltage between terminal EGR of the engine ECU connector and body ground. Ok: Voltage: 9- 14V Reference: INSPECTION USING OSCILLOSCOPE During EGR system is ON (engine speed 1,500 rpm), check the waveform between terminals EGR and E1 of engine ECU con- nector. HINT: The correct waveform is as shown. Air Fitter 2) E-VRV: ON” ELVAV:OFF PREPARATI (@) Disconnect the vacuum hoses from the E-VRV. (b) Connect the hand-held tester to the DLC3. (c) Turn the ignition switch ON and the push hand-held tes- ter main switch ON. (4) Select the ACTIVE TEST mode on the hand-held tester. CHECK: Check the operation of the E-VRV when it is operated by the hand-held tester. OK: E-VRV ON: Air from port E flows out through port F. E-VRV OFF: Air from port E flows out through air filter. OK )} Goto step 10. Di-101 DIAGNOSTICS — ENGINE 8 | Check E-VRV for EGR (See page EC-6). [o«] 9 | Check for open and short in harness and connector between E-VRV and engine ECU, and E-VRV and EFI main relay (Marking : EFI) (See page IN-20). NG | Replace E-VRV. - NG _ | Repair or replace harness or connector. OK NU 10 | Check EGR vaive (See page EC-6). NG_)| Replace the EGR valve. OK nN ee Check and replace engine ECU (See page IN-20). When not using hand-held tester: 1 | Check the connection of vacuum hose. [slewomm oK Di-102 DIAGNOSTICS _— ENGINE 2 | Check vacuum between EGR valve and VSV for EGR at 1,500 rpm (See page I-97, step 2). Type |) Goto step 6. pe Go to step 9. r 3 | Check VSV for EGR (See page EC-6). NG | Replace VSV for EGR. oK (a |Check for open and short in harness and connector between VSV for EGR and | engine ECU (See page IN—20). NG | Repair or replace harness or connector. Diagnostics — DE-103 ENGINE Check operation of E-VRV. EGR ‘@ (o) (c)_ Turn CHECK: Check the (1) E6 Connector (2) ok: Air ft [ &) E-VRV: OFF E-VRV: ON 6 | Check E-VRV (See page EC-6). PREPARATION: Remove the glove compartment door. Disconnect the £6 cannector from the engine ECU. the ignition switch ON. E-VRV operation. Connect between terminal EGR of the engine ECU ‘connector and body ground (ON), Disconnect between terminal EGR of the engine ECU connector and body ground (OFF). E-VRV ON: Air from port E flows out through port F. E-VRV OFF: rom port E flows out through ait filter. Go to step 9. [0 Replace E-VRV. oK od 7 Check for open and short in harness and connector between E-VRV and engine ECU, and E-VRV and EFI main relay (Marking : EFI) (See page IN-20). ws) Repair or replace harness or connector. [«] Di-104 DIAGNOSTICS — ENGINE 8 | Check EGR valve (See page EC-6). NG | Replace EGR val OK Check and replace engine ECU (See page IN-29). Di-105, DIAGNOSTICS_—_ENGINE AIC Signal Circuit CIRCUIT DESCRIPTION When the A/C compressor is ON, the A/C amplifier sends the A/C signal to the engine ECU, then engine ECU inareases the fuel injection volume to improve driveability during engine idling WIRING DIAGRAM Engine ECU AIC Amplifier Oo +B 6 By 4 : eee \NSPECTION PROCEDURE When using hand-held tester: 1 | Connect hand-held tester, and check A/C signal. PREPARATION: (@) Connect the hand-held tester to the DLC3 (b) Turn the ignition switch ON and push the hand-held tester main switch ON. CHECK: Read the A/C signal on the hand-held tester while the A/C compressor is ON. OK: ‘AG Switch Canton OFF ON ‘NC Signal OFF on OK \\| Proceed to next circuit inspection shown on problem symptoms table (See page DI-19). Le] Di-106, DIAGNOSTICS ENGINE 2 Check voltage between terminal A/C of engine ECU copnnector and body ground. PREPARATION: (a) Remove the glove compartment door. {b) Start the engine. CHECK: Measure the voltage between terminal A/C of the engine ECU connector and body ground when the A/C switch is turned to ‘ON and OFF. Ok: ‘AIC Switch Condition votage ON Beow 15V OFF gaav OK \\) Check and replace engine ECU (See page IN~20). [ve] 3 [Check for open and short in harness and connector between engine ECU and AIC amplifier (See page IN-20). oK Check and replace A/C amplifier. | NG | Repair or replace harness or connector. DL-407 DipGNOSTICS — ENGINE When not using hand-held tester: 1 |Check voltage between terminal A/C of engine ECU connector and body orund | PREPARATION: (a) Remove the glove compartment door. (b) Start the engine. CHECK: Measure the voltage between terminal A/C of the engine ECU connector and body ground when the A/C switch is turned to ‘ON and OFF. Ok: (NG Swi Condon Votage ON Bolow 15 OFF av OK \\| Proceed to next circuit inspection shown on problem symptoms table (See page DI-19). [J 2 | Check for open and short in harness and connector between engine ECU and AIC amplifier (See page IN-20). OK Check and replace A/C amplifier. NG_)/| Repair or replace harness or connector. Di-108 DIAGNOSTICS _—_ ENGINE A/C Cut Control Circuit CIRCUIT DESCRIPTION This circuit cuts air conditioning operation during vehicle acceleration in order to increase acceleration per- formance. During acceleration with the vehicle speed at 30 km/h (19 mph) or less and accelerator pedal opening angle at 45° or more, the A/C magnetic switch is turned OFF for several seconds. The air conditioning is also controlled by the ECU out putting the engine coolant temperature to A/C amplifier. WIRING DIAGRAM Engine ECU AC Amplifier +8 6 fe) a) NS ; aaa ca Di-109 DIAGNOSTICS — ENGINE INSPECTION PROCEDURE When using hand-held tester 1 Connect the hand-held tester and check operation of air conditioning cut con- trol. PREPARATION: {@) Connect the hand held tester to the DLC3. (b) Turn the ignition switch ON and push the hand-held tester main switch ON, (c) Start the engine and air conditioning switch ON. HINT: AIC magnetic clutch is turned ON. (d) Select the ACTIVE TEST mode on the hand-held tester. CHECK: Check operation of AIC magnetic clutch cut when air conditioning cut control is operated by the hand-held tester. Ok: AIC magnet clutch is turned OFF. [ve J 2. | Check for open and short in harness and connector between engine ECU and AIC amplifier (See page IN-20). NG_ | Repair or replace harness or connector. oK ok \\| Proceed to next circuit inspection shown on! problem symptoms table (See page DI-19). Di-n10 DIAGNOSTICS ENGINE 3 | Check voltage between terminal ACT of engine ECU and body ground. ] PREPARATION: {@) Remove the glove compartment door. {b) Start the engine. CHECK: Measure voltage between terminal ACT of engine ECU con: nector and body ground when A/C switch is turned to ON and OFF. Ok: ‘NC sich condition votage Engine at iding ena IGON Engine ston 0-3 o%) Check and replace A/C amplifier. [J 4 | Check for open and short in harness and connector between engine ECU and Combination meter (See page IN-20). OK Check and replace engine ECU (See page IN-20). When not using hand-held tester 1 | Check voltage between terminal ACT of engine ECU and body ground (See page Di-108). Check and replace A/C amplifier. NG pent DIAGNOSTICS —_ENGINE 2 | Check voltage between terminal THWO of engine ECU and body ground (See page DI-108). r on) Check and replace A/C amplifier. i) 3 | Check for open and short in harness and connector between engine ECU and A/C amplifier (See page IN-20). NG | Repair or replace harness or connector. OK Check and replace engine ECU. Di1i2 DIAGNOSTICS —_ENGINE Diagnostic Connector (DLC3) Circ CIRCUIT DESCRIPTION Terminals TC and GG are located in the DLCS. The DLC3 is located under the finish tower panel. When terminals TC and CG are connected, DTC in normal mode or test mode can be read from the check engine warning light in the combination meter. ‘Also, terminal SIL is located in the DLC3. This terminal is used by the M-OBD communication with hand— held tester. WIRING DIAGRAM 18 (CHD) c3 J22 (RHD) Engine ECU Check Connector 18 we 18 er a rol Pky Pt, PF FPL aN io Ei ag (Pt 99 (LHD) Top 149 (RHD) B 10 A tac}? —- EB) TACH we a [23 Ho) oe iG 72 (CHD) ples 480 (RHD) wc AX Ie (LH) 1D (RHD} c sta DE413 DIAGNOSTICS —_ ENGINE INSPECTION PROCEDURE 1 | Check check engine warning light condition. [J PREPARATIO! (a) Turn the ignition switch ON. (b) Using SST, connect terminals TC and CG of the DLC3. SST 09843-18040 CHECK: Check the check engine warning light condition. o Check engine warning light : Blinking HINT: If this inspection OK and there is no hand-held tester, do not need to do the following steps and this circuit is OK. Proceed to next circuit inspection shown on problem symptom table (See page DI-19). OK )| Go to step 7. 2 Check voltage between terminals TC and CG of DLC3. @Q™ [J oF O DLc3 PREPARATION: Tur the ignition switch ON. CHECK: Measure the voltage between terminals TC and CG of the DLC: ok: ~~ Voltage :9-14V OK >| Go to step 5. 3 | Check continuity terminal CG of DLC3 and body ground. [x] NG | Repair or replace harness or connector. Dita \GNOSTICS, 4 | Check for open and short in harness and connector between terminal TC of DLC3 and terminal TC of engine ECU (See page IN-20). > Repair or repiace harness or connector. 5 | Check voltage between terminal W of engine ECU connector and body ground. PREPARATION: (a) Remove the glove compartment door. (b) Turn the ignition switch ON. CHECK: Measure the voltage between terminal W of the engine ECU connector and body ground. OK: Voltage: 9-14 V 0K \\| Check and replace engine ECU (See page IN-20). 6 Jenece bulb of check engine warning light. [«] ‘Check for open in harness and connector be tween terminal W of engine ECU and com qu NG )| Replace bulb. te DE15 DIAGNOSTICS —_ ENGINE. 7 | Can you read the DTC (including normal DTC) using hand-held tester? YES\,| Proceed to next circuit inspection shown on problem symptom table (See page DI-19).. [ ] 8 } Check voltage between terminal BATT of DLC3 and body ground. CHE @® ON DLC3 BATT ‘Measure the voltage between terminal BATT of the DLC3 and body ground. Ok: “~~ Voltage: 9-14V ‘Check for open and short in harness and con- nector between terminal BATT of DLC3 and fus- ible link block (See page IN-20). Check for open and short in harness and con- nector between terminal SIL of DLC3 and ter- minal SIL of engine ECU (See page IN-20). Dit DIAGNOSTICS ENGINE Starter Signal Circuit CIRCUIT DESCRIPTION When the engine is being cranked, the intake air flow is slow, so fuel vaporization is poor. A rich mixture is therefore necessary in order to achieve good start ability. While the engine is being cranked, the battery posi- tive voltage is applied to terminal STA of the engine ECU. The starter signal is mainly used to increase the fuel injection volume for the starting injection control and after-start injection control WIRING DIAGRAM Engine Room R/B No. 2 Engine Room RIB Engine ECU ST Relay Bw ST a pe 15. Daf aE 1 we Tez] ma2_(E7) sta | (CHD)(RHD) Dea er | 33 Ww (Mm) TF2 [1M Bw iy (CHO\(RHD) 5 Tn wot 8 (AT) 8-W wi 6 nwa! FY stan sw[P 9 wr | Engine Room R/B Ignition Swit | aw aw (an) 8/sT2_AM2 A a Driver Side WB Ww ws ‘20% 4 St wn wi BW (MT) AlwB BR 14 K en ERE 63) —2-__ep ee} LEB? FL — (LHD)(RHD) = Starter t T | Battery Tr . 4:(LHD) L *2:(AHD) © se DEn7 DIAGNOSTICS — ENGINE INSPECTION PROCEDURE HINT: This diagnostic chart is based on the premise that the engine is being cranked under normal conditions. If the engine does not crank, proceed to the problem symptoms table on page DI+19. When using hand-held tester: 1 | Connect hand-held tester, and check STA signal. PREPARATION: (a) Connect the hand-held tester to the DLC3. (b) _ Turn the ignition switch ON and push the hand-held tester main switch ON. CHECK: Read the STA signal on the hand-held tester while the starter operates. Ok: Ignition Switch Position ON STA STA Signal OFF, ‘ON, OK Proceed to next circuit inspection shown on problem symptoms table (See page DI-19). [J 2 | Check for open in harness and connector between engine ECU and starter relay (Gee page IN-20). [x] Check and replace engine ECU (See page IN-20). NG. | Repair or replace harness or connector. Di-118 DIAGNOSTICS, When not using hand-held tester 1 | Check starter signal. Z START STA be Ong PREPARATION: (@) Remove the glove compartment door. (0) Turn the ignition switeh START. CHECK: Measure the voltage between terminal STA of the engine ECU connector and body ground during cranking, Ok: Voltage: 6.0 V or more OK \\| Proceed to next circuit inspection shown on problem symptoms table (See page DI-19). [ee] 2 | Check for open in harness and connector between engine ECU and starter relay (See page IN-20). L«J Check and replace engine ECU (See page IN-20). NG | Repair or replace hamess or connector. bu IAGNOSTICS ENGINE DE19 Pre—Heating Control! CIRCUIT DESCRIPTION feo B [ee (5 ef} aS} (CHDYRHD), T | Battery 2222 Se GC GR feo Tima} (3 cay) jqet Engine Room AUB No. 2 20"? wie W-8 X “1 (LH) +2: (RHD) ‘When the ignition switch turns ON, the engine ECU calculates Sec. | Sec. | the glow indicator lighting time/heating corresponding to the = 60 + 120 | coolant temperature at that time and turns ON the glow indica- @ A \ © | torlighvgiow plug relay. E \in! @ | As the ceramics is used for a glow plug material, the current e TTY! = | control is not performed. Bs VE A 2297] | 8 3 \ t — 2 0s cl 1 B&B S 76) 4 6 | & (04) Water Temperature hoses WIRING DIAGRAM Combination Short ol Driver Side J/B eter connector Engine ECU 4 GAUGE 23 20 |GLO") 5 L ALae AT on BY ie 21s} C230) (C23-+ GaGa] | (i9G2)™ = (LHDYRHD)}| LHDYRHD) 119 Ignition SW N wo 4ligi_ami 2 BAR DI-120 INSPECTION PROCEDURE DIAGNOSTICS ENGINE 1 | Does glow indicator light up? PREPARATION: Turn the ignition switch ON. cHec Does the glow indicator light up? ol The glow indicator lights up for 0.5 sec. or more. NG OK | Goto step 5. ground. Check voltage between terminal GIND of engine ECU connector and body @Q* E7 Connector GIND \ PREPARATION: (a) Remove the glove compartment door. (b) Disconnect the E7 connector from the engine ECU (c) _ Turn ignition switch ON. CHECK: Measure the voltage between terminal GIND of the engine ECU connector and body ground. OK: Voltage: 9-14 V > Check and replace engine ECU (See page IN-20). Di-t24 DIAGNOSTICS — ENGINE. 3. | Check GAUGE fuse. l PREPARATION move the GAUGE fuse. CHECK: Measure the continuity of the GAUGE fuse. Ok: Continuity Le] | 4 [Check glow indicator light bulb. [*] |” Check for open in harness and connector between combination meter and engine ECU, and com- bination meter and GAUGE fuse (See page IN-20). connected to GAUGE fuse. ") Check for short in all harness and components | NG >| Replace bulb. 5 | Check glow indicator lighting time (See page ST-2). NG \\| Check and replace engine ECU (See page IN-20). [* ] 6 | Are there any DTC being output? Le] ve) Go to relevant DTC chart. Di-122 DIAGNosTICS_—_ ENGINE Check glow plug relay (See page ST-2). LJ Repiace glow plug relay. —— 8 ground at cranking. Check voltage between terminal SREL of engine ECU connector and body a” ‘START PREPARATION: {a} Remove the glove compartment door. {b) Disconnect the E7 connector from the engine ECU (c) Turn the ignition switch START. CHECI Measure the voltage between terminal SREL of the engine ECU connector and body ground at cranking. Ok: Check for open and short in harness and connector between glow plug relay and engine ECU, and glow plug relay and body ground (See page IN-20). y ses Voltage: 9-14 V NG \\| Cheek and replace engine ECU (See page IN-20). OK 9 [oJ NG_)| Repair harness or connector. 10 Check resistance of glow plug (See page ST-2). [« ] NG )| Replace glow plu DI-123 DIAGNOSTICS — ENGINE 11 _ | Inspect glow plug installation. > Tighten glow plug. 12 | Check for open in hamess and connector between glow plug relay and glow plug (See page IN-20). [x] Proceed to next circuit inspection shown on roblem symptoms table {See page D9). [ « ] NN > Repair harness or connector. ENGINE MECHANICAL AIR FILTER. COMPRESSION . VALVE CLEARANCE, IDLE SPEED AND MAXIMUM SPEED TIMING BELT TIMING GEAR CYLINDER HEAD, CYLINDER BLOCK .. EMA EM-2 EM-4 EM-9 EM-410 EMHI9 EM-38 ENL6t ENGINE MECHANICAL —_AIR FILTER AIR FILTER INSPECTION 1. REMOVE AIR FILTER 2. INSPECT AIR FILTER Visually check that the filter is not excessively dirty or oily. 3. CLEAN AIR FILTER Clean the filter element with compressed air. First blow from the inside thoroughly. Then blow off the out side of the filter ele- ment, 4. REINSTALL AIR FILTER EM-2 ENGINE MECHANICAL _— C 4\ SSR OR’ A RTL COMPRESSION COMPRESSION INSPECTION HINT: If there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure. 1. WARM UP AND STOP ENGINE Allow the engine to warm up to normal operating temperature. 2. REMOVE GLOW PLUGS (See page EM-11) 3. DISCONNECT INJECTOR CONNECTORS 4. _ CHECK CYLINDER COMPRESSION PRESSURE HINT: Turn the staner before measuring the compression and dis- charge the foreign objecis. (a) _ Install SST (attachment) to the giow plug hole. SST 09992-00025 (09992-00121) Torque: 13 N-m (133 kgf-cm, 10 ftlbf) {b) Connect SST (compression gauge) to the SST (attach- ment) SST 09992-00025 (09992-00211) (©) Fully open the throttle valve, and start the engine. (4) While cranking the engine, measure the compression pressure. HINT: Always use a fully charged battery to obtain engine revolution of 250 spm or more. (e) Repeat steps (a) through (4) for each cylinder. NOTICE: This measurement must be done in as short a time as pos sible. Compression pressure: 2,700 kPa (27.5 kgticm?, 391 psi) or more Minimum pressure: 2,200 kPa (22.5 kgticm?, 320 psi) or more Difference between each cylinder: 500 kPa (5.0 kgficm2, 71 psi) or less —M-3 ENGINE MECHANICAL COMPRESSION (1) the eylinder compression in one or more cylinders is low, pour a small amount of engine oil into the cylinder the glow plug hole and repeat steps (a) through (d) for the oy- inder with low compression . If adding oil helps the compression, chances are that the piston rings and/or cylinder bore are worn or damaged. + Ii pressure stays low, a valve may be sticking or seating improperly, or there may be leakage past the gasket (g) Remove SST. SST 09992-00025 (09992-00121, 09992-00211) 8, RECONNECT INJECTOR CONNECTORS 6. _ REINSTALL GLOW PLUGS (See page EM-16) 7. START ENGINE AND CHECK FOR LEAK EM ENGINE MECHANICAL VALVE CLEARANCE COMPONENTS Intercooler No.t Air Hose | (ates a] \ ¥2(722,9)_\ ~~ Intake Air Connector @ Gasket |— © No.2 Air Hose (Taree a} ae’ “1 Nozzle Leakage Pipe . (Hea }-——F Te i 6 Washer—— oe es Nozzle Holder Clamp # Noza Sear” [Nim (ketem, fbi |: Specified torque \ @ Non-reusable part * Replace only if damaged p_*? For use with SST “QC a 900 on the inspecting vaive points upward. U - (o) Using a feeler gauge, measure the clearance between ] the valve lifter and camshaft a fh (c) Measure the clearance at 16 places. AF biearance (a) Record the out-of-specification valve clearance mea- oe AD J surements. They will be used later to determine the re- y r ZA 00687 quired replacement adjusting shim. Valve cl Tnane Exhaust 4 =~ 5. ADJUST VALVE CLEARANCE LAIN Boe camtone | (a) Remove the adsting shim KN} kes > (1) Turn the crankshaft so that the cam lobe of the cam- ‘ \\\ USE shaft on the adjusting valve points upward. Ya ] (2) Position the notch of the valve lifter facing the intake V\ oe Ae manifold side. \ we XY ZZ, Intake Nowe ZZ > Meats ENGINE MECHANICAL VALVE CLEARANCE ( sstia) an 109606 (3) Using SST (A), press down the valve lifter and place ‘SST (B) between the camshaft and valve lifter. Re- move SST (A). SST 09248-55050 (09248-05510, 09248-05520) HINT: Apply SST (B) on the side marked with “11” (4) Remove the adjusting shim with a small screwdriver and magnetic finger. (b) Determine the replacement adjusting shim size by follow- ing the Formula or Charts: (1) Using a micrometer, measure the thickness of the removed shim. (2) Calculate the thickness of a new shim so that the valve clearance comes within specified value. T ocsn Thickness of removed adjusting shim A nnn Measured valve clearance N Thickness of new adjusting shim Intake: + (A - 0.25 mm (0.010 in.)) Exhaust: N = T + (A-0.40 mm (0.016 in.)) (3) Select a new shim with a thickness as close as pos- sible to the calculated valve. HINT: Shims are available in 32 sizes in increments of 0.025 mm (0.0020 in.), from 2.525 mm (0.0994 in.) to 3.300 mm (0.1299 in). (©) Place a new adjusting shim on the valve lifter. (d) Using SST (A), press down the valve lifter and remove SST (8), SST 09248-55050 (09248-05510, 09248-05520) {e) Recheck the valve clearance. 6. REINSTALL INJECTORS (See page FU-8) 7. REINSTALL CYLINDER HEAD COVER (See page EM-56) 8 _ REINSTALL INTERCOOLER (See page EM~16) ENGINE MECHANICAL ~ VALVE CLEARANCE asa 2staataa{zafzs|za}27| eto] 203132] a of20f>i]27|2a}zest a2 7| aes |30|31]32 Adjusting Shim Selection Chart (Intake) oucremoares |elels|elalelelelelelelalelalale alslslelelellle voviny | §/8/5/8/8/8)8/8/5/8]8 2 |= 18]2)3 (S|) 5/5] 5 18] Sie giS|g 8/8 mn 5/8 /8]8/8/S]8 Seles Sie le|8\8\a]s 8/8 [8 |s\88|s [2 aisiaigle Se aos | Ton foots osama oa asa aS Tent oor OoME= Ute otal osloelov lola sous iafofatatet it aie Dost aon [UemtePoteE falatofoslos ov oloafe it aot is ate treeless] ier—beee oatzs boost ulster rkoort ria is fa opens Sour owes owes la cae eof feta. ol oleate Soro set aooed= veer Sesto calomel a(t oeoereetese Sista eae oooae vost feetastoslosoelr [soot oti fo stapshler tale aos Ese CT oes OuneE west fa ofasbnlor en arosi2 fa sea] aispooncap sates ora Seta Test oomts=boort 1+ -foraeatafesoeeresn iste vetlel suet ses pseees se (0.187 — 0.199 | 0.0071-0.007a ) [oi] 02]03}04|o8|06[o71o8|o9[10111/12]13]14]15]16] 17|18]19|20] 1|22|o5|balpelbelary a 2200 o3ee OOP Oe : Soro wo aI2E+ (olen en taf acl lo ef ata E391 ne a ntne=0 19+ soe oalr man tl olie{ ol oases ala ala eee a Sagi og eo var aTee ffs oe rats fala tay aa os also Ses rele el a East a sup oes oso eetertaaln oi aii at {lolol eas ear sas at Settee ooo tro aearate oata tease os ores a Sgr ba f ooten=otas | fvanantel tallest abate eae Tess Bope resents San eaae t guneeees + eto of fafa ata ere SENET sEes eee eooBc Sagi Guan: ostae= eatery fall frat alisha ral ool assests els aca ae Sag eee SOT -eetee Ten afta aor nese solos 1 ‘0461-0800 { 00189-00197} |ir]r2f ‘9.501 0590 _{ 00197-00205) [12h] ‘Os2i— asso { 0.0205 0021s) z|i3hia 3|20)>3]22190|24 ‘str aseo (0021 0.0220-) fatal 0212225245 (SET 0880 { 00201 o.o2ee } [oa telrel¥7[tals9[20)2f2a\2a]24[25]24 (9.581 — 0.600 -{ 0.0270--0.0736_} |rs|se[i7lralialzo|2s}2a|2a[2e\25)26]27 (9.801 = 0620-( Oozs7-.02ae [isle 7[1alt9/2012%|22[25124[2sI26]27 (0.521 cea { Oozes 0.0050 } [re|t71 ral ¥0[20)3#[22120124]25|26|27[2al20|a0|33| 32) 9.64} 0-889 { 000952 0.0960 | [17 tel19|20[21|22123]24]>5]26|77[2a\20[30[31 22 3.861 — 0.680 { 00960 -0.096e } [t8|19|20]21122|29]24|79]26]27/2a)20[30|31[ 22 Bas 0-709 (0.0268 0.0376 | [va]20[2 ]P0[ral>4)%0]2e|>7[2e|z0]s0[31[ 20 ‘0.701 0-720 (-Oa276 0.0785.) |14]20)>1|70[29]24]25[26|27|29)78]30|31[ 22 ‘0723-0 740_{ 0.0284 0.0201 1 [20,21122]29{2q[25|25427| 2ao5{>01 13 ‘o741@ 760 { 00202 -0.0206-) [2|22|23]24126|26 27|28]20 503132] ‘0.76% = 07#0_{ 0.0su0-<.0s0/_-[22}2s)24|2sfze|27[2al26|30|31|32 ‘9.7a1 0800 { 0.0307 o0315 ) 2s)zeizehzele7|79)25]30|31| 32 ‘O.aDi = 0,820_[ 0.0315 0.0525 }[2a)za[rs|z9)27|28\za|0j3%122 (0.021 0.840-{ 0.0323-0-0331-} Palr5)z6]27|29)20[ 30 31[32 ‘G.ati — 0.860 (0.0551 0.0938_) PsPe)>7|29)20)30|31]22 Cast oa80-( e930 Coser aleoo ta ast —o.ep0-( 0.0047 Dose 1 [ereal| oof 32, News! mm (in) sor 0579-{ 00055 -o9s8e ereseolsls1 Se) Siw Sim eer Led | 00865-00870) [odes [ste No. [ Sr] thekress | Soi Thickness ser Ded | oso C0878 (2990) 52 | rset wsaD-( 90878-00386) {so s1 2 Tr] esas | asaRTORA] | ase ZERO, eer ceo osas 00808 [oe G2 | ~2550_—|2550(0.1008)| 2960 2950(0-164) TnI 1600 Osos o.oo yf oa | 2675 [257510 1014), 2875 2975(0.171 ogy 1680" wate 0.0400 Te 04 | 2600 2.600(0.1028) [3000 3.000(0.184 ‘06 | “2650 | 2.660 (0.1043)| ~ 3050 ‘07 | "2675 _[2.675(0.1053) | 3075 ‘08 | 2700 | 27000-1063) | 3100 og | 2725 | 2795(9.1073) | 3125 10278 750(0.1083) | — S50. wn 2778 | 2.775(0.1098)| 3175 12] 2a00 [2.800 (0.1102) 2200 13] 2825 [2.805 (0.1112) | 9225 14 | 2a60 [2.850 (0.1122) [2260 Intake valve clearance (Cold): v5] 2875 | 2.875,(0.1192)[ 9275 0.20 - 0.30 mm (0.0079 - 0.0118 in.) 16] 2300 [2.900 (0.1142) 3300. EXAMPLE: The 2.800 mm (0.1102 in.) shim is installed, and the measured clearance is 0.350 mm (0.0138 in.) Replace the 2.890 mm (0.1102 in.) shim with a new No.16 2.900 mm (0.1142 in.) shim, No. 7 16 18 20 ‘05.| 2625 12.925 0.1033) 4025 [at a 2 2s 25, 28